Husqvarna FE 250 2019 Owner's Manual
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Husqvarna FE 250 2019 Owner's Manual

Husqvarna FE 250 2019 Owner's Manual

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OWNER'S MANUAL 2019
FE 250
Art. no. 3402245en
https://www.motorcycle-manual.com/

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Summary of Contents for Husqvarna FE 250 2019

  • Page 1 OWNER'S MANUAL 2019 FE 250 Art. no. 3402245en https://www.motorcycle-manual.com/...
  • Page 2 https://www.motorcycle-manual.com/...
  • Page 3 DEAR HUSQVARNA MOTORCYCLES CUSTOMER Congratulations on your decision to purchase a Husqvarna motorcycle. You are now the owner of a state-of- DEAR HUSQVARNA MOTORCYCLES CUSTOMER the-art sports motorcycle that will give you enormous pleasure if you service and maintain it properly.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS 6.15 Idle speed adjusting screw ....20 MEANS OF REPRESENTATION......6 6.16 Shift lever ..........21 Symbols used ........6 6.17 Foot brake lever ........21 Formats used ........6 6.18 Side stand........... 21 SAFETY ADVICE ..........
  • Page 5 TABLE OF CONTENTS SERVICE SCHEDULE........40 12.11 Checking the play of the steering head bearing ........59 10.1 Additional information......40 12.12 Adjusting the steering head bearing 10.2 Required work........40 play ..........60 10.3 Recommended work......41 12.13 Lubricating the steering head bearing ..........
  • Page 6 TABLE OF CONTENTS 13.4 Adding front brake fluid ....87 17.3 Adjusting the characteristic map of the throttle response ..... 119 13.5 Checking the front brake linings ..88 17.4 Changing the mapping ..... 121 13.6 Changing the front brake linings ..
  • Page 7 TABLE OF CONTENTS 29.2 Green and blue symbols....152 INDEX ..............153 https://www.motorcycle-manual.com/...

  • Page 8: Means Of Representation

    1 MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understand- ing.

  • Page 9: Safety Advice 2

    SAFETY ADVICE 2 Use definition – intended use This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the currently valid regulations and categories of the top international motorsport organizations. Info This vehicle is only authorized for operation on public roads in the homologated (restricted) version.

  • Page 10: Tampering Warning

    An appropriate driver's license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized Husqvarna Motorcycles workshop. Adhere to the information and warning labels on the vehicle.

  • Page 11: Protective Clothing

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, Husqvarna Motorcycles recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks.

  • Page 12: Important Notes

    The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles workshop only and confirmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motor- cycles Dealer.net; otherwise, all warranty claims will be void. Damage or secondary damage caused by tam- pering with and/or conversions on the vehicle are not covered by the warranty.

  • Page 13: Customer Service

    IMPORTANT NOTES 3 Customer service Your authorized Husqvarna Motorcycles dealer will be happy to answer any questions you may have regarding your vehicle and Husqvarna Motorcycles. A list of authorized Husqvarna Motorcycles dealers can be found on the Husqvarna Motorcycles website.

  • Page 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) A00354-10 Hand brake lever ( p. 16) Clutch lever ( p. 16) Filler cap Air filter box cover Side stand ( p. 21) Engine number ( p. 14) Shift lever ( p.

  • Page 15: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) A00355-10 Fork compression adjustment Kill switch ( p. 16) Horn button ( p. 17) Light switch ( p. 17) Turn signal switch ( p. 17) Emergency OFF switch ( p. 17) Electric starter button ( p.

  • Page 16: Serial Numbers

    5 SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 401945-10 Type label Type label is fixed to the front of the steering head. 401946-10 Key number Key number for the steering lock is stamped onto the lable on the key connector.

  • Page 17: Fork Part Number

    SERIAL NUMBERS 5 Fork part number The fork part number is stamped on the inner side of the fork stub. 401947-10 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. H02222-10 https://www.motorcycle-manual.com/...

  • Page 18: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. F00257-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar.

  • Page 19: Horn Button

    CONTROLS 6 Horn button The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – the horn is actuated in this posi- • Horn button tion. F00260-11 Light switch Light switch is fitted on the left side of the handlebar.

  • Page 20: Electric Starter Button

    – The OBD has detected an error in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized Husqvarna Motorcycles workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 21: Opening The Filler Cap

    CONTROLS 6 Turn signal indicator lamp flashes green – The turn signal is switched on. 6.12 Opening the filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...

  • Page 22: Cold Start Button

    6 CONTROLS 6.14 Cold start button The cold start button is fitted on the bottom of the throttle valve body. The injection system extends the injection time if the engine is cold and the outside temperature is low. To help the engine burn the increased amount of fuel, it must be supplied with additional oxygen by pushing the cold start button.

  • Page 23: Shift Lever

    CONTROLS 6 6.16 Shift lever The shift lever is fitted on the left side of the engine. 401950-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.17 Foot brake lever The foot brake lever...

  • Page 24: Steering Lock

    6 CONTROLS The side stand is used for parking the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber band 401944-10 6.19 Steering lock Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering.

  • Page 25: Unlocking The Steering

    CONTROLS 6 6.21 Unlocking the steering – Insert the key in the steering lock ( p. 22), turn it to the left, pull it out, and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock.

  • Page 26: Combination Instrument

    Battery voltage of the combination instrument – Bat- tery voltage of the combination instrument is too low. Change the battery. Service – A service is due. Contact an authorized Husqvarna Motorcycles workshop. 401901-01 Adjusting the combination instrument Condition The motorcycle is stationary.
  • Page 27 COMBINATION INSTRUMENT 7 – Wait for 5 seconds. Combination instrument changes to the next menu item. symbol flashes. – Press one of the buttons to select the 24h or 12h display of the clock. 401911-01 – Wait for 5 seconds. Combination instrument changes to the next menu item.

  • Page 28: Adjusting The Kilometers Or Miles

    7 COMBINATION INSTRUMENT Adjusting the kilometers or miles Info If the unit is changed, the value ODO is retained and converted accordingly. Condition The motorcycle is stationary. – Press and hold both buttons for 3 - 5 seconds. The Setup menu is displayed. The UNIT display flashes. –...

  • Page 29: Adjusting The Service Display

    COMBINATION INSTRUMENT 7 Adjusting the service display Condition The motorcycle is stationary. – Press and hold both buttons for 3 - 5 seconds. The Setup menu is displayed. The UNIT display flashes. – Wait for the menu of the service display to flash.

  • Page 30: Speed, Time, And Dst2 Distance 2

    7 COMBINATION INSTRUMENT Press the DST is reset to 0.0. right button for 3 – 5 sec- onds. Speed, time, and DST2 distance 2 – Press one of the buttons until DST2 appears on the combina- tion instrument. KM/H or M/H shows the speed. shows the time.

  • Page 31: Preparing For Use 8

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized Husqvarna Motorcy- cles workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.

  • Page 32: Running-In The Engine

    8 PREPARING FOR USE – Adjust the basic position of the hand brake lever. ( p. 86) – Adjust the basic position of the foot brake lever. p. 92) – Set the basic position of the shift lever. p. 123) –...

  • Page 33: Starting Power Of Lithium-Ion Batteries At Low Temperatures

    PREPARING FOR USE 8 Starting power of lithium-ion batteries at low temperatures Lithium-ion batteries are far lighter than lead batteries, have a low self-discharge rate, and have more starting power at tem- peratures over 15 °C (60 °F). At low temperatures, however, the starting power of lithium-ion batteries drops to below that of lead batteries.

  • Page 34: Preparing Vehicle For Rides On Dry Sand

    Preparing vehicle for rides on dry sand – Mount a dust cover on the air filter. Dust cover for air filter (79006920000) Info Read the fitting instructions for Husqvarna Motorcy- cles accessories. 102136-01 – Mount a sand cover on the air filter.

  • Page 35: Preparing Vehicle For Rides On Wet And Muddy Circuits

    Preparing vehicle for rides on wet and muddy circuits – Fit a rain cover on the air filter. Waterproofing device for air filter (79006921000) Info Read the fitting instructions for Husqvarna Motorcy- cles accessories. 102137-01 – Mount the steel sprocket.

  • Page 36: Riding Instructions

    9 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info 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 when it is being operated. –...

  • Page 37: Activating Traction Control

    RIDING INSTRUCTIONS 9 – Take the motorcycle off side stand and secure the side stand with rubber band – Shift transmission to neutral. – Turn the emergency OFF switch to the position Condition Ambient temperature: < 20 °C (< 68 °F) –...

  • Page 38: Starting Off

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) https://www.motorcycle-manual.com/...

  • Page 39: Stopping, Parking

    RIDING INSTRUCTIONS 9 Warning Danger of accidents Moisture and dirt impair the brake system. – Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs. – On sandy, wet or slippery surfaces, use the rear brake. –...

  • Page 40: Transporting

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) https://www.motorcycle-manual.com/...
  • Page 41 RIDING INSTRUCTIONS 9 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. – Switch off engine. – Open the filler cap. ( p.

  • Page 42: 10 Service Schedule

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to- date service schedule can always be found on Husqvarna Motorcycles Dealer.net. Your authorized Husqvarna Motorcycles dealer will be glad to advise you.

  • Page 43: Recommended Work

    ● Final check: Check the vehicle is roadworthy and take a test ride. ○ ● ● ● ● Read out the fault memory after the test ride using the Husqvarna Motorcycles diag- nostics tool. ○ ● ● ● ● Make the service entry in the Husqvarna Motorcycles Dealer.net and in the Service and Warranty Booklet.
  • Page 44 10 SERVICE SCHEDULE Annually Every 135 operating hours Every 70 operating hours when used for motorsports Once after 20 operating hours Once after 10 operating hours ● ● Perform engine service including removing and installing the engine. (Change the spark plug and spark plug connector. Change the piston. Check/measure the cylinder. Check the cylinder head.

  • Page 45: Tuning The Chassis 11

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 46: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber.

  • Page 47: Adjusting The Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incor- rectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 48: Checking The Static Sag Of The Shock Absorber

    11 TUNING THE CHASSIS 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 45) – Hold the motorcycle upright with the aid of an assistant. – Again measure the distance between the rear axle and mark- ing SAG on the rear fender using the sag gauge.

  • Page 49: Adjusting The Spring Preload Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring length.

  • Page 50: Adjusting The Riding Sag

    11 TUNING THE CHASSIS 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 53) – Remove the shock absorber. p. 62) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 51: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 11 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn white adjusting screw clockwise as far as it will go. Info Adjusting screw is located at the upper end of the left fork leg.

  • Page 52: Adjusting The Spring Preload Of The Fork

    11 TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counter- clockwise to reduce damping. 11.14 Adjusting the spring preload of the fork Preparatory work – Raise the motorcycle with a lift stand. ( p. 53) Main work – Turn the adjusting wings counterclockwise all the way.

  • Page 53: Handlebar Position

    TUNING THE CHASSIS 11 11.15 Handlebar position On the upper triple clamp, there are two holes at a distance to each other. 15 mm (0.59 in) Hole distance The holes on the handlebar supports are placed at a distance from the center. 3.5 mm (0.138 in) Hole distance The handlebar supports can be mounted in four different posi-...
  • Page 54 11 TUNING THE CHASSIS Info Make sure the gap width is even. https://www.motorcycle-manual.com/...

  • Page 55: Service Work On The Chassis 12

    SERVICE WORK ON THE CHASSIS 12 12.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (81329955100) Neither wheel is in contact with the ground.

  • Page 56: Cleaning The Dust Boots Of The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 53) – Remove the fork protector. ( p. 54) Main work – Push dust boots of both fork legs downward.

  • Page 57: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 12 12.6 Installing the fork protector – Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake line, wiring harness, and clamp. Mount and tighten screws –...

  • Page 58: Installing The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.8 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front. Info The compression damping is located in left fork leg COM (white adjusting screw). The rebound damping is located in right fork leg REB (red adjusting screw).

  • Page 59: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 12 Main work – Open the cable holder in front of the right radiator and detach the wiring harness. – Remove screws and hang the voltage regulator to the side. – Open the cable holder in front of the left radiator and detach the wiring harness.
  • Page 60 12 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the handlebar. – Mount screw but do not tighten yet. S02075-10 – Secure wiring harness and clutch line with cable holder. – Position the voltage regulator, and mount and tighten screws Guideline Remaining screws,...

  • Page 61: Checking The Play Of The Steering Head Bearing

    Checking the play of the steering head bearing Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) https://www.motorcycle-manual.com/...

  • Page 62: Adjusting The Steering Head Bearing Play

    12 SERVICE WORK ON THE CHASSIS Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time. Preparatory work – Raise the motorcycle with a lift stand.

  • Page 63: Lubricating The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 12 Finishing work – Check the play of the steering head bearing. ( p. 59) – Remove the motorcycle from the lift stand. ( p. 53) 12.13 Lubricating the steering head bearing – Remove the lower triple clamp. p.

  • Page 64: Installing Front Fender

    12 SERVICE WORK ON THE CHASSIS 12.15 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F00283-10 Finishing work...
  • Page 65 SERVICE WORK ON THE CHASSIS 12 – Press angle lever toward the rear. – Press linkage lever downward. F00285-10 – Disconnect plug-in connector S02079-10 – Remove screws – Pull off foot brake cylinder from the push rod. S02080-10 – Remove the connecting link of the chain. –...

  • Page 66: Installing The Shock Absorber

    12 SERVICE WORK ON THE CHASSIS – Hold the shock absorber and remove screw – Remove the shock absorber carefully at the bottom. S02112-10 12.17 Installing the shock absorber Main work – Carefully position the shock absorber into the vehicle from the bottom.
  • Page 67 SERVICE WORK ON THE CHASSIS 12 – Position the foot brake cylinder. Push rod engages in the foot brake cylinder. The dust boot is correctly positioned. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S02084-10 –...

  • Page 68: Removing The Seat

    12 SERVICE WORK ON THE CHASSIS 12.18 Removing the seat Preparatory work – Remove the air filter box cover. ( p. 67) Main work – Remove screw with the bushing. – Pull seat back and lift it off. A00107-10 12.19 Mounting the seat Main work –...

  • Page 69: Removing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 12 12.20 Removing the air filter box cover – Pull off the air filter box cover sideways in areas , and remove toward the front. A00109-10 12.21 Installing the air filter box cover – Position air filter box cover on collar bushings and push toward the rear.

  • Page 70: Installing The Air Filter

    12 SERVICE WORK ON THE CHASSIS Main work – Detach retaining tab . Remove air filter with air filter sup- port. – Remove air filter from air filter support. A00111-10 12.23 Installing the air filter Main work – Mount the clean air filter on the air filter support. –...

  • Page 71: Sealing The Air Filter Box

    SERVICE WORK ON THE CHASSIS 12 Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 148) Info Only press the air filter to dry it, never wring it out. –...

  • Page 72: Installing The Right Side Cover

    12 SERVICE WORK ON THE CHASSIS 12.27 Installing the right side cover – Position the side cover on collar bushings , and push toward the rear. – Engage the side cover in areas – Mount and tighten screw Guideline Remaining screws, 5 Nm (3.7 lbf ft) chassis A00349-10...

  • Page 73: Installing The Main Silencer

    SERVICE WORK ON THE CHASSIS 12 12.29 Installing the main silencer Main work (EU) – Position catalytic converter in the main silencer. S02101-10 – Position the main silencer. – Mount screws but do not tighten yet. – Attach spring Spring hook (5030501700004) –...

  • Page 74: Removing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS Main work – Remove all screws on the main silencer. – Take off silencer cap – Take off outer tube – Remove glass fiber yarn filling from the inner tube with connecting cap – Clean the parts that need to be reinstalled and check for damage.
  • Page 75 SERVICE WORK ON THE CHASSIS 12 Main work – Unplug connector of the fuel pump. – Clean plug-in connection of the fuel line thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! F00305-10 –...

  • Page 76: Installing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS 12.32 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 77: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 12 – Position the horn with the horn bracket. – Mount and tighten screws with the collar bushings. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis A00117-11 – Plug in connector for the fuel pump. –...

  • Page 78: Cleaning The Chain

    12 SERVICE WORK ON THE CHASSIS 12.34 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. – Remove the lubricant from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...

  • Page 79: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 12 Main work – Pull the chain at the end of the chain sliding piece upward to measure chain tension Info The lower chain section must be taut. When the chain guard is mounted, it must be possi- ble to pull up the chain at least to the point where it makes contact with chain guard Chain wear is not always even, so you should repeat...

  • Page 80: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    12 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55 … 58 mm (2.17 … 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks...
  • Page 81 SERVICE WORK ON THE CHASSIS 12 – Pull at the top part of the chain with the specified weight Guideline Weight of chain wear mea- 10 … 15 kg (22 … 33 lb.) surement – Measure distance of 18 chain rollers in the lower chain section.
  • Page 82 12 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.

  • Page 83: Checking The Frame

    – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by Husqvarna F00255-01 Motorcycles. 12.39 Checking the swingarm – Check the swingarm for damage, cracking, and deformation.

  • Page 84: Checking The Rubber Grip

    12 SERVICE WORK ON THE CHASSIS Main work – Check throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the fuel tank contact area rubber band.

  • Page 85: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 12 12.42 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info When the adjusting screw is turned clockwise, the clutch lever moves closer to the handlebar.

  • Page 86: Changing The Hydraulic Clutch Fluid

    12 SERVICE WORK ON THE CHASSIS Brake fluid DOT 4 / DOT 5.1 ( p. 146) – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilled brake fluid immediately with water. 12.44 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation.

  • Page 87: Removing The Engine Guard

    SERVICE WORK ON THE CHASSIS 12 – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 146) – On the clutch slave cylinder, remove bleeder screw mount bleeding syringe S02086-10 –...

  • Page 88: 13 Brake System

    Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple...

  • Page 89: Checking The Front Brake Fluid Level

    – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 90: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...

  • Page 91: Changing The Front Brake Linings

    Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 92 13 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Take off cover with membrane S02090-10 – Manually press the brake caliper toward the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, if necessary extract excess.

  • Page 93: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 13 – Correct the brake fluid quantity to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 ( p. 146) – Position cover with membrane – Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water.

  • Page 94: Adjusting The Basic Position Of The Foot Brake Lever

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) https://www.motorcycle-manual.com/...

  • Page 95: Adding Rear Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 96: Checking The Rear Brake Linings

    Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 97 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 98 13 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. H02369-10 – Insert the new brake linings. – Mount pin Leaf spring engages in the groove on the pin. Info Always change the brake linings in pairs.

  • Page 99: Wheels, Tires 14

    WHEELS, TIRES 14 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 53) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pis-...

  • Page 100: Installing The Front Wheel

    14 WHEELS, TIRES 14.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 101: Installing The Rear Wheel

    WHEELS, TIRES 14 Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. –...
  • Page 102 14 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p.

  • Page 103: Checking The Tire Condition

    Checking the tire condition Info Only mount tires approved and/or recommended by Husqvarna Motorcycles. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcy- cle.

  • Page 104: Checking Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) –...

  • Page 105: Electrical System 15

    ELECTRICAL SYSTEM 15 15.1 Removing the battery Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. – Only charge batteries in well-ventilated rooms. –...

  • Page 106: Installing The Battery

    15 ELECTRICAL SYSTEM 15.2 Installing the battery Main work – Insert the battery into the battery compartment with the ter- minals facing forward and secure with holding bracket Battery (HJTZ5S-FP) ( p. 142) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis –...
  • Page 107 ELECTRICAL SYSTEM 15 Note Environmental hazard Batteries contain environmentally-hazardous materials. – Do not dispose of batteries as household waste. – Dispose of batteries at a collection point for used batteries. Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

  • Page 108: Changing The Main Fuse

    The charging time may be longer at low temperatures. These battery chargers are only suitable for lithium iron phosphate batteries. Read the accompanying instructions for Husqvarna Motorcycles accessories. Info Never remove cover – Switch off the battery charger after charging and dis- connect from the battery.

  • Page 109: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 15 – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109120) ( p.
  • Page 110 15 ELECTRICAL SYSTEM – Open fuse box cover – Remove the faulty fuse. Guideline (EU) Fuse 1 ‑ 10 A – EFI control unit, lambda sensor, com- bination instrument, combination switch (optional), fuel injection, diagnostics connector, fuse 4 (AU) F00360-10 Fuse 1 ‑...

  • Page 111: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 15 15.6 Removing the headlight mask with the headlight – Press and hold the kill switch while the engine is idling until the engine stops. – Detach brake line and wiring harness – Release rubber bands . Slide the headlight mask up and swing it forward.

  • Page 112: Changing The Headlight Bulb

    15 ELECTRICAL SYSTEM – Position brake line and wiring harness in the brake line guide. F00342-10 Finishing work – Check the headlight setting. ( p. 111) 15.8 Changing the headlight bulb Note Damage to reflector Grease on the reflector reduces the brightness. Grease on the bulb will evaporate due to the heat and be deposited on the reflector.

  • Page 113: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM 15 15.9 Changing the turn signal bulb Note Damage to reflector Grease on the reflector reduces the brightness. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting. –...

  • Page 114: Adjusting The Headlight Range

    15 ELECTRICAL SYSTEM The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider. » If the light-dark border does not meet specifications: – Adjust the headlight range. ( p. 112) 15.11 Adjusting the headlight range Preparatory work –...

  • Page 115: Diagnostics Connector

    ELECTRICAL SYSTEM 15 – Position protection cap and turn all the way clockwise using a coin. – Press any button on the combination instrument. The combination instrument is activated. – Position the combination instrument in the holder. – Mount and tighten the screws with washers. F00371-10 Finishing work –...

  • Page 116: 16 Cooling System

    16 COOLING SYSTEM 16.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 117: Checking The Coolant Level

    COOLING SYSTEM 16 – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...

  • Page 118: Draining The Coolant

    16 COOLING SYSTEM 16.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
  • Page 119 COOLING SYSTEM 16 Main work – Make sure that the screw is tightened. – Stand the vehicle upright. – Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Coolant 1.2 l (1.3 qt.) Coolant ( p.

  • Page 120: 17 Tuning The Engine

    17 TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 …...

  • Page 121: Adjusting The Characteristic Map Of The Throttle Response

    TUNING THE ENGINE 17 Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop. –...
  • Page 122 17 TUNING THE ENGINE – Remove guide plate from handle tube – Position the required guide plate on the grip tube. Guideline The label OUTSIDE must be visible. Marking must be positioned at marking Grey guide plate (79002014000) Alternative 1 Black guide plate (79002014100) Info The gray guide plate opens the throttle valve more...

  • Page 123: Changing The Mapping

    Adjusting the idle speed Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) https://www.motorcycle-manual.com/...

  • Page 124: Teaching The Throttle Valve Position

    17 TUNING THE ENGINE – Run the engine until warm. The cold start button is deactivated – The cold start but- ton is in its basic position. ( p. 20) Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

  • Page 125: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 17 17.7 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the driver's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...

  • Page 126: 18 Service Work On The Engine

    18 SERVICE WORK ON THE ENGINE 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 127: Checking The Engine Oil Level

    SERVICE WORK ON THE ENGINE 18 Danger 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 an effective exhaust extraction system when starting or running the engine in an enclosed space.
  • Page 128 18 SERVICE WORK ON THE ENGINE Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Drain engine oil with engine at operating temperature. Preparatory work –...
  • Page 129 SERVICE WORK ON THE ENGINE 18 – Remove screws . Remove the oil filter cover with the O- ring. H01680-10 – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Completely drain the engine oil. –...

  • Page 130: Adding Engine Oil

    18 SERVICE WORK ON THE ENGINE Finishing work – Check the engine oil level. ( p. 125) – Install the engine guard. ( p. 85) 18.4 Adding engine oil Info Too little engine oil or poor-quality engine oil will result in premature wear of the engine. Main work –...

  • Page 131: Cleaning, Care 19

    CLEANING, CARE 19 19.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...

  • Page 132: Checks And Maintenance Steps For Winter Operation

    19 CLEANING, CARE – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 148) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 133: Storage 20

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info Husqvarna Motorcycles recommends raising the motorcycle. – Raise the motorcycle with a lift stand. ( p. 53) –...

  • Page 134: Preparing For Use After Storage

    20 STORAGE 20.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 53) – Install the battery. p. 104) – Perform checks and maintenance measures when preparing for use. ( p. 34) – Take a test ride. 401059-01 https://www.motorcycle-manual.com/...

  • Page 135: Troubleshooting 21

    Check the electrical system. tive – Defect in fuel injection system Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the Husqvarna Motorcycles diagnostics tool.
  • Page 136 Possible cause Action – Engine has too little power Defect in fuel injection system Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. – Exhaust system leaky, Check exhaust system for damage. deformed or too little glass –...
  • Page 137 TROUBLESHOOTING 21 Faults Possible cause Action – Battery discharged Undesired power consumer Check the open-circuit current. – Combination instrument values The battery in the combination Change the combination instrument. deleted (time, stop watch, lap instrument is discharged p. 112) times) –...

  • Page 138: 22 Blink Code

    22 BLINK CODE Info The blink codes are only displayed by the derestricted version of the vehicle. Blink code for malfunc- tion indicator lamp 02a Malfunction indicator lamp flashes 2x per second Error level condition Teaching of throttle valve position required Blink code for malfunc- tion indicator lamp 02 Malfunction indicator lamp flashes 2x short...
  • Page 139 BLINK CODE 22 Blink code for malfunc- tion indicator lamp 33 Malfunction indicator lamp flashes 3x long, 3x short Error level condition Injector cylinder 1 - circuit fault Blink code for malfunc- tion indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short Error level condition Ignition coil 1, cylinder 1 - circuit fault Blink code for malfunc-...

  • Page 140: 23 Technical Data

    23 TECHNICAL DATA 23.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 249.91 cm³ (15.2505 cu in) Stroke 52.3 mm (2.059 in) Bore 78 mm (3.07 in) Compression ratio 12.8:1 Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 32.5 mm (1.28 in) Valve diameter, exhaust...

  • Page 141: Engine Tightening Torques

    TECHNICAL DATA 23 23.2 Engine tightening torques Nozzle, crank chamber ventilation 2 Nm (1.5 lbf ft) ® Loctite 243™ Oil nozzle for alternator cooling 2 Nm (1.5 lbf ft) ® Loctite 243™ Oil nozzle for balancer shaft lubri- 2 Nm (1.5 lbf ft) ®...
  • Page 142 23 TECHNICAL DATA Screw, starter motor 10 Nm (7.4 lbf ft) Screw, timing chain guide rail 10 Nm (7.4 lbf ft) ® Loctite 243™ Screw, timing chain securing 10 Nm (7.4 lbf ft) ® Loctite 243™ guide Screw, valve cover 8 Nm (5.9 lbf ft) Screw, water pump cover 10 Nm (7.4 lbf ft)

  • Page 143: Capacities

    TECHNICAL DATA 23 23.3 Capacities 23.3.1 Engine oil Engine oil 1.0 l (1.1 qt.) Engine oil (SAE 10W/50) ( p. 146) 23.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p. 146) 23.3.3 Fuel Super unleaded (ROZ 95/RON 95/PON 91) ( p.

  • Page 144: Electrical System

    140/80 - 18 M/C 70M M+S TT Metzeler MCE 6 Days Extreme Metzeler MCE 6 Days Extreme The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com 23.7 Fork Fork article number 14.15.8S.61...

  • Page 145: Shock Absorber

    TECHNICAL DATA 23 Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 3.8 N/mm (21.7 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 4.0 N/mm (22.8 lb/in) Weight of rider: 85 … 95 kg (187 … 209 lb.) 4.2 N/mm (24 lb/in) Fork length 928 mm (36.54 in)
  • Page 146 23 TECHNICAL DATA Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) Remaining nuts, chassis 5 Nm (3.7 lbf ft) Remaining screws, chassis 5 Nm (3.7 lbf ft) Screw, battery terminal 2.5 Nm (1.84 lbf ft) Screw, shock absorber adjusting 5 Nm (3.7 lbf ft) ring Nut, cable on starter motor...
  • Page 147 TECHNICAL DATA 23 Screw, handlebar holder 40 Nm (29.5 lbf ft) ® Loctite 243™ Screw, top shock absorber 60 Nm (44.3 lbf ft) ® Loctite 2701™ Nut, fuel pump fixation 15 Nm (11.1 lbf ft) Nut, angle lever on swingarm M14x1.5 80 Nm (59 lbf ft) Nut, frame on linkage lever...

  • Page 148: 24 Substances

    24 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 ®...
  • Page 149 SUBSTANCES 24 Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 149) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...

  • Page 150: 25 Auxiliary Substances

    25 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier ® Motorex – Racing Bio Dirt Remover Chain cleaner Recommended supplier ® Motorex – Chain Clean High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier ® Motorex – Bike Grease 2000 Off-road chain spray Recommended supplier...

  • Page 151: Standards 26

    STANDARDS 26 JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 152: 27 Index Of Special Terms

    27 INDEX OF SPECIAL TERMS On-board diagnosis Vehicle system, which monitors the specified param- eters of the vehicle electronics https://www.motorcycle-manual.com/...

  • Page 153: List Of Abbreviations 28

    LIST OF ABBREVIATIONS 28 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly https://www.motorcycle-manual.com/...

  • Page 154: 29 List Of Symbols

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized Husqvarna Motorcy- cles workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.
  • Page 155 INDEX INDEX Chain guide checking ......78 Accessories ......10 Chain tension Air filter adjusting .
  • Page 156 INDEX Engine guard installing ......85 Hand brake lever ..... . 16 removing .
  • Page 157 INDEX lift stand, raising with ....53 Shock absorber removing from lift stand ....53 installing .
  • Page 158 INDEX Turn signal bulb changing ......111 Turn signal switch ..... 17 Type label .
  • Page 159 *3402245en* 3402245en 05/2018 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer, https://www.motorcycle-manual.com/ www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...

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Fe 250 eu 2019Fe 250 au 2019F2103s4F2160s4

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