HUSABERG FE 450 EU - Repair Manual

HUSABERG FE 450 EU

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REPAIR MANUAL

FE 450 EU

FE 450 AUS

FE 450 USA

FE 570 EU

FE 570 AUS

FE 570 USA

2009

Article no. 3803004en

Table of Contents

Table of Contents4
Means of Representation7
Important Notes8
Location of Serial Numbers9
- Chassis Number9
- Type Label (FE EU, FE AUS)9
- Type Label (FE USA)9
- Key Number (FE EU, FE AUS)9
- Engine Number9
- Fork Part Number10
- Shock Absorber Part Number10
Motorcycle11
- Jacking up the Motorcycle11
- Removing the Motorcycle from the Work Stand11
- Starting11
01/Fork, Triple Clamp12
- Adjusting the Compression Damping of the Fork12
- Adjusting the Rebound Damping of the Fork12
- Adjusting the Spring Preload of the Fork12
- Bleeding the Fork Legs13
- Cleaning the Dust Boots of the Fork Legs13
- Loosening the Fork Protection13
- Positioning the Fork Protection14
- Removing the Fork Legs14
- Installing the Fork Legs14
- Removing the Fork Protector15
- Installing the Fork Protector15
- Performing a Fork Service16
- Disassembling the Fork Legs16
- Cartridge Disassembly19
- Disassembling the Compression Damping Fitting21
- Checking the Fork Legs21
- Assembling the Compression Damping Fitting22
- Assembling the Cartridge23
- Assembling the Fork Legs25
- Greasing the Steering Head Bearing29
- Removing the Lower Triple Clamp29
- Installing the Lower Triple Clamp30
- Checking the Play of the Steering Head Bearing31
- Adjusting the Play of the Steering Head Bearing31
03/Frame32
- Removing the Engine Guard32
- Installing the Engine Guard32
04/Shock Absorber, Swingarm33
- Adjusting the High-Speed Compression Damping of the Shock Absorber33
- Adjusting the Low-Speed Compression Damping of the Shock Absorber33
- Adjusting the Rebound Damping of the Shock Absorber34
- Measuring Rear Wheel Sag Unloaded34
- Checking the Static Sag of the Shock Absorber34
- Checking the Riding Sag of the Shock Absorber35
- Adjusting the Spring Preload of the Shock Absorber35
- Adjusting the Riding Sag36
- Removing the Shock Absorber36
- Installing the Shock Absorber36
- Performing a Shock Absorber Service37
- Removing the Spring37
- Disassembling the Shock Absorber38
- Disassembling the Piston Rod39
- Disassembling the Seal Ring Retainer40
- Replacing the Pilot Bushing41
- Checking the Shock Absorber41
- Disassembling the Rebound Adjuster42
- Removing the Heim Joint43
- Installing the Heim Joint43
- Assembling the Rebound Adjuster44
- Assembling the Seal Ring Retainer45
- Assembling the Piston Rod45
- Assembling the Shock Absorber47
- Bleeding and Filling the Shock Absorber49
- Filling the Shock Absorber with Nitrogen51
- Installing the Spring52
- Removing the Swingarm, with Shock Absorber and Rear Wheel53
- Installing the Swingarm, with Shock Absorber and Rear Wheel54
05/Exhaust56
- Removing the Main Silencer56
- Installing the Main Silencer56
- Removing the Exhaust System56
- Installing the Exhaust System57
06/Air Filter59
- Removing the Air Filter59
- Installing the Air Filter59
- Cleaning Air Filter59
07/Fuel Tank, Seat, Trim61
- Removing the Seat61
- Mounting the Seat61
- Removing the Fuel Tank61
- Installing the Fuel Tank62
- Removing the Spoiler63
- Installing the Spoiler63
- Checking the Fuel Pressure64
08/Mask, Fender, Decal65
- Removing the Front Fender65
- Installing the Front Fender65
- Removing the Start Number Plate (FE USA)65
- Installing the Start Number Plate (FE USA)66
09/Front Wheel67
- Removing the Front Wheel67
- Installing the Front Wheel67
- Checking the Tire Air Pressure68
- Checking the Tire Condition68
- Checking the Brake Disks69
10/Rear Wheel70
- Removing the Rear Wheel70
- Installing the Rear Wheel70
- Checking the Chain Tension71
- Adjusting the Chain Tension71
- Checking the Chain Wear72
- Checking the Rear Sprocket/Engine Sprocket for Wear73
- Checking for Chain Dirt Accumulation73
- Cleaning the Chain73
- Adjusting the Chain Guide74
- Checking the Spoke Tension74
11/Wiring Harness, Battery75
- Disconnecting the Negative Cable of the Battery75
- Connecting the Negative Cable of the Battery75
- Changing the Main Fuse75
- Changing the Fuses of Individual Power Consumers76
- Removing the Battery77
- Installing the Battery77
- Charging the Battery78
13/Brake System80
- Checking the Free Travel of the Hand Brake Lever80
- Adjusting the Free Travel of the Handbrake Lever80
- Fe Aus)80
- Adjusting the Basic Position of the Handbrake Lever80
- (Fe Usa)80
- Checking the Front Brake Fluid Level81
- Adding Front Brake Fluid81
- Checking the Front Brake Linings82
- Changing the Front Brake Linings82
- Checking the Free Travel of the Foot Brake Lever84
- Adjusting the Basic Position of the Footbrake Lever84
- Checking the Rear Brake Fluid Level85
- Adding Rear Brake Fluid85
- Checking the Rear Brake Linings86
- Changing the Rear Brake Linings86
14/Lighting System, Instruments88
- Adjusting the Speedometer Functions88
- Setting Kilometers or Miles88
- Activating the Additional Functions89
- Setting the Wheel Circumference89
- Setting the Clock90
- Removing the Headlight Mask with the Headlight (FE EU, FE AUS)90
- Installing the Headlight Mask with the Headlight (FE EU, FE AUS)90
- Checking the Headlight Adjustment (FE EU, FE AUS)91
- Adjusting the Beam Width of the Headlight (FE EU, FE AUS)91
- Changing the Headlight Bulb (FE EU, FE AUS)91
30/Engine93
- Removing the Engine93
- Installing the Engine96
30/Engine Disassembly101
- Clamping the Engine in the Engine Work Stand101
- Draining the Engine Oil101
- Removing the Oil Line101
- Removing the Starter Motor101
- Removing the Oil Filter101
- Removing the Valve Cover102
- Removing the Spark Plug102
- Removing the Generator Cover102
- Positioning the Engine at Ignition Top Dead Center (TDC)102
- Removing the Timing Chain Tensioner103
- Removing the Camshaft103
- Removing the Cylinder Head104
- Removing the Piston104
- Removing the Distance Bushing104
- Removing the Rotor105
- Removing the Balance Weight105
- Removing the Timing Chain Guide Rail105
- Removing the Timing Chain Tensioning Rail105
- Removing the Timing Chain Securing Guide106
- Removing the Timing Chain106
- Removing the Ignition Pulse Generator106
- Removing the Water Pump Cover106
- Removing the Clutch Cover106
- Disassembling the Clutch Disks107
- Removing the Primary Gear Nut107
- Removing the Outer Clutch Hub108
- Removing the Balancer Shaft108
- Removing the Primary Gear108
- Removing the Free Wheel Gear109
- Removing the Torque Limiter109
- Removing the Starter Idler Gear109
- Removing the Oil Pump Gears109
- Removing the Oil Pumps110
- Removing the Shift Shaft110
- Removing the Shift Drum Locating Unit110
- Removing the Locking Lever110
- Removing the Left Section of the Engine Case111
- Removing the Shift Rails111
- Removing the Shift Drum111
- Removing the Shift Forks111
- Removing the Diaphragm112
- Removing the Transmission Shafts112
- Removing the Crankshaft112
30/Engine - Work on the Individual Parts113
- Working on the Right Section of the Engine Case113
- Working on the Left Section of the Engine Case114
- Removing the Oil Pressure Regulator Valve115
- Checking the Spring Length of the Oil Pressure Regulator Valve115
- Installing the Oil Pressure Regulator Valve115
- Removing the Crankshaft Seal Ring in the Clutch Cover115
- Installing the Crankshaft Seal Ring in the Clutch Cover116
- Removing the Water Pump116
- Installing the Water Pump117
- Checking the Balancer Shaft117
- Removing the Timing Chain Sprocket118
- Installing the Timing Chain Sprocket118
- Removing the Crankshaft Bearing Inner Ring118
- Installing the Crankshaft Bearing Inner Ring119
- Changing the Conrod Bearing119
- Checking the Crankshaft Run-Out at the Bearing Pin121
- Measuring the Crankshaft End Play121
- Checking/Measuring the Cylinder122
- Checking/Measuring the Piston122
- Checking the Piston Ring End Gap123
- Piston/Cylinder - Determining the Mounting Clearance123
- Checking the Oil Pumps for Wear124
- Disassembling the Autodecompressor124
- Assembling the Autodecompressor125
- Checking the Camshaft125
- Checking the Timing Assembly126
- Preparing the Timing Chain Tensioner for Installation126
- Removing the Coolant Temperature Sensor127
- Removing the Rocker Arm127
- Removing the Valves127
- Changing the Camshaft Bearing128
- Checking the Valves129
- Checking the Valve Springs129
- Checking the Valve Spring Seat129
- Checking the Cylinder Head130
- Installing the Valves130
- Installing the Rocker Arm131
- Installing the Coolant Temperature Sensor131
- Checking the Clutch132
- Checking the Shift Mechanism133
- Preassembling the Shift Shaft134
- Disassembling the Main Shaft134
- Assembling the Main Shaft134
- Disassembling the Countershaft135
- Assembling the Countershaft135
- Checking the Transmission136
- Checking the Electric Starter Mode137
- Removing the Free Wheel137
- Installing the Free Wheel138
30/Engine Assembly139
- Installing the Crankshaft139
- Installing the Transmission Shafts139
- Installing the Diaphragm139
- Installing the Shift Fork140
- Installing the Shift Drum140
- Installing the Shift Rails140
- Installing the Left Engine Case140
- Installing the Locking Lever141
- Installing the Shift Drum Locating Unit141
- Installing the Shift Shaft141
- Installing the Oil Pumps142
- Installing the Oil Pump Gears142
- Installing the Starter Idler Gear142
- Installing the Torque Limiter143
- Installing the Free Wheel Gear143
- Installing the Primary Gear143
- Installing the Balancer Shaft143
- Installing the Outer Clutch Hub143
- Installing the Primary Gear Nut144
- Installing the Clutch Discs144
- Installing the Clutch Cover145
- Installing the Water Pump Cover145
- Installing the Ignition Pulse Generator145
- Installing the Timing Chain146
- Installing the Timing Chain Securing Guide146
- Installing the Timing Chain Tensioning Rail146
- Installing the Timing Chain Guide Rail146
- Installing the Balance Weight146
- Installing the Rotor147
- Installing the Distance Bushing147
- Installing the Piston147
- Installing the Cylinder Head149
- Installing the Camshaft150
- Installing the Timing Chain Tensioner150
- Checking the Valve Clearance150
- Adjusting the Valve Clearance151
- Installing the Generator Cover151
- Installing the Spark Plug152
- Installing the Valve Cover152
- Installing the Oil Filter152
- Installing the Oil Screen152
- Assembling the Starter Motor153
- Installing the Oil Line153
- Removing the Engine from the Work Stand153
32/Clutch154
- Checking the Fluid Level of the Hydraulic Clutch154
- Changing the Hydraulic Clutch Fluid154
35/Water Pump, Cooling System156
- Checking the Coolant Level156
- Checking the Antifreeze and Coolant Level156
- Draining the Coolant157
- Refilling Coolant157
38/Lubrication System158
- Oil Circuit158
- Checking the Engine Oil Pressure158
- Checking the Engine Oil Level160
- Adding Engine Oil160
- Changing the Engine Oil and Oil Filter, Cleaning the Engine Oil Screen160
- Draining Engine Oil, Cleaning Engine Oil Screen160
- Removing the Oil Filter161
- Installing the Oil Filter162
- Filling up with Engine Oil162
41/Throttle Valve Body163
- Idle Speed Adjusting Screw163
- Taking off the Throttle Valve Body and Allowing It to Hang to the Side163
- Installing the Throttle Valve Body164
- Adjusting the Idle Speed165
Fault Code166
Technical Data - Engine221
- Capacity - Engine Oil221
- Capacity - Coolant221
Technical Data - Engine Tolerances, Wear Limits222
Technical Data - Engine Tightening Torques224
Technical Data - Chassis226
- Lighting Equipment226
- Tires227
- Capacity - Fuel227
Technical Data - Fork228
Technical Data - Shock Absorber229
Technical Data - Chassis Tightening Torques230
Cleaning/Protection231
- Cleaning the Motorcycle231
- Protection for Winter Operation232
Storage233
- Putting into Operation after Storage233
Service Schedule234
- Important Maintenance Work to be Carried out by an Authorized HUSABERG Workshop234
- Important Maintenance Work to be Carried out by an Authorized HUSABERG Workshop. (as Additional Order)235
- Important Checks and Maintenance Work to be Carried out by the Rider236
Wiring Diagram238
- Of 3 (FE EU)238
- Of 3 (FE EU)240
- Of 3 (FE EU)244
- Of 3 (FE USA)248
- Of 3 (FE USA)250
- Of 3 (FE USA)254
- Of 3 (FE AUS)256
- Of 3 (FE AUS)258
- Of 3 (FE AUS)262
Substances265
Auxiliary Substances267
Special Tools269
Standards280
Index281

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