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HUSABERG FE 450 User Manual

HUSABERG FE 450
116 pages
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REPARATURANLEITUNG
REPAIR MANUAL
MANUEL DE REPARATION
04
Edition 2004

Table of Contents

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HUSABERG FE 450 Specifications

General IconGeneral
Engine TypeSingle cylinder, 4-stroke
Displacement449.3 cc
Bore x Stroke95 mm x 63.4 mm
Compression Ratio11.8:1
StarterElectric starter
Transmission6-speed
LubricationPressure lubrication with 2 oil pumps
CoolingLiquid cooling
Fuel SystemKeihin EFI
IgnitionDigital CDI

Summary

REPARATURANLEITUNG / REPAIR MANUAL / MANUEL DE REPARATION

Edition 2004

Specifies the edition year of the repair manual.

GENERAL INFORMATION

OIL CIRCUIT

Diagram and description of the engine's oil circulation system.

ENGINE OIL

Recommendations for using fully synthetic engine oils meeting Jaso T903 MA standards.

CHANGING THE ENGINE OIL

Steps to change the engine oil, including replacing the oil screen and filter.

CHANGING THE OIL FILTER

Detailed steps for removing and replacing the oil filter element and cover.

BLEEDING THE CLUTCH

Steps for bleeding the hydraulic clutch system to remove air.

STORAGE

Procedures for immobilizing the motorcycle for extended periods.

SPECIAL TOOLS - ENGINE

Illustrations and identification of special tools for engine work.

DISMOUNTING AND MOUNTING THE ENGINE

DISMOUNTING THE ENGINE

Step-by-step guide to removing the engine from the motorcycle frame.

MOUNTING THE ENGINE

Initial steps for reinstalling the engine into the frame.

BLEEDING THE COOLING SYSTEM

Procedure for bleeding air from the cooling system.

ADJUSTING THE THROTTLE CABLES

Steps to adjust the throttle cables for correct free travel.

DISASSEMBLING THE ENGINE

LOCKING THE ENGINE

Procedure to lock the engine's crankshaft using a locking bolt.

REMOVING THE ROTOR

Steps to remove the engine's rotor using a special extractor.

REMOVING THE CLUTCH

Steps for disassembling the clutch, including removing the cover and clutch parts.

REMOVING THE OIL PUMP

Procedure for removing the engine's oil pump assembly.

REMOVING THE CRANKSHAFT

How to remove the crankshaft assembly from the engine case.

SERVICING THE INDIVIDUAL PARTS

IMPORTANT INFORMATION ON WORKING WITH THE ENGINE CASE

General advice and precautions for working with engine cases and bearings.

LEFT HOUSING HALF

Detailed steps and diagrams for servicing the left engine housing half.

CRANKSHAFT

Procedures for removing piston, clamping crankshaft, and removing bearings.

PRESS OUT THE CRANK PIN

Detailed steps for pressing out the crankshaft pin using a special tool.

CHECKING THE PISTON

How to check the piston for wear, damage, and ring groove clearance.

SHIFT MECHANISM

Disassembly and checks for shift forks, drum, rollers, and rails.

ASSEMBLING THE ENGINE

MOUNTING THE CRANKSHAFT

Steps for mounting the crankshaft, aligning marks on gears and weight.

MOUNTING THE CYLINDER HEAD

Procedure for mounting the cylinder head and base gasket.

MOUNTING THE TIMING CHAIN

Steps for mounting the timing chain, sprocket, and camshaft.

ADJUSTING THE VALVE CLEARANCE

Procedure for adjusting the valve clearance.

MOUNTING THE KICKSTARTER SHAFT

Steps for mounting the kickstarter shaft, spring, and related parts.

ELECTRIC SYSTEM

CHECKING FOR LOSS OF CURRENT

Procedure to check for current loss using an ammeter.

CHARGING THE BATTERY

Guidelines for checking battery charge level and charging procedures.

CHECKING THE STARTER ENGINE

Procedure to test the starter engine's functionality.

CHECKING THE VOLTAGE REGULATOR

Symptoms of a defective voltage regulator and how to test it.

TROUBLESHOOTING IN THE IGNITION SYSTEM

Steps to check for an ignition spark and identify common ignition system faults.

FUEL SYSTEM

KEIHIN FCR-MX 39/41 CARBURETOR

Exploded view diagram of the Keihin FCR-MX 39/41 carburetor.

DISASSEMBLING THE KEIHIN FCR-MX 39/41 CARBURETOR

Steps for disassembling the carburetor, including removing the slide cover.

CHECKING THE ACCELERATOR PUMP

Checking the accelerator pump diaphragm and holes.

ADJUSTING THE CARBURETOR IDLE

How to adjust idle speed and mixture using adjusting knurl and screw.

CHECKING THE FLOAT LEVEL (FLOAT HEIGHT)

Procedure to check and adjust the float level.

TROUBLESHOOTING

Engine does not switch on (starter)

Causes and remedies for an engine that won't start via starter.

Engine does not have enough power

Causes and remedies for lack of engine power.

Engine gets too hot

Causes and remedies for engine overheating.

High oil consumption

Causes and remedies for high engine oil consumption.

TECHNICAL SPECIFICATIONS - ENGINE

BASIC CARBURETOR SETTING

Basic settings for different carburetor models.

TIGHTENING TORQUES

List of tightening torques for various engine components.

MOUNTING CLEARANCES, WEAR LIMITS

Specifications for mounting clearances and wear limits of engine parts.

TECHNICAL SPECIFICATIONS - CHASSIS

STANDARD FORK ADJUSTMENT

Recommended adjustments for front fork settings.

STANDARD SHOCK ABSORBER ADJUSTMENT

Recommended adjustments for rear shock absorber settings.

TIGHTENING TORQUES

List of tightening torques for various chassis components.

PERIODIC MAINTENANCE SCHEDULE

FC 450/4, FC 550/4 MODEL 2004

Maintenance schedule for FC models based on service hours or fuel consumption.

IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER

Rider-performed checks and maintenance tasks before, during, and after rides.

WIRING DIAGRAMS

Husaberg FC 04

Wiring diagram for Husaberg FC 04 model.

Husaberg FE 04

Wiring diagram for Husaberg FE 04 model.

Cable colours

Key to cable color codes used in wiring diagrams.

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