HUSABERG FE 550 Repair Manual

REPARATURANLEITUNG
REPAIR MANUAL
MANUEL DE REPARATION
“
04
Edition 2004

HUSABERG FE 550 Specifications

General

Displacement	549.1cc
Fuel system	Keihin FCR-MX 41
Cooling system	Liquid-cooled
Starter	Electric starter
Transmission	6 speed
Engine type	Single cylinder, 4-stroke

Summary

General Information

Special Tools for Engine Service

Illustrated list of specialized tools required for engine maintenance.

Engine Removal and Installation

Engine Dismounting Procedure

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

Engine Mounting Procedure

Step-by-step guide to installing the engine back into the frame.

Engine Disassembly

Engine Locking and Rotor Removal

Steps to lock the engine and remove the rotor assembly.

Clutch and Transmission Disassembly

Procedures for removing the clutch and transmission components.

Crankshaft and Housing Separation

Engine Assembly

Crankshaft and Cylinder Head Installation

Timing Chain and Valve Clearance

Drive Components Assembly

Troubleshooting

Starting System Issues

Technical Specifications - Engine (Torques)

Engine Tightening Torques

List of critical bolt tightening torques for engine components.

Technical Specifications - Chassis (Torques)

Chassis Tightening Torques

List of critical bolt tightening torques for chassis components.

Technical Specifications - Engine (Limits)

Mounting Clearances and Wear Limits

Specifications for component clearances and wear limits.

Periodic Maintenance Schedule

Periodic Maintenance Schedule (Rider)

Rider Checks and Maintenance

Routine checks and maintenance tasks for the rider.

Periodic Maintenance Schedule (Competition)

Competition Engine Inspection Schedule

Wiring Diagrams

FE 04 Model Wiring Diagram

Electrical wiring diagram for FE 04 models.

FE USA 04 Model Wiring Diagram

Electrical wiring diagram for FE USA 04 models.

FS 04 Model Wiring Diagram

Electrical wiring diagram for FS 04 models.