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FE 570 EU
HUSABERG FE 570 EU User Manual
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SPECIAL
T
OOLS
273
Separator
plate
500169-01
Art.
no.:
78029009000
Valve
spring
mo
unting
device
500165-01
Art.
no.:
78029060000
Gear
segment
500164-01
Art.
no.:
80029004000
Fitting
for
work
st
and
500281-01
Art.
no.:
81229002000
Work
stand
500280-01
Art.
no.:
81229055000
274
276
Table of Contents
Table of Contents
4
Means of Representation
7
Important Notes
8
Location of Serial Numbers
9
Chassis Number
9
Type Label (FE EU, FE AUS)
9
Type Label (FE USA)
9
Key Number (FE EU, FE AUS)
9
Engine Number
9
Fork Part Number
10
Shock Absorber Part Number
10
Motorcycle
11
Jacking up the Motorcycle
11
Removing the Motorcycle from the Work Stand
11
Starting
11
01/Fork, Triple Clamp
12
Adjusting the Compression Damping of the Fork
12
Adjusting the Rebound Damping of the Fork
12
Adjusting the Spring Preload of the Fork
12
Bleeding the Fork Legs
13
Cleaning the Dust Boots of the Fork Legs
13
Loosening the Fork Protection
13
Positioning the Fork Protection
14
Removing the Fork Legs
14
Installing the Fork Legs
14
Removing the Fork Protector
15
Installing the Fork Protector
15
Performing a Fork Service
16
Disassembling the Fork Legs
16
Cartridge Disassembly
19
Disassembling the Compression Damping Fitting
21
Checking the Fork Legs
21
Assembling the Compression Damping Fitting
22
Assembling the Cartridge
23
Assembling the Fork Legs
25
Greasing the Steering Head Bearing
29
Removing the Lower Triple Clamp
29
Installing the Lower Triple Clamp
30
Checking the Play of the Steering Head Bearing
31
Adjusting the Play of the Steering Head Bearing
31
03/Frame
32
Removing the Engine Guard
32
Installing the Engine Guard
32
04/Shock Absorber, Swingarm
33
Adjusting the High-Speed Compression Damping of the Shock Absorber
33
Adjusting the Low-Speed Compression Damping of the Shock Absorber
33
Adjusting the Rebound Damping of the Shock Absorber
34
Measuring Rear Wheel Sag Unloaded
34
Checking the Static Sag of the Shock Absorber
34
Checking the Riding Sag of the Shock Absorber
35
Adjusting the Spring Preload of the Shock Absorber
35
Adjusting the Riding Sag
36
Removing the Shock Absorber
36
Installing the Shock Absorber
36
Performing a Shock Absorber Service
37
Removing the Spring
37
Disassembling the Shock Absorber
38
Disassembling the Piston Rod
39
Disassembling the Seal Ring Retainer
40
Replacing the Pilot Bushing
41
Checking the Shock Absorber
41
Disassembling the Rebound Adjuster
42
Removing the Heim Joint
43
Installing the Heim Joint
43
Assembling the Rebound Adjuster
44
Assembling the Seal Ring Retainer
45
Assembling the Piston Rod
45
Assembling the Shock Absorber
47
Bleeding and Filling the Shock Absorber
49
Filling the Shock Absorber with Nitrogen
51
Installing the Spring
52
Removing the Swingarm, with Shock Absorber and Rear Wheel
53
Installing the Swingarm, with Shock Absorber and Rear Wheel
54
05/Exhaust
56
Removing the Main Silencer
56
Installing the Main Silencer
56
Removing the Exhaust System
56
Installing the Exhaust System
57
06/Air Filter
59
Removing the Air Filter
59
Installing the Air Filter
59
Cleaning Air Filter
59
07/Fuel Tank, Seat, Trim
61
Removing the Seat
61
Mounting the Seat
61
Removing the Fuel Tank
61
Installing the Fuel Tank
62
Removing the Spoiler
63
Installing the Spoiler
63
Checking the Fuel Pressure
64
08/Mask, Fender, Decal
65
Removing the Front Fender
65
Installing the Front Fender
65
Removing the Start Number Plate (FE USA)
65
Installing the Start Number Plate (FE USA)
66
09/Front Wheel
67
Removing the Front Wheel
67
Installing the Front Wheel
67
Checking the Tire Air Pressure
68
Checking the Tire Condition
68
Checking the Brake Disks
69
10/Rear Wheel
70
Removing the Rear Wheel
70
Installing the Rear Wheel
70
Checking the Chain Tension
71
Adjusting the Chain Tension
71
Checking the Chain Wear
72
Checking the Rear Sprocket/Engine Sprocket for Wear
73
Checking for Chain Dirt Accumulation
73
Cleaning the Chain
73
Adjusting the Chain Guide
74
Checking the Spoke Tension
74
11/Wiring Harness, Battery
75
Disconnecting the Negative Cable of the Battery
75
Connecting the Negative Cable of the Battery
75
Changing the Main Fuse
75
Changing the Fuses of Individual Power Consumers
76
Removing the Battery
77
Installing the Battery
77
Charging the Battery
78
13/Brake System
80
Checking the Free Travel of the Hand Brake Lever
80
Adjusting the Free Travel of the Handbrake Lever
80
Fe Aus)
80
Adjusting the Basic Position of the Handbrake Lever
80
(Fe Usa)
80
Checking the Front Brake Fluid Level
81
Adding Front Brake Fluid
81
Checking the Front Brake Linings
82
Changing the Front Brake Linings
82
Checking the Free Travel of the Foot Brake Lever
84
Adjusting the Basic Position of the Footbrake Lever
84
Checking the Rear Brake Fluid Level
85
Adding Rear Brake Fluid
85
Checking the Rear Brake Linings
86
Changing the Rear Brake Linings
86
14/Lighting System, Instruments
88
Adjusting the Speedometer Functions
88
Setting Kilometers or Miles
88
Activating the Additional Functions
89
Setting the Wheel Circumference
89
Setting the Clock
90
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/Engine
93
Removing the Engine
93
Installing the Engine
96
30/Engine Disassembly
101
Clamping the Engine in the Engine Work Stand
101
Draining the Engine Oil
101
Removing the Oil Line
101
Removing the Starter Motor
101
Removing the Oil Filter
101
Removing the Valve Cover
102
Removing the Spark Plug
102
Removing the Generator Cover
102
Positioning the Engine at Ignition Top Dead Center (TDC)
102
Removing the Timing Chain Tensioner
103
Removing the Camshaft
103
Removing the Cylinder Head
104
Removing the Piston
104
Removing the Distance Bushing
104
Removing the Rotor
105
Removing the Balance Weight
105
Removing the Timing Chain Guide Rail
105
Removing the Timing Chain Tensioning Rail
105
Removing the Timing Chain Securing Guide
106
Removing the Timing Chain
106
Removing the Ignition Pulse Generator
106
Removing the Water Pump Cover
106
Removing the Clutch Cover
106
Disassembling the Clutch Disks
107
Removing the Primary Gear Nut
107
Removing the Outer Clutch Hub
108
Removing the Balancer Shaft
108
Removing the Primary Gear
108
Removing the Free Wheel Gear
109
Removing the Torque Limiter
109
Removing the Starter Idler Gear
109
Removing the Oil Pump Gears
109
Removing the Oil Pumps
110
Removing the Shift Shaft
110
Removing the Shift Drum Locating Unit
110
Removing the Locking Lever
110
Removing the Left Section of the Engine Case
111
Removing the Shift Rails
111
Removing the Shift Drum
111
Removing the Shift Forks
111
Removing the Diaphragm
112
Removing the Transmission Shafts
112
Removing the Crankshaft
112
30/Engine - Work on the Individual Parts
113
Working on the Right Section of the Engine Case
113
Working on the Left Section of the Engine Case
114
Removing the Oil Pressure Regulator Valve
115
Checking the Spring Length of the Oil Pressure Regulator Valve
115
Installing the Oil Pressure Regulator Valve
115
Removing the Crankshaft Seal Ring in the Clutch Cover
115
Installing the Crankshaft Seal Ring in the Clutch Cover
116
Removing the Water Pump
116
Installing the Water Pump
117
Checking the Balancer Shaft
117
Removing the Timing Chain Sprocket
118
Installing the Timing Chain Sprocket
118
Removing the Crankshaft Bearing Inner Ring
118
Installing the Crankshaft Bearing Inner Ring
119
Changing the Conrod Bearing
119
Checking the Crankshaft Run-Out at the Bearing Pin
121
Measuring the Crankshaft End Play
121
Checking/Measuring the Cylinder
122
Checking/Measuring the Piston
122
Checking the Piston Ring End Gap
123
Piston/Cylinder - Determining the Mounting Clearance
123
Checking the Oil Pumps for Wear
124
Disassembling the Autodecompressor
124
Assembling the Autodecompressor
125
Checking the Camshaft
125
Checking the Timing Assembly
126
Preparing the Timing Chain Tensioner for Installation
126
Removing the Coolant Temperature Sensor
127
Removing the Rocker Arm
127
Removing the Valves
127
Changing the Camshaft Bearing
128
Checking the Valves
129
Checking the Valve Springs
129
Checking the Valve Spring Seat
129
Checking the Cylinder Head
130
Installing the Valves
130
Installing the Rocker Arm
131
Installing the Coolant Temperature Sensor
131
Checking the Clutch
132
Checking the Shift Mechanism
133
Preassembling the Shift Shaft
134
Disassembling the Main Shaft
134
Assembling the Main Shaft
134
Disassembling the Countershaft
135
Assembling the Countershaft
135
Checking the Transmission
136
Checking the Electric Starter Mode
137
Removing the Free Wheel
137
Installing the Free Wheel
138
30/Engine Assembly
139
Installing the Crankshaft
139
Installing the Transmission Shafts
139
Installing the Diaphragm
139
Installing the Shift Fork
140
Installing the Shift Drum
140
Installing the Shift Rails
140
Installing the Left Engine Case
140
Installing the Locking Lever
141
Installing the Shift Drum Locating Unit
141
Installing the Shift Shaft
141
Installing the Oil Pumps
142
Installing the Oil Pump Gears
142
Installing the Starter Idler Gear
142
Installing the Torque Limiter
143
Installing the Free Wheel Gear
143
Installing the Primary Gear
143
Installing the Balancer Shaft
143
Installing the Outer Clutch Hub
143
Installing the Primary Gear Nut
144
Installing the Clutch Discs
144
Installing the Clutch Cover
145
Installing the Water Pump Cover
145
Installing the Ignition Pulse Generator
145
Installing the Timing Chain
146
Installing the Timing Chain Securing Guide
146
Installing the Timing Chain Tensioning Rail
146
Installing the Timing Chain Guide Rail
146
Installing the Balance Weight
146
Installing the Rotor
147
Installing the Distance Bushing
147
Installing the Piston
147
Installing the Cylinder Head
149
Installing the Camshaft
150
Installing the Timing Chain Tensioner
150
Checking the Valve Clearance
150
Adjusting the Valve Clearance
151
Installing the Generator Cover
151
Installing the Spark Plug
152
Installing the Valve Cover
152
Installing the Oil Filter
152
Installing the Oil Screen
152
Assembling the Starter Motor
153
Installing the Oil Line
153
Removing the Engine from the Work Stand
153
32/Clutch
154
Checking the Fluid Level of the Hydraulic Clutch
154
Changing the Hydraulic Clutch Fluid
154
35/Water Pump, Cooling System
156
Checking the Coolant Level
156
Checking the Antifreeze and Coolant Level
156
Draining the Coolant
157
Refilling Coolant
157
38/Lubrication System
158
Oil Circuit
158
Checking the Engine Oil Pressure
158
Checking the Engine Oil Level
160
Adding Engine Oil
160
Changing the Engine Oil and Oil Filter, Cleaning the Engine Oil Screen
160
Draining Engine Oil, Cleaning Engine Oil Screen
160
Removing the Oil Filter
161
Installing the Oil Filter
162
Filling up with Engine Oil
162
41/Throttle Valve Body
163
Idle Speed Adjusting Screw
163
Taking off the Throttle Valve Body and Allowing It to Hang to the Side
163
Installing the Throttle Valve Body
164
Adjusting the Idle Speed
165
Fault Code
166
Technical Data - Engine
221
Capacity - Engine Oil
221
Capacity - Coolant
221
Technical Data - Engine Tolerances, Wear Limits
222
Technical Data - Engine Tightening Torques
224
Technical Data - Chassis
226
Lighting Equipment
226
Tires
227
Capacity - Fuel
227
Technical Data - Fork
228
Technical Data - Shock Absorber
229
Technical Data - Chassis Tightening Torques
230
Cleaning/Protection
231
Cleaning the Motorcycle
231
Protection for Winter Operation
232
Storage
233
Putting into Operation after Storage
233
Service Schedule
234
Important Maintenance Work to be Carried out by an Authorized HUSABERG Workshop
234
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 Rider
236
Wiring Diagram
238
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
Substances
265
Auxiliary Substances
267
Special Tools
269
Standards
280
Index
281
4
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HUSABERG FE 570 EU Specifications
General
Brand
HUSABERG
Model
FE 570 EU
Category
Motorcycle
Language
English
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