Husqvarna FC 450 2014

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PIONEERING SINCE 1903

REPAIR MANUAL2014

FC 450 EU

Art. no. 3403000en

Husqrna

MOTORCYCLES

Main Page

Table of Contents4
Means of Representation8
Symbols Used8
Formats Used8
Safety Advice9
Repair Manual9
Degrees of Risk and Symbols9
Work Rules9
Important Notes10
Manufacturer and Implied Warranty10
Operating and Auxiliary Substances10
Spare Parts, Accessories10
Figures10
Serial Numbers11
Chassis Number11
Type Label11
Engine Number11
Fork Part Number11
Shock Absorber Article Number11
Motorcycle12
Raising the Motorcycle with a Lift Stand12
Removing the Motorcycle from the Lift Stand12
Starting12
Starting the Motorcycle for a Check13
Fork, Triple Clamp14
Adjusting the Compression Damping of the 9.8 Fork14
Adjusting the Rebound Damping of the Fork14
Bleeding the Fork Legs14
Cleaning the Dust Boots of the Fork Legs15
Loosening the Fork Protection15
Positioning the Fork Protection15
Removing the Fork Legs16
Installing the Fork Legs16
Removing the Fork Protector17
Installing the Fork Protector17
Conducting Major Fork Service17
Conducting Minor Fork Service18
Disassembling the Fork Legs18
Disassembling the Cartridge21
Disassembling the Piston Rod23
Disassembling the Screw Cap with the Membrane Holder24
Disassembling the Screw Sleeve25
Checking the Fork Legs26
Checking the Fork Legs - During a Minor Fork Service27
Changing the Pilot Bushing28
Assembling the Screw Sleeve29
Assembling the Screw Cap with the Membrane Holder29
Assembling the Piston Rod30
Assembling the Cartridge32
Assembling the Fork Legs33
Bleeding and Filling the Cartridge36
Filling the Cartridge with Nitrogen38
Greasing the Steering Head Bearing39
Removing the Lower Triple Clamp39
Installing the Lower Triple Clamp40
Checking the Steering Head Bearing Play41
Changing the Steering Head Bearing42
Adjusting the Steering Head Bearing Play43
Handlebar,Controls44
Handlebar Position44
Adjusting the Handlebar Position44
Adjusting the Basic Position of the Clutch Lever44
Checking the Throttle Cable Routing45
Checking the Play in the Throttle Cable46
Adjusting the Play in the Throttle Cable46
Frame47
Checking the Frame47
Shock Absorber, Swingarm48
Adjusting the High-Speed Compression Damping of the Shock Absorber48
Adjusting the Low-Speed Compression Damping of the Shock Absorber48
Adjusting the Rebound Damping of the Shock Absorber49
Measuring Rear Wheel Sag Unloaded49
Checking the Static Sag of the Shock Absorber49
Checking the Riding Sag of the Shock Absorber50
Adjusting the Spring Preload of the Shock Absorber50
Adjusting the Riding Sag51
Removing the Shock Absorber51
Installing the Shock Absorber52
Checking the Shock Absorber Linkage53
Clearance54
Servicing the Shock Absorber55
Removing the Spring56
Disassembling the Damper56
Disassembling the Piston Rod57
Disassembling the Seal Ring Retainer58
Changing the Pilot Bushing59
Checking the Damper60
Removing the Heim Joint60
Installing the Heim Joint61
Assembling the Seal Ring Retainer62
Assembling the Piston Rod63
Assembling the Damper64
Bleeding and Filling the Damper66
Filling the Damper with Nitrogen68
Installing the Spring69
Checking the Swingarm70
Removing the Swingarm70
Installing the Swingarm71
Changing the Swingarm Bearing72
Exhaust75
Removing the Manifold75
Installing the Manifold75
Removing the Main Silencer76
Installing the Main Silencer76
Changing the Glass Fiber Yarn Filling of the Main Silencer76
Air Filter78
Removing the Air Filter Box Lid78
Installing the Air Filter Box Lid78
Removing the Air Filter78
Installing the Air Filter78
Cleaning the Air Filter and Air Filter Box79
Sealing the Air Filter Box79
Fuel Tank, Seat, Trim80
Opening the Filler Cap80
Closing the Filler Cap80
Removing the Right Side Cover80
Installing the Right Side Cover81
Removing the Seat81
Mounting the Seat81
Removing the Fuel Tank81
Installing the Fuel Tank82
Checking the Fuel Pressure83
Changing the Fuel Pump84
Changing the Fuel Filter86
Changing the Fuel Screen88
Mask, Fender90
Removing the Front Fender90
Installing the Front Fender90
Removing the Start Number Plate90
Installing the Start Number Plate91
Wheels92
Checking the Tire Air Pressure92
Checking the Tire Condition92
Checking the Brake Discs92
Checking the Spoke Tension93
Front Wheel94
Removing the Front Wheel94
Installing the Front Wheel94
Removing the Brake Disc of the Front Brake95
Installing the Brake Disc of the Front Brake95
Changing the Front Wheel Bearing95
Rear Wheel97
Removing the Rear Wheel97
Installing the Rear Wheel97
Removing the Brake Disc of the Rear Brake98
Installing the Brake Disc of the Rear Brake98
Checking the Chain Tension99
Adjusting the Chain Tension99
Make Sure that Chain Adjusters (D Are Fitted Correctly on Adjusting Screws Check the Chain Tension99
Tighten Nut99
Guideline99
Nut, Rear Wheel Spindle99
I 80 Nm (59 Lbf Ft)99
Info99
Adjusting the Chain Guide100
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide100
Enables Different Secondary Ratios with the same Chain Length100
Chain Adjusters100
Checking for Chain Dirt Accumulation102
Cleaning the Chain102
Finishing Work - Remove the Motorcycle from the Lift Stand102
Preparatory Work - Raise the Motorcycle with a Lift Stand102
Changing the Drivetrain Kit103
Remove the Rear Wheel103
Main Work103
Remove Screws103
Changing the Rear Wheel Bearing104
Guideline104
Nm Loctite (10.3 Lbf Ft)104
Finishing Work - Install the Rear Wheel106
Remove the Motorcycle from the Lift Stand106
Wiring Harness, Battery107
Changing the Main Fuse107
Removing the Battery107
Installing the Battery108
Checking the Charging Voltage108
Checking the Quiescent Current108
Checking the Capacitor109
Checking the Starter Relay109
Brake System111
Checking the Front Brake Linings111
Changing the Front Brake Linings111
Checking the Free Travel of the Hand Brake Lever112
Brake Lever113
Checking the Brake Fluid Level of the Front Brake113
Adding Front Brake Fluid114
Changing the Front Brake Fluid115
Checking the Rear Brake Linings116
Changing the Rear Brake Linings116
Checking the Free Travel of Foot Brake Lever118
Adjusting the Basic Position of the Foot Brake Lever118
Checking the Rear Brake Fluid Level118
Adding Rear Brake Fluid119
Changing the Rear Brake Fluid120
Engine122
Removing the Engine122
Installing the Engine126
Engine Disassembly131
Preparations131
Draining the Engine Oil131
Removing the Clutch Push Rod132
Removing the Oil Filter132
Removing the Starter Motor132
Removing the Spark Plug132
Removing the Valve Cover133
Removing the Alternator Cover133
Positioning the Engine at Ignition Top Dead Center133
Removing the Timing Chain Tensioner134
Removing the Camshaft134
Removing the Cylinder Head135
Removing the Piston135
Removing the Rotor136
Removing the Timing Chain136
Removing the Ignition Pulse Generator137
Removing the Suction Pump137
Removing the Water Pump Cover137
Removing the Clutch Cover138
Removing the Clutch Discs138
Removing the Outer Clutch Hub139
Removing the Torque Limiter140
Removing the Starter Idler Gear140
Removing the Shift Shaft140
Removing the Shift Drum Locating Unit140
Removing the Locking Lever141
Removing the Force Pump141
Removing the Primary Gear142
Removing the Freewheel Gear142
Removing the Left Engine Case Section142
Removing the Shift Rails143
Removing the Shift Drum143
Removing the Shift Forks143
Removing the Transmission Shafts144
Removing the Crankshaft144
Work on Individual Parts144
Work on the Right Section of the Engine Case144
Work on the Left Section of the Engine Case146
Removing the Oil Pressure Regulator Valve147
Checking Spring Length of Oil Pressure Regulator Valve147
Installing the Oil Pressure Regulator Valve148
Changing the Crankshaft Seal Ring in the Clutch Cover148
Removing the Water Pump148
Installing the Water Pump149
Removing the Timing Chain Sprocket150
Installing the Timing Chain Sprocket150
Changing the Connecting Rod, Conrod Bearing, and Crank Pin150
Checking Crankshaft Run-Out at Bearing Pin152
Cylinder - Nikasil ® Coating152
Checking/Measuring the Cylinder152
Checking/Measuring the Piston153
Checking the Piston Ring End Gap153
Measuring the Piston/Cylinder Mounting154
Checking the Oil Pumps154
Disassembling the Autodecompressor154
Assembling the Autodecompressor155
Checking Camshaft156
Checking the Timing Assembly156
Removing the Rocker Arm157
Removing the Valves157
Changing Camshaft Bearing158
Checking the Valves158
Checking Valve Springs159
Checking Valve Spring Seat159
Checking the Cylinder Head159
Checking the Rocker Arm Shafts160
Installing the Valves160
Installing the Rocker Arm161
Checking the Clutch162
Checking the Shift Mechanism163
Preassembling the Shift Shaft164
Disassembling the Main Shaft165
Disassembling the Countershaft165
Checking the Transmission166
Assembling the Main Shaft167
Assembling the Countershaft168
Checking the Starter Drive169
Checking the Freewheel169
Removing the Freewheel170
Installing the Freewheel170
Engine Assembly171
Installing the Crankshaft171
Installing the Transmission Shafts171
Installing the Shift Forks171
Installing the Shift Drum172
Installing the Shift Rails172
Installing the Left Engine Case172
Installing the Freewheel Gear173
Installing the Primary Gear173
Installing the Force Pump173
Installing the Locking Lever174
Installing the Shift Drum Locating Unit175
Installing the Shift Shaft175
Installing the Starter Idler Gear175
Installing the Torque Limiter175
17.5.15 Installing the Outer Clutch Hub175
Installing the Clutch Discs176
Installing the Clutch Cover178
Installing the Water Pump Cover179
Installing the Suction Pump179
Installing the Ignition Pulse Generator179
Installing the Timing Chain180
Installing the Rotor180
Installing the Piston180
Installing the Cylinder Head182
Installing the Camshaft183
Installing the Timing Chain Tensioner183
Checking the Valve Clearance184
Adjusting the Valve Clearance184
Installing the Alternator Cover185
Installing the Valve Cover185
Installing the Spark Plug185
Installing the Starter Motor186
Installing the Oil Filter186
Installing the Clutch Push Rod186
17.5.35 Installing the Oil Screens186
Removing the Engine from the Engine187
Assembly Stand187
Clutch188
Checking/Correcting the Fluid Level of the Hydraulic Clutch188
Changing the Hydraulic Clutch Fluid188
Water Pump, Cooling System189
Cooling System189
Checking the Antifreeze and Coolant Level189
Checking the Coolant Level190
Draining the Coolant190
Refilling Coolant191
Lubrication System192
Oil Circuit192
Checking the Engine Oil Level192
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens193
Adding Engine Oil195
Checking the Engine Oil Pressure195
Ignition System197
Winding197
Checking the Spark Plug Connector197
Alternator - Checking Stator Winding197
Removing the Stator198
Installing the Stator198
Electric Starter199
Checking the Starter Motor199
Throttle Valve Body200
Adjusting the Idle Speed200
Executing the Initialization Run200
Technical Data202
Engine202
Engine Tolerance, Wear Limits202
Engine Tightening Torques203
Capacities204
Engine Oil204
Coolant204
Fuel204
Chassis204
Electrical System205
Tires205
Fork205
Shock Absorber206
Chassis Tightening Torques206
Cleaning/Protective Treatment208
Cleaning the Motorcycle208
Storage209
Preparing for Use after Storage209
Service Schedule210
Service Work (as Additional Order)211
Wiring Diagram213
Substances218
Auxiliary Substances219
Special Tools221
Standards235
Index236

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Husqvarna FC 450 2014 Specifications

General

Brand	Husqvarna
Model	FC 450 2014
Category	Motorcycle
Language	English

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