Husqvarna FE 450 2014

To Next Page

PIONEERING SINCE 1903

REPAIR MANUAL2014

FE 450

FE 501

Art. no. 3403003en

Husqrna

MOTORCYCLES

Main Page

Table of Contents4
Removing the Shift Rails6
Means of Representation9
Symbols Used9
Formats Used9
Safety Advice10
Repair Manual10
Degrees of Risk and Symbols10
Work Rules10
Important Notes11
Manufacturer and Implied Warranty11
Operating and Auxiliary Substances11
Spare Parts, Accessories11
Figures11
Serial Numbers12
Chassis Number12
Key Number (FE EU/AU)12
Engine Number12
Fork Part Number13
Shock Absorber Article Number13
Motorcycle14
Raising the Motorcycle with a Lift Stand14
Removing the Motorcycle from the Lift Stand14
Starting14
Starting the Motorcycle for a Check15
Fork, Triple Clamp16
Adjusting the Compression Damping of the Fork16
Adjusting the Rebound Damping of 9 the Fork16
Bleeding the Fork Legs17
Cleaning the Dust Boots of the Fork Legs17
Loosening the Fork Protector18
Positioning the Fork Protector18
Removing the Fork Legs18
Installing the Fork Legs19
Removing the Fork Protector20
Installing the Fork Protector20
Performing a Fork Service20
Removing the Spring23
Disassembling the Cartridge24
Disassembling the Piston Rod26
Disassembling the Hydrostop Unit27
Disassembling the Seal Ring Retainer28
Checking the Fork Legs28
Assembling the Seal Ring Retainer30
Assembling the Hydrostop Unit30
Assembling the Piston Rod31
Assembling the Cartridge32
Assembling the Fork Legs34
Lubricating the Steering Head Bearing38
Removing the Lower Triple Clamp39
Installing the Lower Triple Clamp40
Checking the Play of the Steering Head Bearing42
Changing the Steering Head Bearing42
Adjusting the Steering Head Bearing Play44
7 Handlebar,Controls45
Handlebar Position45
Adjusting the Handlebar Position45
Adjusting the Basic Position of the Clutch Lever46
Checking the Routing of the Throttle Cable46
Checking the Play in the Throttle Cable47
Adjusting the Play in the Throttle Cable47
Frame49
Removing the Engine Guard49
Installing the Engine Guard49
Checking the Frame49
Shock Absorber, Swingarm50
Adjusting the High-Speed Compression Damping of the Shock Absorber50
Adjusting the Low-Speed Compression Damping of the Shock Absorber50
Adjusting the Rebound Damping of the Shock Absorber51
Measuring Rear Wheel Sag Unloaded52
Checking the Static Sag of the Shock Absorber52
Checking the Riding Sag of the Shock Absorber53
Adjusting the Spring Preload of the Shock Absorber53
Adjusting the Riding Sag54
Removing the Shock Absorber55
Installing the Shock Absorber56
Checking the Shock Absorber Linkage56
Servicing the Shock Absorber58
Removing the Spring59
Disassembling the Damper60
Disassembling the Piston Rod61
Disassembling the Seal Ring Retainer62
Changing the Pilot Bushing63
Checking the Damper64
Removing the Heim Joint65
Installing the Heim Joint66
Assembling Seal Ring Retainer66
Assembling the Piston Rod67
Assembling the Damper69
Bleeding and Filling the Damper71
Filling Damper with Nitrogen74
Installing the Spring75
Checking the Swingarm76
Checking the Swingarm Bearing for Play76
Removing the Swingarm77
Installing the Swingarm78
Changing the Swingarm Bearing80
Exhaust83
Removing the Manifold83
Installing the Manifold85
Removing the Main Silencer86
Installing the Main Silencer87
Changing the Glass Fiber Yarn Filling in the Main Silencer87
11 Air Filter89
Removing the Air Filter Box Cover89
Installing the Air Filter Box Cover89
Removing the Air Filter89
Installing the Air Filter90
Cleaning the Air Filter and Air Filter Box90
Sealing the Air Filter Box91
12 Fuel Tank, Seat, Trim92
Opening Filler Cap92
Closing Filler Cap92
Removing the Right Side Cover93
Installing the Right Side Cover93
Removing the Seat93
Mounting the Seat93
Removing the Fuel Tank94
Installing the Fuel Tank95
Changing the Fuel Screen97
Changing the Fuel Filter98
Changing the Fuel Pump100
Checking the Fuel Pressure102
13 Mask, Fender104
Removing Front Fender104
Installing Front Fender104
Removing the Headlight Mask with the Headlight105
Installing the Headlight Mask with the Headlight105
14 Wheels106
Checking the Tire Air Pressure106
Checking the Tire Condition106
Checking the Wheel Bearing for Play107
Checking the Brake Discs108
Checking Spoke Tension108
Checking the Rim Run-Out109
Front Wheel110
Removing the Front Wheel110
Installing the Front Wheel111
Removing the Front Brake Disc111
Lnstalling the Front Brake Disc112
Changing Front Wheel Bearing112
Rear Wheel113
Removing the Rear Wheel113
Installing the Rear Wheel114
Removing the Rear Brake Disc115
Installing the Rear Brake Disc115
Checking the Chain Tension116
Adjusting the Chain Tension116
Checking the Chain, Rear Sprocket, Motor Sprocket, and Chain Guide117
Checking for Chain Dirt Accumulation120
Cleaning the Chain120
Changing the Drivetrain Kit120
Changing the Rear Wheel Bearing122
15 Wiring Harness, Battery125
Changing the Fuses of Individual Power Consumers125
Changing the Main Fuse126
Checking the Starter Relay126
Removing the Battery127
Installing the Battery128
Recharging the Battery128
Checking the Charging Voltage130
Checking the Open-Circuit Current130
Brake System131
Checking the Front Brake Linings131
Changing the Front Brake Linings131
Checking the Free Travel of the Hand Brake Lever133
Adjusting the Basic Position of the Hand Brake Lever (FE 501 US)134
Adjusting Free Travel of Hand Brake Lever (FE EU/ AU)134
Checking the Front Brake Fluid Level135
Adding Front Brake Fluid135
Changing the Front Brake Fluid136
Checking the Rear Brake Linings138
Changing the Rear Brake Linings138
Brake Lever141
Adjusting the Basic Position of the Foot Brake Lever142
Checking the Rear Brake Fluid Level142
Adding Rear Brake Fluid143
Changing the Rear Brake Fluid144
17 Lighting System, Instruments147
Adjusting the Combination Instrument147
Adjusting the Kilometers or Miles148
Adjusting the Clock148
Setting the Wheel Circumference149
Adjusting the Service Display149
Checking the Headlight Setting150
Adjusting the Headlight Range150
18 Engine151
Removing the Engine151
Installing the Engine156
Engine Disassembly161
Preparations161
Draining the Engine Oil161
Removing the Clutch Push Rod162
Removing the Oil Filter162
Removing the Starter Motor163
Removing the Spark Plug163
Removing the Valve Cover163
Removing the Alternator Cover164
Positioning the Engine at Ignition Top Dead Center164
Removing the Timing Chain Tensioner165
Removing the Camshaft165
Removing the Cylinder Head166
Removing the Piston166
Removing the Rotor166
Removing the Timing Chain Guide Rail167
Removing the Timing Chain Tensioning Rail167
Removing the Timing Chain Securing Guide167
Removing the Timing Chain168
Removing the Ignition Pulse Generator168
Removing the Suction Pump168
Removing the Water Pump Cover169
Removing the Clutch Cover169
Removing the Clutch Discs170
Removing the Primary Gear Nut171
Removing the Outer Clutch Hub171
Removing the Torque Limiter172
Removing the Starter Idler Gear172
Removing the Shift Shaft172
Removing the Shift Drum Locating Unit172
Removing the Locking Lever173
Removing the Oil Pump Gear Wheels173
Removing the Force Pump174
Removing the Primary Gear174
Removing the Freewheel Gear174
Removing the Left Section of the Engine Case175
Removing the Shift Drum176
Removing the Shift Forks176
Removing the Transmission Shafts176
Removing the Crankshaft177
Working on Individual Parts177
Work on the Right Section of the Engine Case177
Working on the Left Section of the Engine Case179
Removing the Oil Pressure Regulator Valve181
Checking Spring Length of Oil Pressure Regulator Valve181
Installing the Oil Pressure Regulator Valve182
Removing the Crankshaft Seal Ring in the Clutch Cover182
Installing the Crankshaft Seal Ring in the Clutch Cover182
Removing the Water Pump182
Installing the Water Pump183
Removing the Timing Chain184
Sprocket184
Installing the Timing Chain184
Changing the Connecting Rod, Conrod Bearing and Crank Pin185
Checking Crankshaft Run-Out at Bearing Pin187
Cylinder - Nikasil ® Coating187
Checking/Measuring the Cylinder187
Checking/Measuring the Piston188
Checking the Piston Ring End Gap189
Measuring the Piston/Cylinder Mounting Clearance189
Checking the Oil Pumps190
Disassembling the Autodecompressor190
Assembling the Autodecompressor191
Checking Camshaft192
Checking the Timing Assembly192
Removing the Rocker Arm193
Removing the Valves193
Changing the Camshaft194
Bearing194
Checking the Valves195
Checking Valve Springs195
Checking Valve Spring Seat196
Checking the Cylinder Head196
Checking the Rocker Arm Shafts197
Installing the Valves197
Installing the Rocker Arm198
Checking the Clutch199
Checking the Shift Mechanism200
Preassembling the Shift Shaft201
Disassembling the Main Shaft202
18.4.38 Assembling the Main Shaft202
Disassembling the Countershaft204
Assembling the Countershaft204
Checking the Transmission205
Checking the Starter Drive207
Removing the Freewheel208
Checking the Freewheel208
Installing the Freewheel208
Engine Assembly209
Installing the Crankshaft209
Installing the Transmission Shafts209
Installing the Shift Forks210
Installing the Shift Drum210
Installing the Shift Rails211
Installing the Left Engine Case211
Installing the Freewheel Gear212
Installing the Primary Gear212
Installing the Force Pump212
Installing the Oil Pump Gear Wheels213
Installing the Locking Lever213
Installing the Shift Drum Locating Unit214
Installing the Shift Shaft214
Installing the Starter Idler Gear214
Installing the Torque Limiter214
Installing the Outer Clutch Hub215
Installing the Primary Gear Nut215
Installing the Clutch Discs216
Installing the Clutch Cover218
Installing the Water Pump Cover218
Installing the Suction Pump219
Installing the Ignition Pulse Generator219
Installing the Timing Chain220
Installing the Timing Chain Securing Guide220
Installing the Timing Chain Tensioning Rail220
Installing the Timing Chain Guide Rail220
Installing the Rotor221
Installing the Piston221
Installing the Cylinder Head223
Installing the Camshaft224
Installing the Timing Chain Tensioner224
Checking the Valve Clearance225
Adjusting the Valve Clearance225
Installing the Alternator Cover226
Installing the Valve Cover226
Installing the Spark Plug227
Installing the Starter Motor227
Installing the Oil Filter227
Installing the Clutch Push Rod228
Installing the Oil Screen228
Removing the Engine from the Engine Assembly Stand229
19 Clutch230
Checking/Correcting the Fluid Level230
Changing the Hydraulic Clutch Fluid231
20 Water Pump, Cooling System232
Cooling System232
Checking the Antifreeze and Coolant Level232
Checking the Coolant Level233
Draining the Coolant234
Refilling Coolant234
Lubrication System236
Oil Circuit236
Checking the Engine Oil Level236
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens237
Adding Engine Oil239
Checking the Engine Oil Pressure240
22 Ignition System242
Ignition Coil - Checking the242
Secondary Winding242
Checking the Spark Plug Connector242
Winding242
Removing the Stator243
Installing the Stator244
23 Electric Starter245
Checking the Starter Motor245
Throttle Valve Body246
Adjusting the Idle Speed246
Executing the Initialization Run246
25 Technical Data248
Engine248
Tolerance, Engine Wear Limits249
Engine Tightening Torques250
Capacities252
Engine Oil252
Coolant252
Fuel252
Chassis252
Electrical System253
Tires253
Fork254
Shock Absorber254
Chassis Tightening Torques255
26 Cleaning, Care257
Cleaning the Motorcycle257
Checks and Maintenance Steps for Winter Operation258
27 Storage259
Preparing for Use after Storage260
28 Service Schedule261
Service Work (as Additional Order)262
Fe Eu)264
29 Wiring Diagram265
Fe Eu)266
Fe Eu)268
Fe Eu)270
Fe Eu)272
Fe Eu)274
Fe Eu)276
Fe Eu)278
Fe Au)280
Fe Au)282
Fe Au)284
Fe Au)286
Fe Au)288
Fe Au)290
Fe Au)292
Fe Au)294
Fe 501 Us)296
Fe 501 Us)298
Fe 501 Us)300
Fe 501 Us)302
Fe 501 Us)304
Fe 501 Us)306
30 Substances308
Auxiliary Substances310
32 Special Tools312
Standards329
34 List of Abbreviations330
Index331

Brand	Husqvarna
Model	FE 450 2014
Category	Motorcycle
Language	English

Husqvarna FE 450 2014 - User Manual

Table of Contents

Husqvarna FE 450 2014 Specifications

Related product manuals