Husqvarna FS 450 2016

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PIONEERING SINCE 1903

REPAIR MANUAL2016

FS 450

Art. no. 3403034en

Husqrna

MOTORCYCLES

Main Page

Table of Contents4
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
Type Label12
Engine Number12
Fork Part Number12
Shock Absorber Article Number13
Motorcycle14
Raising the Motorcycle with a Lift Stand14
Removing the Motorcycle from the Lift Stand14
Starting14
Starting the Motorcycle to Check the Function15
Fork, Triple Clamp16
Of the Fork16
Adjusting the Rebound Damping of the Fork16
Bleeding the Fork Legs17
Cleaning the Dust Boots of the Fork Legs17
Removing the Fork Legs18
Installing the Fork Legs18
Removing the Fork Protector19
Installing the Fork Protector19
Conducting Major Fork Service19
Conducting Minor Fork Service20
Disassembling the Fork Legs21
Disassembling the Cartridge24
Disassembling the Piston Rod26
Disassembling the Screw Cap with 9.4 the Membrane Holder28
Disassembling the Screw Sleeve29
Checking the Fork Legs29
Checking the Fork Legs - During a Minor Fork Service31
Changing the Pilot Bushing33
Assembling the Screw Sleeve34
Membrane Holder34
Assembling the Piston Rod35
Assembling the Cartridge37
Assembling the Fork Legs39
Bleeding and Filling the Cartridge43
Filling the Cartridge with Nitrogen45
Lubricating the Steering Head Bearing46
Removing the Lower Triple Clamp46
Installing the Lower Triple Clamp47
Checking the Steering Head Bearing Play49
Changing the Steering Head Bearing49
Adjusting the Steering Head Bearing51
Play51
7 Handlebar,Controls52
Handlebar Position52
Adjusting the Handlebar Position52
Adjusting the Basic Position of the Clutch Lever53
Checking the Rubber Grips53
Checking the Throttle Cable Routing53
Checking the Play in the Throttle Cable54
Adjusting the Play in the Throttle Cable55
Adjusting the Characteristic Map of the Throttle Response56
Frame58
Checking the Frame58
Changing the Footrests58
Shock Absorber, Swingarm60
Adjusting the High-Speed Compression Damping of the Shock Absorber60
Adjusting the Low-Speed Compression Damping of the Shock Absorber60
Adjusting the Rebound Damping of the Shock Absorber61
Measuring the Rear Wheel Dimension Unloaded62
Checking the Static Sag of the Shock Absorber62
Checking the Riding Sag of the Shock Absorber63
Shock Absorber63
Adjusting the Riding Sag64
Removing the Shock Absorber65
Installing the Shock Absorber66
Checking the Shock Absorber Linkage68
Servicing the Shock Absorber70
Removing the Spring71
Disassembling the Damper72
Disassembling the Piston Rod73
Disassembling the Seal Ring Retainer74
Changing the Pilot Bushing75
Checking the Damper76
Removing the Heim Joint77
Installing the Heim Joint78
Assembling Seal Ring Retainer78
Assembling the Piston Rod79
Assembling the Damper81
Bleeding and Filling the Damper83
Filling the Damper with Nitrogen86
Installing the Spring87
Checking the Swingarm88
Checking the Swingarm Bearing for Play88
Removing the Swingarm89
Installing the Swingarm90
Changing the Swingarm Bearing92
Exhaust95
Removing the Manifold95
Installing the Manifold96
Removing the Main Silencer97
Installing the Main Silencer97
Changing the Glass Fiber Yarn Filling of the Main Silencer98
11 Air Filter99
Removing the Air Filter Box Cover99
Installing the Air Filter Box Cover99
Removing the Air Filter99
Installing the Air Filter100
Cleaning the Air Filter and Air Filter Box100
Sealing the Air Filter Box101
12 Fuel Tank, Seat, Trim102
Opening the Filler Cap102
Closing the Filler Cap102
Removing the Right Side Cover103
Installing the Right Side Cover103
Removing the Seat103
Mounting the Seat104
Removing the Fuel Tank105
Installing the Fuel Tank106
Checking the Fuel Pressure108
Changing the Fuel Pump109
Changing the Fuel Filter111
Changing the Fuel Screen114
13 Mask, Fender116
Removing Front Fender116
Installing Front Fender116
Removing the Start Number Plate117
Installing the Start Number Plate117
14 Wheels118
Checking the Tire Air Pressure118
Checking the Tire Condition118
Checking the Wheel Bearing for Play119
Checking the Brake Discs120
Checking Spoke Tension120
Front Wheel121
Removing the Front Wheel121
Installing the Front Wheel122
Changing the Front Brake Disc123
Changing Front Wheel Bearing123
Checking the Rim Run-Out125
Rear Wheel125
Removing the Rear Wheel125
Installing the Rear Wheel126
Changing the Rear Brake Disc127
Checking the Chain Tension128
Adjusting the Chain Tension129
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide129
Checking for Chain Dirt Accumulation132
Cleaning the Chain132
Changing the Drivetrain Kit132
Changing the Rear Wheel Bearing134
15 Wiring Harness, Battery137
Changing the Main Fuse137
Removing the Battery138
Installing the Battery139
Recharging the Battery139
Checking the Charging Voltage141
Checking the Open-Circuit Current141
Checking the Capacitor142
Checking the Starter Relay143
16 Brake System144
Checking the Front Brake Linings144
Changing the Front Brake Linings144
Hand Brake Lever146
Checking the Front Brake Fluid Level147
Adding Front Brake Fluid147
Changing the Front Brake Fluid148
Checking the Brake Linings of the Rear Brake150
Changing the Rear Brake Linings150
Checking the Free Travel of Foot152
Brake Lever152
Adjusting the Basic Position of the Foot Brake Lever153
Checking the Rear Brake Fluid Level153
Adding Rear Brake Fluid154
Changing the Rear Brake Fluid155
17 Engine158
Removing the Engine158
Installing the Engine165
Engine Disassembly173
Preparations173
Draining the Engine Oil173
Removing the Clutch Push Rod174
Removing the Oil Filter174
Removing the Starter Motor175
Removing the Spark Plug175
Removing the Valve Cover175
Removing the Alternator Cover175
Removing the Camshaft177
Removing the Cylinder Head177
Removing the Piston178
Removing the Rotor178
Removing the Timing Chain179
Removing the Suction Pump179
Removing the Gear Position Sensor180
Removing the Water Pump Cover180
Removing the Clutch Cover181
Removing the Clutch Discs181
Removing the Outer Clutch Hub182
Removing the Torque Limiter183
Removing the Starter Idler Gear183
Removing the Force Pump183
Removing the Shift Shaft184
Removing the Shift Drum Locating Unit185
Removing the Locking Lever185
Removing the Primary Gear185
Removing the Freewheel Gear185
Removing the Left Engine Case Section186
Removing the Shift Rails187
Removing the Shift Drum187
Removing the Shift Forks187
Removing the Transmission Shafts187
Removing the Crankshaft188
Working on Individual Parts188
Working on the Right Section of the Engine Case188
Working on the Left Section of the Engine Case190
Removing the Oil Pressure Regulator Valve191
Checking Spring Length of Oil Pressure Regulator Valve191
Installing the Oil Pressure Regulator Valve192
Changing the Crankshaft Seal Ring in the Clutch Cover192
Removing the Water Pump192
Installing the Water Pump193
Removing the Crankshaft Bearing Inner Race194
Installing the Crankshaft Bearing Inner Race195
Changing the Connecting Rod, Conrod Bearing, and Crank Pin195
Checking Crankshaft Run-Out at Bearing Pin197
Measuring the Crankshaft End Play197
Cylinder - Nikasil ® Coating198
Checking/Measuring the Cylinder198
Checking/Measuring the Piston199
Checking the Piston Ring End Gap200
Measuring the Piston/Cylinder Mounting Clearance200
Checking the Oil Pumps201
Disassembling the Autodecompressor201
Assembling the Autodecompressor202
Checking Camshaft203
Checking the Timing Assembly203
Removing the Rocker Arm204
Removing the Valves204
Changing the Camshaft Bearing205
Checking the Valves206
Checking Valve Springs207
Checking Valve Spring Seat207
Checking the Cylinder Head207
Checking the Rocker Arm Shafts208
Installing the Valves208
Installing the Rocker Arm209
17.4.34 Disassembling the Antihopping Clutch210
Preassembling the Antihopping Clutch211
Checking the Clutch212
Checking the Shift Mechanism213
Preassembling the Shift Shaft214
Disassembling the Main Shaft215
Disassembling the Countershaft216
Checking the Transmission216
Assembling the Main Shaft218
17 .4.43 Assembling the Countershaft219
Checking the Starter Drive220
Checking the Freewheel221
Removing the Freewheel221
Installing the Freewheel221
Engine Assembly222
Installing the Crankshaft222
Installing the Transmission Shafts223
Installing the Shift Forks223
Installing the Shift Drum224
Installing the Shift Rails224
Installing the Left Engine Case224
Installing the Freewheel Gear225
Installing the Primary Gear225
Installing the Locking Lever226
Installing the Shift Drum Locating Unit226
Installing the Shift Shaft226
Installing the Force Pump226
Installing the Starter Idler Gear227
Installing the Torque Limiter228
Installing the Clutch Basket228
Installing the Clutch Discs229
Installing the Clutch Cover230
Installing the Water Pump Cover230
Installing the Gear Position Sensor231
Installing the Suction Pump231
Installing the Timing Chain232
Installing the Rotor232
Installing the Piston233
Installing the Cylinder Head235
Installing the Camshaft236
Installing the Timing Chain Tensioner236
Checking the Valve Clearance237
17.5.28 Adjusting the Valve Clearance238
Installing the Alternator Cover238
Installing the Valve Cover239
Installing the Spark Plug239
Installing the Starter Motor239
Installing the Oil Filter239
Installing the Clutch Push Rod240
Installing the Oil Screens240
Removing the Engine from the Engine Assembly Stand241
18 Clutch242
Checking/Correcting the Fluid Level of the Hydraulic Clutch242
Changing the Hydraulic Clutch Fluid243
Anti Hopping Clutch244
Adjusting the Antihopping Clutch245
19 Water Pump, Cooling System247
Cooling System247
Checking the Antifreeze and Coolant Level247
Checking the Coolant Level248
Draining the Coolant249
Refilling Coolant249
20 Lubrication System251
Oil Circuit251
Checking the Engine Oil Level251
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens252
Adding Engine Oil255
Checking the Engine Oil Pressure256
Ignition System258
Ignition Coil - Checking the258
Secondary Winding258
Checking the Spark Plug Connector258
Alternator - Checking Stator Winding258
Removing the Stator259
Installing the Stator259
22 Cylinder Head260
Checking the Valve Clearance260
Adjusting the Valve Clearance262
23 Electric Starter264
Checking the Starter Motor264
24 Throttle Valve Body265
Adjusting the Idle Speed265
Executing the Initialization Run265
25 Technical Data267
Engine267
Tolerance, Engine Wear Limits268
Engine Tightening Torques268
Capacities270
Engine Oil270
Coolant270
Fuel270
Chassis270
Electrical System271
Tires271
Fork272
Shock Absorber272
Chassis Tightening Torques273
26 Cleaning/Protective Treatment275
Cleaning the Motorcycle275
27 Storage277
Preparing for Use after Storage278
28 Service Schedule279
Additional Information279
Required Work279
Recommended Work280
29 Wiring Diagram283
Substances288
Auxiliary Substances290
Special Tools292
Standards312
List of Abbreviations313
Index314

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Husqvarna FS 450 2016 Specifications

General

Brand	Husqvarna
Model	FS 450 2016
Category	Motorcycle
Language	English

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