Husqvarna FS 450 2017

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PIONEERING SINCE 1903

REPAIR MANUAL2017

FS 450

Art. no. 3403050en

Husqrna

MOTORCYCLES

Main Page

Table of Contents4
Means of Representation 19
Symbols Used9
Formats Used9
Safety Advice10
Repair Manual10
Degrees of Risk and Symbols10
Work Rules10
Important Notes 311
Manufacturer and Implied Warranty11
Fuel, Auxiliary Substances11
Spare Parts, Accessories11
Figures11
Serial Numbers12
Vehicle Identification 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
Starting the Vehicle14
Starting the Motorcycle to Check the 8 Function15
Fork, Triple Clamp16
Air Suspension AER 4816
Checking the Basic Setting of the Fork16
Adjusting the Fork Air Pressure17
Adjusting the Compression Damping of the Fork18
Adjusting the Rebound Damping of the Fork18
Bleeding the Fork Legs19
Cleaning the Dust Boots of the Fork Legs19
Removing the Fork Legs20
Installing the Fork Legs21
Removing the Fork Protector21
Installing the Fork Protector22
Servicing the Fork22
Disassembling the Fork Legs23
Disassembling the Air Cartridge27
Disassembling the Shock Absorber Cartridge28
Checking the Fork Legs30
Assembling the Shock Absorber Cartridge31
Assembling the Air Cartridge33
Assembling the Fork Legs35
Lubricating the Steering Head Bearing41
Removing the Lower Triple Clamp41
Installing the Lower Triple Clamp42
Checking Steering Head Bearing Play44
Changing the Steering Head Bearing45
Adjusting Steering Head Bearing Play46
7 Handlebar,Controls48
Handlebar Position48
Adjusting the Handlebar Position48
Clutch Lever49
Checking the Rubber Grips49
Checking Throttle Cable Routing50
Checking Throttle Cable Play50
Adjusting Throttle Cable Play51
Adjusting the Characteristic Map of the Throttle Response52
Frame54
Checking the Frame54
Changing the Footrests54
Shock Absorber, Link Fork56
Adjusting the High-Speed Compression Damping of the Shock Absorber56
Adjusting the Low-Speed Compression Damping of the Shock Absorber56
Adjusting the Rebound Damping of the Shock Absorber57
Measuring the Rear Wheel Dimension Unloaded58
Checking the Static Sag of the Shock Absorber58
Checking the Riding Sag of the Shock Absorber59
Shock Absorber59
Adjusting the Riding Sag60
Removing the Shock Absorber61
Installing the Shock Absorber62
Checking the Shock Absorber Linkage64
Servicing the Shock Absorber66
Removing the Spring67
Disassembling the Damper68
Disassembling the Piston Rod69
Disassembling the Seal Ring Retainer70
Changing the Pilot Bushing71
Checking the Damper72
Removing the Heim Joint73
Installing the Heim Joint74
Assembling the Seal Ring Retainer75
Assembling the Piston Rod75
Assembling the Damper77
Bleeding and Filling the Damper79
Filling Damper with Nitrogen82
Installing the Spring83
Checking the Link Fork84
Checking the Fork Bearing for Play84
Removing the Link Fork85
Installing the Link Fork86
Changing the Fork Bearing88
Checking the Heim Joint for Play91
Changing the Heim Joint91
Exhaust System93
Removing the Manifold93
Installing the Manifold94
Removing the Main Silencer95
Installing the Main Silencer96
Of the Main Silencer96
11 Air Filter98
Removing the Air Filter Box Cover98
Installing the Air Filter Box Cover98
Removing the Air Filter98
Installing the Air Filter99
Cleaning the Air Filter and Air Filter Box99
Sealing the Air Filter Box100
Fuel Tank, Seat, Trim101
Opening Fuel Tank Filler Cap101
Closing the Fuel Tank Filler Cap101
Removing the Right Side Cover102
Installing the Right Side Cover102
Removing the Seat102
Mounting the Seat103
Removing the Fuel Tank104
Installing the Fuel Tank105
Checking the Fuel Pressure107
Changing the Fuel Pump108
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 Tire Pressure118
Checking the Tire Condition118
Checking the Wheel Bearing for Play119
Checking the Brake Discs120
Checking Spoke Tension120
Checking the Rim Run-Out121
Front Wheel122
Removing the Front Wheel122
Installing the Front Wheel123
Changing the Front Brake Disc124
Changing the Front Wheel Bearing124
Rear Wheel126
Removing the Rear Wheel126
Installing the Rear Wheel127
Changing the Rear Brake Disc128
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 Kit133
Changing the Rear Wheel Bearing135
Wiring Harness, Battery 15137
Changing the Main Fuse137
Of the 12 V Battery138
Connecting the Negative Cable of the 12 V Battery138
Removing the 12 V Battery139
Installing the 12 V Battery140
Charging the 12 V Battery141
Checking the Charging Voltage142
Checking the Open-Circuit Current143
Checking the Capacitor143
Checking the Starter Relay144
16 Brake System146
Checking the Front Brake Linings146
Changing the Front Brake Linings146
Adjusting the Basic Position of the148
Hand Brake Lever148
Checking the Front Brake Fluid Level149
Adding Front Brake Fluid149
Changing the Front Brake Fluid150
Checking the Brake Linings of the Rear Brake152
Changing the Rear Brake Linings152
Checking the Free Travel of Foot154
Brake Lever154
Adjusting the Basic Position of the Foot Brake Lever155
Checking the Rear Brake Fluid Level155
Adding Rear Brake Fluid156
Changing the Rear Brake Fluid157
17 Engine160
Removing the Engine160
Installing the Engine167
Engine Disassembly175
Preparations175
Draining the Engine Oil175
Removing the Clutch Push Rod176
Removing the Starter Motor177
Removing the Spark Plug177
Removing the Valve Cover177
Removing the Alternator Cover177
Positioning the Engine at Ignition Top Dead Center178
Removing the Timing Chain Tensioner178
Removing the Camshaft179
Removing the Cylinder Head179
Removing the Piston180
Removing the Rotor180
Removing the Timing Chain181
Removing the Suction Pump181
Removing the Gear Position Sensor182
Removing the Water Pump Cover182
Removing the Clutch Cover183
Removing the Clutch Discs183
Removing the Clutch Basket184
Removing the Torque Limiter185
Removing the Starter Idler Gear185
Removing the Force Pump185
Removing the Shift Shaft186
Removing the Shift Drum Locating Unit187
Removing the Locking Lever187
Primary Gear Wheel, Removing187
Removing the Freewheel Gear187
Removing the Left Engine Case Section188
Removing the Shift Rails189
Removing the Shift Drum189
Removing the Shift Forks189
Removing the Transmission Shafts189
Removing the Crankshaft190
Working on Individual Parts190
Working on the Right Section of the Engine Case190
Working on the Left Section of the Engine Case192
Oil Pressure Control Valve, Removing193
Spring Length of the Oil Pressure Control Valve, Checking194
Oil Pressure Control Valve, Installing194
Crankshaft Seal Ring in the Clutch Cover, Changing194
Removing the Water Pump194
Installing the Water Pump195
Removing the Timing Chain196
Sprocket196
Installing the Timing Chain196
Removing the Crankshaft Bearing Inner Race197
Installing the Crankshaft Bearing Inner Race197
Changing the Connecting Rod, Conrod Bearing, and Crank Pin198
Checking Crankshaft Run-Out at Bearing Pin200
Measuring the Crankshaft End Play200
Cylinder - Nikasil ® - Coating201
Checking/Measuring the Cylinder201
Checking/Measuring the Piston202
Checking the Piston Ring End Gap203
Measuring the Piston/Cylinder Mounting Clearance203
Checking the Oil Pumps204
Disassembling the Autodecompressor204
17 .4.23 Assembling the Autodecompressor205
Checking Camshaft206
Checking the Timing Assembly206
Removing the Rocker Arm207
Removing the Valves207
Changing the Camshaft Bearing208
Checking the Valves209
Checking Valve Springs210
Checking Valve Spring Seat210
Checking the Cylinder Head210
Checking the Rocker Arm Shafts211
Installing the Valves211
Installing the Rocker Arm212
Disassembling the Antihopping Clutch213
Preassembling the Antihopping Clutch214
Checking the Clutch215
Checking the Shift Mechanism216
Preassembling the Shift Shaft217
Disassembling the Main Shaft218
Disassembling the Countershaft219
Checking the Transmission219
17.4.44 Assembling the Main Shaft221
17.4.45 Assembling the Countershaft222
Checking the Starter Drive223
Checking the Freewheel224
Removing the Freewheel224
Freewheel, Installing224
Engine Assembly225
Installing the Crankshaft225
Installing the Transmission Shafts226
Installing the Shift Forks226
Installing the Shift Drum227
Installing the Shift Rails227
Installing the Left Engine Case227
Installing the Freewheel Gear228
Primary Gear Wheel, Installing228
Installing the Locking Lever229
Installing the Shift Drum Locating Unit229
Installing the Shift Shaft229
Installing the Force Pump229
Installing the Starter Idler Gear230
Installing the Torque Limiter231
Installing the Clutch Basket231
Installing the Clutch Discs232
Installing the Clutch Cover233
Installing the Water Pump Cover234
Installing the Gear Position Sensor234
Installing the Suction Pump234
Installing the Timing Chain235
Installing the Rotor236
Installing the Piston236
Installing the Cylinder Head238
Installing the Camshaft239
Installing the Timing Chain Tensioner239
Checking the Valve Clearance240
17.5.28 Adjusting the Valve Clearance241
Installing the Alternator Cover241
Installing the Valve Cover242
Installing the Spark Plug242
Installing the Starter Motor242
Installing the Oil Filter242
Installing the Clutch Push Rod243
Installing the Oil Screens243
Removing the Engine from the Engine Assembly Stand244
Clutch245
Checking/Correcting the Fluid Level of the Hydraulic Clutch245
Changing the Hydraulic Clutch Fluid246
Anti Hopping Clutch247
Adjusting the Antihopping Clutch248
19 Water Pump, Cooling System250
Cooling System250
Checking the Antifreeze and Coolant Level250
Checking the Coolant Level251
Draining the Coolant252
Refilling Coolant252
Lubrication System254
Oil Circuit254
Checking the Engine Oil Level254
Changing the Engine Oil and Oil Filter Cleaning the Oil Screens255
Adding Engine Oil258
Checking the Oil Pressure259
Ignition System261
Secondary Winding261
Connector261
Changing the Spark Plug261
Winding262
Removing the Stator263
Installing the Stator263
22 Cylinder Head264
Checking the Valve Clearance264
Adjusting the Valve Clearance266
Electric Starter System269
Checking the Starter Motor269
24 Throttle Valve Body270
Adjusting the Idle Speed270
Performing the Initialization Run270
25 Technical Data272
Engine272
Tolerance, Engine Wear Limits273
Engine Tightening Torques273
Capacities275
Engine Oil275
Coolant275
Fuel275
Chassis275
Electrical System276
Tires276
Fork277
Shock Absorber277
Chassis Tightening Torques278
26 Cleaning/Protective Treatment280
Cleaning the Motorcycle280
27 Storage282
Preparing for Use after Storage283
28 Service Schedule284
Additional Information284
Required Work284
Recommended Work285
Wiring Diagram 29287
Ignition Coil - Checking the 30 SUBSTANCES292
Auxiliary Substances294
Special Tools296
Standards315
List of Abbreviations316
Index317

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Husqvarna FS 450 2017 Specifications

General

Brand	Husqvarna
Model	FS 450 2017
Category	Motorcycle
Language	English

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