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Table of Contents
Related Manuals for Husqvarna FE 450 2016
Summary of Contents for Husqvarna FE 450 2016
- Page 1 OWNER'S MANUAL 2016 FE 450 FE 501 Art. no. 3402066en...
- Page 3 Husqvarna Motorcy- cles accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.
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Page 4: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS Setting the kilometers or miles ......22 MEANS OF REPRESENTATION........5 Setting the clock ..........23 Symbols used ............5 Setting the service display........23 Formats used ............5 Speed, time, and DST distance 1 ....... 24 SAFETY ADVICE ............... - Page 5 TABLE OF CONTENTS 12.4 Cleaning the dust boots of the fork legs..... 42 13.7 Checking the front brake linings ......70 12.5 Removing the fork protector....... 43 13.8 Changing the front brake linings ..... 71 12.6 Installing the fork protector......... 43 13.9 Checking the free travel of foot brake lever..
- Page 6 TABLE OF CONTENTS BLINK CODE ..............105 TECHNICAL DATA ............107 23.1 Engine ............... 107 23.2 Engine tightening torques......... 107 23.3 Capacities ............109 23.3.1 Engine oil............109 23.3.2 Coolant ............109 23.3.3 Fuel............... 109 23.4 Chassis ............. 109 23.5 Electrical system..........
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Page 7: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interests of your own safety, have these jobs performed by an authorized Husqvarna Motorcycles workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required. -
Page 8: Safety Advice
Use definition – intended use (FE EU/AU) Husqvarna motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcy- cles comply with currently valid regulations and categories of the top international motorsport organizations. Info The vehicle should only be used by trained persons. -
Page 9: Safe Operation
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized Husqvarna Motorcycles dealer will be glad to advise you. -
Page 10: Owner's Manual
SAFETY ADVICE Owner's Manual It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual con- tains useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury. -
Page 11: Important Notes
Manufacturer and implied warranty The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles workshop only and con- firmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motorcycles Dealer.net; otherwise, all warranty claims will be void. -
Page 12: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) H00210-10 Filler cap Air filter box lid Side stand ( p. 19) Engine number ( p. 12) Shift lever ( p. 18) -
Page 13: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) H00209-10 Fork compression adjustment Kill switch ( p. 14) Horn button ( p. 15) Light switch ( p. 15) Turn signal switch ( p. 15) Emergency OFF switch ( p. 15) Electric starter button ( p. -
Page 14: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 401945-10 Type label (FE EU/AU) The type label is fixed to the front of the steering head. 401946-10 Key number (FE EU/AU) ... -
Page 15: Shock Absorber Article Number
SERIAL NUMBERS Shock absorber article number The shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 0 0 1 401948-10... -
Page 16: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. H00165-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The hand brake lever is used to activate the front brake. -
Page 17: Horn Button (Fe Eu/Au)
CONTROLS Horn button (FE EU/AU) The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – the horn is actuated in this position. • Horn button H00168-11 Light switch (FE EU/AU) ... -
Page 18: Electric Starter Button (Fe Eu/Us)
CONTROLS 6.11 Electric starter button (FE EU/US) The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – the electric starter is actuated in this position. •... -
Page 19: Closing The Filler Cap
CONTROLS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. -
Page 20: Idle Speed Adjusting Screw
CONTROLS 6.17 Idle speed adjusting screw Idle speed adjusting screw is located at the top left of the throttle valve body. The idle speed adjusting screw has two functions. Turning it controls the idle speed. Pulling it out all the way raises the idle speed during a cold start. Possible states RPM increase activated –... -
Page 21: Side Stand
CONTROLS 6.20 Side stand The side stand is located on the left side of the vehicle. 401943-10 The side stand is used for parking the motorcycle. Info When you are riding, the side stand must be folded up and secured with ... -
Page 22: Unlocking The Steering (Fe Eu/Au)
CONTROLS 6.23 Unlocking the steering (FE EU/AU) – Insert the key in the steering lock ( p. 19), turn it to the left, pull it out, and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock. -
Page 23: Speedometer
Message on the speedometer Possible states Battery voltage of the speedometer – Battery voltage of the speedometer is too low. Change the battery. Service – A service is due. Contact an authorized Husqvarna Motorcy- cles workshop. 401901-01 Setting the speedometer Condition The motorcycle is stationary. -
Page 24: Setting The Kilometers Or Miles
SPEEDOMETER – Wait for 5 seconds. The speedometer changes to the next menu item. The symbol flashes. Resetting the time – Press the left button. The value decreases. Advancing the time – Press the right button. The value increases. 401912-01 –... -
Page 25: Setting The Clock
SPEEDOMETER Setting the clock Condition The motorcycle is stationary. – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. – Wait for the menu of the clock to flash. – Press one of the buttons to select the 24h or 12h display of the clock. 401911-01 –... -
Page 26: Speed, Time, And Dst Distance 1
SPEEDOMETER Speed, time, and DST distance 1 – Press one of the buttons until DST appears on the speedometer. KM/H or M/H shows the speed. shows the time. DST shows the distance since the last reset, such as between two refueling stops. Info If the value of 39999.9 is exceeded, DST is automatically reset to 0.0. -
Page 27: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized Husqvarna Motorcycles workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover. -
Page 28: Running-In The Engine
PREPARING FOR USE – Do not make any off-road trips that exceed your ability and experience. – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – If you carry any luggage, make sure you fix it firmly as close as possible to the center of the vehicle and ensure even weight dis- tribution between the front and rear wheels. -
Page 29: Preparing For Rides On Dry Sand
– Fit a dust cover on the air filter. Dust protection device for air filter (77206920100) Info See the Husqvarna Motorcycles accessories fitting instructions. M00999-01 – Fit a sand cover on the air filter. Sand protection device for air filter (59006922000) Info See the Husqvarna Motorcycles accessories fitting instructions. -
Page 30: Preparing For Rides On Wet And Muddy Surfaces
Preparing for rides on wet and muddy surfaces – Fit a waterproofing device on the air filter. Waterproofing device for air filter (77206921100) Info See the Husqvarna Motorcycles accessories fitting instructions. M01001-01 – Fit the steel sprocket. – Clean the motorcycle. ( p. -
Page 31: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 96) –... -
Page 32: Starting Off
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized Husqvarna Motorcycles workshop. -
Page 33: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –... -
Page 34: Refueling
– In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards. -
Page 35: Service Schedule
○ ● ● Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics tool. ○ ● ● Make the service entry in the Husqvarna Motorcycles Dealer.net and in the Service and Warranty Booklet. ○ One-time interval... -
Page 36: Service Work (As Additional Order)
SERVICE SCHEDULE ● Periodic interval 10.2 Service work (as additional order) Annually Every 135 operating hours Every 70 operating hours after sporting use Every 45 operating hours Once after 15 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. ●... -
Page 37: Tuning The Chassis
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber. -
Page 38: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber. -
Page 39: Measuring Rear Wheel Sag Unloaded
TUNING THE CHASSIS 11.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work – Measure the distance – as vertically as possible – between the rear axle and a fixed point such as a mark on the side cover. -
Page 40: Adjusting The Spring Preload Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 41: Adjusting The Riding Sag
TUNING THE CHASSIS 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) – Remove the right side cover. ( p. 58) – Remove the main silencer. ( p. 55) – Remove the seat. ( p. -
Page 42: Adjusting The Compression Damping Of The Fork
TUNING THE CHASSIS 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn the white adjusting screw all the way clockwise. Info The adjusting screw is located at the upper end of the left fork leg. The compression damping is located in the left fork leg COMP (white adjusting screw). -
Page 43: Adjusting The Handlebar Position
TUNING THE CHASSIS 11.15 Adjusting the handlebar position Warning Danger of accidents Handlebar breakage. – If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace han- dlebar. – Remove screws . Take off the handlebar clamps. Take off the handlebar and lay it to one side. -
Page 44: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (81329955100) Neither wheel is in contact with the ground. -
Page 45: Removing The Fork Protector
SERVICE WORK ON THE CHASSIS Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Clean and oil the dust boots and inner fork tubes of both fork legs. -
Page 46: Installing The Fork Legs
SERVICE WORK ON THE CHASSIS – Release screws . Take out the left fork leg. – Release screws . Take out the right fork leg. H00179-10 12.8 Installing the fork legs Main work – Position the fork legs. ... -
Page 47: Installing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS Main work – Open cable holder in front of the right radiator and detach the wiring harness. H00215-10 – Remove screw . Remove screw , take off the upper triple clamp with the handlebar and set it aside. - Page 48 SERVICE WORK ON THE CHASSIS – Position the fork legs. Bleeder screws are positioned toward the front. Info The compression damping is located in the left fork leg COMP (white adjusting screw). The rebound damping is located in the right fork leg REB (red adjusting screw).
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Page 49: Checking The Steering Head Bearing Play
Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time. -
Page 50: Lubricating The Steering Head Bearing
SERVICE WORK ON THE CHASSIS 12.13 Lubricating the steering head bearing – Remove the lower triple clamp. p. 44) – Install the lower triple clamp. p. 45) 800010-10 12.14 Removing the front fender Preparatory work – Switch off all power consumers and switch off the engine. –... -
Page 51: Removing The Shock Absorber
SERVICE WORK ON THE CHASSIS – Check the headlight setting. ( p. 88) 12.16 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) – Remove the right side cover. ( p. 58) –... -
Page 52: Mounting The Seat
SERVICE WORK ON THE CHASSIS – Raise the rear of the seat, push the seat back, and lift it off. H00183-11 12.19 Mounting the seat – Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear, and simultaneously push the seat forward. -
Page 53: Removing The Air Filter
SERVICE WORK ON THE CHASSIS 12.22 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 54: Sealing The Air Filter Box
SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaning agent ( p. 114) Info Only press the air filter to dry it, never wring it out. –... - Page 55 SERVICE WORK ON THE CHASSIS – Lift the swingarm. H00224-10 – Remove screws on both sides. – Loosen screws on both sides. M00389-10 – Remove screw – Raise the rear frame slightly and lower the shock absorber. S00892-10 –...
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Page 56: Installing The Manifold
SERVICE WORK ON THE CHASSIS (FE EU) – Remove screw – Disconnect plug-in connector on lambda sensor and remove cable binder. – Take off the manifold. S00912-10 (FE AU/US) – Remove screw – Take off the manifold. S00911-10 12.27 Installing the manifold... -
Page 57: Removing The Main Silencer
SERVICE WORK ON THE CHASSIS – Mount and tighten screws on both sides. Guideline Screw, subframe 35 Nm Loctite ® 2701™ (25.8 lbf ft) – Remove screws on both sides. – Mount and tighten screws on both sides. Guideline Loctite ®... -
Page 58: Cleaning The Spark Arrestor (Fe Us)
SERVICE WORK ON THE CHASSIS Main work – Disconnect spring Spring hooks (50305017000) – Remove screws and take off the main silencer. S00907-10 12.29 Cleaning the spark arrestor (FE US) Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. –... -
Page 59: Installing The Main Silencer
SERVICE WORK ON THE CHASSIS – Clean main silencer housing and screen of the spark arrestor with compressed air. – Mount a new O-ring on silencer cap – Position silencer cap . Mount and tighten screws Guideline Screws on the main silencer 7 Nm (5.2 lbf ft) -
Page 60: Removing The Right Side Cover
SERVICE WORK ON THE CHASSIS (FE US) – Remove screws of connecting cap – Remove the connecting cap with the perforated pipe, O-ring , and glass fiber yarn filling – Remove screws and silencer cap with O-ring –... -
Page 61: Removing The Fuel Tank
SERVICE WORK ON THE CHASSIS 12.34 Removing the fuel tank Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 62: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Remove screw with the rubber bushing. H00189-10 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. H00190-10 12.35 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. –... -
Page 63: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS (FE US) – Position the collar bushings, and mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) S00906-11 – Plug in the connector for the fuel pump. – Remove the wash cap set. –... -
Page 64: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS Main work – Clean the chain regularly and then treat with chain spray. Offroad chain spray ( p. 114) 400725-01 Finishing work – Remove the motorcycle from the lift stand. ( p. 42) 12.38 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. -
Page 65: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide
SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55… 58 mm (2.17… 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference ... - Page 66 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the bottom edge of the chain bolt is in line with or below the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...
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Page 67: Checking The Frame
If the frame exhibits cracks or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechan- ical impact. Repair of the frame is not authorized by Husqvarna Motorcycles. 401799-01 12.42 Checking the swingarm –... -
Page 68: Checking The Rubber Grip
SERVICE WORK ON THE CHASSIS 12.44 Checking the rubber grip – Check the rubber grips on the handlebar for damage, wear, and looseness. » If a rubber grip is damaged, worn, or loose: – Change and secure the rubber grip. Grip adhesive (00062030051) ( p. -
Page 69: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS 12.48 Changing the hydraulic clutch fluid Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –... -
Page 70: Brake System
BRAKE SYSTEM 13.1 Checking free travel of hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating. -
Page 71: Checking The Brake Discs
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. -
Page 72: Checking The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 73: Changing The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. -
Page 74: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100397-01 – Insert the new brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs. -
Page 75: Adjusting The Basic Position Of The Foot Brake Lever
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) – Stand the vehicle upright. -
Page 76: Adding Rear Brake Fluid
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 77: Checking The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. - Page 78 BRAKE SYSTEM – Stand the vehicle upright. – Remove screw cap with membrane and the O-ring. B01793-10 – Press the brake caliper onto the brake disc by hand in order to push back the brake piston and ensure that brake fluid does not flow out of the brake fluid reser- voir, extracting it by suction if it does.
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Page 79: Wheels, Tires
WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes. -
Page 80: Removing The Rear Wheel
WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. The brake linings are positioned. – Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc. -
Page 81: Installing The Rear Wheel
Checking the tire condition Info Only mount tires approved and/or recommended by Husqvarna Motorcycles. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcycle. -
Page 82: Checking The Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. - Page 83 WHEELS, TIRES – Tap each spoke with a screwdriver. Info The sound frequency depends on the length and thickness of the spoke. If there are different sound frequencies in spokes with the same length and thickness, this indicates different spoke tensions. You should hear a high note.
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Page 84: Electrical System
ELECTRICAL SYSTEM 15.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –... -
Page 85: Charging The Battery
Environmental hazard Batteries contain environmentally-hazardous materials. – Do not dispose of batteries as household waste. – Return batteries to your authorized Husqvarna Motorcycles dealer or dispose of them at a collection point for used bat- teries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 86: Changing The Main Fuse
ELECTRICAL SYSTEM 15.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box lid. Preparatory work –... -
Page 87: Removing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM – Remove the defective fuse. Guideline Fuse 1 - 10 A - EFI control unit Fuse 2 - 10 A - fuel pump Fuse 3 - 10 A - high beam, low beam, parking light, tail light, license plate lamp Fuse 4 - 10 A - horn, brake light, turn signal, radiator fan Fuses res - 10 A - spare fuses S00901-10... -
Page 88: Installing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM – Detach plug-in connector and take off the headlight mask with the head- light. S00893-10 15.7 Installing the headlight mask with the headlight Main work (FE EU/AU) – Connect plug-in connectors H00220-11 – Position the headlight mask and secure it with rubber bands The holding lugs engage in the fender. -
Page 89: Changing The Headlight Bulb
ELECTRICAL SYSTEM – Position brake line and wiring harness in the brake line guide. S00894-10 Finishing work – Check the headlight setting. ( p. 88) 15.8 Changing the headlight bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. -
Page 90: Changing The Turn Signal Bulb
ELECTRICAL SYSTEM 15.9 Changing the turn signal bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. Main work (FE EU/AU) –... -
Page 91: Adjusting The Headlight Range
ELECTRICAL SYSTEM 15.11 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 88) Main work – Loosen screw – Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver (instructions on how to apply the mark: Checking the headlight setting). -
Page 92: Cooling System
COOLING SYSTEM 16.1 Cooling system The water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. -
Page 93: Checking The Coolant Level
COOLING SYSTEM 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. -
Page 94: Refilling Coolant
COOLING SYSTEM 16.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately. -
Page 95: Tuning The Engine
TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back and forth slightly to ascertain play in the throttle cable. Play in throttle cable 3…... -
Page 96: Adjusting The Idle Speed
TUNING THE ENGINE 17.3 Adjusting the idle speed Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. - Page 97 TUNING THE ENGINE – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle compo- nents during the shift procedure.
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Page 98: Service Work On The Engine
SERVICE WORK ON THE ENGINE 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 99: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens
SERVICE WORK ON THE ENGINE 18.3 Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage. - Page 100 SERVICE WORK ON THE ENGINE – Position oil screen with the O-rings on a pin wrench. – Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case. – Push the oil screen all the way into the engine case. B01761-10 –...
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Page 101: Adding Engine Oil
SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. -
Page 102: Cleaning, Care
CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts. -
Page 103: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If you use the vehicle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt. -
Page 104: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info Husqvarna Motorcycles recommends raising the motorcycle. – Raise the motorcycle with a lift stand. ( p. 42) –... -
Page 105: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Carry out the start procedure. ( p. 29) tric starter) – Battery is discharged Charge the battery. p. 83) – Check the charging voltage. – Check the closed current. –... - Page 106 TROUBLESHOOTING Faults Possible cause Action – Engine overheats Insufficient airflow Switch off engine when stationary. – Radiator fins very dirty Clean radiator fins. – Foam formation in cooling system Drain the coolant. p. 91) – Refill the coolant. p. 92) –...
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Page 107: Blink Code
BLINK CODE Blink code FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high Blink code FI warning... - Page 108 BLINK CODE Blink code FI warning lamp (MIL) 45 FI warning lamp (MIL) flashes 4x long, 5x short Error level condition FE EU Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit FE EU Lambda sensor heater cylinder 1, sensor 1 - input signal too high...
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Page 109: Technical Data
TECHNICAL DATA 23.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement (All 450 models) 449.3 cm³ (27.418 cu in) Displacement (All 501 models) 510.4 cm³ (31.147 cu in) Stroke (All 450 models) 63.4 mm (2.496 in) Stroke (All 501 models) 72 mm (2.83 in) Bore 95 mm (3.74 in) Compression ratio... - Page 110 TECHNICAL DATA ® Loctite 243™ Screw, stator 6 Nm (4.4 lbf ft) ® Nut, water pump impeller 8 Nm (5.9 lbf ft) Loctite 243™ ® Loctite 243™ Plug, vacuum connection 2.5 Nm (1.84 lbf ft) ® Screw plug EVAP 5 Nm (3.7 lbf ft) Loctite 243™...
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Page 111: Capacities
TECHNICAL DATA – Oil pressure control valve plug M12x1.5 20 Nm (14.8 lbf ft) – Plug, SLS M12x1.5 20 Nm (14.8 lbf ft) – Plug, rocker arm M14x1.25 20 Nm (14.8 lbf ft) – Nut, inner clutch hub M18x1.5 80 Nm (59 lbf ft) ®... -
Page 112: Electrical System
90/90 - 21 54M TT 110/100 - 18 64M TT Dunlop GEOMAX AT81F Dunlop GEOMAX AT81 Additional information is available in the Service section under: www.husqvarna-motorcycles.com 23.7 Fork Fork part number 24.18.7P.69 WP Performance Systems Up Side Down 4860 MXMA 4CS... -
Page 113: Shock Absorber
TECHNICAL DATA Spring length with preload spacer(s) 475 mm (18.7 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.4 N/mm (25.1 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 4.6 N/mm (26.3 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 4.8 N/mm (27.4 lb/in) Fork length 932 mm (36.69 in) - Page 114 TECHNICAL DATA ® Loctite 243™ Screw, chain sliding guard 6 Nm (4.4 lbf ft) ® Screw, front brake disc 14 Nm (10.3 lbf ft) Loctite 243™ ® Loctite 243™ Screw, rear brake disc 14 Nm (10.3 lbf ft) – Screw, throttle grip 5 Nm (3.7 lbf ft) –...
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Page 115: Substances
SUBSTANCES Brake fluid DOT 4 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the cor- responding properties. Recommended supplier ® Bel‑Ray – Super DOT 4 Brake Fluid Coolant Guideline –... -
Page 116: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel‑Ray – Foam Filter Cleaner & Degreaser Grip adhesive (00062030051) Recommended supplier KTM AG – GRIP GLUE High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier ® Bel‑Ray –... -
Page 117: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines. -
Page 118: List Of Abbreviations
LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly... -
Page 119: Lisy Of Symbols
LISY OF SYMBOLS 28.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. FI warning lamp (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault. The low fuel warning lamp lights up orange –... -
Page 120: Index
INDEX INDEX fluid, changing ......67 Clutch lever ....... . 14 Accessories . - Page 121 INDEX Foot brake lever ......18 Kill switch ........14 basic position, adjusting .
- Page 122 INDEX securing ....... . . 66 Throttle grip ....... . 14 Tire air pressure checking .
- Page 123 *3402066en* 3402066en 07/2015 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer, www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...