Husqvarna FC 450 2014 Manuals

Manuals and User Guides for Husqvarna FC 450 2014. We have 1 Husqvarna FC 450 2014 manual available for free PDF download: Repair Manual

Husqvarna FC 450 2014 Repair Manual (241 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 72.61 MB

Table of Contents
4
Means of Representation
8
Symbols Used
8
Formats Used
8
Safety Advice
9
Repair Manual
9
Degrees of Risk and Symbols
9
Work Rules
9
Important Notes
10
Manufacturer and Implied Warranty
10
Operating and Auxiliary Substances
10
Spare Parts, Accessories
10
Figures
10
Serial Numbers
11
Chassis Number
11
Type Label
11
Engine Number
11
Fork Part Number
11
Shock Absorber Article Number
11
Motorcycle
12
Raising the Motorcycle with a Lift Stand
12
Removing the Motorcycle from the Lift Stand
12
Starting
12
Starting the Motorcycle for a Check
13
Fork, Triple Clamp
14
Adjusting the Compression Damping of the 9.8 Fork
14
Adjusting the Rebound Damping of the Fork
14
Bleeding the Fork Legs
14
Cleaning the Dust Boots of the Fork Legs
15
Loosening the Fork Protection
15
Positioning the Fork Protection
15
Removing the Fork Legs
16
Installing the Fork Legs
16
Removing the Fork Protector
17
Installing the Fork Protector
17
Conducting Major Fork Service
17
Conducting Minor Fork Service
18
Disassembling the Fork Legs
18
Disassembling the Cartridge
21
Disassembling the Piston Rod
23
Disassembling the Screw Cap with the Membrane Holder
24
Disassembling the Screw Sleeve
25
Checking the Fork Legs
26
Checking the Fork Legs - During a Minor Fork Service
27
Changing the Pilot Bushing
28
Assembling the Screw Sleeve
29
Assembling the Screw Cap with the Membrane Holder
29
Assembling the Piston Rod
30
Assembling the Cartridge
32
Assembling the Fork Legs
33
Bleeding and Filling the Cartridge
36
Filling the Cartridge with Nitrogen
38
Greasing the Steering Head Bearing
39
Removing the Lower Triple Clamp
39
Installing the Lower Triple Clamp
40
Checking the Steering Head Bearing Play
41
Changing the Steering Head Bearing
42
Adjusting the Steering Head Bearing Play
43
Handlebar,Controls
44
Handlebar Position
44
Adjusting the Handlebar Position
44
Adjusting the Basic Position of the Clutch Lever
44
Checking the Throttle Cable Routing
45
Checking the Play in the Throttle Cable
46
Adjusting the Play in the Throttle Cable
46
Frame
47
Checking the Frame
47
Shock Absorber, Swingarm
48
Adjusting the High-Speed Compression Damping of the Shock Absorber
48
Adjusting the Low-Speed Compression Damping of the Shock Absorber
48
Adjusting the Rebound Damping of the Shock Absorber
49
Measuring Rear Wheel Sag Unloaded
49
Checking the Static Sag of the Shock Absorber
49
Checking the Riding Sag of the Shock Absorber
50
Adjusting the Spring Preload of the Shock Absorber
50
Adjusting the Riding Sag
51
Removing the Shock Absorber
51
Installing the Shock Absorber
52
Checking the Shock Absorber Linkage
53
Clearance
54
Servicing the Shock Absorber
55
Removing the Spring
56
Disassembling the Damper
56
Disassembling the Piston Rod
57
Disassembling the Seal Ring Retainer
58
Changing the Pilot Bushing
59
Checking the Damper
60
Removing the Heim Joint
60
Installing the Heim Joint
61
Assembling the Seal Ring Retainer
62
Assembling the Piston Rod
63
Assembling the Damper
64
Bleeding and Filling the Damper
66
Filling the Damper with Nitrogen
68
Installing the Spring
69
Checking the Swingarm
70
Removing the Swingarm
70
Installing the Swingarm
71
Changing the Swingarm Bearing
72
Exhaust
75
Removing the Manifold
75
Installing the Manifold
75
Removing the Main Silencer
76
Installing the Main Silencer
76
Changing the Glass Fiber Yarn Filling of the Main Silencer
76
Air Filter
78
Removing the Air Filter Box Lid
78
Installing the Air Filter Box Lid
78
Removing the Air Filter
78
Installing the Air Filter
78
Cleaning the Air Filter and Air Filter Box
79
Sealing the Air Filter Box
79
Fuel Tank, Seat, Trim
80
Opening the Filler Cap
80
Closing the Filler Cap
80
Removing the Right Side Cover
80
Installing the Right Side Cover
81
Removing the Seat
81
Mounting the Seat
81
Removing the Fuel Tank
81
Installing the Fuel Tank
82
Checking the Fuel Pressure
83
Changing the Fuel Pump
84
Changing the Fuel Filter
86
Changing the Fuel Screen
88
Mask, Fender
90
Removing the Front Fender
90
Installing the Front Fender
90
Removing the Start Number Plate
90
Installing the Start Number Plate
91
Wheels
92
Checking the Tire Air Pressure
92
Checking the Tire Condition
92
Checking the Brake Discs
92
Checking the Spoke Tension
93
Front Wheel
94
Removing the Front Wheel
94
Installing the Front Wheel
94
Removing the Brake Disc of the Front Brake
95
Installing the Brake Disc of the Front Brake
95
Changing the Front Wheel Bearing
95
Rear Wheel
97
Removing the Rear Wheel
97
Installing the Rear Wheel
97
Removing the Brake Disc of the Rear Brake
98
Installing the Brake Disc of the Rear Brake
98
Checking the Chain Tension
99
Adjusting the Chain Tension
99
Make Sure that Chain Adjusters (D Are Fitted Correctly on Adjusting Screws Check the Chain Tension
99
Tighten Nut
99
Guideline
99
Nut, Rear Wheel Spindle
99
I 80 Nm (59 Lbf Ft)
99
Info
99
Adjusting the Chain Guide
100
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
100
Enables Different Secondary Ratios with the same Chain Length
100
Chain Adjusters
100
Checking for Chain Dirt Accumulation
102
Cleaning the Chain
102
Finishing Work - Remove the Motorcycle from the Lift Stand
102
Preparatory Work - Raise the Motorcycle with a Lift Stand
102
Changing the Drivetrain Kit
103
Remove the Rear Wheel
103
Main Work
103
Remove Screws
103
Changing the Rear Wheel Bearing
104
Guideline
104
Nm Loctite (10.3 Lbf Ft)
104
Finishing Work - Install the Rear Wheel
106
Remove the Motorcycle from the Lift Stand
106
Wiring Harness, Battery
107
Changing the Main Fuse
107
Removing the Battery
107
Installing the Battery
108
Checking the Charging Voltage
108
Checking the Quiescent Current
108
Checking the Capacitor
109
Checking the Starter Relay
109
Brake System
111
Checking the Front Brake Linings
111
Changing the Front Brake Linings
111
Checking the Free Travel of the Hand Brake Lever
112
Brake Lever
113
Checking the Brake Fluid Level of the Front Brake
113
Adding Front Brake Fluid
114
Changing the Front Brake Fluid
115
Checking the Rear Brake Linings
116
Changing the Rear Brake Linings
116
Checking the Free Travel of Foot Brake Lever
118
Adjusting the Basic Position of the Foot Brake Lever
118
Checking the Rear Brake Fluid Level
118
Adding Rear Brake Fluid
119
Changing the Rear Brake Fluid
120
Engine
122
Removing the Engine
122
Installing the Engine
126
Engine Disassembly
131
Preparations
131
Draining the Engine Oil
131
Removing the Clutch Push Rod
132
Removing the Oil Filter
132
Removing the Starter Motor
132
Removing the Spark Plug
132
Removing the Valve Cover
133
Removing the Alternator Cover
133
Positioning the Engine at Ignition Top Dead Center
133
Removing the Timing Chain Tensioner
134
Removing the Camshaft
134
Removing the Cylinder Head
135
Removing the Piston
135
Removing the Rotor
136
Removing the Timing Chain
136
Removing the Ignition Pulse Generator
137
Removing the Suction Pump
137
Removing the Water Pump Cover
137
Removing the Clutch Cover
138
Removing the Clutch Discs
138
Removing the Outer Clutch Hub
139
Removing the Torque Limiter
140
Removing the Starter Idler Gear
140
Removing the Shift Shaft
140
Removing the Shift Drum Locating Unit
140
Removing the Locking Lever
141
Removing the Force Pump
141
Removing the Primary Gear
142
Removing the Freewheel Gear
142
Removing the Left Engine Case Section
142
Removing the Shift Rails
143
Removing the Shift Drum
143
Removing the Shift Forks
143
Removing the Transmission Shafts
144
Removing the Crankshaft
144
Work on Individual Parts
144
Work on the Right Section of the Engine Case
144
Work on the Left Section of the Engine Case
146
Removing the Oil Pressure Regulator Valve
147
Checking Spring Length of Oil Pressure Regulator Valve
147
Installing the Oil Pressure Regulator Valve
148
Changing the Crankshaft Seal Ring in the Clutch Cover
148
Removing the Water Pump
148
Installing the Water Pump
149
Removing the Timing Chain Sprocket
150
Installing the Timing Chain Sprocket
150
Changing the Connecting Rod, Conrod Bearing, and Crank Pin
150
Checking Crankshaft Run-Out at Bearing Pin
152
Cylinder - Nikasil ® Coating
152
Checking/Measuring the Cylinder
152
Checking/Measuring the Piston
153
Checking the Piston Ring End Gap
153
Measuring the Piston/Cylinder Mounting
154
Checking the Oil Pumps
154
Disassembling the Autodecompressor
154
Assembling the Autodecompressor
155
Checking Camshaft
156
Checking the Timing Assembly
156
Removing the Rocker Arm
157
Removing the Valves
157
Changing Camshaft Bearing
158
Checking the Valves
158
Checking Valve Springs
159
Checking Valve Spring Seat
159
Checking the Cylinder Head
159
Checking the Rocker Arm Shafts
160
Installing the Valves
160
Installing the Rocker Arm
161
Checking the Clutch
162
Checking the Shift Mechanism
163
Preassembling the Shift Shaft
164
Disassembling the Main Shaft
165
Disassembling the Countershaft
165
Checking the Transmission
166
Assembling the Main Shaft
167
Assembling the Countershaft
168
Checking the Starter Drive
169
Checking the Freewheel
169
Removing the Freewheel
170
Installing the Freewheel
170
Engine Assembly
171
Installing the Crankshaft
171
Installing the Transmission Shafts
171
Installing the Shift Forks
171
Installing the Shift Drum
172
Installing the Shift Rails
172
Installing the Left Engine Case
172
Installing the Freewheel Gear
173
Installing the Primary Gear
173
Installing the Force Pump
173
Installing the Locking Lever
174
Installing the Shift Drum Locating Unit
175
Installing the Shift Shaft
175
Installing the Starter Idler Gear
175
Installing the Torque Limiter
175
17.5.15 Installing the Outer Clutch Hub
175
Installing the Clutch Discs
176
Installing the Clutch Cover
178
Installing the Water Pump Cover
179
Installing the Suction Pump
179
Installing the Ignition Pulse Generator
179
Installing the Timing Chain
180
Installing the Rotor
180
Installing the Piston
180
Installing the Cylinder Head
182
Installing the Camshaft
183
Installing the Timing Chain Tensioner
183
Checking the Valve Clearance
184
Adjusting the Valve Clearance
184
Installing the Alternator Cover
185
Installing the Valve Cover
185
Installing the Spark Plug
185
Installing the Starter Motor
186
Installing the Oil Filter
186
Installing the Clutch Push Rod
186
17.5.35 Installing the Oil Screens
186
Removing the Engine from the Engine
187
Assembly Stand
187
Clutch
188
Checking/Correcting the Fluid Level of the Hydraulic Clutch
188
Changing the Hydraulic Clutch Fluid
188
Water Pump, Cooling System
189
Cooling System
189
Checking the Antifreeze and Coolant Level
189
Checking the Coolant Level
190
Draining the Coolant
190
Refilling Coolant
191
Lubrication System
192
Oil Circuit
192
Checking the Engine Oil Level
192
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens
193
Adding Engine Oil
195
Checking the Engine Oil Pressure
195
Ignition System
197
Winding
197
Checking the Spark Plug Connector
197
Alternator - Checking Stator Winding
197
Removing the Stator
198
Installing the Stator
198
Electric Starter
199
Checking the Starter Motor
199
Throttle Valve Body
200
Adjusting the Idle Speed
200
Executing the Initialization Run
200
Technical Data
202
Engine
202
Engine Tolerance, Wear Limits
202
Engine Tightening Torques
203
Capacities
204
Engine Oil
204
Coolant
204
Fuel
204
Chassis
204
Electrical System
205
Tires
205
Fork
205
Shock Absorber
206
Chassis Tightening Torques
206
Cleaning/Protective Treatment
208
Cleaning the Motorcycle
208
Storage
209
Preparing for Use after Storage
209
Service Schedule
210
Service Work (as Additional Order)
211
Wiring Diagram
213
Substances
218
Auxiliary Substances
219
Special Tools
221
Standards
235
Index
236

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Husqvarna FC 450 2014 Repair Manual (241 pages)

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