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04
"
REPARATURANLEITUNG
REPAIR MANUAL
MANUEL DE REPARATION
Edition 2004

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Troubleshooting

   Related Manuals for HUSABERG FE 450

   Summary of Contents for HUSABERG FE 450

  • Page 1

    “ REPARATURANLEITUNG REPAIR MANUAL MANUEL DE REPARATION Edition 2004...

  • Page 2

    NOTE: provides useful information. Only use ORIGINAL HUSABERG SPARE PARTS if parts need to be replaced. The engine will only continue to operate safely if the prescribed service work is performed regularly and professionally.

  • Page 4

    INDEX GENERAL INFORMATION DISMOUNTING AND MOUNTING THE ENGINE DISASSEMBLING THE ENGINE SERVICING THE INDIVIDUAL PARTS ASSEMBLING THE ENGINE ELECTRIC SYSTEM FUEL SYSTEM TROUBLESHOOTING TECHNICAL SPECIFICATIONS PERIODIC MAINTENANCE SCHEDULE WIRING DIAGRAMS...

  • Page 5: Table Of Contents

    Timing train ......D15 FE 450 - 650e/6, FS 450, 650e/6 ....J2 Checking the clutch for wear .

  • Page 6: General Information

    GENERAL INFORMATION OIL CIRCUIT DESCRIPTION: The oil pump (1) draws the engine oil from the oil sump through the oil screen (2) and pumps it past the pressure relief valve (3) to the oil filter (4). It continues to the crankshaft (5), partly branching off through a hole to lubricate and cool the piston (6) and the piston pin bearing.

  • Page 7: Changing The Engine Oil

    GENERAL INFORMATION CHANGING THE ENGINE OIL NOTE: Replace the oil screen and the oil filter when you change the engine oil. Change the engine oil when the engine is at operating temperature. WARNING: the engine oil will be very hot when the engine is at operating temperature –...

  • Page 8: Changing The Oil Filter

    GENERAL INFORMATION CHANGING THE OIL FILTER – Place a suitable vessel under the engine to allow the oil to drain. – Remove both bolts (1) and screw an M6 bolt in the center hole (2) of the oil filter cover. NOTE: only tighten the bolt by hand, otherwise you will damage the oil filter cover.

  • Page 9: Checking The Oil Level In The Hydraulic Clutch

    GENERAL INFORMATION CHECKING LEVEL HYDRAULIC CLUTCH Remove the cover to check the oil level in the master cylinder of the clutch. Remove the screws (1) and lift off the cover together with the rubber boot (2). The oil level should be 4 mm below the upper edge when the master cylinder is in a horizontal position.

  • Page 10: Cleaning

    GENERAL INFORMATION CLEANING Clean the motorcycle regularly to retain the beauty of the plastic parts. Use warm water with a commercial detergent and a sponge. Coarse dirt can be removed with a soft water jet. CAUTION: never clean the motorcycle with a power washer or a high pressure jet. This will cause the water to reach the electric components, socket connectors, cables, bearings, carburetor, etc.

  • Page 11

    GENERAL INFORMATION SPECIAL TOOLS - ENGINE...

  • Page 12: Special Tools

    GENERAL INFORMATION SPECIAL TOOLS - ENGINE PART NUMBER DESCRIPTION 560.12.001.000 Universal engine work stand 800.29.002.000 Engine holder for universal engine work stand 309098 Silicone three bond sealing compound 6 899 785 Loctite 243 blue 10 ml 800.29.059.000 Loctite 2701 green 10 ml 503.29.050.000 Bleeder syringe for hydraulic clutch 590.29.041.000...

  • Page 14: Dismounting And Mounting The Engine

    DISMOUNTING AND MOUNTING THE ENGINE DISMOUNTING THE ENGINE – Thoroughly clean the motorcycle and jack up on a sturdy work stand. – Remove the seat. – Unscrew the air filter (1). – Close both fuel taps and disconnect the fuel hoses –...

  • Page 15

    DISMOUNTING AND MOUNTING THE ENGINE – Dismount the right frame protector (1). – Unscrew the bearing bolt (2) on the foot brake lever and tilt the foot brake lever aside. – Remove the retaining clip from the push rod holder (3), pull out the bolt and the foot brake lever –...

  • Page 16

    DISMOUNTING AND MOUNTING THE ENGINE – Remove the retaining bolt from the starter relay (1), disconnect the connectors from the starter relay and lift out the starter relay. – Unscrew the nut on the chain roller bolt (2). – Dismount the starter holding bridge (3) and lift the battery out of the frame together with the battery case.

  • Page 17

    DISMOUNTING AND MOUNTING THE ENGINE – Remove the nut from the swing arm pivot (1) and knock out the swing arm pivot with a suitable pipe. – Pull the swing arm towards the back and let it rest against the frame. –...

  • Page 18: Mounting The Engine

    DISMOUNTING AND MOUNTING THE ENGINE MOUNTING THE ENGINE – Lift the engine into the frame, position the engine mounting plates (1), insert the bolts and screw on the nuts but do not tighten yet. – Position the swing arm and push in the swing arm pivot (2) from the right until it touches the engine.

  • Page 19

    DISMOUNTING AND MOUNTING THE ENGINE – Mount the intermediate exhaust pipe (1) and tighten the bolt (2). – Use a suitable tool (hooked handle) to mount the rear exhaust springs (3). – Apply copper paste to the front exhaust pipe at the connections to the cylinder head and mount.

  • Page 20

    DISMOUNTING AND MOUNTING THE ENGINE – Mount the clutch slave cylinder (1) and tighten the bolts to 6 Nm. – Position the chain and mount the chain joint (2). – Connect the generator and pickup connector (3) and fasten the wiring harness to the clutch line with cable clips.

  • Page 21

    DISMOUNTING AND MOUNTING THE ENGINE – Mount both radiator hoses and tighten the hose clamps (1). – Connect the overflow hose (2) and attach to the frame with cable clips. – Connect the battery cables. – Mount the tank and tighten the two bolts (4) on the side of the spoiler.

  • Page 22: Bleeding The Cooling System

    DISMOUNTING AND MOUNTING THE ENGINE BLEEDING THE COOLING SYSTEM – Add cooling liquid until it reaches approx. 10 mm over the radiator fins. – Open the bleeder bolt (1) on the cylinder head until cooling liquid escapes without bubbles, tighten the bleeder bolt again to 6 Nm.

  • Page 24: Disassembling The Engine

    DISASSEMBLING THE ENGINE – Thoroughly clean the outside of the engine and clamp on a universal engine work stand. – Drain the engine oil, remove the oil filter and the oil screen (see Chapter A). – Remove the kickstarter and the shift lever. –...

  • Page 25: Removing The Rotor

    DISASSEMBLING THE ENGINE REMOVING THE ROTOR – Remove the pickup sensor (1). – Loosen the rotor nut (2) (17 mm – LH thread!) and remove together with the corrugated washer. – Screw the extractor 580.12.009.000 (3) to the rotor, hold the extractor while you screw in the extractor bolt until the rotor is released from the crankshaft.

  • Page 26: Removing The Clutch

    DISASSEMBLING THE ENGINE – Remove the circlip (1) from the water pump shaft. – Carefully pull out the water pump wheel (2) with pliers and remove the pin (3) from the shaft. – Remove all of the bolts in the clutch cover and remove the clutch cover.

  • Page 27: Removing Inner Clutch Hub

    DISASSEMBLING THE ENGINE REMOVING THE INNER CLUTCH HUB – Unscrew the locking bolt. – Insert the clutch holder (1) 800.29.003.000 in the outer clutch hub with at least 6 clutch sleeves, lock the outer clutch hub with the gear wheel segment (2) (800.29.004.000) as shown in the photo and loosen the nut (27 mm).

  • Page 28: Removing The Oil Pump

    DISASSEMBLING THE ENGINE – Pull the idler (1) and the freewheel (2) from the engine case (only applies to starter models). – Remove the circlip on the kickstarter idler gear (3) and pull the kickstarter idler gear with the upper and lower disk and the needle bearing off of the bearing bolt.

  • Page 29: Removing The Chain Tensioner

    DISASSEMBLING THE ENGINE REMOVING THE CHAIN TENSIONER – Remove the bolt (1) together with the seal ring and chain tensioning spring. – Unscrew the chain tensioner (2). – Remove both valve covers, discarding the gaskets. – Loosen the bolts on the cylinder head top section, carefully tap on the side with a plastic hammer and remove the cylinder head top section.

  • Page 30: Removing The Cylinder Head

    DISASSEMBLING THE ENGINE – Pull the rear sprocket (1) off of the idler shaft with the extractor 590.29.033.000. CAUTION: Hold the extractor and do not let it touch the chain guide. – Pry the woodruff key from the shaft. REMOVING THE CYLINDER HEAD –...

  • Page 31: Removing The Crankshaft

    DISASSEMBLING THE ENGINE REMOVING THE CRANKSHAFT – Lift the crankshaft out of the housing together with the conrod, piston and cylinder liner, tapping gently on the rear crankshaft with a plastic hammer if necessary. REMOVING THE TRANSMISSION – Pull both shift rails (1) out of the housing. –...

  • Page 32: Removing The Idler Shaft

    DISASSEMBLING THE ENGINE REMOVING THE IDLER SHAFT – Knock the idler shaft out of the bearing seat from behind with a plastic hammer.

  • Page 34: Servicing The Individual Parts

    SERVICING THE INDIVIDUAL PARTS IMPORTANT INFORMATION ON WORKING WITH THE ENGINE CASE Generally, all gaskets, O-rings, crankshaft bearings and the transmission shaft bearings should be replaced when repairing the engine. In addition, all of the parts need to be cleaned thoroughly, removing any residual sealant from the sealing areas.

  • Page 35: Right Housing Half

    SERVICING THE INDIVIDUAL PARTS – Check the oil pump housing for scores and seizing marks. – Blow compressed air through all oil ducts and make sure they are not clogged. – Check the diaphragm valve for damage, replace the diaphragm if necessary. –...

  • Page 36: Pressure Relief Valve

    SERVICING THE INDIVIDUAL PARTS PRESSURE RELIEF VALVE – Check the valve ball (1) and the pressure spring (2) for damage. CLUTCH COVER – Pry the shaft seal ring for the shift shaft (3), the kickstarter shaft (4) and the water pump shaft (5) out of the clutch cover.

  • Page 37: Crankshaft

    SERVICING THE INDIVIDUAL PARTS CRANKSHAFT – Pull the cylinder liner off of the piston, lift the piston pin retainer out of the groove and push the piston pin out of the piston. – Clamp the crankshaft into the vise – use protective jaws.

  • Page 38: Press Out The Crank Pin

    SERVICING THE INDIVIDUAL PARTS – Press the outer ball bearing out of the balance weight (on the side with the toothing). NOTE: the ball bearing cannot be pressed out through the bottom since it will be blocked by the ring (1). PRESS OUT THE CRANK PIN –...

  • Page 39: Press In The Crank Pin

    SERVICING THE INDIVIDUAL PARTS PRESS IN THE CRANK PIN – Press in the crankpin until flush. The lubrication bore (1) must point to the exact center (2) of the crankshaft web, as shown in the photo. CAUTION: if the lubrication bore is incorrectly aligned the conrod bearing will not be supplied with lubricating oil and which will lead to engine damage.

  • Page 40: Outer Dimension Of The Crankshaft Webs

    SERVICING THE INDIVIDUAL PARTS CHECKING THE CRANKSHAFT FOR LATERAL RUNOUT – Place the crankshaft on a roller stand or similar support and use a dial gauge to check the crankshaft for lateral runout. Lateral runout: max. 0.12 mm Check the radial clearance and axial clearance at the conrod bearing.

  • Page 41: Balancing The Axial Clearance Of The Crankshaft

    SERVICING THE INDIVIDUAL PARTS – Press the inner ball bearing (1) on the balance weight (2) onto the crankshaft with a suitable pipe – Only press on the inner ring. Press on the balance weight with the outer ball bearing (3) – only press on the inner ring.

  • Page 42: Nikasil Cylinder Coating

    SERVICING THE INDIVIDUAL PARTS NIKASIL CYLINDER COATING Nikasil is the brand name for a cylinder coating process developed by the Mahle piston company. The name is derived from the two materials used in the process – one layer of nickel in which the exceptionally hard silicon carbite is embedded.

  • Page 43: Checking The Piston

    SERVICING THE INDIVIDUAL PARTS CHECKING THE PISTON – Replace the piston if oil consumption is high or the piston skirt is excessively grooved. – If the piston is to be remounted: 1. Check the piston bearing surface for damage 2. Piston ring grooves: use a feeler gauge (A) to measure the piston ring clearance in the piston ring groove.

  • Page 44: Cylinder Head Top Section

    SERVICING THE INDIVIDUAL PARTS CYLINDER HEAD TOP SECTION – Remove the circlip (1) and the decompression shaft (2) out of the bore together with the spring (3). – Pull the 2 end pieces (4) out of the cylinder head top section together with the rocker arm shafts (5) + (6).

  • Page 45: Cylinder Head

    SERVICING THE INDIVIDUAL PARTS CYLINDER HEAD – Remove the chain tensioning rail. – Remove valves with special tool 590.29.019.000. NOTE: if you are mounting the used valves again, they must be mounted in the same valve guide as before. For this purpose, place the valves in a box, marking the position they were mounted in the cylinder head (see photo).

  • Page 46

    SERVICING THE INDIVIDUAL PARTS Valve guides Use the limit plug gauge 590.29.026.006 (A) (Ø 6.05 mm) to check the valve guides. If the limit plug gauge can easily be pushed into the valve guide, the valve guide needs to be replaced at a special workshop. Valve springs Check the valve springs for fractures or other wear (visual check).

  • Page 47: Camshaft

    SERVICING THE INDIVIDUAL PARTS CAMSHAFT – Use the extractor 590.29.033.000 to pull both grooved ball bearings (1) off of the camshaft (see illustration). CAUTION: never clamp the camshaft in a vise on the cams. – Detach the spring (2) on the automatic decompression shaft (3) while pulling the automatic decompression shaft out of the camshaft.

  • Page 48: Timing Chain Tensioner

    SERVICING THE INDIVIDUAL PARTS TIMING CHAIN TENSIONER – Pull the pressure bolt all the way out of the timing chain tensioner and check for smooth operation. – Check the toothing on the pressure bolt and the ratchet for wear. – To mount, press the ratchet in the direction shown by the arrow to keep the pressure bolt from locking and push the pressure bolt all the way into the tensioner housing.

  • Page 49: Checking The Clutch For Wear

    SERVICING THE INDIVIDUAL PARTS CHECKING THE CLUTCH FOR WEAR Pressure piece (1) Check for seizing marks and smooth operation. Axial needle bearing (2) Check for damage. Push rod (3) Place on a flat surface and check for eccentricity. Clutch springs (4) Minimum length 41.5 mm (new 43 mm), replace all 6 springs if necessary.

  • Page 50: Checking The Kickstarter For Wear

    SERVICING THE INDIVIDUAL PARTS CHECKING THE KICKSTARTER FOR WEAR Remove all parts from the kickstarter shaft, clean and perform the following visual test: – Check the toothing and the driver running surface on the kickstarter wheel (1) for wear. – Check the kickstarter shaft (2) for wear or damage. –...

  • Page 51: Shift Mechanism

    SERVICING THE INDIVIDUAL PARTS SHIFT MECHANISM – Disassemble the shift shaft and clean the individual parts. – Check the shift forks (1) at the blade (A) for wear. They are 3.9 mm thick when new; the wear limit is 3.6 mm. –...

  • Page 52: Assembling The Main Shaft (four-speed)

    SERVICING THE INDIVIDUAL PARTS GENERAL INFORMATION ON WORKING WITH THE TRANSMISSION Clamp the main shaft or countershaft in a vise (use protective jaws). Remove the gears. NOTE: if the 2nd fixed gear cannot be removed from the main shaft, use the extractor 590.29.033.000 to pull it off together with the 6th idler gear.

  • Page 53: Assembling The Main Shaft (six-speed)

    SERVICING THE INDIVIDUAL PARTS ASSEMBLING THE MAIN SHAFT (6-SPEED) – Clamp the main shaft in a vise with the thread facing down (use protective jaws). – Carefully oil all parts before assembling. – Mount the needle bearing (1), slip on the 5-speed idler (2) with the shift dogs facing up.

  • Page 54

    SERVICING THE INDIVIDUAL PARTS ASSMBLING THE COUNTERSHAFT (4-SPEED/6-SPEED) – Clamp the countershaft in a vise with the toothing for the Ritzel facing down (use protective jaws). – Carefully oil all parts before assembling. – Mount the needle bearing (1) and the 2nd gear idler (2) on the countershaft with the recess for the shift dogs facing up.

  • Page 55: Starter Drive

    SERVICING THE INDIVIDUAL PARTS STARTER DRIVE – Check the toothing and the pivot point on the starter idler (1) for wear. Also check the bearing bolt for running marks. – Check the toothing and pivot point on the freewheel gear (2) for wear. Also check the bearing bolt on the freewheel gear for running marks.

  • Page 56: Assembling The Engine

    ASSEMBLING THE ENGINE MOUNTING THE IDLER SHAFT – Clamp the left housing half in the universal engine work stand. – Briefly heat the bearing (1) of the idler shaft (2) with a hot-air blower and mount the idler shaft, carefully tapping with a plastic hammer to the stop if necessary.

  • Page 57: Mounting The Crankshaft

    ASSEMBLING THE ENGINE MOUNTING THE CRANKSHAFT – Turn the mark on the idler shaft gear (1) towards the bottom as shown in the photo. – The toothing on the balance weight has a punch mark between teeth directly opposite compensating mass. Use a felt-tip pen to draw the mark on the outer side of the balance weight (see photo).

  • Page 58

    ASSEMBLING THE ENGINE – Mount new O-rings on the cylinder liner and lubricate with a little oil. – Position the well-lubricated piston on the cylinder liner and clamp the piston rings together with the piston ring clamp 600.29.015.000 (1). – Tap on the top of the piston ring clamp with a hammer to make it fit flush with the cylinder liner.

  • Page 59: Mounting The Cylinder Head

    ASSEMBLING THE ENGINE – Degrease the sealing areas on both engine case halves and apply a thin coat of silicone gasket sealant 309098 to the sealing area on the left housing half; mount the dowels – Place protective sleeve 800.29.105.000 crankshaft (1) mount the right engine housing half.

  • Page 60: Mounting The Timing Chain

    ASSEMBLING THE ENGINE – Screw on the oiled cylinder head bolts (1) with the washers. – Tighten the cylinder head bolts crosswise until you feel a slight resistance. – Tigthen the cylinder head bolts crosswise to 40 Nm. – Tighten the cylinder head bolts crosswise to 50 Nm. –...

  • Page 61

    ASSEMBLING THE ENGINE – Turn the camshaft gear until the marks (1) are aligned with the edge of the cylinder head. – Allow the chain to fall into the chain compartment on the guide side; insert the end of the chain at approx. 45º...

  • Page 62: Mounting The Timing Chain Tensioner

    ASSEMBLING THE ENGINE – Degrease the sealing area on the cylinder head and the cylinder head top section and apply a thin layer of M6x55 M6x55 silicone gasket sealant 309098 to the sealing area of the cylinder head. – Mount the dowels and the cylinder head top section. –...

  • Page 63: Mounting The Oil Pump

    ASSEMBLING THE ENGINE MOUNTING THE OIL PUMP – Oil the outer rotor (1) and insert in the engine case with the mark towards the inside (the mark should no longer be visible once mounted). – Insert the pin in the oil pump shaft and slide on the inner rotor (2).

  • Page 64: Mounting The Kickstarter Shaft

    ASSEMBLING THE ENGINE MOUNTING THE KICKSTARTER SHAFT – Attach kickstarter spring behind transmission gear (2) in the engine case and push the kickstarter shaft into the bearing seat. – Slide the kickstarter (3) on the kickstarter shaft as shown in the photo. –...

  • Page 65

    ASSEMBLING THE ENGINE – Make sure the marks on the primary pinion and the idler shaft gear are aligned and loosen the crankshaft locking bolt 580.30.080.000. – Lock the primary pinion (1) with the special tool 800.29.004.000 (gear segment) as shown in the photo, apply Loctite 2701 to the thread of the nut M16x1 (30 mm) and tighten to 110 Nm.

  • Page 66: Mounting The Clutch Cover

    ASSEMBLING THE ENGINE – Mount the pressure cap (1) with the collar bolts, clutch springs and spring retainers. – Secure the collar bolts with Loctite 243 and tighten in several stages crosswise to 8 Nm. MOUNTING THE CLUTCH COVER – Insert a new O-ring in the groove around the water duct (2).

  • Page 67

    ASSEMBLING THE ENGINE M6x25 M6x25 M6x25 M6x25 M6x25 M6x30 M6x30 M6x25 M6x25 M6x25 – Screw in the bolts (see photo for bolt lengths). – Tightening torque: 10 Nm. – Insert the pin (1) in the water pump shaft, slip on the water pump wheel (2) and mount the circlip (3).

  • Page 68: Mounting The Pressure Relief Valve

    ASSEMBLING THE ENGINE MOUNTING THE PRESSURE RELIEF VALVE – Slide the ball (1) and spring (2) in the hole, screw in the plug (3) with a new seal ring and tighten to 20 Nm. MOUNTING THE ROTOR AND THE PICK UP –...

  • Page 70: Electric System

    ELECTRIC SYSTEM CHECKING FOR LOSS OF CURRENT Check for loss of current before you check the voltage regulator-rectifier. – Switch off the ignition and disconnect the ground cable (1) from the battery. – Clamp an ampmeter between the ground cable and the negative pole (2) of the battery.

  • Page 71: Filling The Battery

    ELECTRIC SYSTEM FILLING THE BATTERY – Take the battery and electrolyte container out of the packing. Read the instructions for use carefully before you fill the battery. – Remove the cover from the electrolyte container. – Insert the electrolyte container in the openings in the battery and press down firmly.

  • Page 72: Checking The Starter Relay

    ELECTRIC SYSTEM CHECKING THE STARTER RELAY – Unscrew the brake fluid reservoir for the foot brake and let it hang down on the side. – Unscrew the negative pole from the battery and the two cables (1) from the starter relay. –...

  • Page 73: Checking The Voltage Regulator

    ELECTRIC SYSTEM CHECKING THE VOLTAGE REGULATOR A defective voltage regulator (1) can have the following effect: – No voltage in the circuit In this case, disconnect the voltage regulator with the engine at idle speed. If the consumers run, the voltage regulator is defective. If there is still no voltage, the error must be in the switch, the wiring harness or in the ignition system.

  • Page 74: Troubleshooting In The Ignition System

    ELECTRIC SYSTEM TROUBLESHOOTING IN THE IGNITION SYSTEM Before checking the ignition, make sure: – The emergency OFF switch is in the ON position – The battery is charged – The main fuse is OK Check whether there is an ignition spark upon starting: –...

  • Page 75: Cdi Unit

    ELECTRIC SYSTEM CDI UNIT Check the cables and socket connections to the CDI unit. The CDI unit can only be tested on an ignition test stand. CAUTION: never test the CDI unit with a conventional measuring device. Highly sensitive electronic components could be destroyed. CHECKING THE IGNITION COIL –...

  • Page 76: Ignition System

    ELECTRIC SYSTEM IGNITION SYSTEM General information The measurements described below will only detect serious defects. Short circuits in the coil that lead to a weak ignition spark or poor generator capacity can only be established on an ignition test stand. In case of a defect, check the cable and the plug and socket connections in the ignition system first.

  • Page 77: Static Ignition Values Kokusan 4k-3a/b

    ELECTRIC SYSTEM STATIC IGNITION VALUES - KOKUSAN 4K-3A, B Measuring conditions: – Cold engine – Seat and tank removed – All plugs and the ground connections are in a non-corroding condition, plugs are tightly connected – Battery charged (if installed) and the light switch turned off –...

  • Page 78

    ELECTRIC SYSTEM...

  • Page 79: Static Generator Values Kokusan 4k3b

    ELECTRIC SYSTEM STATIC GENERATOR VALUES - KOKUSAN 4K-3B Measuring conditions: – Cold engine – Seat and tank removed – All plugs and the ground connections are in a non-corroding condition, plugs are tightly connected – Battery charged (if installed) and the light switch turned off –...

  • Page 80

    ELECTRIC SYSTEM...

  • Page 82: Fuel System

    FUEL SYSTEM KEIHIN FCR-MX 39/41 CARBURETOR...

  • Page 83

    FUEL SYSTEM DISASSEMBLING THE KEIHIN FCR-MX 39/41 CARBURETOR NOTE: Before you start to disassemble the carburetor, make sure your workplace is clean and offers enough room to spread out the individual carburetor parts. – Dismount the carburetor and remove any accumulated dirt. –...

  • Page 84

    FUEL SYSTEM – Turn the carburetor around, remove the 3 screws and remove the cover on the accelerator pump. NOTE: When dismounting the cover, pay special attention to the spring and seal rings since they are easily lost. – Take the 2 seal rings, spring and membrane out of the pump housing.

  • Page 85

    FUEL SYSTEM – Remove screws with special tool 800.29.052.000 and take off the throttle sensor (2). NOTE: Only remove the throttle sensor if it is defective. throttle sensor must readjusted if the screws (1) are loosened. – Remove the screw (3) and pull the connecting piece out of the carburetor.

  • Page 86: Accelerator Pump

    FUEL SYSTEM CHECKING THE CHOKE SLIDE AND THE HOT START KNOB Choke slide: The choke slide must be easily actuated. The piston (1) on the choke slide may not have any deep scores or deposits. Hot start knob: The hot start knob must be easily actuated. The piston on the hot start knob may not have any deep scores or deposits.

  • Page 87: Throttle Slide

    FUEL SYSTEM CHECKING THE THROTTLE SLIDE The rollers (1) on the throttle slide should be easy to turn and not have any flat areas. Check the throttle slide shim (2) for damage. ASSEMBLING THE KEIHIN FCR-MX 39/41 CARBURETOR – Mount the idle-air jet (3) and the main air jet (4). –...

  • Page 88

    FUEL SYSTEM – Mount the spring, washer and the O-ring on the mixture control screw (1) and turn the mixture control screw all the way in to the stop. – Now unscrew the mixture control screw the number of turns written down during disassembly. NOTE: Basic carburetor setting: see Technical specifications.

  • Page 89

    FUEL SYSTEM – Place the spring and the diaphragm (1) in the pump housing with the inscription facing up. – Place the O-ring (2) in the groove. Fix the seal ring (3) in the cover with a little grease and fasten the cover with the 3 screws.

  • Page 90

    FUEL SYSTEM – Position the slide cover with the gasket and fasten with the 2 screws (1). – Attach the vent hoses to the float chamber with the 2 screws (2).

  • Page 91: Adjusting The Throttle Sensor Position

    FUEL SYSTEM ADJUSTING POSITION THROTTLE SENSOR NOTE: The idle speed must be correctly adjusted before you check the position of the throttle sensor. – Disconnect the plug and socket connection on the throttle sensor. – Connect a multimeter (measuring range Ω x 1k) to the blue (+) and the black (–) cable on the throttle sensor and measure the throttle resistance.

  • Page 92: Checking The Throttle Sensor

    FUEL SYSTEM CHECKING THE THROTTLE SENSOR NOTE: The following measurement must be performed at a component temperature of approx. 20°C. – Disconnect the plug connection on the throttle sensor. – Connect a multimeter (measuring range . x 1k) to the blue (+) and the black (–) cable on the throttle sensor.

  • Page 93: Adjusting The Idle

    1 Turn the mixture control screw (2) in all the way to the stop and adjust to the basic setting specified by Husaberg (see Technical Specifications - Engine). 2 Run the engine warm 3 Use the adjusting knurl (1) to set a normal idle speed (1400 - 1500/min).

  • Page 94

    FUEL SYSTEM GENERAL INFORMATION ON CARBURETOR WEAR Engine vibrations make the throttle slide, jet needle and main jet holder subject to increased wear. Wear leads to malfunctioning of the carburetor (e.g. over enrichment). These parts should be replaced after 200 operating hours.

  • Page 96: Troubleshooting

    TROUBLESHOOTING REMEDY ERROR CAUSE Switch on the emergency OFF switch (Australia only) Engine does not switch on Operating error (starter) Replace the fuse in the starter relay Fuse is blown Battery is dead Charge the battery and determine the cause of discharging Low outdoor temperature Start the engine with the kickstarter...

  • Page 97

    TROUBLESHOOTING REMEDY ERROR CAUSE Disassemble the carburetor and check for wear Engine won't rev up Carburetor overflows because the float needle is soiled or worn Loose carburetor jets Tighten the jets Electronic ignition advance is Check the ignition system defective Engine does have...

  • Page 98: Technical Specifications

    TECHNICAL SPECIFICATIONS - ENGINE Engine FC 450/4 FE 450e/6 FS 450e/6 FE 501e/6 Design Liquid-cooled, 1-cylinder 4-stroke Otto engine with balancer weight Displacement 449 cm 501 cm Bore/Stroke 100 / 57,2 mm 95 / 70,7 mm Compression ratio 13:1 11,6:1 Keihin carburetor FCR-MX 41 FCR-MX 39...

  • Page 99: Engine 450, 501

    TECHNICAL SPECIFICATIONS - ENGINE Engine FC 550/4 FE 550e/6 FE 650e/6 FS 650e/6 Design Liquid-cooled, 1-cylinder 4-stroke Otto engine with balancer weight Displacement 550 cm 644 cm Bore/Stroke 100 / 70 mm 100 / 82 mm Compression ratio 11,8:1 11,5:1 Keihin carburetor FCR-MX 41 Fuel...

  • Page 100: Chassis

    1490 ± 10 mm Seat height, unloaded 930 mm 870 mm Ground clearance, unloaded 380 mm 320 mm STANDARD FORK ADJUSTMENT FC 450/4, 550/4 FE 450/501/550/650e/6 FS 450e/6, 650e/6 WP4860MXMA WP4860MXMA WP4860MXMA 14.45Y7.28 14.45Y7.29 14.45Y7.30 Compression damping Rebound damping Spring...

  • Page 101

    TECHNICAL SPECIFICATIONS - ENGINE TIGHTENING TORQUES HH collar bolts on housing, clutch cover, ignition cover 10 Nm Oil drain plug M12x1,5 20 Nm HH plug oil screen M20x1,5 15 Nm AH collar bolt on oil filter cover 6 Nm Plug on pressure relief valve M12x1,5 20 Nm HH bolts on oil pump cover...

  • Page 102: Tightening Torques

    TECHNICAL SPECIFICATIONS - CHASSIS TIGHTENING TORQUES Collar bolt on front wheel spindle M24x1,5 40 Nm Bolts on front brake caliper Loctite 243 + 25 Nm Collar bolts of front brake pads - FS models only 10 Nm Bolts on brake disks Loctite 243 + 10 Nm Clamp bolts on top triple clamp 20 Nm...

  • Page 103: Mounting Clearances, Engine Wear Limits

    TECHNICAL SPECIFICATIONS - ENGINE MOUNTING CLEARANCES, WEAR LIMITS Crankshaft Axial clearance 450......0,15 - 0,25 mm Axial clearance 501, 550.

  • Page 104: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE SCHEDULE FC 450/4, FC 550/4 2004 MODEL 1. service after after/every A clean motorcycle can be checked more quickly which saves money! 2 hours 10 hours 15 l fuel 60 l fuel Change engine oil and oil filter Clean oil screen and drain plug magnet Replace spark plug (after 30 hours) Check and adjust valve clearance...

  • Page 105

    PERIODIC MAINTENANCE SCHEDULE FE 450,501,550,650 /6, FS 450,650 2004 MODEL 1. service after after/every A clean motorcycle can be checked more quickly which saves money! 3 hours 15 hours 20 l fuel 100 l fuel Change engine oil and oil filter...

  • Page 106

    PERIODIC MAINTENANCE SCHEDULE MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER After every For cross- Before each start cleaning country use Check oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regularly...

  • Page 107

    PERIODIC MAINTENANCE SCHEDULE ECOMMENDED INSPECTION OF THE USABERG ENGINES USED FOR HOBBY ENDURO COMPETITIONS BY YOUR USABERG WORKSHOP ADDITIONAL ORDER FOR THE USABERG WORKSHOP a 100 liter fuel consumption is equivalent to approx. 15 operating hours Check the clutch disks for wear Check the length of the clutch springs Check the cylinder and piston for wear Check the groove on the piston pin retainer for wear (visual check)

  • Page 108: Wiring Diagrams

    WIRING DIAGRAMS...

  • Page 109

    WIRING DIAGRAMS...

  • Page 110: Cable Colors

    WIRING DIAGRAMS light switch high/low beam switch cable horn switch color cable LIGHT OFF color P.LIGHT HORN P.LIGHT flasher switch cable brake switch harness cable cable harness switch cable switch TURN L pushed TURN R unpushed start switch cable switch START unpushed...

  • Page 111

    WIRING DIAGRAMS...

  • Page 112

    WIRING DIAGRAMS start switch cable switch START unpushed...

  • Page 113

    WIRING DIAGRAMS...

  • Page 114

    WIRING DIAGRAMS light switch high/low beam switch cable color horn switch LIGHT OFF cable color P.LIGHT HORN P.LIGHT flasher switch cable harness brake switch cable cable switch harness cable TURN L switch TURN R pushed unpushed ignition switch start switch cable switch START...

  • Page 115

    WIRING DIAGRAMS Cable colours bl: black ye: yellow bu: blue gn: green re: red wh: white br: brown or: orange pi: pink gr: grew pu: purple...

  • Page 116

    HUSABERG - a company of the KTM Group Stallhofner Straße 3, A-5230 Mattighofen E-mail: info @ husaberg.cc, Internet: www.husaberg.cc...

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