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INTRODUCTION
SAFETY AND PRECAUTIONS Page 4-
GENERAL INFORMATION
MAINTENANCE SCHEDULE
CONTROLS
STARTING PROCEDURE
ENGINE
FUEL & COOLING
CLUTCH & DECOMPRESSION Page 22
WHEELS & BRAKES
SUSPENSION
WIRING DIAGRAMS
INDEX
Page 2-
Page 6-
Page 9-
Page 12-
Page 15
Page 16-
Page 20-
Page 23-
Page 28-
Page 31-
A LUBRICATION SYSTEM
B IGNITION
C AIR FILTER
D VALVE ADJUSTMENT
A CARBURETTOR
B FUEL
C COOLING SYSTEM
A WHEELS
B CHAIN
C BRAKES
A SUSPENSION
B STEERING HEAD
C SWINGARM
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   Summary of Contents for HUSABERG ENDURO FE 400

  • Page 1 INDEX INTRODUCTION Page 2- SAFETY AND PRECAUTIONS Page 4- GENERAL INFORMATION Page 6- MAINTENANCE SCHEDULE Page 9- CONTROLS Page 12- STARTING PROCEDURE Page 15 A LUBRICATION SYSTEM ENGINE Page 16- B IGNITION C AIR FILTER D VALVE ADJUSTMENT FUEL & COOLING Page 20- A CARBURETTOR B FUEL...
  • Page 2: Introduction

    The material and information included in this Owner’s Manual are all of the latest editions available at the time of the printing. Husaberg Motor AB reserves the right to make changes regarding the products at any time without prior notice.
  • Page 3 Husaberg dealer take care of at least the parts we’ve mentioned under: Also, part of the maintenance has to be performed by an authorized dealer in order to fulfill the terms of warranty.
  • Page 4: Safety And Precautions

    MOTORCYCLE: The motorcycle may become dangerous to ride if it is modified or if any other parts than original Husaberg parts are used. The use of other parts than original makes the warranty no longer valid. Always keep your motorcycle in a safe state and in the best of conditions.
  • Page 5 SAFETY AND PRECAUTIONS PRE-RIDE INSPECTION CHECK LIST Engine oil Check the level and fill up if necessary. Check for any leakages in the casing. Ignition Check the sparkplug cap/HV lead for damages. Radiator Check the coolant level and fill up if necessary. Check for leakages and/or damages of the cells and hoses and attachments.
  • Page 6: General Information

    GENERAL INFORMATION SPECIFICATIONS SUBJECT/MODEL ENDURO MOTOCROSS ELDURO DESERT (FX) Engine type Liquid cooled, 4-stroke single cylinder, SOHC-4 valves Displacements 400-models: 399cc / Bore 92,0 mm x Stroke 60,1 mm 501-models: 501cc / Bore 95,0 mm x Stroke 70,7 mm 600-models: 595cc / Bore 95,0 mm x Stroke 84,0 mm Compression ratio 400-models: 12,0:1 501-models: 11,8:1...
  • Page 7: Specifications

    WP MXMA 4358 HUSABERG-MX Rear suspension Progressive Damping System - PDS Progressive Damping System - PDS WP 5018 HUSABERG-E 320 mm WP 5018 HUSABERG-MX 320 mm Front brake BREMBO, hydraulic, twin piston (Super Motard four piston) floating caliper ø 260 mm (Super Motard ø 320 mm) stainless steel brake disc...
  • Page 8 GENERAL INFORMATION CARBURETTOR STD. JETTINGS MODEL/SUBJECT Main Needle Needle Needle Pilot Throttle Float Start Mixture clip pos. valve screw (Exploded view number) # 26 # 33 ENDURO FE 400 DR 270 K 35 2 turns FE 501 DR 270 K 51 1½...
  • Page 9: Maintenance Schedule

    GENERAL INFORMATION TORQUE VALUES SUBJECT TORQUE NOTE Intake manifold screws 5 Nm Oil filter cover screws 5 Nm Reed valve screws Apply a threadlock liquid 5 Nm Valve inspection cover screws 5 Nm Waterpump cover screws 5 Nm Stator screws 8 Nm Crankcase screws 10 Nm...
  • Page 10 MAINTENANCE SCHEDULE Engine - Motocross and Desert models Please observe: Riding under hard conditions demands more frequent maintenance 5 5 5 5 5 l i o R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C t l i f R R R R R...
  • Page 11 MAINTENANCE SCHEDULE Engine - Enduro and Elduro models Please observe: Riding under hard conditions demands more frequent maintenance l i o R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C t l i f R R R R R...
  • Page 12: Controls

    CONTROLS IDENTIFACTION NUMBERS Fig. The Vehicle Identification Number is placed on the right side of the steering head (Fig. 5A-1). The Engine Number is placed on the right side of the engine, just below the cylinder (Fig. 5B-1). STEERING LOCK The lock (if incl.
  • Page 13 CONTROLS Fig. 5E Combination switch Type I: Fig. 1- Headlight switch (Parking - Off - Low - High beam) 2- Turn signal switch 3- Horn button 4- Engine shortcircuit button 5- Clutch lever adjustment 6- Clutch lever 7- Manual dekompression lever Fig.
  • Page 14 CONTROLS Fig 5I 1- Twistgrip Fig. (Electrical starter models) 2- Electrical starter button 3- Engine shortcircuit switch Fig. Fig. 7A Fig. 5K 1- Twistgrip Fig. (Non-electrical starter models) 2- Frontbrake lever 3- Frontbrake fluid reservoir Fig. 5L 1- Speedometer Fig. (If incl.
  • Page 15: Starting Procedure

    STARTING PROCEDURE Kick starter models: Fig. Follow the checklist on page 5. Turn the fuel tap/taps (Fig. 6A-1) to position ON (Fig. 6B-1). Cold engine: Turn the choke lever (Fig 6A-2) to position ON (Fig. 6B-2) by pulling it downwards and twisting it 90°.
  • Page 16: Engine

    ENGINE LUBRICATION SYSTEM: Fig. Always use a synthetic oil of a well-known brand, viscosity SAE 5W-50. Depending on the basic design of the engine; competition purposes = equal to a small sized engine thus giving a small capacity of oil, it is vital that the oil is frequently changed.
  • Page 17 ENGINE IGNITION: Fig. The ignition system is a CDI-system without any contact-breaker to change or any other moving parts apart from the flywheel. However, the system has to be frequently checked and cleaned for a maximum of durability and performance. The inside of the ignition cover, the stator, the flywheel and the surroundings are preferably cleaned after every time the motorcycle has...
  • Page 18 ENGINE AIRFILTER: Fig. To avoid any engine damages or lack of power the air filter has to be frequently cleaned or replaced. Always use a well-known brand of filter oil after cleaning. Use an airfilter cleaning solvent of a well-known brand. Always check the surface of the filter attachment and the filter basket for any damages.
  • Page 19 ENGINE VALVES: Fig. The clearances between the valve adjustment screws and the valve stems have to be checked after 2 hours of operation when the engine is brand new or any parts of the valves, valve seats or rockerarms have been changed. The interval between the checks of the clearences is afterwards every 10 hours (Motocross and Desert models) or 20 hours (all...
  • Page 20: Fuel & Cooling

    FUEL & COOLING CARBURETTOR: Fig. Always make sure that the throttle (Fig. 8A-1) returns to a fully closed position. Always make sure that the twistgrip and cable move easily. Always keep the twistgrip and cable well cleaned and lubricated. The tube on top of the carburettor (Fig.
  • Page 21 FUEL & COOLING 8 B/C FUEL: Fig. The Husaberg motorcycle is developed and designed for competition use and this makes a high compression ratio a necessity. In order to avoid any damages caused by too low grade of octane we highly recommend you to use a fuel of minimum 98 octane.
  • Page 22: Clutch & Decompression

    CLUTCH & DECOMPRESSION CLUTCH: Fig. Check the hydraulic line for any leakages or deterioration. Always check the level of fluid in the reservoir. The cover of the reservoir has to be removed in order to check the level (Fig. 9A-1). Adjust the pressure point of the lever according to your own preferences with the adjustment knob (Fig.
  • Page 23: Wheels & Brakes

    WHEELS & BRAKES 10 A FRONT WHEEL: Fig. Always check the front wheel for any damages regarding the rim, the spokes and the nipples. Check the bearings for any wear and/or damages. Tighten any loose spokes (spoke wrench No.5.5). All spokes have to be equally tensioned. Removal of front wheel: Remove the hexagon nut (Fig.
  • Page 24 WHEELS & BRAKES 10 A WHEEL BEARING RENEWAL: Fig. Remove the wheel (see previous page). Position the wheel so that the bearings (Fig. 10C2-2) are easily removed from the inside of the hub. Remove the radial sealing (Fig. 10C-1) in order to be able to remove the circlip (Fig.
  • Page 25 WHEELS & BRAKES 10 B CHAIN: Fig. The Husaberg motorcycle is delivered with a chain of X-ring type. If properly serviced it will last for a long period. Always keep the chain well cleaned and lubricated and make sure that the chain is Maximum 272 mm properly tensioned.
  • Page 26 WHEELS & BRAKES 10 C FRONT BRAKE: Fig. The Husaberg motorcycle is equipped with a Brembo hydraulic disc brake. For your own safety it needs to be frequently serviced and checked. Always check the level of brake fluid in the reservoir.
  • Page 27 WHEELS & BRAKES 10 C REAR BRAKE: Fig. The Husaberg motorcycle is equipped with a Brembo hydraulic disc brake. For your own safety it needs to be frequently serviced and checked. Always check the level of brake fluid in the reservoir (Fig.
  • Page 28: Suspension

    SUSPENSION 11 A FRONT SUSPENSION: Fig. The Husaberg motorcycle is delivered with an adjustable front fork from WP. For a maximum performance it needs to be adjusted according to the riding conditions and the rider's weight and preferences. The front fork is pre-adjusted...
  • Page 29 SUSPENSION 11 A REAR SUSPENSION: Fig. The Husaberg motorcycle is delivered with an adjustable shock absorber from WP. For a maximum performance it needs to be adjusted according to the riding conditions and the rider's weight and preferences. The shock absorber is...
  • Page 30 SUSPENSION 11 B/C STEERING HEAD: Fig. The clearance has to be checked frequently. Put the motorcycle on a centerstand with the front wheel fully off the ground. Turn the handlebar in both directions. It should not be either too easy nor too hard to move. Also move it front and backwards in order to check the clearance (no "clicking"...
  • Page 31: Wiring Diagrams

    WIRING DIAGRAMS NOTE ! The alternator delivers 70W in each of the yellow wires. Only one of these is connected from the factory. Both wires only to be connected whenever in a need of more than 70W though this creates more heat which causes a higher risk of failure to the alternator.
  • Page 32 WIRING DIAGRAMS NOTE ! The alternator delivers 70W in each of the yellow wires. Only one of these is connected from the factory. Both wires only to be connected whenever in a need of more than 70W though this creates more heat which causes a higher risk of failure to the alternator.
  • Page 33 WIRING DIAGRAMS below Elduro and Dual Sport models except Elduro US-models...
  • Page 34 WIRING DIAGRAMS Elduro models USA Desert models...

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