HUSABERG FE 450 EU Repair Manual
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HUSABERG FE 450 EU Repair Manual

2009 year
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REPAIR MANUAL
FE 450 EU
FE 450 AUS
FE 450 USA
FE 570 EU
FE 570 AUS
FE 570 USA
2009
Article no. 3803004en

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Summary of Contents for HUSABERG FE 450 EU

  • Page 1 REPAIR MANUAL FE 450 EU FE 450 AUS FE 450 USA FE 570 EU FE 570 AUS FE 570 USA 2009 Article no. 3803004en...
  • Page 3 It is assumed that repair work will be performed by a fully trained mechanic. All specifications are non-binding. HUSABERG, a division of KTM SMC AG (referred to herein as HUSABERG), specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice.

  • Page 4: Table Of Contents

    CONTENTS Disassembling the rebound adjuster ........ 40 CONTENTS MEANS OF REPRESENTATION ..........5 Removing the heim joint ..........41 IMPORTANT NOTES ............6 Installing the heim joint ..........41 LOCATION OF SERIAL NUMBERS ........7 Assembling the rebound adjuster ........42 Chassis number...............
  • Page 5 CONTENTS 13/BRAKE SYSTEM............78 Removing the primary gear ........... 106 Checking the free travel of the hand brake lever ....78 Removing the free wheel gear ........107 Adjusting the free travel of the handbrake lever (FE EU, Removing the torque limiter ......... 107 FE AUS) ...............
  • Page 6 Installing the piston............. 145 Important maintenance work to be carried out by an Installing the cylinder head .......... 147 authorized HUSABERG workshop. (as additional order) ... 233 Installing the camshaft ..........148 Important checks and maintenance work to be carried Installing the timing chain tensioner ......

  • Page 7: Means Of Representation

    MEANS OF REPRESENTATION Symbols used The symbols used are explained in the following. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Identifies a page reference (more information is provided on the specified page). Formats used The typographical and other formats used are explained in the following.

  • Page 8: Important Notes

    Warranty The work prescribed in the service schedule must be carried out in an authorized HUSABERG workshop and confirmed in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 9: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head.  100345-10 Type label (FE EU, FE AUS) The type label is fixed to the frame at the front right.  100458-10 Type label (FE USA) The type label...

  • Page 10: Fork Part Number

    LOCATION OF SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub.  100348-10 Shock absorber part number The shock absorber part number is stamped on the upper part of the shock absorber ...

  • Page 11: Motorcycle

    MOTORCYCLE Jacking up the motorcycle Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. – Jack up the motorcycle underneath the engine. The wheels must no longer touch the ground.

  • Page 12: 01/Fork, Triple Clamp

    01/FORK, TRIPLE CLAMP Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Remove protection covers  – Turn adjusting screws clockwise until they stop.  Info Adjusting screws are located at the bottom end of the fork legs. ...

  • Page 13: Bleeding The Fork Legs

    01/FORK, TRIPLE CLAMP Info Turn clockwise to increase spring preload, turn counterclockwise to reduce spring preload. Adjusting the spring preload has no influence on the absorption setting of the rebound damping. Basically, however, you should set the rebound damping higher with a higher spring preload.

  • Page 14: Positioning The Fork Protection

    01/FORK, TRIPLE CLAMP Positioning the fork protection – Position the fork protection on the left fork leg. Mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake line and cable harness. Put the clamp on, and mount and tighten screws ...

  • Page 15: Removing The Fork Protector

    01/FORK, TRIPLE CLAMP – Tighten screws  Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – Tighten screws  Guideline Screw, bottom triple clamp 12 Nm (8.9 lbf ft) 300715-11 – Position the brake caliper. Mount and tighten screws ...

  • Page 16: Performing A Fork Service

    01/FORK, TRIPLE CLAMP Performing a fork service 5.12 Info These operations are the same on both fork legs. Condition The fork legs have been removed. – Disassemble the fork legs. ( p. 14) – Disassemble the cartridge. ( p. 17) –...
  • Page 17 01/FORK, TRIPLE CLAMP – Loosen Preload Adjuster  Pin wrench (T103) ( p. 274) Info The Preload Adjuster cannot be taken off yet. 200737-10 – Take out the fork leg and clamp in with the axle clamp. Info Use soft jaws. 200690-10 –...
  • Page 18 01/FORK, TRIPLE CLAMP – Drain the fork oil. Info Pull out and push in the piston rod several times in order to pump out the cartridge until it is empty. 200650-01 – Clamp in the fork leg with the axle clamp. –...

  • Page 19: Cartridge Disassembly

    01/FORK, TRIPLE CLAMP – Remove upper sliding bushing  Info Gently pull them apart without using any tool. 200658-01 – Take off the lower sliding bushing  – Take off support ring  – Take off seal ring  – Take off lock ring ...
  • Page 20 01/FORK, TRIPLE CLAMP – Degrease the cartridge and clamp using the pecial tool. Clamping stand (T14015S) ( p. 276) – Warm up the cartridge in the area of  Guideline 50 °C (122 °F) – Unscrew and remove screwsleeve  Info 200749-10 This step is unnecessary for the further disassembly.

  • Page 21: Disassembling The Compression Damping Fitting

    01/FORK, TRIPLE CLAMP Disassembling the compression damping fitting 5.15 Info The steps are identical for both fork legs. – Disassemble the fork legs. ( p. 14) – Clamp the compression damping fitting in a bench vise using soft jaws. – Remove nut ...

  • Page 22: Assembling The Compression Damping Fitting

    01/FORK, TRIPLE CLAMP – Measure the run-out of the inner tube. ≤ 0.20 mm (≤ 0.0079 in) Inner tub run-out » If the measured value is larger than the specified value: – Replace the inner tube. 200685-10 – Check the outer tube for damage. »...

  • Page 23: Assembling The Cartridge

    01/FORK, TRIPLE CLAMP – Mount shim stack  Info Mount the smaller shims below. – Mount pistons with O-ring   Info The side with the largest inside diameter faces upward.  200705-10 – Grease the piston O-ring. Fork oil (SAE 5) ( p.
  • Page 24 01/FORK, TRIPLE CLAMP Info The side with the largest inside diameter faces downward. – Mount shim stack  Info Align the triangular plate exactly with the piston opening. – Mount and tighten nut  Guideline Tap rebound nut M6x0.5 5 Nm (3.7 lbf ft) 200720-10 Info Mount the nut with the collar facing downward.

  • Page 25: Assembling The Fork Legs

    01/FORK, TRIPLE CLAMP Assembling the fork legs 5.19 Info The steps are identical for both fork legs. – Check the fork legs. ( p. 19) – Assemble the cartridge. ( p. 21) – Assemble the compression damping fitting. ( p. 20) –...
  • Page 26 01/FORK, TRIPLE CLAMP – Position the support ring. – Hold the seal ring with the shorter shoulder of the special tool. Assembly tool (T1402S) ( p. 276) – Press the outer tube all the way in. 200724-10 – Mount lock ring ...
  • Page 27 01/FORK, TRIPLE CLAMP – Clamp in the fork vertically. – Fill with fork oil. Fork oil per fork 620 ml Fork oil (SAE 5) ( p. 263) (20.96 fl. oz.) Info Pull out and push in the piston rod several times in order to bleed air from the cartridge.
  • Page 28 01/FORK, TRIPLE CLAMP – Push the outer tube upward. – Clamp the outer tube in the area of lower triple clamp. Clamping stand (T1403S) ( p. 277) – Grease the Preload Adjuster O-ring. Lubricant (T158) ( p. 265) – Screw on and tighten the Preload Adjuster. Guideline 200744-10 Preload Adjuster on the outer tube...

  • Page 29: Greasing The Steering Head Bearing

    01/FORK, TRIPLE CLAMP Greasing the steering head bearing 5.20 – Remove the lower triple clamp. ( p. 27) – Install the lower triple clamp. ( p. 28) 800010-10 Removing the lower triple clamp 5.21 – Remove the fork legs. ( p.

  • Page 30: Installing The Lower Triple Clamp

    01/FORK, TRIPLE CLAMP Installing the lower triple clamp 5.22 – Clean and grease the earings and sealing elements. Long-life grease ( p. 265) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. – Slide on protective ring and O-ring ...

  • Page 31: Checking The Play Of The Steering Head Bearing

    01/FORK, TRIPLE CLAMP Checking the play of the steering head bearing 5.23 Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. Info If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time.

  • Page 32: 03/Frame

    03/FRAME Removing the engine guard – Remove screw . Remove the engine guard.  100450-10 Installing the engine guard – Attach the engine guard on the frame at the rear and swing it up and forward. Mount and tighten screw ...

  • Page 33: 04/Shock Absorber, Swingarm

    04/SHOCK ABSORBER, SWINGARM Adjusting the high-speed compression damping of the shock absorber Danger 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. Info The high-speed setting can be seen during the fast compression of the shock absorber. –...

  • Page 34: Adjusting The Rebound Damping Of The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Adjusting the rebound damping of the shock absorber Danger 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. – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 35: Checking The Riding Sag Of The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 32)  – With another person holding the motorcycle, the rider, wearing full protective cloth- ing, sits on the saddle in a normal sitting position (feet on footrests) and bounce up and down a few times until the rear suspension levels out.

  • Page 36: Adjusting The Riding Sag

    04/SHOCK ABSORBER, SWINGARM Adjusting the riding sag – Remove the shock absorber. ( p. 34) – After removing the shock absorber, clean it thoroughly. – Choose and mount a suitable spring. Guideline Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 69 N/mm (394 lb/in) Weight of rider: 75…...

  • Page 37: Performing A Shock Absorber Service

    04/SHOCK ABSORBER, SWINGARM Performing a shock absorber service 7.11 Condition The shock absorber has been removed. – Remove the spring. ( p. 35) – Disassemble the shock absorber. ( p. 36) – Disassemble the piston rod. ( p. 37) – Disassemble the seal ring retainer.

  • Page 38: Disassembling The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Disassembling the shock absorber 7.13 – Remove the spring. ( p. 35) – Take note of the present state of rebound damping and compression damp-   – Completely open the adjustment elements of the rebound damping and compres- sion damping.

  • Page 39: Disassembling The Piston Rod

    04/SHOCK ABSORBER, SWINGARM – Remove adjusting ring with the intermediate washer.  200759-10 – Remove compression damping adjuster . Remove the spring and piston.  200760-10 Disassembling the piston rod 7.14 – Disassemble the shock absorber. ( p. 36) – Clamp the piston rod with the fork in a bench vise.

  • Page 40: Disassembling The Seal Ring Retainer

    04/SHOCK ABSORBER, SWINGARM – Remove piston  – Remove compression damping shim stack  Info Guide the compression damping shim stack onto a screwdriver and put them aside together. 200764-10 – Remove rebound damping washer  – Remove seal ring retainer ...

  • Page 41: Replacing The Pilot Bushing

    04/SHOCK ABSORBER, SWINGARM Replacing the pilot bushing 7.16 – Disassemble the seal ring retainer. ( p. 38) – Press pilot bushing out of seal ring retainer using the special tool.   Press drift (T1504) ( p. 277) 200796-10 – Slide the new pilot bushing onto the special tool.

  • Page 42: Disassembling The Rebound Adjuster

    04/SHOCK ABSORBER, SWINGARM – Measure the diameter of the piston rod. Piston rod ≥ 17.95 mm (≥ 0.7067 in) Diameter » If the specified value was not attained: – Replace the piston rod. – Measure the run-out of the piston rod. Piston rod 200812-10 ≤...

  • Page 43: Removing The Heim Joint

    04/SHOCK ABSORBER, SWINGARM Removing the heim joint 7.19 Condition The shock absorber has been demounted. – Clamp shock absorber in a bench vise using soft jaws. – Remove the collar bushing of the heim joint with a punch. – Turn the shock absorber around and remove the second heim joint collar bushing with a punch.

  • Page 44: Assembling The Rebound Adjuster

    04/SHOCK ABSORBER, SWINGARM – Press the heim joint against the lock ring using the special tool. Pressing tool (T1207S) ( p. 275) – Mount the second lock ring  200801-10 – Mount seal ring on both sides.  200800-11 – Position both collar bushings and press in.

  • Page 45: Assembling The Seal Ring Retainer

    04/SHOCK ABSORBER, SWINGARM Assembling the seal ring retainer 7.22 – Mount dust boot with the special tool.  Mounting sleeve (T1204) ( p. 274) – Grease the sealing lip of the dust boot. Lubricant (T625) ( p. 266) 200792-10 – Grease the O-ring groove.
  • Page 46 04/SHOCK ABSORBER, SWINGARM – Mount rebound damping washer  – Mount compression damping shim stack with the smaller shims facing down-  ward. 200767-10 – Grind piston on both sides on a surface plate using 1200 grit sandpaper.  – Clean the piston.

  • Page 47: Assembling The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM – Align both pistons using the special tool. Centering sleeve (T1214) ( p. 275) – Tighten the nut. Guideline Piston rod nut M16x1 40 Nm (29.5 lbf ft) – Remove the special tool. 200776-10 Assembling the shock absorber 7.24 –...
  • Page 48 04/SHOCK ABSORBER, SWINGARM – Mount seal ring retainer and slide it under the ring groove.  – Mount lock ring  Info Do not scratch the inner surface. – Pull out the piston rod in order that the seal ring retainer fits closely against the lock ring.

  • Page 49: Bleeding And Filling The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Alternative 2 Warning Danger of accidents Modifications to the chassis can seriously alter the vehicle's handling characteristics. – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. –...
  • Page 50 04/SHOCK ABSORBER, SWINGARM – As soon as the vacuum gauge has attained the specified value, turn the Oil reser- voir control lever to Equalize pressure.  Guideline 4 mbar The pressure gauge rises to the specified value. 0 bar 200267-10 –...

  • Page 51: Filling The Shock Absorber With Nitrogen

    04/SHOCK ABSORBER, SWINGARM – As soon as the pressure gauge has attained the specified value, turn the Damper  control lever to Vacuum. Guideline 3 bar The pressure gauge drops to the specified value. 0 bar – As soon as the pressure gauge has attained the specified value hat, turn off the On/Off switch.

  • Page 52: Installing The Spring

    04/SHOCK ABSORBER, SWINGARM – Position the shock absorber in the special tool. The hexagonal part of tap handle engages in the hexagon socket of the  screw of the filling port. – Open spigot  – Fill the shock absorber for at least 15 seconds. Guideline Gas pressure 10 bar (145 psi)

  • Page 53: Removing The Swingarm, With Shock Absorber And Rear Wheel

    04/SHOCK ABSORBER, SWINGARM – Tighten the spring by turning the adjusting ring to the measured value deter- mined when it was removed. Hook wrench (T106S) ( p. 274) – Tighten screw  Guideline Screw, shock absorber adjusting ring 5 Nm (3.7 lbf ft) 200750-11 Removing the swingarm, with shock absorber and rear wheel 7.28...

  • Page 54: Installing The Swingarm, With Shock Absorber And Rear Wheel

    04/SHOCK ABSORBER, SWINGARM – Remove nut  – Remove the swingarm pivot. 300685-10 – Remove the swingarm, with the shock absorber and rear wheel. 300686-10 Installing the swingarm, with shock absorber and rear wheel 7.29 Condition The motorcycle is jacked up. The fuel tank has been removed.
  • Page 55 04/SHOCK ABSORBER, SWINGARM – Position the master brake cylinder. – Mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Mount and tighten screw  Guideline Screw, ball joint of push rod on foot- 10 Nm (7.4 lbf ft) brake cylinder 300682-11 –...

  • Page 56: 05/Exhaust

    05/EXHAUST Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. – Disconnect spring  – Remove screws and take off the main silencer. ...

  • Page 57: Installing The Exhaust System

    05/EXHAUST – Remove screws  – Take off the exhaust manifold along with gasket. 300678-10 – Remove screw  300680-10 – Remove screws  – Take off the right engine mounting bracket. – Maneuver out the exhaust pipe. 300679-10 Installing the exhaust system –...
  • Page 58 05/EXHAUST – Mount and tighten screw  Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) – Tighten screw  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the exhaust clamp. 300677-11 – Tighten screw  Guideline Screw, exhaust clamp on manifold 8 Nm (5.9 lbf ft) –...

  • Page 59: 06/Air Filter

    06/AIR FILTER Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 60 06/AIR FILTER Info Only press the air filter to dry it, never wring it out. – Oil the dry air filter with a high quality filter oil. Oil for foam air filter ( p. 266) – Clean the intake flange and check it for damage and tightness. –...

  • Page 61: 07/Fuel Tank, Seat, Trim

    07/FUEL TANK, SEAT, TRIM Removing the seat 10.1 – Pull on the loop while raising the rear of the seat.  – Pull the seat back and lift it off. 100362-10 Mounting the seat 10.2 – Attach the seat to the hooks on fuel tank and on the top part of subframe ...

  • Page 62: Installing The Fuel Tank

    07/FUEL TANK, SEAT, TRIM – Detach connector of the fuel pump.  100434-10 – Thoroughly clean the plug-in connection of the fuel line using compressed air.  Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line will clog the fuel injection jets.

  • Page 63: Removing The Spoiler

    07/FUEL TANK, SEAT, TRIM – Remove the wash cap set. Oil the O-ring and connect plug-in connector of the  fuel line. Info Route the cable and fuel line at a safe distance from the exhaust system. 100439-10 – Position the top part of the subframe. –...

  • Page 64: Checking The Fuel Pressure

    07/FUEL TANK, SEAT, TRIM Checking the fuel pressure 10.7 – Press on the small metal plate and disconnect the fuel hose connection  300727-10 – Mount the special tool. Pressure testing tool (61029094000) ( p. 269) Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon- sciousness and/or death.

  • Page 65: 08/Mask, Fender, Decal

    08/MASK, FENDER, DECAL Removing the front fender 11.1 (FE EU, FE AUS) – Remove the headlight mask with the headlight. ( p. 88) (FE USA) – Remove the start number plate. ( p. 63) – Remove screws  – Take out the brake line and wiring harness from the brake line guide. (FE EU, FE AUS) –...

  • Page 66: Installing The Start Number Plate (Fe Usa)

    08/MASK, FENDER, DECAL Installing the start number plate (FE USA) 11.4 – Position the start number plate. Mount and tighten screw  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Info Ensure engagement of the holding lugs on the fender. –...

  • Page 67: 09/Front Wheel

    09/FRONT WHEEL Removing the front wheel 12.1 – Jack up the motorcycle. ( p. 9) – Press the brake caliper by hand on to the brake disc in order to press 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 68: Checking The Tire Air Pressure

    12.4 Info Only mount tires approved or recommended by HUSABERG. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.

  • Page 69: Checking The Brake Disks

    DOT code. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. HUSABERG recommends replacing the tires after five years at the latest, regardless of the actual wear. »...

  • Page 70: 10/Rear Wheel

    10/REAR WHEEL Removing the rear wheel 13.1 – Jack up the motorcycle. ( p. 9) – Press the brake caliper by hand on to the brake disc in order to press back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

  • Page 71: Checking The Chain Tension

    10/REAR WHEEL – Position chain adjuster . Mount nut , but do not tighten it yet.   – Check the chain tension. ( p. 69) – Make sure that chain adjusters are fitted correctly on adjusting screws   –...

  • Page 72: Checking The Chain Wear

    10/REAR WHEEL – Push the chain at the end of the chain sliding component upwards to measure the chain tension  Info The upper chain section must be taut.  Because chain wear is not always even, you should repeat this measurement at different chain positions.

  • Page 73: Checking The Rear Sprocket/Engine Sprocket For Wear

    10/REAR WHEEL Checking the rear sprocket/engine sprocket for wear 13.6 – Check the rear sprocket/engine sprocket for wear. » If the rear sprocket/engine sprocket are worn: – Replace the rear sprocket/engine sprocket. Info When fitting the chain joint, always make sure that the closed side of the joint faces forward (riding direction).

  • Page 74: Adjusting The Chain Guide

    10/REAR WHEEL Adjusting the chain guide 13.9 – Remove screws . Take off the chain guide.   Condition Number of teeth: ≤ 44 teeth – Insert nut in hole . Position the chain guide.   – Mount and tighten screws ...

  • Page 75: 11/Wiring Harness, Battery

    11/WIRING HARNESS, BATTERY Disconnecting the negative cable of the battery 14.1 – Switch off all power consumers and the engine. – Remove the seat. ( p. 59) – Disconnect negative cable of the battery.  Info Pay attention to the contact disks between the cable sockets and battery terminals.

  • Page 76: Changing The Fuses Of Individual Power Consumers

    11/WIRING HARNESS, BATTERY – Remove faulty main fuse  Info You can recognize a faulty fuse by the burned-out fuse wire  A reserve fuse is located in the starter relay.  – Insert a new main fuse. Fuse (58011109120) –...

  • Page 77: Removing The Battery

    11/WIRING HARNESS, BATTERY – Check that the power consumer is functioning properly. – Close the fuse box cover. – Mount the seat. ( p. 59) Removing the battery 14.5 Warning Risk of injury Battery acid and battery gases cause serious chemical burns. –...

  • Page 78: Charging The Battery

    – Do not dispose of batteries with the regular garbage. Dispose of defective batteries in an environmentally responsible man- ner. Take the batteries to your HUSABERG dealer or to a collection point for old batteries. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 79 If the vehicle is not ridden for more than two weeks, we recommend trickle 100425-10 charging the battery with the HUSABERG battery charger. The battery is first charged completely and then maintained at this level over the subse- quent period. Thus, the battery is always fully charged when the vehicle is put into operation.

  • Page 80: 13/Brake System

    13/BRAKE SYSTEM Checking the free travel of the hand brake lever 15.1 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 in the brake system. The front brake can fail due to overheating.

  • Page 81: Checking The Front Brake Fluid Level

    13/BRAKE SYSTEM Checking the front brake fluid level 15.4 Warning Danger of accidents Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding.

  • Page 82: Checking The Front Brake Linings

    13/BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  – Remove cover with membrane   – Add brake fluid to level  Guideline Measurement of 5 mm (0.2 in) ...
  • Page 83 HUSABERG brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

  • Page 84: Checking The Free Travel Of The Foot Brake Lever

    13/BRAKE SYSTEM – Correct the brake fluid quantity to level  Guideline Measurement of 5 mm (0.2 in)  Brake fluid DOT 4 / DOT 5.1 ( p. 263) – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water.

  • Page 85: Checking The Rear Brake Fluid Level

    13/BRAKE SYSTEM Checking the rear brake fluid level 15.10 Warning Danger of accidents Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding.

  • Page 86: Checking The Rear Brake Linings

    HUSABERG brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
  • Page 87 13/BRAKE SYSTEM – Stand the vehicle upright. – Remove screw cap with membrane and the O-ring.   – Press the brake caliper by hand on to the brake disc in order to press back the brake piston. Ensure that brake fluid does not overflow from the brake fluid reser- voir, using suction to remove it if it does.

  • Page 88: 14/Lighting System, Instruments

    14/LIGHTING SYSTEM, INSTRUMENTS Adjusting the speedometer functions 16.1 Info Upon delivery, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is standing. – briefly and repeatedly until H appears at the bottom right of the Press the button display.

  • Page 89: Activating The Additional Functions

    14/LIGHTING SYSTEM, INSTRUMENTS Activating the additional functions 16.3 Danger Voiding of the government approval for road use and the insurance coverage The vehicle is only authorized for operation on pub- lic roads in the homologous version. – If the vehicle is modified in any way, then it may only be operated in closed off areas remote from public road traffic. Advise the vehicle owner and rider of this.

  • Page 90: Setting The Clock

    14/LIGHTING SYSTEM, INSTRUMENTS Info If no button is actuated for 20 seconds or there is no signal from the wheel speed sensor, then the settings are automatically stored and the setup menu closed. Setting the clock 16.5 Condition The motorcycle is standing. –...

  • Page 91: Checking The Headlight Adjustment (Fe Eu, Fe Aus)

    14/LIGHTING SYSTEM, INSTRUMENTS – Wrap rubber band around the fork legs and close it.  The wiring harness and brake line are routed in front of the headlight mask.  – Check the headlight adjustment. ( p. 89) 100461-10 Checking the headlight adjustment (FE EU, FE AUS) 16.8 –...
  • Page 92 14/LIGHTING SYSTEM, INSTRUMENTS – Press headlight bulb into the bulb socket lightly, turn it counterclockwise all the  way and pull it out. – Insert a new headlight bulb. Headlight (S2/socket BA20d) ( p. 224) – Insert the rubber cap together with the bulb socket into the reflector, turn it clock- wise all the way.

  • Page 93: 30/Engine

    30/ENGINE Removing the engine 17.1 – Remove the engine guard. ( p. 30) – Jack up the motorcycle. ( p. 9) – Disconnect the negative cable of the battery. ( p. 73) – Drain the coolant. ( p. 155) – Remove the main silencer.
  • Page 94 30/ENGINE – Remove screws  – Remove screw  – Take off the engine sprocket cover. 300692-10 – Remove screw  – Take off the clutch slave cylinder and allow it to hang to the side. Info Do not allow the clutch line to become kinked. Do not actuate the clutch lever while the slave cylinder of the clutch is removed.
  • Page 95 30/ENGINE – Remove spring  300695-10 – Take off the spark plug connector. – Disconnect coolant temperature sensor connector  300702-10 – Expose the cable. – Separate plug-in connector of the ignition pulse generator.  300696-10 – Separate plug-in connector of the generator.

  • Page 96: Installing The Engine

    30/ENGINE – Lift out the engine from the side. Info It is recommended to have assistance for performing this step. Ensure that the motorcycle is sufficiently secured against falling over. Protect the frame and attachments against damage. 300700-10 Installing the engine 17.2 –...
  • Page 97 30/ENGINE – Tighten screw  Guideline Engine carrying screw 60 Nm (44.3 lbf ft) – Tighten screws  Guideline Screw, engine brace 33 Nm (24.3 lbf ft) – Tighten the swingarm pivot nut. Guideline Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) 300685-12 –...
  • Page 98 30/ENGINE – Mount the radiator hose. – Mount hose clip and tighten it.  300707-10 – Mount the radiator hose. – Mount hose clip and tighten it.  300708-10 – Mount the radiator hose. – Mount hose clip and tighten it. ...
  • Page 99 30/ENGINE – Position the clutch slave cylinder. – Mount and tighten screw  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the shift lever. – Mount and tighten screw  Guideline Loctite 243™ Screw, shift lever 10 Nm ®...
  • Page 100 – Refill the coolant. ( p. 155) – Make a short test ride. – Read out the fault memory using the HUSABERG diagnostic tool. – Check the engine for leakage. 300804-10 – Check the engine oil level. ( p. 158) –...

  • Page 101: 30/Engine Disassembly

    30/ENGINE DISASSEMBLY Clamping the engine in the engine work stand 18.1 – Mount special tool on engine work stand   Engine work stand (61229001000) ( p. 270) Fitting for work stand (81229002000) ( p. 273) – Mount the engine on special tool ...

  • Page 102: Removing The Valve Cover

    30/ENGINE DISASSEMBLY – Pull oil filter element out of the oil filter housing.  Circlip pliers reverse (51012011000) ( p. 268) 300294-10 Removing the valve cover 18.6 – Remove screws . Remove the valve cover with the valve cover seal. ...

  • Page 103: Removing The Timing Chain Tensioner

    30/ENGINE DISASSEMBLY – Remove screw  Info Check through the drill hole whether the position groove of the crankshaft is visible. 300299-10 – Screw in special tool  Crankshaft locking bolt (113080802) ( p. 267) 300300-10 Removing the timing chain tensioner 18.10 –...

  • Page 104: Removing The Cylinder Head

    30/ENGINE DISASSEMBLY – Pull the camshaft out of the bearing seats. Take the timing chain off of the camshaft gear. Remove the camshaft. 300305-10 Removing the cylinder head 18.12 – Remove screw  – Unscrew screws in a crisscross pattern and remove. ...

  • Page 105: Removing The Rotor

    30/ENGINE DISASSEMBLY Removing the rotor 18.15 – Remove nut with the spring washer.  300309-10 – Attach special tool to the rotor. Counteracting with the special tool, pull off the  rotor by screwing in the screw. Extractor (58012009000) ( p.

  • Page 106: Removing The Timing Chain Securing Guide

    30/ENGINE DISASSEMBLY Removing the timing chain securing guide 18.19 – Remove screws . Take off the timing chain securing guide.  300315-10 Removing the timing chain 18.20 – Take off the timing chain. Info Identify the direction of travel. 300316-10 Removing the ignition pulse generator 18.21 –...

  • Page 107: Disassembling The Clutch Disks

    30/ENGINE DISASSEMBLY – Take out dowels . Take off clutch cover gasket   300320-10 Disassembling the clutch disks 18.24 – Unscrew bolts and remove them with washers and springs.  – Take off the pressure cap. 300321-10 – Remove pressure piece ...

  • Page 108: Removing The Outer Clutch Hub

    30/ENGINE DISASSEMBLY Removing the outer clutch hub 18.26 – Bend the lock washer. – Counterhold the inner clutch hub with the special tool. Loosen nut  Clutch holder (51129003000) ( p. 268) – Remove the nut with the lock washer. Dispose of the lock washer. 300325-10 –...

  • Page 109: Removing The Free Wheel Gear

    30/ENGINE DISASSEMBLY Removing the free wheel gear 18.29 – Remove the spring washer. – Remove free wheel gear  300449-10 Removing the torque limiter 18.30 – Remove the screw with the washer. Remove torque limiter  – Remove washer. 300330-10 Removing the starter idler gear 18.31 –...

  • Page 110: Removing The Oil Pumps

    30/ENGINE DISASSEMBLY Removing the oil pumps 18.33 – Remove screws  – Take off oil pump cover  300334-10 – Take out both oil pump shafts together with pin, internal rotor and external   rotor  300335-10 Removing the shift shaft 18.34 –...

  • Page 111: Removing The Left Section Of The Engine Case

    30/ENGINE DISASSEMBLY Removing the left section of the engine case 18.37 – Remove all engine housing bolts. – Tilt the left section of the engine case upward and remove the threaded fasteners of the engine holder. 300337-10 – Mount special tool with the appropriate bolts.

  • Page 112: Removing The Diaphragm

    30/ENGINE DISASSEMBLY Removing the diaphragm 18.41 – Remove diaphragm  300375-10 Removing the transmission shafts 18.42 – Secure the engine in an upright position. – Remove lock ring  300342-10 – Pull out both transmission shafts together from the bearing seats. Info Do not lose the washers.

  • Page 113: 30/Engine - Work On The Individual Parts

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Working on the right section of the engine case 19.1 – Remove the oil pressure regulator valve. ( p. 113) – Remove bearing retainers from main shaft bearing , shift drum bearing  ...

  • Page 114: Working On The Left Section Of The Engine Case

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS – Mount and tighten oil jet  Guideline Oil jet, piston cooling 2 Nm Loctite ® 243™ (1.5 lbf ft) – Blow out all oil holes with compressed air and check that they are clear. –...

  • Page 115: Removing The Oil Pressure Regulator Valve

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS – Press countershaft shaft seal ring and shift shaft in flush, with the open side   facing inward. – Mount and tighten oil jet  Guideline Oil jet, piston cooling 2 Nm Loctite ®...

  • Page 116: Installing The Crankshaft Seal Ring In The Clutch Cover

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Installing the crankshaft seal ring in the clutch cover 19.7 – Press crankshaft seal ring into the clutch cover with the open side flush toward  the inside. – Grease the sealing lip. 300348-10 Removing the water pump 19.8...

  • Page 117: Installing The Water Pump

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Installing the water pump 19.9 – Press water pump shaft bearing in flush using the appropriate tool.  Info Provide suitable support for the clutch cover while pressing in. 300351-11 – Press in shaft seal ring all the way, with the open side facing inward.

  • Page 118: Removing The Timing Chain Sprocket

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Removing the timing chain sprocket 19.11 – Warm up the timing chain sprocket with a blow-dryer.  – Detach the timing chain sprocket. Info The timing chain sprocket is usually damaged by the disassembly and must be replaced.

  • Page 119: Installing The Crankshaft Bearing Inner Ring

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Installing the crankshaft bearing inner ring 19.14 – Secure the crankshaft in a bench vise using special tool  Separator plate (78029009000) ( p. 273) – Push on compensating disk. – Warm up the special tool. Mount the inner bearing race. Guideline 120 °C (248 °F) –...
  • Page 120 30/ENGINE - WORK ON THE INDIVIDUAL PARTS – Mount bearing and connecting rod   Info Thoroughly oil the bearing. 200214-10 – Position special tools on the press.   Pressing device for crankshaft, complete (75029047000) ( p. 270) Insert for crankshaft pressing device (78029008000) ( p.

  • Page 121: Checking The Crankshaft Run-Out At The Bearing Pin

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Checking the crankshaft run-out at the bearing pin 19.16 – Position the crankshaft on a roller block. – Turn the crankshaft slowly. – Check the crankshaft run-out on both bearing pins. ≤ 0.16 mm (≤ 0.0063 in) Crankshaft - run-out at bearing pin »...

  • Page 122: Checking/Measuring The Cylinder

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Checking/measuring the cylinder 19.18 – Check the cylinder bearing surface for damage. » If the cylinder bearing surface is damaged: – Change the cylinder and piston. – ‑ and ‑axes using a Measure the cylinder diameter at several locations on the ...

  • Page 123: Checking The Piston Ring End Gap

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS » If the piston pin shows severe discoloration/signs of wear: – Replace the piston pin. – Place the piston pin in the connecting rod and check the seating for play. » If the piston pin seating has excessive play: –...

  • Page 124: Checking The Oil Pumps For Wear

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Checking the oil pumps for wear 19.22 – Use feeler gauge to measure the play between the external rotor and the engine  case. Oil pump ≤ 0.20 mm (≤ 0.0079 in) External rotor/engine case clear- ance »...

  • Page 125: Assembling The Autodecompressor

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Assembling the autodecompressor 19.24 – Insert long flange of the autodecompression spring in the hole, push the  autodecompression spring over bearing bolt and hook it into autodecompression  weight  300453-10 – Mount autodecompression shaft in the camshaft.

  • Page 126: Checking The Timing Assembly

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Checking the timing assembly 19.26 – Clean all parts well. – Check the timing chain wheel/timing chain sprocket for damage and wear.  » If there is damage or wear: 0 0 1 –...

  • Page 127: Removing The Coolant Temperature Sensor

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Removing the coolant temperature sensor 19.28 – Remove the coolant temperature sensor  300369-10 Removing the rocker arm 19.29 – Remove screws of the rocker arm shafts. Remove plugs   300370-10 – Screw appropriate screw into the rocker arm shafts.

  • Page 128: Changing The Camshaft Bearing

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS – Mark the valves corresponding to their installation position. Info Place the valves in a carton corresponding to their installation position in and label them. 200189-10 Changing the camshaft bearing 19.31 – Mount the cylinder head. Clamping plate (75029050000) ( p.

  • Page 129: Checking The Valves

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Checking the valves 19.32 Info The valve shaft is hard-chrome plated; wear generally appears at the valve guide. – Check the valve plate for run-out. Valve ≤ 0.05 mm (≤ 0.002 in) Run-out at valve plate »...

  • Page 130: Checking The Cylinder Head

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Checking the cylinder head 19.35 – Check the exhaust valve guides using special tool  Limit plug gauge (59029026006) ( p. 269) » If the special tool is easy to insert in the valve guide: –...

  • Page 131: Installing The Rocker Arm

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS – Mount the valve keys. Info When mounting the valve keys, ensure that they are seated properly; it is recommended to secure the valve keys to the valves with a small amount of grease.

  • Page 132: Checking The Clutch

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Checking the clutch 19.39 – Check the pressure piece for damage and wear.  » If there is damage or wear: 0 0 b k – Change the pressure piece. – Check axial bearing for damage and wear.

  • Page 133: Checking The Shift Mechanism

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Checking the shift mechanism 19.40 – Check shift forks for wear on blade   Shift fork 0 0 7 Sheet thickness 4.85… 4.95 mm (0.1909… 0 0 D 0.1949 in) 0 0 C »...

  • Page 134: Preassembling The Shift Shaft

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Preassembling the shift shaft 19.41 – Secure the short end of the shift shaft in the bench vise. 0 0 5 Guideline Use soft jaws. 0 0 1 – Mount gliding plate with the guide pin facing downward and put the guide pin ...

  • Page 135: Disassembling The Countershaft

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS – Mount split needle bearing , attach 5th gear idler gear with shift dog facing upward.   – Mount stop disk and lock ring   – Attach 3rd/4th gear sliding gear with the small toothed wheel facing downward and mount lock ring ...

  • Page 136: Checking The Transmission

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS – Mount lock ring and stop disk   – Mount needle bearing and the fourth gear idler gear with the collar facing up.   – Mount needle bearing and the 3rd gear idler gear with the collar facing down.

  • Page 137: Checking The Electric Starter Mode

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS – Change the solid gear or the countershaft. – Check stop disks for damage and wear.  » If there is damage or wear: – Change the stop disks. – Use new lock rings with every repair.

  • Page 138: Installing The Free Wheel

    30/ENGINE - WORK ON THE INDIVIDUAL PARTS Installing the free wheel 19.49 – Thoroughly oil all parts. – Slide free wheel into the primary pinion.  Info Note the direction of rotation. 200184-11 – Mount spreader ring  300457-10 – Ensure that all lugs of the spreader ring pass through the slots of the free wheel ...

  • Page 139: 30/Engine Assembly

    30/ENGINE ASSEMBLY Installing the crankshaft 20.1 – Tighten the right section of the engine case in the engine work stand. – Mount the special tool on the clutch end of the crankshaft. Mounting sleeve (78029005100) ( p. 272) – Push crankshaft all the way into the bearing seat of the right section of the ...

  • Page 140: Installing The Shift Fork

    30/ENGINE ASSEMBLY Installing the shift fork 20.4 – Thoroughly oil all parts. – Shift fork has a small inside diameter; mount this in the shift groove of the main  shaft. – Mount shift fork in the lower shift groove of the countershaft. ...

  • Page 141: Installing The Locking Lever

    30/ENGINE ASSEMBLY – Mount the left section of the engine case. If necessary, strike it lightly with a rub- ber mallet. Info Do not use the screws to pull the two sections of the engine case together. – Mount screws and, once all screws of the left section of the engine case have ...

  • Page 142: Installing The Oil Pumps

    30/ENGINE ASSEMBLY Installing the oil pumps 20.11 – Oil the oil pump shaft, internal rotor and external rotor before assembly. Engine oil (SAE 10W/50) ( p. 263) – Assemble both oil pump shafts , together with the pin and internal rotor ...

  • Page 143: Installing The Torque Limiter

    30/ENGINE ASSEMBLY Installing the torque limiter 20.14 – Mount the washer and torque limiter  – Mount and tighten the screw with the washer. Guideline Screw, torque limiter 10 Nm Loctite ® 243™ (7.4 lbf ft) 300330-10 Installing the free wheel gear 20.15 –...

  • Page 144: Installing The Primary Gear Nut

    30/ENGINE ASSEMBLY – Slide the outer clutch hub onto the gearbox main shaft. Turn the oil pump gear until the gear of the outer clutch hub meshes. – Slide on washer and inner clutch hub   300326-11 – Position the new lock washer and mount nut .

  • Page 145: Installing The Clutch Cover

    30/ENGINE ASSEMBLY Installing the clutch cover 20.21 – Mount dowels . Put clutch cover gasket in place.   300320-11 – Mount the clutch cover. Info Turn the water pump impeller slightly in order to engage the water pump drive. –...

  • Page 146: Installing The Timing Chain

    30/ENGINE ASSEMBLY Installing the timing chain 20.24 – Thread in the timing chain and place it over the timing chain sprocket. Info If the timing chain is used, ensure it is running in the correct direction. 300316-10 Installing the timing chain securing guide 20.25 –...

  • Page 147: Installing The Rotor

    30/ENGINE ASSEMBLY – Secure the nut with the lock washer. Installing the rotor 20.29 – Ensure that the spring washers are seated properly. Mount the rotor. – Mount and tighten the spring washer and nut . Tighten the nut.  Guideline Nut, rotor M12x1...
  • Page 148 30/ENGINE ASSEMBLY – Mount dowels and put cylinder base gasket in place.   300308-11 – Ensure that piston mark faces toward the exhaust side.  200089-01 – Cover the engine housing opening with a cloth. Thread the timing chain through the chain shaft.

  • Page 149: Installing The Cylinder Head

    30/ENGINE ASSEMBLY – Insert the special tool and press it forcefully to the piston. – Turn the special tool counterclockwise, thereby pushing the piston pin retainer into the groove. Insert for piston pin retainer (77329030100) ( p. 272) – Ensure that the piston pin retainer is seated properly on both sides. 200084-10 –...

  • Page 150: Installing The Camshaft

    30/ENGINE ASSEMBLY Installing the camshaft 20.33 – Wrap the timing chain around the camshaft. Push the camshaft into the bearing seats. The cylinder head and camshaft markings are lined up with each other.   Info Ensure that the crankshaft is at top dead center (TDC). 300517-10 –...

  • Page 151: Adjusting The Valve Clearance

    30/ENGINE ASSEMBLY – Check the valve clearance at all valves between the valve and rocker arm. Guideline Valve clearance Exhaust at: 20 °C (68 °F) 0.12… 0.17 mm (0.0047… 0.0067 in) Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039… 0.0059 in) Feeler gauge (59029041100) ( p.

  • Page 152: Installing The Spark Plug

    30/ENGINE ASSEMBLY Installing the spark plug 20.38 – Mount and tighten the spark plug with the special tool. Guideline Spark plug M12x1.25 15… 20 Nm (11.1… 14.8 lbf ft) Spark plug wrench (75029172000) ( p. 271) 300296-10 Installing the valve cover 20.39 –...

  • Page 153: Assembling The Starter Motor

    30/ENGINE ASSEMBLY Assembling the starter motor 20.42 – Grease the O-ring. Position the starter motor. Long-life grease ( p. 265) – Mount and tighten screws  Guideline Screw, starter motor 10 Nm (7.4 lbf ft) 300293-10 Installing the oil line 20.43 –...

  • Page 154: 32/Clutch

    32/CLUTCH Checking the fluid level of the hydraulic clutch 21.1 Info The fluid level rises with increasing wear of the clutch lining disks. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...
  • Page 155 32/CLUTCH – Inject the liquid into the system until it escapes from drill hole of the clutch  slave cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the clutch slave cylinder reser- voir. – Remove the bleeding syringe. Mount and tighten screws bleeder screw. –...

  • Page 156: 35/Water Pump, Cooling System

    35/WATER PUMP, COOLING SYSTEM Checking the coolant level 22.1 Warning Scalding hazard During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, radiator hoses and other components of the cooling system while the engine is warm. Let the engine and cooling system cool down first.

  • Page 157: Draining The Coolant

    35/WATER PUMP, COOLING SYSTEM Alternative 2 Coolant (mixed ready to use) ( p. 263) – Refit the radiator cap. Draining the coolant 22.3 Warning Scalding hazard During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, radiator hoses and other components of the cooling system while the engine is warm. Let the engine and cooling system cool down first.

  • Page 158: 38/Lubrication System

    38/LUBRICATION SYSTEM Oil circuit 23.1 400560-60 Oil screen Force pump Suction pump Oil filter Oil pressure regulator valve Timing chain tensioner Rocker arm shaft Gearbox Oil jet, piston cooling Crankshaft Banjo bolt oil screen Checking the engine oil pressure 23.2 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.
  • Page 159 38/LUBRICATION SYSTEM – Remove screw  300725-10 – Position the banjo bolt with the connection and seal rings. Mount and tighten the banjo bolt. Guideline Banjo bolt M10x1 8 Nm (5.9 lbf ft) Oil pressure adapter (77329006000) ( p. 272) –...

  • Page 160: Checking The Engine Oil Level

    38/LUBRICATION SYSTEM Checking the engine oil level 23.3 Info The engine oil level must be checked when the engine is cold. – Stand the motorcycle upright on a horizontal surface. Condition The engine is cold. – Check the engine oil level. The engine oil level must be within range ...

  • Page 161: Removing The Oil Filter

    38/LUBRICATION SYSTEM – Place the motorcycle upright on a horizontal surface (not on the side stand). – Place a suitable container under the engine. – Remove oil drain plug with the magnet and seal ring.  100454-10 – Remove engine oil screen plug with engine oil screen ...

  • Page 162: Installing The Oil Filter

    38/LUBRICATION SYSTEM Installing the oil filter 23.8 – Insert oil filter into the oil filter housing.  – Oil O-ring of the oil filter cover.  – Mount oil filter cover  – Mount and tighten the screws. Guideline Screw, oil filter cover 6 Nm (4.4 lbf ft) 100456-10 Filling up with engine oil...

  • Page 163: 41/Throttle Valve Body

    41/THROTTLE VALVE BODY Idle speed adjusting screw 24.1 Idle speed adjusting screw is attached to the throttle valve body on the left side.  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 164: Installing The Throttle Valve Body

    41/THROTTLE VALVE BODY – Take off the throttle valve body and allow it to hang tension-free to the side. 300691-10 Installing the throttle valve body 24.3 Condition The battery has been disconnected. – Position the throttle valve body. – Mount hose clip and tighten it.

  • Page 165: Adjusting The Idle Speed

    41/THROTTLE VALVE BODY Adjusting the idle speed 24.4 – Idle speed adjusting screw is attached to the throttle valve body on the left side.  – Run the engine warm and push the idle speed adjusting screw all the way in. –...

  • Page 166: Fault Code

    Select "Heating lambda sensor cylinder 1". – Press "Continue". – Read the information page in the HUSABERG diagnostic tool and, with "Continue", begin the actuator test. Lambda sensor "Function Hego Sensor Bank 1" at test start Voltage "Hego1AD" Lambda sensor "Function Hego Sensor Bank 1"...
  • Page 167 FAULT CODE 400588-10 400607-11 Heating lambda sensor - check the power supply – Measure the voltage between the specified points. Connector CU Pin 3 – measuring point Ground(−) Info For the measurement, the measurement points must be loaded with a 12V/21W bulb. The value should not vary more than 1V from the battery voltage "VBAT".
  • Page 168 FAULT CODE 600849-01 400588-10 Heating lambda sensor - check the control line for an open circuit – Measure the resistance between the specified points. Break Out Box DT Pin 11 – Connector CU Pin 4 ≤ 0.6 Ω Resistance » If the measured value does not correspond to the specified value: –...
  • Page 169 FAULT CODE » If the measured value does not correspond to the specified value: – Check the cable from connector DT pin 11 to connector CU pin 4 for a short circuit to ground (terminal 31). » If the measured value corresponds to the specified value: –...
  • Page 170 FAULT CODE Flash code FI warning lamp (MIL) 09 FI warning lamp (MIL) flashes 9x short Display on diagnostic tool P0107 "Manifold absolute pressure sensor cylinder 1" "Input signal too low" Manifold absolute pressure sensor voltage "PM1AD": ≤ 0.215 V Error level condition Time: ≥...
  • Page 171 FAULT CODE » If the measured value corresponds to the specified value: – Check the next possible cause: Manifold absolute pressure sensor - signal line has a short circuit to ground (terminal 31) ( p. 169) Manifold absolute pressure sensor - signal line has a short circuit to ground (terminal 31) Condition Th e diagnostic tool is disconnected.
  • Page 172 FAULT CODE Flash code FI warning lamp (MIL) 09 FI warning lamp (MIL) flashes 9x short Display on diagnostic tool P0108 "Manifold absolute pressure sensor cylinder 1" "Input signal too high" Manifold absolute pressure sensor voltage "PM1AD": ≥ 4.121 V Error level condition Time: ≥...
  • Page 173 FAULT CODE 600849-01 400595-10 Manifold absolute pressure sensor - check the signal line for an open circuit – Measure the resistance between the specified points. Break Out Box DT Pin 6 – Connector DX Pin 2 ≤ 0.6 Ω Resistance »...
  • Page 174 FAULT CODE 600849-01 400607-11 Manifold absolute pressure sensor - check the signal line for a short circuit to plus (terminal 30) – Measure the voltage between the specified points. Break Out Box DT Pin 6 – measuring point Ground(−) Voltage <...
  • Page 175 FAULT CODE Flash code FI warning lamp (MIL) 13 FI warning lamp (MIL) flashes 1x long, 3x short Display on diagnostic tool P0112 "Intake air temperature sensor" "Input signal too low" Intake air temperature sensor voltage "TAAD": ≤ 0.195 V Error level condition Time: ≥...
  • Page 176 FAULT CODE Intake air temperature sensor - signal line has a short circuit to sensor ground Condition Th e diagnostic tool is disconnected. The EFI control unit is disconnected. The breakout box is connected to the wiring harness. The intake air temperature sensor is disconnected. Intake air temperature sensor - check the signal line for a short circuit to sensor ground –...
  • Page 177 FAULT CODE Flash code FI warning lamp (MIL) 13 FI warning lamp (MIL) flashes 1x long, 3x short Display on diagnostic tool P0113 "Intake air temperature sensor" "Input signal too high" Intake air temperature sensor voltage "TAAD": ≥ 4.824 V Error level condition Time: ≥...
  • Page 178 FAULT CODE 600849-01 400607-11 Intake air temperature sensor - check the signal line for a short circuit to plus (terminal 30) – Measure the voltage between the specified points. Break Out Box DT Pin 25 – measuring point Ground(−) ≤ 0.1 V Voltage »...
  • Page 179 FAULT CODE Intake air temperature sensor - signal line is open Condition Th e diagnostic tool is disconnected. The EFI control unit is disconnected. The breakout box is connected to the wiring harness. 600849-01 400587-10 Intake air temperature sensor - check the signal line for an open circuit –...
  • Page 180 FAULT CODE Intake air temperature sensor - value not plausible Condition Th e diagnostic tool is disconnected. The breakout box is connected to the wiring harness. Intake air temperature sensor - check the resistance – Measure the resistance between the specified points. Break Out Box DT Pin 24 –...
  • Page 181 FAULT CODE Flash code FI warning lamp (MIL) 12 FI warning lamp (MIL) flashes 1x long, 2x short Display on diagnostic tool P0117 "Coolant temperature sensor" "Input signal too low" Coolant temperature sensor cylinder 1 voltage "TWAD": ≤ 0.137 V Error level condition Time: ≥...
  • Page 182 FAULT CODE 216… 264 Ω Resistance at: 90 °C (194 °F) 165… 202 Ω Resistance at: 100 °C (212 °F) 128… 156 Ω Resistance at: 110 °C (230 °F) 100… 122 Ω Resistance at: 120 °C (248 °F) » If the measured value does not correspond to the specified value: –...
  • Page 183 FAULT CODE Flash code FI warning lamp (MIL) 12 FI warning lamp (MIL) flashes 1x long, 2x short Display on diagnostic tool P0118 "Coolant temperature sensor" "Input signal too high" Coolant temperature sensor cylinder 1 voltage "TWAD": ≥ 4.785 V Error level condition Time: ≥...
  • Page 184 FAULT CODE 526… 642 Ω Resistance at: 60 °C (140 °F) 385… 471 Ω Resistance at: 70 °C (158 °F) 286… 350 Ω Resistance at: 80 °C (176 °F) 216… 264 Ω Resistance at: 90 °C (194 °F) 165… 202 Ω Resistance at: 100 °C (212 °F) 128…...
  • Page 185 FAULT CODE – Check the next possible cause: Coolant temperature sensor - signal line has a short circuit to the sensor power supply ( p. 183) Coolant temperature sensor - signal line has a short circuit to the sensor power supply Condition Th e diagnostic tool is disconnected.
  • Page 186 FAULT CODE 600849-01 400586-10 Coolant temperature sensor - check the ground line for an open circuit – Measure the resistance between the specified points. Break Out Box DT Pin 24 – Connector AX Pin 2 ≤ 0.6 Ω Resistance » If the measured value does not correspond to the specified value: –...
  • Page 187 FAULT CODE Flash code FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Display on diagnostic tool P0122 "Throttle position sensor circuit A" "Input signal too low" Throttle position sensor voltage "THAD": ≤ 0.352 V Error level condition Time: ≥...
  • Page 188 FAULT CODE » If the measured value does not correspond to the specified value: – Check connector EX pin 2. – Check the cable from connector EX pin 2 to the next node in the cable harness for an open circuit. »...
  • Page 189 FAULT CODE 600849-01 400597-10 Throttle position sensor - check the signal line for an open circuit – Measure the resistance between the specified points. Break Out Box DT Pin 5 – Connector EX Pin 1 ≤ 0.6 Ω Resistance » If the measured value does not correspond to the specified value: –...
  • Page 190 FAULT CODE Flash code FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Display on diagnostic tool P0123 "Throttle position sensor circuit A" "Input signal too high" Throttle position sensor voltage "THAD": ≥ 4.785 V Error level condition Time: ≥...
  • Page 191 FAULT CODE » If the measured value does not correspond to the specified value: – Check the cable from connector DT pin 5 to connector EX pin 1 for a short circuit to plus (terminal 30). » If the measured value corresponds to the specified value: –...
  • Page 192 FAULT CODE 600849-01 400597-10 Throttle position sensor - check the ground line for an open circuit – Measure the resistance between the specified points. Break Out Box DT Pin 24 – Connector EX Pin 3 ≤ 0.6 Ω Resistance » If the measured value does not correspond to the specified value: –...
  • Page 193 FAULT CODE Flash code FI warning lamp (MIL) 17 FI warning lamp (MIL) flashes 1x long, 7x short Display on diagnostic tool P0130 "Lambda sensor cylinder 1, sensor 1" "Malfunction in the circuit" Malfunction in the circuit: ≥ 60 s Error level condition Function check Lambda sensor - checking the voltage (...
  • Page 194 FAULT CODE 600849-01 400607-11 Lambda sensor - check the signal line for a short circuit to ground (terminal 31) – Measure the resistance between the specified points. Break Out Box DT Pin 7 – measuring point Ground(−) ∞ Ω Resistance »...
  • Page 195 FAULT CODE » If the measured value does not correspond to the specified value: – Check the cable from connector DT pin 7 to connector CU pin 2 for a short circuit to plus (terminal 30). » If the measured value corresponds to the specified value: –...
  • Page 196 FAULT CODE 600849-01 400588-10 Intake air temperature sensor - check the signal line for an open circuit – Measure the resistance between the specified points. Break Out Box DT Pin 7 – Connector CU Pin 2 ≤ 0.6 Ω Resistance »...
  • Page 197 Press "Continue". – Select "Injection valve cylinder 1". – Press "Continue". – Read the information page in the HUSABERG diagnostic tool and, with "Continue", begin the actuator test. Injection valve Function noise » If the specification is attained: – Delete the fault code.
  • Page 198 FAULT CODE Injection valve - power supply is faulty Condition The diagnostic tool is connected and active. The EFI control unit is connected. The injection valve is disconnected. 400591-10 400607-11 Injection valve - check the power supply – Measure the voltage between the specified points. Connector DQ Pin 1 –...
  • Page 199 FAULT CODE Injection valve - control line has a short circuit to ignition plus (terminal 15) Condition Th e diagnostic tool is disconnected. The EFI control unit is disconnected. The breakout box is connected to the wiring harness. The injection valve is disconnected. Injection valve - check the control line for a short circuit to ignition plus (terminal 15) –...
  • Page 200 FAULT CODE – Check connector DT pin 16 and connector DQ pin 2. – Check the cable from connector DT pin 16 to connector DQ pin 2 for an open circuit. » If the measured value corresponds to the specified value: –...
  • Page 201 FAULT CODE Flash code FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Display on diagnostic tool P0335 "Circuit ignition pulse generator" "Malfunction in the circuit" Error level condition The manifold absolute pressure sensor is generating a standard signal (the engine is running), whereas the ignition pulse generator is not generating any signal.
  • Page 202 FAULT CODE Ignition pulse generator - signal lines are open Condition Th e diagnostic tool is disconnected. The EFI control unit is disconnected. The breakout box is connected to the wiring harness. Ignition pulse generator is connected. Ignition pulse generator - check the signal lines for an open circuit –...
  • Page 203 FAULT CODE 600849-01 400607-11 Ignition pulse generator - check the signal lines for a short circuit to ground (terminal 31) – Measure the resistance between the specified points. Break Out Box DT Pin 3 – measuring point Ground(−) ∞ Ω Resistance »...
  • Page 204 FAULT CODE 600849-01 400607-11 Ignition pulse generator - check the signal lines for a short circuit to plus (terminal 30) – Measure the voltage between the specified points. Break Out Box DT Pin 3 – measuring point Ground(−) Voltage < 0.1 V »...
  • Page 205 FAULT CODE » If the measured value corresponds to the specified value: – Contact customer service.
  • Page 206 Press "Continue". – Select "Ignition cylinder 1". – Press "Continue". – Read the information page in the HUSABERG diagnostic tool and, with "Continue", begin the actuator test. Spark plug Function noise » If the specification is attained: – Delete the fault code.
  • Page 207 FAULT CODE Injection coil - control line has a short circuit to ground (terminal 31) Condition Th e diagnostic tool is disconnected. The EFI control unit is disconnected. The breakout box is connected to the wiring harness. The control line of the ignition coil is disconnected. 600849-01 400607-11 Ignition coil - check the control line for a short circuit to ground (terminal 31)
  • Page 208 FAULT CODE 600849-01 400607-11 Ignition coil - check the control line for a short circuit to plus (terminal 30) – Measure the voltage between the specified points. Break Out Box DT Pin 18 – measuring point Ground(−) Voltage < 0.1 V »...
  • Page 209 FAULT CODE 600849-01 400607-11 Ignition coil - check the control line for an open circuit – Measure the voltage between the specified points. Break Out Box DT Pin 18 – measuring point Ground(−) Info For the measurement, the measurement points must be loaded with a 12V/21W bulb. The value should not vary more than 1V from the battery voltage "VBAT".
  • Page 210 Press "Continue". – Select "Function fuel pump relay". – Press "Continue". – Read the information page in the HUSABERG diagnostic tool and, with "Continue", begin the actuator test. Fuel pump Function noise » If the specification is attained: – Delete the fault code.
  • Page 211 FAULT CODE Fuel pump - control line is open Condition Th e diagnostic tool is disconnected. The EFI control unit is disconnected. The breakout box is connected to the wiring harness. Fuel pump is disconnected. 600849-01 400593-10 Fuel pump - check the control line for an open circuit –...
  • Page 212 FAULT CODE Fuel pump - control line has a short circuit to ground (terminal 31) Condition Th e diagnostic tool is disconnected. The EFI control unit is disconnected. The breakout box is connected to the wiring harness. Fuel pump is disconnected. 600849-01 400607-11 Fuel pump - check the control line for a short circuit to ground (terminal 31)
  • Page 213 Press "Continue". – Select "Function fuel pump relay". – Press "Continue". – Read the information page in the HUSABERG diagnostic tool and, with "Continue", begin the actuator test. Fuel pump Function noise » If the specification is attained: – Delete the fault code.
  • Page 214 FAULT CODE » If the measured value corresponds to the specified value: – Check the next possible cause: Fuel pump - power supply is faulty ( p. 212) Fuel pump - power supply is faulty Condition The diagnostic tool is connected and active. The breakout box is connected to the EFI control unit and wiring harness.
  • Page 215 FAULT CODE Flash code FI warning lamp (MIL) 15 FI warning lamp (MIL) flashes 1x long, 5x short Display on diagnostic tool P1631 "Rollover sensor (A/D type)" "Input signal too low" Signal voltage "(A/D type)": ≤ 0.176 V Error level condition Time: ≥...
  • Page 216 FAULT CODE 600849-01 400607-11 Rollover sensor - check the signal line for a short circuit to ground (terminal 31) – Measure the resistance between the specified points. Break Out Box DT Pin 2 – measuring point Ground(−) ∞ Ω Resistance »...
  • Page 217 FAULT CODE » If the measured value does not correspond to the specified value: – Check connector AP pin 6. – Check the cable from connector AP pin 6 to the next node in the cable harness for an open circuit. »...
  • Page 218 FAULT CODE Flash code FI warning lamp (MIL) 15 FI warning lamp (MIL) flashes 1x long, 5x short Display on diagnostic tool P1632 "Rollover sensor (A/D type)" "Input signal too high" Voltage "(A/D type)": ≥ 4.57 V Error level condition Time: ≥...
  • Page 219 FAULT CODE 600849-01 400607-11 Rollover sensor - check the signal line for a short circuit to plus (terminal 30) – Measure the voltage between the specified points. Break Out Box DT Pin 2 – measuring point Ground(−) Voltage < 0.1 V »...
  • Page 220 FAULT CODE Rollover sensor - signal line is open Condition Th e diagnostic tool is disconnected. The EFI control unit is disconnected. The breakout box is connected to the wiring harness. The rollover sensor is disconnected. 600849-01 400583-10 Rollover sensor - check the signal line for an open circuit –...

  • Page 221: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cylinder 4-stroke engine, water-cooled Displacement (All 450 models) 449.3 cm³ (27.418 cu in) Displacement (All 570 models) 565.5 cm³ (34.509 cu in) Stroke (All 450 models) 63.4 mm (2.496 in) Stroke (All 570 models) 72 mm (2.83 in) Bore (All 450 models) 95 mm (3.74 in) Bore (All 570 models)

  • Page 222: Technical Data - Engine Tolerances, Wear Limits

    TECHNICAL DATA - ENGINE TOLERANCES, WEAR LIMITS Camshaft - cam height Exhaust 33.10… 33.30 mm (1.3031… 1.311 in) Camshaft - cam height (All 450 models) Intake 33.90… 34.10 mm (1.3346… 1.3425 in) Camshaft - cam height (All 570 models) Intake 34.40…...
  • Page 223 TECHNICAL DATA - ENGINE TOLERANCES, WEAR LIMITS ≤ 0.20 mm (≤ 0.0079 in) External rotor/engine case clearance ≤ 0.20 mm (≤ 0.0079 in) External rotor/internal rotor clearance ≤ 0.15 mm (≤ 0.0059 in) End play Shift fork Sheet thickness 4.85… 4.95 mm (0.1909… 0.1949 in) Shift shaft - sliding plate/shift quadrant clearance 0.40…...

  • Page 224: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, cable holder in generator cover 4 Nm (3 lbf ft) Loctite 243™ ® Locking screw for bearing 6 Nm (4.4 lbf ft) Loctite 243™ ® Oil jet, piston cooling 2 Nm (1.5 lbf ft) Loctite 243™...
  • Page 225 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Screw, cylinder head M10x1.25 Tightening sequence: lubricated with engine oil Tighten diagonally, begin- ning with the rear screw on the chain shaft. Step 1 10 Nm (7.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 50 Nm (36.9 lbf ft) –...

  • Page 226: Technical Data - Chassis

    Seat height, unloaded 985 mm (38.78 in) Ground clearance, unloaded 390 mm (15.35 in) Weight without fuel, approx. (FE 450 EU, FE 450 AUS) 116.5 kg (256.8 lb.) Weight without fuel, approx. (FE 570 EU, FE 570 AUS) 117 kg (258 lb.) Weight without fuel, approx.

  • Page 227: Tires

    80/100 - 21 51M TT 110/100 - 18 64M TT Bridgestone M59 Bridgestone M402 Additional information is available in the Service section under: www.husaberg.com Capacity - fuel 29.3 Total fuel tank capacity, 8.2 l (2.17 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.

  • Page 228: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number 14.45.7E.02 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 26 clicks Standard 22 clicks Sport 18 clicks Rebound damping Comfort 22 clicks Standard 20 clicks Sport 18 clicks Spring length with preload spacer(s) 510 mm (20.08 in) Spring rate Weight of rider: 65…...

  • Page 229: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 12.45.7E.02 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 18 clicks Standard 15 clicks Sport 12 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn Rebound damping Comfort 26 clicks...

  • Page 230: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, battery terminal 3 Nm (2.2 lbf ft) – Screw, intake air temperature sensor 2 Nm (1.5 lbf ft) – Spoke nipple, rear wheel 5…...

  • Page 231: Cleaning/Protection

    CLEANING/PROTECTION Cleaning the motorcycle 33.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 232: Protection For Winter Operation

    CLEANING/PROTECTION – Push back the protection covers on the handlebar instruments to allow water to evaporate. – After the motorcycle has cooled off, oil or grease all moving parts and bearings. – Clean the chain. ( p. 71) – Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.

  • Page 233: Storage

    Storage temperature of battery without direct sunlight. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature fluctuations. Info HUSABERG recommends jacking up the motorcycle. – Jack up the motorcycle. ( p. 9) –...

  • Page 234: Service Schedule

    SERVICE SCHEDULE Important maintenance work to be carried out by an authorized HUSABERG workshop 35.1 S15A S30A Engine Change the engine oil and oil filter, clean the engine oil screen. ( p. 158) • • • • Replace the spark plug.

  • Page 235: Important Maintenance Work To Be Carried Out By An Authorized Husaberg Workshop. (As Additional Order)

    SERVICE SCHEDULE S15A: every 15 service hours / after every race S30A: every 30 service hours Important maintenance work to be carried out by an authorized HUSABERG workshop. (as additional order) 35.2 Competition use Hobby use S15N S45A S15A S30A...

  • Page 236: Important Checks And Maintenance Work To Be Carried Out By The Rider

    SERVICE SCHEDULE Important checks and maintenance work to be carried out by the rider 35.3 NB1A Check the engine oil level. ( p. 158) • Check the front brake fluid level. ( p. 79) • Check the rear brake fluid level. ( p.

  • Page 238: Wiring Diagram

    WIRING DIAGRAM 1 of 3 (FE EU) 36.1 110,111 94,110 FB/4 FA/4 600831-01...
  • Page 239 WIRING DIAGRAM Component: Battery A5‑6 Generator C6‑7 Starter relay with main fuse A5 Power relay E‑F5 Starter motor A5 Radiator fan E‑F4 Voltage regulator/rectifier C6‑7 Temperature switch for radiator fan E‑F3 Electric starter button A3 Diode E‑F4 Cable colors: Brown Brown Black Black...

  • Page 240: Of 3 (Fe Eu)

    WIRING DIAGRAM 2 of 3 (FE EU) 36.2 92,93 66,67 600832-01...
  • Page 241 WIRING DIAGRAM Component: EFI control unit F4‑5 Roll angle sensor F4 Map‑Select switch F3 (optional) throttle position sensor F2 Manifold absolute pressure sensor F2 Lambda sensor F1 Coolant temperature sensor F6 Intake air temperature sensor F6 FI Warning lamp (MIL) A4 Pulse generator F3 Ignition coil F7 Fuel pump F8...
  • Page 242 WIRING DIAGRAM Black-blue Black-blue Orange White-black Brown Brown Brown Black Blue Blue Black Orange Black Brown Black Orange Brown Black Orange Brown Black...
  • Page 243 WIRING DIAGRAM...

  • Page 244: Of 3 (Fe Eu)

    WIRING DIAGRAM 3 of 3 (FE EU) 36.3 DI/2 CW/2 CW/2 CX/2 CX/2 CX/2 CZ/3 DB/4 DG/4 CW/2 CY/3 DA/4 BP/4 23,121 34,35 19,36 BS/2 BY/4 -X200 -X300 CV/4 BV/2 22,24,27 2.1 2.2 2.3 BG/3 -X400 AJ/3 AJ/3 BG/3 CX/2 CX/2 CW/2 CW/2...
  • Page 245 WIRING DIAGRAM Component: Wheel speed sensor B1‑2 Turn signal, front left E1 Turn signal, front right B‑C1 Turn signal indicator lamp C1 Turn signal, rear right C8 Turn signal, rear left E8 High beam indicator light C1 Parking light D1 Low beam/high beam D1 Horn E6 License plate lamp D‑E8...
  • Page 246 WIRING DIAGRAM Brown Blue Blue White Green Black-yellow Yellow Brown Brown Yellow-blue Yellow-blue White-blue Purple Black Brown Brown Black-yellow...
  • Page 247 WIRING DIAGRAM...

  • Page 248: Of 3 (Fe Usa)

    WIRING DIAGRAM 1 of 3 (FE USA) 36.4 110,111 94,110 FB/4 FA/4 600837-01...
  • Page 249 WIRING DIAGRAM Component: Battery A5‑6 Generator C6‑7 Starter relay with main fuse A5 Power relay E‑F5 Starter motor A5 Radiator fan E‑F4 Voltage regulator/rectifier C6‑7 Temperature switch for radiator fan E‑F3 Electric starter button A3 Diode E‑F4 Cable colors: Brown Brown Black Black...

  • Page 250: Of 3 (Fe Usa)

    WIRING DIAGRAM 2 of 3 (FE USA) 36.5 92,93 66,67 600838-01...
  • Page 251 WIRING DIAGRAM Component: EFI control unit F4‑5 Rollover sensor F4 Map‑Select switch F7 (optional) Throttle position sensor F2 Manifold absolute pressure sensor F2 Lambda sensor F1 Coolant temperature sensor F6 Intake air temperature sensor F6 Warning lamp FI (MIL) A4 Pulse generator F3 Ignition coil F7 Fuel pump F8...
  • Page 252 WIRING DIAGRAM Black-blue Black-blue Orange White-black Brown Brown Brown Black Blue Blue Black Orange Black Brown Black Orange Brown Black Orange Brown Black...
  • Page 253 WIRING DIAGRAM...

  • Page 254: Of 3 (Fe Usa)

    WIRING DIAGRAM 3 of 3 (FE USA) 36.6 -X509 CX/2 CZ/3 DB/4 CW/2 CY/3 DA/4 -X501 BP/4 121,23 35,34 19,36 BY/4 BS/2 -X200 -X300 CV/4 BV/2 24,22,27 AJ/3 -X504 600839-01...
  • Page 255 WIRING DIAGRAM Component: Wheel speed sensor B1‑2 Speedometer A‑B1 Short circuit button E3‑4 X501 Plug-in connector for low beam/high beam D1 (optional) X503 Plug-in connector for light switch E4‑5 (optional) X504 Plug-in connector for low beam/high beam D8 (optional) X507 Plug-in connector for brake light switch, front E3 (optional) X508 Plug-in connector for brake light switch, rear E7 (optional)

  • Page 256: Of 3 (Fe Aus)

    WIRING DIAGRAM 1 of 3 (FE AUS) 36.7 110,111 94,110 FB/4 FA/4 600834-01...
  • Page 257 WIRING DIAGRAM Component: Battery A5‑6 Generator C6‑7 Starter relay with main fuse A5 Power relay E‑F5 Starter motor A5 Radiator fan E‑F4 Voltage regulator/rectifier C6‑7 Temperature switch for radiator fan E‑F3 Electric starter button, emergency OFF switch A3 Diode E‑F4 Cable colors: Brown Brown...

  • Page 258: Of 3 (Fe Aus)

    WIRING DIAGRAM 2 of 3 (FE AUS) 36.8 92,93 66,67 600835-01...
  • Page 259 WIRING DIAGRAM Component: EFI control unit F4‑5 Roll angle sensor F4 Map‑Select switch F2 (optional) throttle position sensor F2 Manifold absolute pressure sensor F2 Lambda sensor F1 Coolant temperature sensor F6 Intake air temperature sensor F6 FI Warning lamp (MIL) A4 Pulse generator F3 Ignition coil F7 Fuel pump F8...
  • Page 260 WIRING DIAGRAM Black-blue Black-blue Orange White-black Brown Brown Brown Black Blue Blue Black Orange Black Brown Black Orange Brown Black Orange Brown Black...
  • Page 261 WIRING DIAGRAM...

  • Page 262: Of 3 (Fe Aus)

    WIRING DIAGRAM 3 of 3 (FE AUS) 36.9 DI/2 CW/2 CW/2 CX/2 CX/2 CX/2 CZ/3 DB/4 DG/4 CW/2 CY/3 DA/4 BP/4 23,121 34,35 19,36 BY/4 BS/2 -X200 -X300 CV/4 BV/2 22,24,27 2.1 2.2 2.3 BG/3 -X400 AJ/3 AJ/3 BG/3 CX/2 CX/2 CW/2 CW/2...
  • Page 263 WIRING DIAGRAM Component: Wheel speed sensor B1‑2 Turn signal, front left E1 Turn signal, front right B‑C1 Turn signal indicator lamp C1 Turn signal, rear right C8 Turn signal, rear left E8 High beam indicator light C1 Parking light D1 Low beam/high beam D1 Horn E6 License plate lamp D‑E8...
  • Page 264 WIRING DIAGRAM Brown Blue Blue White Green Black-yellow Yellow Brown Brown Yellow-blue Yellow-blue White-blue Purple Black Brown Brown Black-yellow...

  • Page 265: Substances

    – Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. HUSABERG recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 266 SUBSTANCES Supplier ® Motorex – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180342S1) According to – SAE ( p. 278) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.

  • Page 267: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaning agent Specification – ® HUSABERG recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Specification – ® HUSABERG recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Specification –...
  • Page 268 AUXILIARY SUBSTANCES Lubricant (T511) Specification – ® HUSABERG recommends Lubcon products. Supplier ® Lubcon – ® Turmsilon GTI 300 P Lubricant (T159) Specification – ® HUSABERG recommends Bel‑Ray products. Supplier ® Bel‑Ray – ® MC‑11 Lubricant (T625) Specification – ®...

  • Page 269: Special Tools

    SPECIAL TOOLS Breakout box Art. no.: 00029095000 200930-10 Crankshaft locking bolt Art. no.: 113080802 400035-01 Bearing puller Art. no.: 15112017000 400037-01 Insert for bearing puller Art. no.: 15112018100 Feature 18… 23 mm (0.71… 0.91 in) 400038-01 Bleed syringe Art. no.: 50329050000 400058-01...
  • Page 270 SPECIAL TOOLS Circlip pliers reverse Art. no.: 51012011000 400059-01 Clutch holder Art. no.: 51129003000 400289-01 Extractor Art. no.: 58012009000 400073-01 Tool for inner bearing race Art. no.: 58429037043 400082-01 Torque wrench with various accessories in set Art. no.: 58429094000 200910-10...
  • Page 271 SPECIAL TOOLS Valve spring mounter Art. no.: 59029019000 400101-01 Limit plug gauge Art. no.: 59029026006 400104-01 Feeler gauge Art. no.: 59029041100 400110-01 Piston ring mounting tool Art. no.: 60029015000 400123-01 Pressure testing tool Art. no.: 61029094000 400149-01...
  • Page 272 SPECIAL TOOLS Engine work stand Art. no.: 61229001000 200306-01 Extractor Art. no.: 75029021000 400157-01 Push-in drift Art. no.: 75029044010 500163-01 Push-in drift Art. no.: 75029044020 500162-01 Pressing device for crankshaft, complete Art. no.: 75029047000 400185-01...
  • Page 273 SPECIAL TOOLS Extractor Art. no.: 75029048000 400162-01 Clamping plate Art. no.: 75029050000 400163-01 Push-out drift Art. no.: 75029051000 400164-01 Spark plug wrench Art. no.: 75029172000 400170-01 Limit plug gauge Art. no.: 77029026000 400104-01...
  • Page 274 SPECIAL TOOLS Oil pressure adapter Art. no.: 77329006000 400176-01 Insert for piston pin retainer Art. no.: 77329030100 400160-01 Release device for timing chain tensioner Art. no.: 77329051000 400181-01 Mounting sleeve Art. no.: 78029005100 500167-01 Insert for crankshaft pressing device Art. no.: 78029008000 500170-01...
  • Page 275 SPECIAL TOOLS Separator plate Art. no.: 78029009000 500169-01 Valve spring mounting device Art. no.: 78029060000 500165-01 Gear segment Art. no.: 80029004000 500164-01 Fitting for work stand Art. no.: 81229002000 500281-01 Work stand Art. no.: 81229055000 500280-01...
  • Page 276 SPECIAL TOOLS Pin wrench Art. no.: T103 200734-10 Hook wrench Art. no.: T106S 301085-01 Depth micrometer Art. no.: T107S 300577-10 Mounting sleeve Art. no.: T1204 200788-10 Calibration pin Art. no.: T1205 200790-10...
  • Page 277 SPECIAL TOOLS Pressing tool Art. no.: T1206 200583-10 Pressing tool Art. no.: T1207S 200585-01 Centering sleeve Art. no.: T1214 200777-10 Mounting sleeve Art. no.: T1215 300568-10 Disassembly tool Art. no.: T1216 200816-10...
  • Page 278 SPECIAL TOOLS Protecting sleeve Art. no.: T1401 200635-10 Clamping stand Art. no.: T14015S 200733-10 Clamping stand Art. no.: T14016S 200688-10 Gripping tool Art. no.: T14026S1 200639-10 Assembly tool Art. no.: T1402S 200634-10...
  • Page 279 SPECIAL TOOLS Open-end wrench Art. no.: T14032 200640-10 Clamping stand Art. no.: T1403S 200637-10 Press drift Art. no.: T1504 200789-10 Assembly tool Art. no.: T150S 200791-10 Nitrogen filling tool Art. no.: T170S1 300574-10...

  • Page 280: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.

  • Page 281: Index

    INDEX Coolant INDEX draining ....... . 155 Accessories ........6 refilling .
  • Page 282 INDEX Engine assembly locking lever, removing ..... . 108 adjusting the valve clearance ....149 oil filter, removing .
  • Page 283 INDEX checking ....... . . 19 compression damping fitting, assembling ... 20 Oil circuit .
  • Page 284 INDEX setting kilometers or miles ..... 86 setting the clock ......88 wheel circumference, setting .
  • Page 285 HUSABERG eine Division der KTM SMC AG Stallhofnerstraße 3 5230 Mattighofen, Austria www.husaberg.com *3803004en* 3803004en...

This manual is also suitable for:

Fe 570 euFe 570 usaFe 450 usaFe 570 ausFe 450 aus

Table of Contents