Husqvarna FS 450 2022 Owner's Manual
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Husqvarna FS 450 2022 Owner's Manual

Husqvarna FS 450 2022 Owner's Manual

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OWNER'S MANUAL 2022
FS 450
Art. no. 3402545en

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Summary of Contents for Husqvarna FS 450 2022

  • Page 1 OWNER'S MANUAL 2022 FS 450 Art. no. 3402545en...
  • Page 3 DEAR HUSQVARNA MOTORCYCLES CUSTOMER Congratulations on your decision to purchase a Husqvarna motorcycle. You are now the owner of a state-of- DEAR HUSQVARNA MOTORCYCLES CUSTOMER the-art, sporty motorcycle that you will continue to enjoy for a long time if you maintain it properly.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS 6.15 Service hour counter......21 MEANS OF REPRESENTATION......5 PREPARING FOR USE........22 Symbols used ........5 Formats used ........5 Advice on preparing for first use..22 Running in the engine ......23 SAFETY ADVICE ..........
  • Page 5 TABLE OF CONTENTS 10.14 Adjusting the compression damping 11.36 Checking the chain tension ....67 of the fork..........41 11.37 Adjusting the chain tension....68 10.15 Adjusting the rebound damping of 11.38 Checking the chain, rear sprocket, the fork..........41 engine sprocket, and chain guide..
  • Page 6 TABLE OF CONTENTS 15.4 Draining the coolant ...... 101 STANDARDS ..........136 15.5 Refilling coolant ......101 INDEX OF SPECIAL TERMS ......137 15.6 Changing the coolant......102 LIST OF ABBREVIATIONS ......138 TUNING THE ENGINE ........104 LIST OF SYMBOLS ........139 16.1 Checking the play in the throttle 28.1...

  • Page 7: Means Of Representation 1

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have this work performed by an authorized Husqvarna Motorcycles workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations. Info Only operate this vehicle in closed-off areas remote from public road traffic.

  • Page 9: Tampering Warning

    Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. Have malfunctions that impair safety promptly eliminated by an authorized Husqvarna Motorcycles workshop. Adhere to the information and warning labels on the vehicle.

  • Page 10: Protective Clothing

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, Husqvarna Motorcycles recommends that you only operate the vehicle while wearing protective clothing. Work rules Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).
  • Page 11 SAFETY ADVICE 2 The Owner's Manual is also available for download from your authorized Husqvarna Motorcycles dealer and on the Husqvarna Motorcycles website. A printed copy can also be ordered from your authorized Husqvarna Motorcycles dealer. International Husqvarna Motorcycles website: www.husqvarna-motorcycles.com...

  • Page 12: Important Notes

    3 IMPORTANT NOTES Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized Husqvarna Motorcy- cles workshop and confirmed in the Husqvarna Motorcycles Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 13: Customer Service

    IMPORTANT NOTES 3 Customer service Your authorized Husqvarna Motorcycles dealer will be happy to answer any questions you may have regarding your vehicle and Husqvarna Motorcycles. A list of authorized Husqvarna Motorcycles dealers can be found on the Husqvarna Motorcycles website.

  • Page 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) S03023-10 Hand brake lever ( p. 16) Clutch lever ( p. 16) Fuel tank filler cap Plug-in stand ( p. 20) Air filter box cover Engine number ( p. 14) Shift lever ( p.

  • Page 15: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) S03024-10 Fork air pressure adjuster Combination switch ( p. 17) Stop button ( p. 16) Start button ( p. 17) Throttle grip ( p. 16) Fork compression adjuster Foot brake lever ( p.

  • Page 16: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number The engine number is stamped on the left side of the engine.

  • Page 17: Shock Absorber Article Number

    SERIAL NUMBERS 5 Shock absorber article number The shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 401948-10...

  • Page 18: Controls

    6 CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. D07662-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. H01726-10 Throttle grip The throttle grip...

  • Page 19: Start Button

    Malfunction indicator lamp lights up/flashes orange – The OBD has detected a malfunction in the vehicle electronics. Come safely to a halt, and contact an authorized Husqvarna Motorcycles workshop. Malfunction indicator lamp flashes orange rapidly – Launch control is activated.

  • Page 20: Opening Fuel Tank Filler Cap

    6 CONTROLS Opening fuel tank filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 21: Cold Start Button

    CONTROLS 6 6.10 Cold start button Cold start button is fitted to the bottom of the throttle valve body. The electronic fuel injection system extends the injection time if the engine is cold and the ambient temperature is low. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pushing the cold start button.

  • Page 22: Shift Lever

    6 CONTROLS 6.12 Shift lever Shift lever is mounted on the left of the engine. 401950-10 The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears. 401950-13 6.13 Foot brake lever Foot brake lever is located in front of the right footrest.

  • Page 23: Service Hour Counter

    CONTROLS 6 6.15 Service hour counter The service hour counter is fitted in front of the handlebar. It shows the total number of service hours of the engine. The service hour counter begins counting when the engine is started and stops when the engine is switched off. Info The value indicated by the service hour counter cannot be cleared or adjusted.

  • Page 24: Preparing For Use

    When using the motorcycle, remember that others may be disturbed by excessive noise. – Ensure that the pre-sale inspection work has been carried out by an authorized Husqvarna Motorcycles workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 25: Running In The Engine

    PREPARING FOR USE 7 – Adjust the basic position of the hand brake lever. ( p. 76) – Adjust the basic position of the foot brake lever. p. 81) – Adjust the basic position of the shift lever. p. 109) –...

  • Page 26: Riding Instructions

    8 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 27: Activating Launch Control

    RIDING INSTRUCTIONS 8 – Remove plug-in stand – Shift the transmission into neutral. 402001-10 Condition Ambient temperature: < 20 °C (< 68 °F) – Push the cold start button in all the way. – Press start button Info Press the start button for a maximum of 5 seconds. Wait for 30 seconds before a further attempt at start- ing.

  • Page 28: Activating Traction Control

    Do not change into a low gear at high engine speed. Info If unusual noises occur while riding, stop immediately, switch off the engine, and contact an authorized Husqvarna Motorcycles workshop. First gear is used for starting off and for steep inclines. –...

  • Page 29: Applying The Brakes

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 30: Transporting

    8 RIDING INSTRUCTIONS Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. –...
  • Page 31 In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Note Environmental hazard Improper handling of fuel is a danger to the environment.

  • Page 32: Service Schedule

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up- to-date service schedule can always be found on Husqvarna Motorcycles Dealer.net. Your authorized Husq- varna Motorcycles dealer will be glad to advise you.

  • Page 33: Recommended Work

    Final check: Check the vehicle for operating safety and take a test ride. ○ ● ● ● ● ● Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics tool. ○ ● ● ● ● ●...
  • Page 34 9 SERVICE SCHEDULE every 48 months every 12 months Every 100 operating hours Every 50 operating hours After 20 operating hours After 10 operating hours ● Perform major engine service including removing and installing the engine. (Change valves, valve springs, valve spring seats, and valve spring retainers. Change the connecting rod, conrod bearing and crank pin.

  • Page 35: Tuning The Chassis 10

    – In the delivered condition, Husqvarna motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 75 …...

  • Page 36: Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock absorber.

  • Page 37: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.

  • Page 38: Measuring The Rear Wheel Dimension Unloaded

    10 TUNING THE CHASSIS – Turn adjusting screw clockwise up to the last perceptible click. – Turn counterclockwise by the number of clicks correspond- ing to the shock absorber type. Guideline Rebound damping Comfort 17 clicks Standard 15 clicks V01427-10 Sport 13 clicks Info...

  • Page 39: Checking The Static Sag Of The Shock Absorber

    TUNING THE CHASSIS 10 10.8 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 36) – Hold the motorcycle upright with aid of an assistant. – Measure the distance again between the rear axle and mark- ing SAG on the rear fender using the sag gage.

  • Page 40: Adjusting The Spring Preload Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info Note the current adjustment before changing the spring preload - e.g. measure the spring length.

  • Page 41: Adjusting The Riding Sag

    TUNING THE CHASSIS 10 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) – Remove the shock absorber. p. 54) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 42: Adjusting The Fork Air Pressure

    10 TUNING THE CHASSIS 10.13 Adjusting the fork air pressure Warning Danger of accident Modifications to the suspension setting may seriously alter the handling charac- teristic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components. –...

  • Page 43: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 10 When disconnecting, excess pressure will escape from the hose – the fork leg itself does not lose any air. The fork airpump indicator switches off automatically after 80 seconds. – Mount the protection cap. Info Only tighten the protection cap by hand. Finishing work –...

  • Page 44: Handlebar Position

    10 TUNING THE CHASSIS Guideline Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Info Turn clockwise to increase damping; turn counter- clockwise to reduce damping. – Mount protection cap 10.16 Handlebar position On the upper triple clamp, there are 2 holes at a distance of to each other.
  • Page 45 TUNING THE CHASSIS 10 Info Make sure the cables and wiring are positioned cor- rectly. – Position handlebar clamps. – Mount screws but do not tighten yet. – First bolt the handlebar clamps with screws onto the longer, higher side of the handlebar supports so that both parts touch.

  • Page 46: 11 Service Work On The Chassis

    11 SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (80329955100) Neither wheel is in contact with the ground.

  • Page 47: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) – Remove the fork protector. ( p. 45) Main work – Push dust boots of both fork legs downward.

  • Page 48: Installing The Fork Protector

    11 SERVICE WORK ON THE CHASSIS 11.6 Installing the fork protector – Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake line and clamp. Mount and tighten screws –...

  • Page 49: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.8 Installing the fork legs Main work – Position the fork legs. Air release screw of the right fork leg is positioned to the front. Valve of the left fork leg faces the front. Info Grooves are milled into the side of the upper end of the fork legs.

  • Page 50: Installing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS Main work – Remove indicator lamp holder. – Open cable holder on the left and detach the wiring har- ness. – Remove screw – Remove screw – Take off the upper triple clamp with the handlebar and place to one side.
  • Page 51 SERVICE WORK ON THE CHASSIS 11 – Position the upper triple clamp with the handlebar. – Mount screw , but do not tighten yet. Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head V01434-10 – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front.

  • Page 52: Checking The Steering Head Bearing Play

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

  • Page 53: Adjusting Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bear- ing. » If there is detectable play: –...

  • Page 54: Lubricating The Steering Head Bearing

    11 SERVICE WORK ON THE CHASSIS 11.13 Lubricating the steering head bearing – Remove the lower triple clamp. p. 47) – Install the lower triple clamp. p. 48) Info The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp.

  • Page 55: Installing Front Fender

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove screws . Take off the front fender. F00382-10 11.17 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F00382-10 Finishing work...

  • Page 56: Removing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS 11.18 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) Main work – Remove the cable ties. – Remove screws with the washers. – Detach the frame protector in area and take it off.

  • Page 57: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 – Remove nut and pull out the swingarm pivot. – Push the link fork back and secure it against falling over. V01442-10 – Hold the shock absorber and remove screw S03020-10 – Remove the shock absorber carefully at the bottom. K01096-10 11.19 Installing the shock absorber...
  • Page 58 11 SERVICE WORK ON THE CHASSIS – Mount the chain. – Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel. 120325-10 – Position the foot brake cylinder. Push rod engages in the foot brake cylinder.

  • Page 59: Removing The Seat

    SERVICE WORK ON THE CHASSIS 11 11.20 Removing the seat Preparatory work – Remove the air filter box cover. ( p. 58) Main work – Remove screw V01430-10 – Raise the rear of the seat, pull the seat back, and lift it off. H02218-10 11.21 Mounting the seat...

  • Page 60: Removing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS 11.22 Removing the air filter box cover – Pull off the air filter box cover sideways in areas and take off toward the rear. V01443-10 11.23 Installing the air filter box cover – Attach catch of the air filter box in area and push for- ward.

  • Page 61: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 Main work – Detach retaining tab – Remove air filter with air filter support. – Remove air filter from air filter support. K01080-10 11.25 Installing the air filter Main work – Mount the clean air filter on the air filter support. –...

  • Page 62: Removing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 134) Info Only press the air filter to dry it, never wring it out. –...

  • Page 63: Installing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11 11.28 Installing the main silencer – Position the main silencer. – Mount screws with the washers, but do not tighten yet. V01446-10 – Attach spring Spring hook (50305017000C1) – Tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V01445-11...

  • Page 64: Removing The Right Side Cover

    11 SERVICE WORK ON THE CHASSIS Main work – Remove all the screws on the silencer cap. – Take off silencer cap and O-ring – Pull glass fiber yarn filling out of the silencer cap. – Pull glass fiber yarn filling from the inner tube.

  • Page 65: Installing The Right Side Cover

    SERVICE WORK ON THE CHASSIS 11 11.31 Installing the right side cover Main work – Attach side cover with the holding lugs from below and push upward. – Engage the side cover in areas V01448-10 Finishing work – Mount the seat. ( p.
  • Page 66 11 SERVICE WORK ON THE CHASSIS – Remove the seat. ( p. 57) – Remove the right side cover. ( p. 62) Main work – Unplug connector of the fuel pump. – Pull the fuel tank breather hose off the fuel tank lid. –...

  • Page 67: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 11.33 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 68: Checking For Chain Dirt Accumulation

    11 SERVICE WORK ON THE CHASSIS – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V01451-11 – Plug in connector for the fuel pump. – Remove the wash cap set and thoroughly clean the quick release coupling using compressed air.

  • Page 69: Cleaning The Chain

    SERVICE WORK ON THE CHASSIS 11 11.35 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. – Remove lubricants from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...

  • Page 70: Adjusting The Chain Tension

    11 SERVICE WORK ON THE CHASSIS Main work – Pull the chain at the end of the chain sliding piece upward to measure chain tension Info Lower chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 71: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 11 Guideline Nut, rear wheel spin- M25x1.5 80 Nm (59 lbf ft) Info The wide adjustment range of the chain adjusters (32 mm (1.26 in)) enables different secondary ratios with the same chain length. Chain adjusters can be turned by 180°.
  • Page 72 11 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with, or below, the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.

  • Page 73: Checking The Frame

    If the link fork exhibits damage, cracking, or deformation: – Change the link fork. Info Always replace a damaged link fork. Repair of the link fork is not authorized by Husqvarna Motorcycles. 401520-01 11.41 Checking the throttle cable routing Preparatory work –...

  • Page 74: Checking The Rubber Grips

    11 SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the rubber strap of the fuel tank support.

  • Page 75: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 11 11.43 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info When the adjusting screw is turned counterclockwise, the clutch lever moves away from the handlebar.

  • Page 76: Changing The Hydraulic Clutch Fluid

    11 SERVICE WORK ON THE CHASSIS Info Clean up overflowed or spilled brake fluid immediately with water. 11.45 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. –...
  • Page 77 SERVICE WORK ON THE CHASSIS 11 – Now press the fluid into the system until it emerges from hole of the master cylinder without bubbles. – Occasionally extract the fluid from the master cylinder reser- voir to prevent overflowing. – Tighten the bleeder screw and remove the bleeding syringe with the hose.

  • Page 78: 12 Brake System

    Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple...

  • Page 79: Checking The Front Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Preparatory work –...

  • Page 80: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...

  • Page 81: Changing The Front Brake Linings

    Changing the front brake linings Warning Danger of accidents Incorrect servicing will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation.
  • Page 82 12 BRAKE SYSTEM – Move the brake reservoir mounted on the handlebar to a hori- zontal position. – Remove screws – Take off cover with membrane V01453-11 – Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir;...

  • Page 83: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 12 – Fill brake fluid up to the MAX marking. Brake fluid DOT 4 / DOT 5.1 ( p. 132) – Position cover with membrane . Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water.

  • Page 84: Checking The Rear Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Preparatory work –...

  • Page 85: Adding Rear Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 86: Checking The Brake Linings Of The Rear Brake

    Checking the brake linings of the rear brake Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 87 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.
  • Page 88 12 BRAKE SYSTEM – Insert the new brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs. Make sure that decoupling plate is mounted on the piston side brake lining. – Operate the foot brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure F00406-10 point.

  • Page 89: Wheels, Tires 13

    WHEELS, TIRES 13 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) Main work – Remove screws with washers – Press back the brake linings by slightly tilting the brake caliper laterally on the brake disc. –...

  • Page 90: Installing The Front Wheel

    13 WHEELS, TIRES 13.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 91: Removing The Rear Wheel

    WHEELS, TIRES 13 – Remove the motorcycle from the lift stand. ( p. 44) – Operate the front brake and compress the fork a few times firmly. The fork legs straighten. – Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) G04197-10 13.3 Removing the rear wheel...

  • Page 92: Installing The Rear Wheel

    13 WHEELS, TIRES – Remove spacers H03002-10 13.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Main work –...

  • Page 93: Checking The Tire Condition

    Checking the tire condition Info Only mount tires approved and/or recommended by Husqvarna Motorcycles. Other tires could have a negative effect on handling characteristics. The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle.

  • Page 94: Checking Tire Pressure

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
  • Page 95 WHEELS, TIRES 13 – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diameter. If spokes of the same length and diameter vibrate with a different tone, this is an indication that the spoke tensions differ.

  • Page 96: 14 Electrical System

    14 ELECTRICAL SYSTEM 14.1 Removing the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms.

  • Page 97: Installing The 12 V Battery

    ELECTRICAL SYSTEM 14 14.2 Installing the 12 V battery Main work – Position the 12 V battery in the battery compartment with the terminals facing forward, and secure with holding bracket 12 V battery (HJTZ5S-FP-C) ( p. 128) – Mount and tighten screw Guideline Remaining nuts, 10 Nm (7.4 lbf ft)
  • Page 98 14 ELECTRICAL SYSTEM Note Environmental hazard 12 V batteries contain environmentally hazardous materials. – Do not dispose of 12 V batteries as household waste. – Dispose of 12 V batteries at a collection point for used batteries. Info Even when there is no load on the 12 V battery, it discharges steadily. The charging level and the method of charging are very important for the service life of the 12 V battery.

  • Page 99: Changing Main Fuse

    ELECTRICAL SYSTEM 14 These battery chargers are only suitable for lithium iron phosphate batteries. Read the accompanying instructions for Husqvarna Motorcycles accessories. Info Never remove cover – Switch off the battery charger after charging and disconnect from the 12 V battery.
  • Page 100 14 ELECTRICAL SYSTEM – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. – Insert a new main fuse. Fuse (58011109110) ( p.

  • Page 101: Cooling System 15

    COOLING SYSTEM 15 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 102: Checking The Coolant Level

    15 COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...

  • Page 103: Draining The Coolant

    COOLING SYSTEM 15 15.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 104: Changing The Coolant

    15 COOLING SYSTEM – Make sure that screw is tightened. – Position the motorcycle upright. – Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Dimension over the radi- ator fins Coolant 1.20 l Coolant ( p.
  • Page 105 COOLING SYSTEM 15 – Mount and tighten screw with a new seal ring. Guideline Screw, water pump 10 Nm (7.4 lbf ft) cover – Pour coolant in up to level above the radiator fins. Guideline 10 mm (0.39 in) Distance above the radi- ator fins V01456-10...

  • Page 106: 16 Tuning The Engine

    16 TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 …...

  • Page 107: Adjusting The Characteristic Map Of The Throttle Response

    TUNING THE ENGINE 16 Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop. –...
  • Page 108 16 TUNING THE ENGINE – Remove guide plate from handle tube – Position the required guide plate on the grip tube. Guideline The label OUTSIDE must be visible. Marking must be positioned at marking Grey guide plate (79002014000) Alternative 1 Black guide plate (79002014100) Info The gray guide plate opens the throttle valve more...

  • Page 109: Changing The Mapping

    Adjusting the idle speed Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)

  • Page 110: Programming The Throttle Valve Position

    16 TUNING THE ENGINE – Run the engine until warm. The cold start button is deactivated – The cold start but- ton is in its basic position. ( p. 19) Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

  • Page 111: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 16 16.7 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...

  • Page 112: 17 Service Work On The Engine

    17 SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 113: Checking The Engine Oil Level

    SERVICE WORK ON THE ENGINE 17 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 114: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    17 SERVICE WORK ON THE ENGINE 17.3 Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. – Wear suitable protective clothing and safety gloves. –...
  • Page 115 SERVICE WORK ON THE ENGINE 17 – Mount and tighten screw plug with the short oil screen and the O-rings. Guideline Screw plug, oil M20x1.5 15 Nm (11.1 lbf ft) screen K01069-11 – Position long oil screen with the O-rings on a pin wrench. –...

  • Page 116: Adding Engine Oil

    17 SERVICE WORK ON THE ENGINE – Lay the motorcycle on its side and fill the oil filter housing to about ⅓ full with engine oil. – Place the new oil filter into the housing. – Lubricate the O-ring of the oil filter cover and mount it with oil filter cover –...
  • Page 117 SERVICE WORK ON THE ENGINE 17 Info In order to achieve optimal engine oil performance, it is not advisable to mix different engine oils. Husqvarna Motorcycles recommends changing the engine oil. – Mount and tighten the filler plug together with the O-ring.

  • Page 118: Cleaning, Care

    18 CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 119 CLEANING, CARE 18 – After the motorcycle has cooled down, lubricate all moving parts and pivot points. – Clean the chain. ( p. 67) – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p.

  • Page 120: 19 Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info Husqvarna Motorcycles recommends raising the motorcycle. – Raise the motorcycle with a lift stand. ( p. 44) –...

  • Page 121: Preparing For Use After Storage

    STORAGE 19 Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust.

  • Page 122: 20 Troubleshooting

    – Check the electrical system. – Malfunction in the electronic Read out the fault memory using the fuel injection Husqvarna Motorcycles diagnostics tool. – Engine does not speed up Malfunction in the electronic Read out the fault memory using the...
  • Page 123 Check the wiring for damage and the electrical plug-in connections for cor- rosion and damage. – Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary.

  • Page 124: 21 Blink Code

    21 BLINK CODE Blink code for malfunc- tion indicator lamp 02 Malfunction indicator lamp flashes 2x short Crankshaft speed sensor – circuit fault Error level condition Blink code for malfunc- tion indicator lamp 02a Malfunction indicator lamp flashes 2x per second Error level condition Throttle valve position programming necessary Blink code for malfunc-...
  • Page 125 BLINK CODE 21 Blink code for malfunc- tion indicator lamp 33 Malfunction indicator lamp flashes 3x long, 3x short Injection valve cylinder 1 – circuit fault Error level condition Blink code for malfunc- tion indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short Ignition coil –...

  • Page 126: 22 Technical Data

    22 TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.9 cm³ (27.455 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 12.75:1 Idle speed 2,100 … 2,200 rpm Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust...

  • Page 127: Engine Tightening Torques

    TECHNICAL DATA 22 22.2 Engine tightening torques Screw, oil nozzle for piston cool- 2.5 Nm (1.84 lbf ft) ® Loctite 243™ Crankshaft speed sensor screw 6 Nm (4.4 lbf ft) ® Loctite 243™ and cable retainer Oil nozzle for clutch lubrication 2.5 Nm (1.84 lbf ft) Oil nozzle for piston cooling 2.5 Nm (1.84 lbf ft)

  • Page 128: Capacities

    22 TECHNICAL DATA Oil nozzle for conrod bearing M6x0.75 2 Nm (1.5 lbf ft) lubrication Plug, oil channel 9 Nm (6.6 lbf ft) ® Loctite 243™ Screw, rocker arm bearing M7x1 15 Nm (11.1 lbf ft) Crankshaft clamp screw plug 10 Nm (7.4 lbf ft) Plug, timing chain tensioner 8 Nm (5.9 lbf ft)

  • Page 129: Chassis

    TECHNICAL DATA 22 22.4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP XACT 5448 Suspension travel front 280 mm (11.02 in) rear 266 mm (10.47 in) Fork offset 16 mm (0.63 in) Shock absorber WP XACT 5750 Brake system front Single disc brake with radially screwed four-piston...

  • Page 130: Electrical System

    165/630 R 17 TL Bridgestone Battlax Supermoto BM01Z Bridgestone Battlax Racing R02Z The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com 22.7 Fork Fork article number 0262C108U406000 Fork...

  • Page 131: Shock Absorber

    TECHNICAL DATA 22 22.8 Shock absorber Shock absorber article number 0262C408U408000 Shock absorber WP XACT 5750 Lowspeed compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Highspeed compression damping Comfort 2 turns Standard 1.5 turns Sport 1 turn Rebound damping Comfort 17 clicks...
  • Page 132 22 TECHNICAL DATA Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) Remaining nuts, chassis 5 Nm (3.7 lbf ft) Remaining screws, chassis 5 Nm (3.7 lbf ft) Screw, battery terminal 2.5 Nm (1.84 lbf ft) Screw, frame protector 3 Nm (2.2 lbf ft)
  • Page 133 TECHNICAL DATA 22 Screw, front brake caliper 45 Nm (33.2 lbf ft) ® Loctite 243™ Screw, handlebar support 40 Nm (29.5 lbf ft) ® Loctite 243™ Screw, top shock absorber 60 Nm (44.3 lbf ft) ® Loctite 2701™ Nut, fuel pump 15 Nm (11.1 lbf ft) Nut, angle lever to link fork M14x1.5...

  • Page 134: 23 Substances

    23 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 ®...
  • Page 135 SUBSTANCES 23 Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 136) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...

  • Page 136: 24 Auxiliary Substances

    24 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier ® MOTOREX – Racing Bio Dirt Remover Chain cleaner Recommended supplier ® MOTOREX – Chain Clean Fuel additive Recommended supplier ® MOTOREX – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 137 AUXILIARY SUBSTANCES 24 Silicone spray Recommended supplier ® MOTOREX – Silicone Spray Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier ® MOTOREX – Quick Cleaner Special grease (00062010053) Recommended supplier ® Klüber Lubrication – KLÜBERFOOD NH1 34‑401 Universal oil spray Recommended supplier...

  • Page 138: Standards

    25 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 139: Index Of Special Terms

    INDEX OF SPECIAL TERMS 26 Launch control Vehicles electronics functions for achieving the best possible acceleration from a standing position On-board diagnosis Vehicle system, which monitors the specified param- eters of the vehicle electronics...

  • Page 140: List Of Abbreviations

    27 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 141: List Of Symbols

    Malfunction indicator lamp lights up/flashes orange – The OBD has detected a malfunction in the vehicle electronics. Come safely to a halt, and contact an authorized Husqvarna Motorcycles workshop. Malfunction indicator lamp flashes orange rapidly – Launch control is activated.

  • Page 142: Index

    INDEX INDEX Chain guide checking ......69 12 V battery Chain tension charging ......95 adjusting .
  • Page 143 INDEX removing ......46 Low-speed compression damping shock absorber, adjusting ....34 Fork part number .
  • Page 144 INDEX Riding sag adjusting ......39 Technical data Right side cover capacities ......126 installing .
  • Page 145 *3402545en* 3402545en 08/2021 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer/KISKA, www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...

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