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Manuals
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HUSABERG Manuals
Engine
FE 550
Repair manual
HUSABERG FE 550 Repair Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
General Information
Oil Circuit
Engine Oil
Checking the Oil Level
Changing the Engine Oil
Cleaning the Oil Screen
Changing the Oil Filter
Checking the Oil Level in the Hydraulic Clutch
Bleeding the Clutch
Cleaning
Preservation for Winter Operation
Storage
Special Tools
Dismounting and Mounting the Engine
Dismounting the Engine
Mounting the Engine
Bleeding the Cooling System
Adjusting the Throttle Cable
Disassembling the Engine
Blocking the Engine
Removing the Rotor
Removing the Clutch
Removing Inner Clutch Hub
Removing Primary Pinion and the Idler Shaft Gear
Removing the Oil Pump
Removing the Chain Tensioner
Separating the Timing Chain
Removing the Cylinder Head
Separating the Housing
Removing the Crankshaft
Removing the Transmission
Removing the Idler Shaft
Servicing the Individual Parts
Important
Left Housing Half
Right Housing Half
Pressure Relief Valve
Clutch Cover
Crankshaft
Press out the Crank Pin
Press in the Crank Pin
Outer Dimension of the Crankshaft Webs
Balancing the Axial Clearance of the Crankshaft
Nikasil Cylinder Coating
Measuring the Piston and Cylinder Liner
Checking the Piston
Checking the Piston Ring End Gap
Checking the Oil Pump for Wear
Cylinder Head Top Section
Cylinder Head
Camshaft
Timing Chain Tensioner
Timing Train
Checking the Clutch for Wear
Checking the Kickstarter for Wear
Shift Mechanism
Assembling the Main Shaft (Four-Speed)
Assembling the Main Shaft (Six-Speed)
Starter Drive
Checking the Freewheel
Assembling the Engine
Mounting the Idler Shaft
Mounting the Crankshaft
Mounting the Cylinder Head
Mounting the Timing Chain
Mounting the Timing Chain Tensioner
Adjusting the Valve Clearance
Mounting the Oil Pump
Mounting the Shift Mechanism
Mounting the Kickstarter Shaft
Mounting the Clutch
Mounting the Clutch Cover
Mounting the Pressure Relief Valve
Electric System
Checking for Loss of Current
Dismounting/Mounting the Battery
Charging the Battery
Filling the Battery
Checking the Starter
Checking the Starter Relay
Checking the Voltage Regulator
Troubleshooting in the Ignition System
CDI Unit
Checking the Ignition Coil
Ignition System
Checking the Stator and Pulse Generator
Static Ignition Values Kokusan 4K-3A/B
Static Generator Values Kokusan 4K3B
Fuel System
Keihin Fcr-MX 39/41
Accelerator Pump
Jet Needle
Throttle Slide
Adjusting the Throttle Sensor Position
Checking the Throttle Sensor
Dismounting and Mounting the Throttle Sensor
Adjusting the Idle
Troubleshooting
Technical Specifications
Engine 450, 501
Chassis
Tightening Torques
Mounting Clearances, Engine Wear Limits
Periodic Maintenance Schedule
Wiring Diagrams
Cable Colors
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04
"
REPARATURANLEITUNG
REPAIR MANUAL
MANUEL DE REPARATION
Edition 2004
Table of
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Table of Contents
Troubleshooting
Troubleshooting in the ignition system
74
Troubleshooting
96
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Related Manuals for HUSABERG FE 550
Engine HUSABERG FE 450 Repair Manual
(116 pages)
Engine HUSABERG FS 450 Repair Manual
(116 pages)
Summarization of Contents
General Information
Engine Oil
Specifies the type of engine oil and precautions for use.
Checking the Engine Oil Level
Instructions on how to correctly check the engine oil level.
Changing the Engine Oil
Step-by-step guide for performing an engine oil change.
Changing the Oil Filter
Detailed procedure for replacing the engine oil filter element.
Bleeding the Clutch
Steps for removing air from the hydraulic clutch system.
Storage
Guidelines for safely storing the motorcycle for extended periods.
Dismounting and Mounting the Engine
Dismounting the Engine
Comprehensive guide on how to remove the engine from the motorcycle frame.
Mounting the Engine
Step-by-step instructions for reinstalling the engine into the motorcycle frame.
Disassembling the Engine
Locking the Engine
Procedure to lock the crankshaft for safe disassembly.
Removing the Rotor
Steps for safely removing the engine rotor assembly.
Removing the Clutch
Detailed instructions for disassembling the clutch components.
Separating the Housing Halves
Procedure for splitting the engine crankcase halves.
Servicing the Individual Parts
Left Housing Half
Procedures for servicing the left engine crankcase half and its components.
Crankshaft
Steps for inspecting and servicing the engine's crankshaft.
Measuring the Piston and Cylinder Liner, Establishing the Mounting Clearance of the Piston
How to measure cylinder liner and piston for correct fitment.
Checking the Clutch for Wear
Inspection procedure for clutch components to detect wear.
Assembling the Engine
Mounting the Crankshaft
Step-by-step guide for installing the crankshaft into the engine case.
Mounting the Cylinder Head
Procedure for correctly installing the cylinder head assembly.
Adjusting the Valve Clearance
How to properly adjust the engine's valve clearance.
Mounting the Kickstarter Shaft
Procedure for installing the kickstarter shaft assembly.
Electric System
Charging the Battery
Guidelines and safety precautions for charging the motorcycle battery.
Checking the Starter Engine
Method for testing the functionality of the starter motor.
Checking the Voltage Regulator
Diagnostic steps for a faulty voltage regulator.
Troubleshooting in the Ignition System
Steps to diagnose and resolve ignition system faults.
Fuel System
Keihin FCR-MX 39/41 Carburetor
Exploded view and identification of Keihin FCR-MX carburetor parts.
Disassembling the Keihin FCR-MX 39/41 Carburetor
Step-by-step instructions for disassembling the Keihin carburetor.
Adjusting the Carburetor Idle
Guide for adjusting engine idle speed and mixture control.
Troubleshooting
Engine does not switch on (starter)
Steps to diagnose why the starter does not engage.
Engine does not start (kickstarter)
Troubleshooting steps if the engine fails to start via kickstarter.
Engine gets too hot
Diagnosing and resolving issues causing the engine to overheat.
Technical Specifications
Engine Specifications Table
Key technical data and specifications for the engine.
Basic Carburetor Setting
Recommended settings for the carburetor based on model.
Tightening Torques
Specific torque values for engine component fasteners.
Mounting Clearances, Wear Limits
Critical measurements for engine part fitment and wear.
Periodic Maintenance Schedule
FC 450/4, FC 550/4 Model 2004
Recommended maintenance intervals for FC 450/4 and FC 550/4 models.
Important Checks and Maintenance to be Carried Out by the Rider
Routine checks and maintenance tasks for the rider.
Wiring Diagrams
Wiring Diagramm Husaberg FE 04
Electrical schematic for the Husaberg FE 04 model.
Cable Colours
Key for understanding wire colors used in the diagrams.
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