HUSABERG Edition 2004 Owner's Manual
  1. Manuals
  2. Brands
  3. HUSABERG Manuals
  4. Motorcycle
  5. Edition 2004
  6. Owner's manual
HUSABERG Edition 2004 Owner's Manual

HUSABERG Edition 2004 Owner's Manual

4 stroke force
Hide thumbs
Table of Contents

Advertisement

Quick Links

04
"
BEDIENUNGSANLEITUNG
OWNERS MANUAL
MANUEL D'UTILISATION
Edition 2004

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Edition 2004 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for HUSABERG Edition 2004

Summary of Contents for HUSABERG Edition 2004

  • Page 1 “ BEDIENUNGSANLEITUNG OWNERS MANUAL MANUEL D’UTILISATION Edition 2004...

  • Page 2: Table Of Contents

    Checking the oil level of the hydraulic clutch ..51 Running in the Husaberg models ....20 Bleeding of the hydraulic clutch ....51 Carburetor –...

  • Page 3: Introduction

    INTRODUCTION IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COM- PLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS: WARNING: IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY...
  • Page 4 INTRODUCTION We would like to congratulate you on your purchase of a Husaberg motorcycle. You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appro- priately.

  • Page 5: Important Limited Warranty And Limited Guarantee

    INTRODUCTION IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION Husaberg sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations.

  • Page 6: Serial Number Locations

    SERIAL NUMBER LOCATIONS CHASSIS NUMBER The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 2. ENGINE-NUMBER The engine number is embossed in the engine case on the left side of the engine under the radiator hose.

  • Page 7: Operation Instruments

    OPERATION INSTRUMENTS CLUTCH LEVER The clutch lever (1) is located on the left side of the handlebar. The adjusting screw (A) is used to change the original position of the clutch lever (see maintenance work on chassis and engine). HAND DECOMPRESSION LEVER The hand decompression lever (2) is needed only if the carburetor overflows after a fall.

  • Page 8: Combination Switch

    OPERATION INSTRUMENTS COMBINATION SWITCH The light switch has 2, respectively 3 switch positions. A = Light off (this function is not available in all models) B = Low beam on C = High beam on You may use button (1) to actuate the horn. The red short circuit button (2) serves to switch off the engine.

  • Page 9: Indicator Lamps

    OPERATION INSTRUMENTS INDICATOR LAMPS The green control lamp (1) flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp (2) lights up when the high beam is STARTER BUTTON Pushing the black starter button (3) will actuate the E-starter. EMERGENCY OFF SWITCH (AUSTRALIA) The red emergency-OFF switch (4) is arranged adjacent to the throttle grip.

  • Page 10: Tripmaster-Switch

    The displayed figure cannot be cleared. Service intervals are indicated in operating hours for some Husaberg offroad motorcycles, making the operating hour counter a very practical function. SPEED/ODO DISPLAY MODE The SPEED/ODO mode shows the speed and the total kilometers travled.
  • Page 11 OPERATION INSTRUMENTS SPEED/ODO DISPLAY MODE SPEED displays the speed in KPH or MPH. The displayed figure cannot be cleared. ODO displays the kilometers or miles traveled. The displayed figure cannot be cleared. + button no function – button no function press the MODE button to change to the next mode press and hold the MODE button 3 seconds to change to the next mode...
  • Page 12 The displayed figure cannot be cleared. Service intervals are indicated in operating hours for some Husaberg offroad motorcycles, making the operating hour counter a very practical function. + button no function –...
  • Page 13 OPERATION INSTRUMENTS SPEED/AVS1 (AVERAGE SPEED 1) DISPLAY MODE AVS1 is always active and shows the average speed based on the TRP1 and STP1 figures. The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received.

  • Page 14: Setting The Clock

    OPERATION INSTRUMENTS SPEED/STP2 (STOP 2) DISPLAY MODE STP2 is a manual stop watch. Start the stop watch by pressing the + button, press again to hold. Press again to continue timing. Press the MODE button to change to the next mode. The STP2 dis- play will blink in the other modes if STP2 continues to run in the background.

  • Page 15: Kilometers Or Miles

    OPERATION INSTRUMENTS KILOMETERS OR MILES The unit (kilometers or miles) can also be changed. The ODO figure will be retained and converted accordingly. The TRP1, AVS1, STP1, TRP2 and AVS2 figures will be cleared. To select the unit, select the SPEED/H mode and hold the MODE button for 3 seconds to access the SETUP menu.

  • Page 16: Filler Cap

    OPERATION INSTRUMENTS FILLER CAP To open the filler cap: Turn the filler cap counter-clockwise. To close the filler cap: Put the filler cap on and tighten it by turning it clockwise. Install the tank breather hose (1) without kinks. FUEL TAPS In this position the fuel taps are closed.

  • Page 17: Shift Lever

    OPERATION INSTRUMENTS SHIFT LEVER The shift lever is mounted on the left side of the engine. The posi- tion of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear. 2,3,4 (5,6) KICKSTARTER The kickstarter is located on the left side of the engine.

  • Page 18: Compression Damping Of Fork

    OPERATION INSTRUMENTS COMPRESSION DAMPING OF FORK Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs.Remove the protecting cap (1). Turn the adjusting screws (2) clockwise to increase damping, turn it counterclockwise to reduce damping during compression.

  • Page 19: Damping Action During Compression Of Shock Absorber

    DAMPING ACTION DURING COMPRESSION OF SHOCK ABSORBER The shock absorber can synchronize the compression damping in the low and high-speed range separately (Dual Compression Control). Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle. The low and high-speed technology overlaps.

  • Page 20: Rebound Damping Of Shock Absorber

    REBOUND DAMPING OF SHOCK ABSORBER By using the adjusting screw (1), the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during rebo- unding. STANDARD ADJUSTMENT: – turn the adjusting screw clockwise to the stop. –...

  • Page 21: Tips And Warnings For Starting The Motorcycle

    INSTRUCTIONS FOR INITIAL OPERATION WARNING: Wear suitable clothing when driving a motorcycle. Clever Husaberg drivers always wear – Verify that your Husaberg dealer performed the PREPA- a helmet, boots, gloves and a jacket, regardless of RATION OF VEHICLE jobs (see Customer Service whether driving all day or just for a short trip.

  • Page 22: Driving Instructions

    Arrange for the braking system to be checked by a Husaberg specialist, as com- plete failure of the braking system can be avoided.

  • Page 23: Starting When The Engine Is Cold

    STARTING WHEN THE ENGINE IS COLD 1 Open the fuel taps (1). 2 Swing up the side stand or center stand. 3 Put the gear in neutral. 4 Operate the choke (2). 5 Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E-starter.

  • Page 24: Shifting/Riding

    NOTE: Dedicated to nothing but offroad racing, Dirty brake discs cause increased tear of brake Husaberg models make no compromises in their pads and brake discs. design. As such, they do not include any radiator fan, and the size of the radiator is dimensioned When you brake, the brake discs, brake pads, for optimum ergonomics.

  • Page 25: Stopping And Parking

    STOPPING AND PARKING Decelerate and switch the engine into neutral. To switch off the engine at idling speed, press the short-circuit switch or the emer- gency off switch until the engine is off or switch off the ignition. Close the fuel taps, park the motorcycle on a firm surface and lock. WARNING: Motorcycle engines produce a great amount of heat while running.
  • Page 26 - 25 -...

  • Page 27: Periodic Maintenance Schedule 2004

    PERIODIC MAINTENANCE SCHEDULE 2004 FC 450/4, FC 550/4 2004 MODEL after/every 1. service after A clean motorcycle can be checked more quickly which saves money! 10 hours 2 hours 60 l fuel 15 l fuel Change engine oil and oil filter Clean oil screen and drain plug magnet Replace spark plug (after 30 hours) Check and adjust valve clearance...
  • Page 28 PERIODIC MAINTENANCE SCHEDULE 2004 FE 450,501,550,650 /6, FS 450,650 2004 MODEL 1. service after after/every A clean motorcycle can be checked more quickly which saves money! 3 hours 15 hours 20 l fuel 100 l fuel Change engine oil and oil filter Clean oil screen and drain plug magnet Replace spark plug (after 30 hours) Check and adjust valve clearance...
  • Page 29 PERIODIC MAINTENANCE SCHEDULE 2004 MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER Before each After every For cross- start cleaning country use Check oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regularly...
  • Page 30 PERIODIC MAINTENANCE SCHEDULE 2004 ECOMMENDED INSPECTION OF THE USABERG ENGINES USED FOR ENDURO COMPETITIONS BY YOUR USABERG WORKSHOP ADDITIONAL ORDER FOR THE USABERG WORKSHOP a 100 liter fuel consumption is equivalent to approx. 15 operating hours Check the clutch disks for wear Check the length of the clutch springs Check the cylinder and piston for wear Check the groove on the piston pin retainer for wear (visual check)

  • Page 31: Maintenance Work On Chassis And Engine

    WARNING: Maintenance and adjusting work marked with an asterisk (*) requires expert skills and technical know-how. For your own safety, always have such work performed by a specialized Husaberg dealer where your motorcycle will be optimally serviced by appropriately qualified, skilled staff.

  • Page 32: Breather Plug Front Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE BREATHER PLUG FRONT FORK After every 5 hours of use for competitive racing, slacken the breat- her plugs (1) a few turns in order to relieve excess pressure from the inside of the fork. To do this, place the motorcycle on a stand with the front wheel lifted off the ground.

  • Page 33: Basic Suspension Setup For The Weight Of The Driver

    At delivery, Husaberg's offroad motorcycles are set to accommodate a driver weighing 70 - 80 kg (wearing full protective clothing).

  • Page 34: Checking The Basic Setup Of The Telescopic Fork

    The standard spring is shown in bold print. The type number of the telescopic fork is embossed on the caps on the top of the telescopic fork. If you are uncertain which spring to use, contact your Husaberg workshop. ODELL...

  • Page 35: How To Change The Handlebar Position

    MAINTENANCE WORK ON CHASSIS AND ENGINE HOW TO CHANGE THE HANDLEBAR POSITION The handlebar position can be readjusted by 22 mm. Thus, you can put the handlebar in the position that is the most convenient for you. The upper triple clamp (1) includes 2 bores arranged at a distance of 15 mm (0.6 in) from one another.

  • Page 36: Check Chain Tension

    WARNING: If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque cor- rected by a Husaberg dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle.

  • Page 37: Chain Maintenance

    MAINTENANCE WORK ON CHASSIS AND ENGINE CHAIN MAINTENANCE For a long chain life, good maintenance is very important. Chains without X-rings should be cleaned in fireproof solvent regularly and afterwards treated with hot grease or chain spray (e.g. Motorex Chainlube 622). X-ring chains on the other hand are very simple to clean.

  • Page 38: General Information About Husaberg Disc Brakes

    Husaberg dealer immediately. BRAKE FLUID: Husaberg fills the brake systems with Motorex Brake Fluid DOT 5.1 brake fluid, one of the best brake currently available. We recom- mend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color.

  • Page 39: Changing The Basic Position The Hand Brake Lever (Fc, Fe)

    In this case, consult an autho- rized Husaberg dealer immediately. REFILLING THE FRONT BRAKE FLUID RESERVOIR * Loosen screws (4) and remove lid (5) and membrane (6).

  • Page 40: Checking The Front Brake Pads

    WARNING: Brake fluid can cause skin irritation. Avoid contact with skin and eyes. If you get brake fluid in your 5 mm eyes, rinse with plenty of water and consult a doctor CAUTION: Don’t let brake fluid get in contact with paint, it is an effective paint remover.

  • Page 41: Changing The Basic Position Of The Foot Brake Pedal

    In this case, consult an authorized Husaberg dealer immediately. REFILLING THE REAR BRAKE FLUID RESERVOIR * When the brake fluid level has dropped to the MIN mark, you need to refill the brake fluid reservoir.

  • Page 42: Checking The Rear Brake Pads

    MAINTENANCE WORK ON CHASSIS AND ENGINE CHECKING THE REAR BRAKE PADS The brake pads can be inspected from the rear. The thickness of the linings may not be less than 1 mm (0.04 in). WARNING: At their most worn point brake pad linings should not be thinner than 1 mm, otherwise they could min.

  • Page 43: Dismounting And Mounting The Front Wheel

    WARNING: If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque cor- rected by a Husaberg dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle.

  • Page 44: Dismounting And Mounting The Rear Wheel

    WARNING: If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque cor- rected by a Husaberg dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle.

  • Page 45: Checking The Shock Absorption Rubbers In The Rear Hub

    (see photo). A clear tone must be the result. Dull tones are indicators of loose spokes. If necessary, have the spokes retightened and the wheel centered by a Husaberg dealer. WARNING: Spokes can tear if you continue to ride with them loose.

  • Page 46: Tires, Air Pressure

    Proper pressure ensures optimum driving comfort and extends the life of your tires. WARNING: Do not mount tires which have not been TIRES PRESSURE approved by Husaberg. Other tires could have adverse effects on the way your motorcycle behaves. front rear Front and rear wheels may only be fitted with tires having the same tread layout.

  • Page 47: Battery

    MAINTENANCE WORK ON CHASSIS AND ENGINE BATTERY The battery (1) is located in front of the shock absorber and is main- tenance-free. It is not necessary to check the electrolyte level or to add water. Merely keep the battery poles clean and grease slightly with acid- free grease if required.

  • Page 48: Fuse (Fe/Fs)

    Replace a blown fuse only with an equivalent one. If a new fuse that has just been installed gets blown again, you are strongly advi- sed to have it inspected by a Husaberg dealer. The fuse capacity is 10 Ampere.

  • Page 49: Cooling System

    MAINTENANCE WORK ON CHASSIS AND ENGINE COOLING SYSTEM Coolant is circulated by a water pump (1) located in the engine. Air blowing in through the radiators cools the coolant. The slower the speed of the motorcycle, the less the coolant is cooled down. Dirty radiators also reduce the cooling efficiency.

  • Page 50: Bleeding The Cooling System

    NOTE: In every exhaust repair procedure, the O-rings must be replaced by new ones. Glass fiber yarn packings are available from your licensed Husaberg mechanic. WARNING: The exhaust system becomes very hot while the motorcycle is running. to avoid burns do not start work on the exhaust system until it has properly cooled down.

  • Page 51: Cleaning The Air Filter

    CAUTION: Do not clean air filter with fuel or petroleum since these damage the foam. Husaberg recommends the products of the company „Motorex“ for air filter mainte- nance. (Motorex Bio Dirt Remover + Motorex Liquid Bio Popwer) Never operate your motorcycle without air filter.

  • Page 52: Changing The Original Position Of The Clutch Lever

    (7) of the master cylinder in a bubble- free state. Make sure that the oil does not overflow. The bleeder syringe can be purchased from your Husaberg dealer.Having com- pleted the bleeding procedure, you have to verify that the oil level in the master cylinder is correct.If necessary, fill up with...

  • Page 53: Carburetor - Adjust Idling

    MAINTENANCE WORK ON CHASSIS AND ENGINE CARBURETOR – ADJUST IDLING * Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly.

  • Page 54: Checking The Float Level (Float Height)

    MAINTENANCE WORK ON CHASSIS AND ENGINE CHECKING THE FLOAT LEVEL (FLOAT HEIGHT) * For this purpose, dismount the carburetor and remove the float chamber. Hold the carburetor in a slanted position such that the float will abut the float needle valve but not compress it. In this position, the edge of the float should be parallel with the float chamber sealing surface (see illustration).

  • Page 55: Checking The Engine Oil Level

    0°C cial requirements. 32°F Only use fully synthetic engine oils that meet the JASO MA quality requirements (see information on the can). Husaberg recommends 5W/40 10W/50 Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).

  • Page 56: Changing The Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE CHANGING THE OIL FILTER Place a suitable vessel under the engine to allow the oil to drain. Remove both screws (1) and screw an M6 screw in the center hole (2) of the oil filter cover. NOTE: only tighten the screw by hand, otherwise you will damage the oil filter cover.

  • Page 57: Troubleshooting

    Dismount the left paneling and the filter box cover and Blown fuse replace the fuse in the starter relay. Discharged battery. Recharge the battery and investigate the causes for discharging; contact a Husaberg dealer. Low outside temperature Start the engine with the kickstarter Engine cranks but doesn’t Operating error Open fuel tap, tank fuel, actuate choke.
  • Page 58 TROUBLESHOOTING REMEDY ERROR CAUSE Engine won't rev up Carburetor overflows because Disassemble the carburetor and check for wear the float needle is soiled or worn Loose carburetor jets Tighten the jets Electronic ignition advance is Have the ignition system checked defective Clean and check the fuel system and carburetor Engine...

  • Page 59: Cleaning, Conservation, Storage

    CLEANING, CONSERVATION, STORAGE CLEANING Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet. CAUTION: Never clean your motorcycle with a high-pressured cleaner or a high-pressured water jet.

  • Page 60: Technical Data - Engine

    TECHNICAL DATA - ENGINE Engine FC 450/4 FE 450e/6 FS 450e/6 FE 501e/6 Design 1-cylinder 4-stroke engine with balancer shaft, liquid cooled Displacement 449 cm 501 cm Bore/Stroke 100 / 57,2 mm 95 / 70,7 mm Ratio 12,7:1 11,6:1 Carburetor Keihin FCR-MX 41 FCR-MX 39 Fuel...
  • Page 61 TECHNICAL DATA - ENGINE Engine FC 550/4 FE 550e/6 FE 650e/6 FS 650e/6 Design Liquid-cooled, 1-cylinder 4-stroke Otto engine with balancer weight Displacement 550 cm 644 cm Bore/Stroke 100 / 70 mm 100 / 82 mm Compression ratio 11,8:1 11,5:1 Keihin carburetor FCR-MX 41 Fuel...

  • Page 62: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS 450/4, 550/4 FE 450/501/550/650e/6 FS 450e/6, 650e/6 Frame tubular chrome-molybdenum-steel frame, powder-coated Fork WP Up Side Down 4860 MXMA Spring travel, front/rear 295/320 mm 260/287 mm Rear suspension WP Progressive Damping System shock absorber, aluminum rear swinging fork Front brake Disk brake,perforated Ø...
  • Page 63 TECHNICAL DATA - ENGINE TIGHTENING TORQUES HH collar screws on housing, clutch cover, ignition cover 10 Nm Oil drain plug M12x1,5 20 Nm HH plug oil screen M20x1,5 15 Nm AH collar screw on oil filter cover 6 Nm Plug on pressure relief valve M12x1,5 20 Nm HH screws on oil pump cover...
  • Page 64 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES - CHASSIS Collar screw, front wheel spindle M24x1,5 40 Nm Brake caliper, front Loctite 243 + 25 Nm Collar screw FS models only brake pads front - 10 Nm Brake discs Loctite 243 + 10 Nm Clamping screws, upper fork bridge 20 Nm Clamping screws, lower fork bridge...

  • Page 65: Head Word Index

    ..51 Running in the Husaberg models ....20 Checking the rear brake pads ....41 Serial number locations .
  • Page 66 SCHALTPLÄNE red-black red-white - 1 -...
  • Page 67 SCHALTPLÄNE light/brakelight rear wh-gn re-wh re-bl ye-re wh-re ye-re black wh-re ye-re ye-bl re-bl re-wh ye-bl bu-wh ye-re ye-re ye-re bl-wh ye-bl ye-bl lamp control flasher lamp light driving switch brake front headlight light position multi-func.-digital-speedometer - 2 -...
  • Page 68 SCHALTPLÄNE light switch high/low beam switch cable horn switch color cable LIGHT OFF color P.LIGHT HORN P.LIGHT flasher switch cable brake switch harness cable cable harness switch cable switch TURN L pushed TURN R unpushed start switch cable switch START unpushed - 3 -...
  • Page 69 SCHALTPLÄNE light/brakelight rear re-wh re-bl ye-re wh-re black wh-re ye-re re-bl re-wh ye-re ye-bl bu-wh bl-wh ye-bl multi-func.-digital-speedometer headlight - 4 -...
  • Page 70 SCHALTPLÄNE start switch cable switch START unpushed - 5 -...
  • Page 71 SCHALTPLÄNE light/brakelight rear wh-gn re-wh re-bl ye-re wh-re ye-re black wh-re ye-re ye-bl re-bl re-wh ye-bl bu-wh ye-re ye-re ye-re bl-wh ye-bl ye-bl lamp control flasher lamp light driving switch brake front headlight light position multi-func.-digital-speedometer - 6 -...
  • Page 72 SCHALTPLÄNE light switch high/low beam switch cable color horn switch LIGHT OFF cable color P.LIGHT HORN P.LIGHT flasher switch cable harness brake switch cable cable switch harness cable TURN L switch TURN R pushed unpushed ignition switch start switch cable switch START unpushed...
  • Page 73 SCHALTPLÄNE ENGLISCH DEUTSCH FRANZÖSISCH Battery Batterie Batterie Cooling fan Lüftermotor Ventilateur Driving light lamp Fernlichtkontrollampe temoin feu route Flasher control lamp Blinkerkontrollampe temoin de clignoteur Flasher relay Blinkerrelais Relais de clignotants Flasher switch Blinkerschalter Bouton de clignotants Flasher system Blinksystem Systeme de clignotants Front brake switch vorderer Bremslichtschalter...
  • Page 74 HUSABERG - a company of the KTM Group Stallhofner Straße 3, A-5230 Mattighofen E-mail: info @ husaberg.cc, Internet: www.husaberg.cc...

This manual is also suitable for:

2004 fc series2004 fe series2004 fs series2004 fc 450/42004 fe 450e/62004 fs 450e/6 ... Show all

Table of Contents

Save PDF