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05
"
BEDIENUNGSANLEITUNG
OWNERS MANUAL
MANUEL D'UTILISATION
Edition 2005

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Table of Contents

   Summary of Contents for HUSABERG "05

  • Page 1 " BEDIENUNGSANLEITUNG OWNERS MANUAL MANUEL D’UTILISATION Edition 2005...
  • Page 2: Table Of Contents

    Cleaning the air filter ......50 Running in the Husaberg models ....19 Checking the adjustment of the hand decompression release cable .
  • Page 3: Introduction

    INTRODUCTION IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLE- TELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFOR- MATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PRO- PERLY.
  • Page 4 The work marked with an * in the chapter "Servicing the chassis and engine" must be perfor- med by an authorized Husaberg dealer. If such service work becomes necessary during a competition, it must be performed by a trained mechanic.
  • Page 5: Important Limited Warranty And Limited Guarantee Information

    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 adjust- ing 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 over- flows 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: Starter Button

    OPERATION INSTRUMENTS STARTER BUTTON Pushing the black starter button (1) will actuate the E-starter EMERGENCY OFF SWITCH (AUSTRALIA) The red emergency-OFF switch (2) is arranged adjacent to the throttle grip. In this position, the E-starter is operational and the engine can be started.
  • Page 10 The displayed figure cannot be changed. Service intervals are indicated in service hours for some Husaberg offroad motorcycles, making the service hour counter a very practical function. SPEED / ODO DISPLAY MODE (ODOMETER) The SPEED/ODO mode displays the speed and the total distance trave- led.
  • Page 11: Activating And Deactivating Display Modes

    OPERATION INSTRUMENTS ACTIVATING AND DEACTIVATING DISPLAY MODES In the display mode SPEED/H, press and hold the button for 3 seconds to access the SETUP menu. The active functions will be displayed. The blinking function can be activated by pressing the + button and deacti- vated by pressing the –...
  • Page 12 OPERATION INSTRUMENTS LAP / LAP DISPLAY MODE (TO VIEW LAP TIMES) The LAP/LAP display mode will only be shown if lap times have been sto- red and the front wheel has stopped. It will display the lap number and the stopped lap time in hours, minutes and seconds. Press the + button to access the next lap time.
  • Page 13 OPERATION INSTRUMENTS SPEED / A1 DISPLAY MODE (AVERAGE SPEED 1) A1 shows the average speed based on the TR1 (tripmaster 1) and S1 (stop watch 1) 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: 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 TR1, A1, S1, TR2 and A2 figu- res will be cleared. To select the unit, select the SPEED/H mode and hold the button for 3 seconds to access the SETUP menu.
  • Page 15: 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 16: Shift Lever

    OPERATION INSTRUMENTS SHIFT LEVER The shift lever is mounted on the left side of the engine. The position 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 17: 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 adjus- ting screws at the bottom of the fork legs.Remove the protecting cap (1). Turn the adjusting screws (2) clockwise to increase damping, turn it coun- terclockwise to reduce damping during compression.
  • Page 18: Damping Action During Compression Of Shock Absorber

    OPERATION INSTRUMENTS 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.
  • Page 19: Rebound Damping Of Shock Absorber

    OPERATION INSTRUMENTS 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 coun- terclockwise to reduce damping during rebounding. STANDARD ADJUSTMENT: –...
  • Page 20: Instructions For Initial Operation

    WARNING: Wear suitable clothing when driving a motorcycle. Clever Husaberg drivers always wear a hel- – Verify that your Husaberg dealer performed the PREPARATION met, boots, gloves and a jacket, regardless of whether OF VEHICLE jobs (see Customer Service Manual).
  • Page 21: Driving Instructions

    Arrange for the braking system to be che- cked by a Husaberg specialist, as complete failure of the braking sys- tem can be avoided.
  • Page 22: Starting When The Engine Is Cold

    DRIVING INSTRUCTIONS 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 23: Shifting/riding

    Don’t ride your motorcycle anymore without first having up, thereby heating up the cooling system. You should the brake system looked over by a Husaberg dealer. drive at low speeds (4-stroke style - letting the engine pull you) and not at high speeds not by letting the clutch slip (2-stroke style).
  • Page 24: Stopping And Parking

    DRIVING INSTRUCTIONS 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 emergency off switch until the engine is off. Close the fuel taps, park the motorcycle on a firm surface and lock.
  • Page 25: Periodic Maintenance Schedule

    IF MOTORCYCLE IS USED FOR COMPETITION 10 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE. Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by Husaberg authorised workshops is not a substitute for care and checks done by the rider. - 24 -...
  • Page 26 IF MOTORCYCLE IS USED FOR COMPETITION 15 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE. Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by Husaberg authorised workshops is not a substitute for care and checks done by the rider. - 25 -...
  • Page 27 Treat ignition and steering locks and light switches with contact spray Check tightness of screws, nuts and hose clamps regularly RECOMMENDED INSPECTION OF THE HUSABERG - ENGINES USED FOR HOBBY-ENDURO COMPETITIONS BY YOUR HUSABERG WORKSHOP (ADDITIONAL ORDER FOR THE HUSABERG WORKSHOP) a 100 liter fuel consumption is equivalent to approx.
  • Page 28 PERIODIC MAINTENANCE SCHEDULE RECOMMENDED INSPECTION OF THE HUSABERG - ENGINES USED FOR ENDURO COMPETITIONS BY YOUR HUSAB- ERG WORKSHOP (ADDITIONAL ORDER FOR THE HUSABERG WORKSHOP) a 100 liter fuel consumption is equivalent to approx. hours hours hours hours hours hours...
  • Page 29: Maintenance Work On Chassis And Engine

    When transporting your Husaberg, ensure that it is held upright with restraining straps or other mechanical fastening devices and that the fuel tap is in the OFF position - if the motorcycle should fall over, no fuel can leak from the car-...
  • Page 30: 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 breather 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 31: Basic Suspension Setup For The Weight Of The Driver

    At delivery, Husaberg's offroad motorcycles are set to accommodate a driver weig- hing 70 - 80 kg (wearing full protective clothing). If your weight exceeds or falls short of this range, you will need to adjust the basic setup for the suspension components accordingly.
  • Page 32: Checking The Basic Setup Of The Telescopic Fork

    RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM 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. According to our experience, the damping rate of the compression stage can remain unchanged.
  • Page 33: Changing The Fork Offset (caster) (fs)

    MAINTENANCE WORK ON CHASSIS AND ENGINE CHANGING THE FORK OFFSET (CASTER) (FS) * The fork offset (A) in the FS models (center fork legs - center steering head angle) can be set to either 16 or 18 mm. This allows you to optimize the handling to match the race course.
  • Page 34 MAINTENANCE WORK ON CHASSIS AND ENGINE Remove the collar screw from the lower triple clamp and pull out the stee- ring stem. Thoroughly clean all parts. Turn the steering stem 180° and insert it in the triple clamp, tighten the collar screw all the way to the stop. WARNING:A plastic insert in the collar screw thread makes the collar screw self-locking.
  • 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 corrected 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

    BRAKE FLUID: Husaberg fills the brake systems with Motorex Brake Fluid DOT 5.1 brake fluid, one of the best brake currently available. We recommend 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)

    WARNING: If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are com- pletely worn. In this case, consult an authorized 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

    MAINTENANCE WORK ON CHASSIS AND ENGINE WARNING: Brake fluid can cause skin irritation. Avoid contact with skin and eyes. If you get brake fluid in your eyes, rinse 5 mm 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

    WARNING: If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are com- pletely worn. 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 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 corrected 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 corrected 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

    MAINTENANCE WORK ON CHASSIS AND ENGINE CHECKING THE SHOCK ABSORPTION RUBBERS IN THE REAR HUB* The FS models have a damped rear wheel hub. For this purpose, the engine power is conveyed from the rear sprocket via 6 shock absorption rubbers (1) to the rear wheel.
  • Page 46: Tires-air Pressure

    WARNING: Do not mount tires which have not been appro- ved by Husaberg. Other tires could have adverse effects on the way your motorcycle behaves. Front and rear wheels may only be fitted with tires having the TIRES-AIR PRESSURE 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 mainte- nance-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 advised to have it inspected by a Husaberg dealer. The fuse capacity is 10 Ampere. CAUTION: Under no circumstances is a stronger fuse allo- wed to be installed or a fuse allowed to be “repaired”.
  • 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 avai- lable 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 maintenance. (Motorex Bio Dirt Remover + Motorex Liquid Bio Power) Never operate your motorcycle without air filter.
  • Page 52: Changing The Original Position Of The Clutch Lever

    SAE 10 (e.g. Motorex Kupplungs-Fluid 75). Biodegradable hydraulic oil is available from your Husaberg dealer (50ml). CAUTION: Husaberg uses biodegradable hydraulic oil for the hydraulic clutch control.
  • 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 cham- ber sealing surface (see illustration).
  • Page 55: Checking The Engine Oil Level

    0°C Only use fully synthetic engine oils that meet the JASO MA quality requi- 32°F rements (see information on the can). Husaberg recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C, 32°F) 5W/40 10W/50 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 replace the fuse in the starter relay. Discharged battery. Recharge the battery and investigate the causes for discharg- ing; contact a Husaberg dealer. Low outside temperature Start the engine with the kickstarter Engine cranks but doesn’t start (E- Operating error Open fuel tap, tank fuel, actuate choke.
  • Page 58 TROUBLESHOOTING ERROR CAUSE REMEDY Engine won't rev up Carburetor overflows because the Disassemble the carburetor and check for wear float needle is soiled or worn Loose carburetor jets Tighten the jets Electronic ignition advance is Have the ignition system checked defective Engine does not have enough Fuel supply is interrupted or the car-...
  • 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.
  • Page 60: Technical Data - Engine

    TECHNICAL DATA - ENGINE ENGINE FC 450/4 FE 450E/6 FS 450E/6 Design 1-cylinder 4-stroke engine with balancer shaft, liquid cooled Displacement 449 cm Bore/Stroke 100 / 57,2 mm Ratio 13:1 Carburetor Keihin FCR-MX 41 FCR-MX 39 FCR-MX 41 Fuel unleaded fuel with at least RON 95 (USA = Premium RON91) Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Valve diameter Intake...
  • 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 628 cm Bore/Stroke 100 / 70 mm 100 / 82 mm Ratio 11,8:1 11,5:1 Carburetor Keihin FCR-MX 41 Fuel unleaded fuel with at least RON 95 (USA = Premium RON 91)
  • Page 62 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 63: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS FC 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 300/320 mm 295/320 mm 275/288 mm Rear suspension WP Progressive Damping System shock absorber, aluminum rear swinging fork Front brake Disk brake,perforated Ø...
  • Page 64 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES - CHASSIS Collar screw, front wheel spindle M24x1,5 40 Nm Brake caliper, front FE/FC Loctite 243 + 25 Nm Brake caliper, front FS Loctite 243 + 40 Nm Collar screw brake pads front - FS models only 10 Nm Brake discs Loctite 243 + 10 Nm...
  • Page 65: Head Word Index

    Checking the oil level of the hydraulic clutch ... 51 Running in the Husaberg models ....19 Checking the rear brake pads.
  • Page 66 SCHALTPLÄNE red-white red-black - 1 -...
  • Page 67 SCHALTPLÄNE multi-func.-digital-speedometer driving light lamp flasher control lamp position light headlight front brake switch ye-bl bl-wh ye-re ye-re ye-re bu-wh ye-bl re-wh re-bl ye-bl ye-re wh-re black re-wh ye-re ye-re re-bl re-wh wh-gn rear light/brakelight - 2 -...
  • Page 68 SCHALTPLÄNE g i l c t i c t i c t i c t i l i k c t i c t i - 3 -...
  • Page 69 SCHALTPLÄNE multi-func.-digital-speedometer headlight bl-wh bu-wh ye-bl ye-re re-wh re-bl ye-re re-wh black re-wh ye-re re-bl re-wh rear light/brakelight - 4 -...
  • Page 70 SCHALTPLÄNE start switch cable switch START unpushed - 5 -...
  • Page 71 SCHALTPLÄNE ENGLISH DEUTSCH FRANCAIS 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 72 HUSABERG - a company of the KTM Group Stallhofner Straße 3, A-5230 Mattighofen E-mail: info @ husaberg.cc, Internet: www.husaberg.cc...

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