Related Manuals for Husqvarna FE 450 EU
Summary of Contents for Husqvarna FE 450 EU
- Page 1 OWNER'S MANUAL 2014 FE 450 EU FE 450 AUS FE 501 EU FE 501 AUS FE 501 USA Art. no. 3402008en...
- Page 3 Husqvarna accepts no liability for delivery options, deviations from illustrations and descriptions or misprints and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS Setting kilometers or miles ........21 MEANS OF REPRESENTATION ......... 5 Setting the clock ..........22 Symbols used ............5 Setting the service display........22 Formats used............5 Speed, time, and DST distance 1......23 SAFETY ADVICE .............. - Page 5 TABLE OF CONTENTS 12.7 Removing the fork legs......... 42 13.9 Checking the free travel of foot brake lever... 69 12.8 Installing the fork legs ........43 13.10 Adjusting the basic position of the foot brake lever ..............69 12.9 Removing the fork protector ......
- Page 6 TABLE OF CONTENTS 23.3 Capacities............104 23.3.1 Engine oil............104 23.3.2 Coolant ............104 23.3.3 Fuel ............... 104 23.4 Chassis.............. 104 23.5 Electrical system ..........105 23.6 Tires..............105 23.7 Fork ..............105 23.8 Shock absorber ..........106 23.9 Chassis tightening torques ......... 106 SUBSTANCES ...............
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Page 7: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized Husqvarna workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required. -
Page 8: Safety Advice
Use definition - intended use (FE EU, FE AUS) Husqvarna sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcy- cles comply with currently valid regulations and categories of the top international motorsport organizations. -
Page 9: Safe Operation
Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. In the interest of your own safety, Husqvarna recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks. -
Page 10: Owner's Manual
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized Husqvarna dealer. -
Page 11: Important Information
Manufacturer and implied warranty The work prescribed in the service schedule must be carried out by an authorized Husqvarna workshop only and confirmed in the cus- tomer's service record and in the Husqvarna dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle. -
Page 12: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) C00576-10 Filler cap Air filter box lid Shift lever ( p. 18) Engine number ( p. 12) Side stand ( p. 18) -
Page 13: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) C00575-10 Fork compression adjustment Kill switch ( p. 14) Horn button ( p. 15) Light switch ( p. 15) Turn signal switch ( p. 15) Emergency OFF switch ( p. 15) Electric starter button ( p. -
Page 14: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 401945-10 Type label (FE EU, FE AUS) The type label is fixed to the front of the steering head. 401946-10 Key number (FE EU, FE AUS) The key number for the steering lock is stamped onto the key connector. -
Page 15: Shock Absorber Part Number
SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side. 0 0 1 401948-10... -
Page 16: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. C00530-10 Hand brake lever Hand brake lever is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. C00545-10 Throttle grip The throttle grip... -
Page 17: Horn Button (Fe Eu, Fe Aus)
CONTROLS Horn button (FE EU, FE AUS) The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – the horn is actuated in this position. • Horn button C00590-11 Light switch (FE EU, FE AUS) The light switch is fitted on the left side of the handlebar. -
Page 18: Electric Starter Button (All 501 Models, Fe Eu)
CONTROLS 6.11 Electric starter button (all 501 models, FE EU) The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – the electric starter is actuated in this position. •... -
Page 19: Closing Filler Cap
CONTROLS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. -
Page 20: Shift Lever
CONTROLS 6.18 Shift lever Shift lever is mounted on the left side of the engine. 401950-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.19 Foot brake lever Foot brake lever is located in front of the right footrest. -
Page 21: Steering Lock (Fe Eu, Fe Aus)
CONTROLS 6.21 Steering lock (FE EU, FE AUS) Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering. Steering, and therefore riding, is no longer possible. C00538-10 6.22 Locking the steering (FE EU, FE AUS) Note Danger of damage The parked vehicle may roll away or fall over. -
Page 22: Speedometer
Message on the speedometer Possible states Battery voltage of the speedometer – Battery voltage of the speedometer is too low. Change the battery. Service – Service is due. Contact an authorized Husqvarna workshop. 401901-01 Setting the speedometer Condition The motorcycle is stationary. -
Page 23: Setting Kilometers Or Miles
SPEEDOMETER – Wait for 5 seconds. The speedometer changes to the next menu item. The symbol flashes. Resetting the time – Press the left button. The value decreases. Advancing the time – Press the right button. The value increases. 401912-01 –... -
Page 24: Setting The Clock
SPEEDOMETER Setting the clock Condition The motorcycle is stationary. – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. – Wait for the menu of the clock to flash. – Press one of the buttons to select the 24h or 12h display of the clock. 401911-01 –... -
Page 25: Speed, Time, And Dst Distance 1
SPEEDOMETER Speed, time, and DST distance 1 – Press one of the buttons until DST appears on the speedometer. KM/H or M/H shows the speed. shows the time. DST shows the distance since the last reset, such as between two refueling stops. Info If the value of 39999.9 is exceeded, DST is automatically reset to 0.0. -
Page 26: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized Husqvarna workshop. You receive a delivery certificate and the service record at vehicle handover. -
Page 27: Running-In The Engine
For this reason, it may be necessary to inspect or replace parts before the next scheduled service. – Husqvarna recommends using the specified engine oil when operating the vehicle under harsh conditions and to increase motorcycle performance. Engine oil (SAE 10W/60) ( p. -
Page 28: Preparing For Rides On Dry Sand
PREPARING FOR USE Preparing for rides on dry sand – Fit a dust cover on the air filter. Dust protection device for air filter (77206920000) Info Observe the Husky Power fitting instructions. B00435-01 – Fit a sand cover on the air filter. Sand protection device for air filter (59006022000) Info Observe the Husky Power fitting instructions. -
Page 29: Preparing For Rides On Wet And Muddy Surfaces
PREPARING FOR USE Preparing for rides on wet and muddy surfaces – Fit a rain cover on the air filter. Waterproofing device for air filter (77206921000) Info Observe the Husky Power fitting instructions. B00437-01 – Fit the steel sprocket. – Clean the motorcycle. -
Page 30: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 91) –... -
Page 31: Starting Off
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized Husqvarna workshop. First gear is used for starting off or for steep inclines. -
Page 32: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –... -
Page 33: Refueling
– In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized Husqvarna workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards. -
Page 34: Service Schedule
Final check: Check the vehicle for roadworthiness and take a test ride. ○ ● ● Read out the fault memory using the Husqvarna diagnostics tool after a test ride. ○ ● ● Make the service entry in Husqvarna Dealer.net and in the service booklet. -
Page 35: Service Work (As Additional Order)
SERVICE SCHEDULE 10.2 Service work (as additional order) Annually Every 135 operating hours/every 70 operating hours when used for motorsports Every 45 operating hours Once after 15 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. ●... -
Page 36: Tuning The Chassis
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized Husqvarna work- shop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 37: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized Husqvarna work- shop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber. -
Page 38: Measuring Rear Wheel Sag Unloaded
TUNING THE CHASSIS 11.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p. 41) Main work – Measure the distance – as vertically as possible – between the rear axle and a fixed point such as a mark on the side cover. -
Page 39: Adjusting The Spring Preload Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized Husqvarna work- shop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 40: Checking Basic Setting Of Fork
TUNING THE CHASSIS Main work – Choose and mount a suitable spring. Guideline Spring rate Weight of rider: 65… 75 kg (143… 54 N/mm (308 lb/in) 165 lb.) Weight of rider: 75… 85 kg (165… 57 N/mm (325 lb/in) 187 lb.) Weight of rider: 85…... -
Page 41: Adjusting The Rebound Damping Of The Fork
TUNING THE CHASSIS Guideline Compression damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. –... - Page 42 TUNING THE CHASSIS – Remove screws . Take off the handlebar clamps. Take off the handlebar and lay it to one side. Info Protect the motorcycle and its attachments against damage by covering them. Do not bend the cables and lines. –...
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Page 43: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (81329955000) The wheels must no longer touch the ground. -
Page 44: Loosening The Fork Protector
SERVICE WORK ON THE CHASSIS Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Clean and oil the dust boots and inner fork tube of both fork legs. -
Page 45: Installing The Fork Legs
SERVICE WORK ON THE CHASSIS – Release screws . Take out the left fork leg. – Release screws . Take out the right fork leg. C00579-10 12.8 Installing the fork legs Main work – Position the fork legs. Info The compression damping is located in the left fork leg COMP (white adjust- ing screw). -
Page 46: Installing The Fork Protector
SERVICE WORK ON THE CHASSIS Main work – Remove screws on the left fork leg. Remove the fork protector upwards. – Remove the screws on the right fork leg. Remove the fork protector upwards. C00565-10 12.10 Installing the fork protector Main work –... -
Page 47: Installing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS – Remove O-ring . Remove protective ring – Take off the lower triple clamp with the steering stem. – Remove the upper steering head bearing. C00567-11 12.12 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. -
Page 48: Checking The Steering Head Bearing Play
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized Husqvarna workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become damaged... -
Page 49: Adjusting The Play Of The Steering Head Bearing
SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with a lift stand. ( p. 41) Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. -
Page 50: Removing The Front Fender
SERVICE WORK ON THE CHASSIS 12.16 Removing the front fender Preparatory work – Switch off all power consumers and switch off the engine. – Remove the headlight mask with the headlight. ( p. 82) Main work – Disconnect plug-in connectors of the turn signals. -
Page 51: Removing The Shock Absorber
SERVICE WORK ON THE CHASSIS 12.18 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 41) – Remove the right side cover. ( p. 55) – Remove the main silencer. ( p. 54) –... -
Page 52: Removing The Air Filter Box Lid
SERVICE WORK ON THE CHASSIS 12.22 Removing the air filter box lid – Release catch , pull off the air filter box lid sideways in areas remove toward the rear. B01817-10 12.23 Installing the air filter box lid – Position the air filter box lid and tab . -
Page 53: Cleaning The Air Filter And Air Filter Box
SERVICE WORK ON THE CHASSIS – Insert both parts together, position them, and fasten them using air filter holder area The arrow of marking UP faces up. Info If the air filter is not correctly mounted, dust and dirt can enter the engine and cause damage. -
Page 54: Removing The Manifold
SERVICE WORK ON THE CHASSIS 12.28 Removing the manifold Preparatory work – Remove the seat. ( p. 49) – Remove the right side cover. ( p. 55) – Remove the main silencer. ( p. 54) – Raise the motorcycle with a lift stand. ( p. -
Page 55: Installing The Manifold
SERVICE WORK ON THE CHASSIS – Remove springs 309324-10 – Remove screw and take off the manifold. 309325-10 12.29 Installing the manifold Main work – Position the manifold and mount springs Spring hooks (50305017000) 309324-11 – Mount and tighten screw Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) -
Page 56: Removing The Main Silencer
SERVICE WORK ON THE CHASSIS – Position the angle lever and linkage lever. – Mount and tighten fitting Guideline Nut, linkage lever on angle lever M14x1.5 80 Nm (59 lbf ft) – Mount and tighten screw Guideline Screw, bottom shock 60 Nm Loctite ®... -
Page 57: Removing The Right Side Cover
SERVICE WORK ON THE CHASSIS Preparatory work – Remove the right side cover. ( p. 55) – Remove the main silencer. ( p. 54) Main work (FE EU, FE AUS) – Remove all screws on the main silencer. – Take off silencer cap and O-ring –... -
Page 58: Installing The Right Side Cover
SERVICE WORK ON THE CHASSIS 12.34 Installing the right side cover – Position the side cover and engage in area – Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B01813-10 12.35 Removing the fuel tank Danger Fire hazard Fuel is highly flammable. -
Page 59: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Remove screw with the rubber bushing. B01809-11 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. B01810-01 12.36 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. –... -
Page 60: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS – Attach connector of the fuel pump. – Remove the wash cap set. – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Never let dirt enter the fuel line. Dirt in the fuel line clogs the injection valve. –... -
Page 61: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS 12.39 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases. -
Page 62: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide
SERVICE WORK ON THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 41) 12.41 Checking the chain, rear sprocket, engine sprocket and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. -
Page 63: Checking The Frame
SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the bottom edge of the chain bolt is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated. »... -
Page 64: Checking The Swingarm
If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info A damaged swingarm must always be changed. Repair of the swingarm is not authorized by Husqvarna. 401520-01 12.44 Checking the routing of the throttle cable Preparatory work –... -
Page 65: Additionally Securing The Rubber Grip
SERVICE WORK ON THE CHASSIS 12.46 Additionally securing the rubber grip Preparatory work – Check the rubber grip. ( p. 62) Main work – Secure the rubber grip at two points using the securing wire. Securing wire (54812016000) Wire twister forceps (U6907854) The twisted wire ends face away from the hands and are bent toward the rubber grip. -
Page 66: Removing The Engine Guard
SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane B01538-10 – Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. -
Page 67: Brake System
BRAKE SYSTEM 13.1 Checking free travel of hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating. -
Page 68: Checking The Brake Discs
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. -
Page 69: Checking The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 70: Changing The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. -
Page 71: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100397-01 – Insert the new brake linings, insert the pin, and mount the cotter pin. Info Always change the brake linings in pairs. –... -
Page 72: Checking The Rear Brake Fluid Level
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna workshop will be glad to help.) – Stand the vehicle upright. -
Page 73: Checking The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 74: Changing The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. - Page 75 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated properly. L00194-10 – Insert the new brake linings, insert the pin, and mount the cotter pin. Info Always change the brake linings in pairs. –...
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Page 76: Wheels, Tires
WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 41) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 77: Removing The Rear Wheel
WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. The brake linings are positioned. – Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc. -
Page 78: Installing The Rear Wheel
Checking the tire condition Info Only mount tires approved and/or recommended by Husqvarna. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a significant impact on the handling characteristics of the motorcycle. -
Page 79: Checking The Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized Husqvarna workshop will be glad to help.) Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. - Page 80 WHEELS, TIRES – Tap each spoke with a screwdriver. Info The sound frequency depends on the length and thickness of the spoke. If there are different sound frequencies in spokes with the same length and thickness, this indicates different spoke tensions. You should hear a high note.
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Page 81: Electrical System
ELECTRICAL SYSTEM 15.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –... -
Page 82: Charging The Battery
– Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give it to your Husqvarna dealer or to a disposal center for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 83: Changing The Main Fuse
ELECTRICAL SYSTEM 15.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box lid. Preparatory work –... -
Page 84: Removing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM – Remove the defective fuse. Guideline Fuse 1 - 10 A - EFI control unit Fuse 2 - 10 A - fuel pump Fuse 3 - 10 A - high beam, low beam, parking light, tail light, license plate lamp Fuse 4 - 10 A - horn, brake light, turn signal, radiator fan (optional) Fuses res - 10 A - spare fuses B01642-10... -
Page 85: Changing The Headlight Bulb
ELECTRICAL SYSTEM – Position rubber bands around the fork legs and close them. The wiring harness and brake line are routed in front of the headlight mask. B01784-10 Finishing work – Check the headlight setting. ( p. 84) 15.8 Changing the headlight bulb Note Damage to reflector Reduced brightness. -
Page 86: Checking The Headlight Setting
ELECTRICAL SYSTEM Main work – Remove the screw on the rear of the turn signal housing. – Carefully remove diffuser – Lightly squeeze orange cap in the area of the holding lugs and take it off. – Press the turn signal bulb lightly into the socket, turn it counterclockwise by about 30°, and take it out of the socket. -
Page 87: Changing The Speedometer Battery
ELECTRICAL SYSTEM 15.12 Changing the speedometer battery Preparatory work – Switch off all power consumers and switch off the engine. – Remove the headlight mask with the headlight. ( p. 82) Main work – Remove screws – Pull the speedometer upward out of the holder. B01786-10 –... -
Page 88: Cooling System
COOLING SYSTEM 16.1 Cooling system The water pump in the engine forces the coolant to flow. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . The specified coolant temperature is therefore permissible without the danger of malfunctions. -
Page 89: Checking The Coolant Level
COOLING SYSTEM 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. -
Page 90: Refilling Coolant
COOLING SYSTEM 16.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme- diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swal- lowed, contact a physician immediately. -
Page 91: Tuning The Engine
TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back and forth slightly to ascertain play in the throttle cable. Play in throttle cable 3…... -
Page 92: Adjusting The Idle Speed
TUNING THE ENGINE 17.3 Adjusting the idle speed – Run the engine warm and push the idle speed adjusting screw all the way in. – Set the desired idle speed by turning the idle speed adjusting screw. Guideline Idle speed 1,950…... -
Page 93: Service Work On The Engine
SERVICE WORK ON THE ENGINE 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 94: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens
SERVICE WORK ON THE ENGINE 18.3 Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage. - Page 95 SERVICE WORK ON THE ENGINE – Position oil screen with the O-rings on a pin wrench. – Insert the pin wrench through the drill hole of the screw plug and into the engine case on the opposite side. – Push the oil screen all the way into the engine case. B01761-10 –...
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Page 96: Adding Engine Oil
SERVICE WORK ON THE ENGINE – Install and tighten the oil filler plug with O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effec- tive exhaust extraction system. -
Page 97: Cleaning, Care
CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts. - Page 98 CLEANING, CARE – Clean the motorcycle. ( p. 95) – Clean the brake system. Info After EVERY trip on salted roads, thoroughly wash the brake calipers and brake linings with cold water and dry carefully. This should be done after the parts are cooled down and while they are installed.
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Page 99: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info Husqvarna recommends raising the motorcycle. – Raise the motorcycle with a lift stand. ( p. 41) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materi- als since they prevent humidity from escaping, thus causing corrosion. -
Page 100: Troubleshooting
– Check the electrical system. switch defective – Defect in fuel injection system Read out the fault memory using the Husqvarna diagnostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the Husqvarna diagnostics tool. - Page 101 See blink code – Check the cabling for damage and the electrical plug-in connections for corrosion and damage. – Read out the fault memory using the Husqvarna diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary.
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Page 102: Blink Code
BLINK CODE Blink code FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high Blink code FI warning... - Page 103 BLINK CODE Blink code FI warning lamp (MIL) 45 FI warning lamp (MIL) flashes 4x long, 5x short Error level condition FE EU, FE 501 AUS Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit FE EU, FE 501 AUS Lambda sensor heater cylinder 1, sensor 1 - input signal too high...
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Page 104: Technical Data
TECHNICAL DATA 23.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement (all 450 models) 449.3 cm³ (27.418 cu in) Displacement (all 501 models) 510.4 cm³ (31.147 cu in) Stroke (all 450 models) 63.4 mm (2.496 in) Stroke (all 501 models) 72 mm (2.83 in) Bore 95 mm (3.74 in) Compression ratio... - Page 105 TECHNICAL DATA ® Nut, water pump impeller 8 Nm (5.9 lbf ft) Loctite 243™ ® Plug, vacuum connection 2.5 Nm (1.84 lbf ft) Loctite 243™ ® Screw plug EVAP 5 Nm (3.7 lbf ft) Loctite 243™ – Screw, alternator cover M6x25 10 Nm (7.4 lbf ft) ®...
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Page 106: Capacities
TECHNICAL DATA – Nut, inner clutch hub M18x1.5 80 Nm (59 lbf ft) ® Nut, primary gear M20LHx1.5 100 Nm (73.8 lbf ft) Loctite 648™ – Screw plug, engine oil screen M20x1.5 15 Nm (11.1 lbf ft) – Screw plug, gear oil screen M20x1.5 15 Nm (11.1 lbf ft) 23.3... -
Page 107: Electrical System
(FE 501 USA) 80/100 - 21 M/C 51M TT 110/100 - 18 M/C 64M TT Dunlop GEOMAX MX51 FA Dunlop GEOMAX MX51 Additional information is available in the Service section under: www.husqvarna-motorcycles.com 23.7 Fork Fork part number 24.18.7N.69 Fork WP Suspension Up Side Down 4860 4CS... -
Page 108: Shock Absorber
TECHNICAL DATA Oil capacity per fork leg 635 ml (21.47 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 108) 23.8 Shock absorber Shock absorber part number 18.15.7N.69 Shock absorber WP Suspension 5018 BAVP DCC Compression damping, low-speed Comfort 20 clicks Standard 18 clicks Sport... - Page 109 TECHNICAL DATA – Remaining nuts, chassis 25 Nm (18.4 lbf ft) – Remaining screws, chassis 25 Nm (18.4 lbf ft) – Screw, bottom triple clamp 15 Nm (11.1 lbf ft) – Screw, chain sliding piece 15 Nm (11.1 lbf ft) –...
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Page 110: Substances
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 possesses the corre- sponding properties. Coolant Guideline – Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming. –... - Page 111 SUBSTANCES Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e.
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Page 112: Auxiliary Substances
AUXILIARY SUBSTANCES High viscosity grease Recommended supplier ® – LGHB 2 Rubber grip adhesive (00062030051) Recommended supplier KTM-Sportmotorcycle AG – GRIP GLUE... -
Page 113: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines. -
Page 114: Index
INDEX INDEX fluid, changing ......63 Clutch lever ....... . 14 Accessories . - Page 115 INDEX Foot brake lever ......18 basic position, adjusting ..... . . 69 Light switch .
- Page 116 INDEX Throttle grip ....... . 14 Safe operation ....... 7 Tire air pressure checking .
- Page 117 *3402008en* 3402008en 09/2013 Husqvarna Motorcycles GmbH 5230 Mattighofen Stallhofnerstraße 3 Photo: Austria Mitterbauer/Husqvarna Motorcycles GmbH...