HUSABERG FE 450 AUS Motorcycle Manuals

Manuals and User Guides for HUSABERG FE 450 AUS Motorcycle. We have 3 HUSABERG FE 450 AUS Motorcycle manuals available for free PDF download: Repair Manual, Owner's Manual

HUSABERG FE 450 AUS Repair Manual

HUSABERG FE 450 AUS Repair Manual (285 pages)

2009 year

Brand: HUSABERG | Category: Motorcycle | Size: 11 MB

Table of Contents

Table of Contents
4
Means of Representation
7
Important Notes
8
Location of Serial Numbers
9
- Chassis Number
  9
- Type Label (FE EU, FE AUS)
  9
- Type Label (FE USA)
  9
- Key Number (FE EU, FE AUS)
  9
- Engine Number
  9
- Fork Part Number
  10
- Shock Absorber Part Number
  10
Motorcycle
11
01/Fork, Triple Clamp
12
03/Frame
32
- Removing the Engine Guard
  32
- Installing the Engine Guard
  32
04/Shock Absorber, Swingarm
33
05/Exhaust
56
06/Air Filter
59
- Removing the Air Filter
  59
- Installing the Air Filter
  59
- Cleaning Air Filter
  59
07/Fuel Tank, Seat, Trim
61
- Removing the Seat
  61
- Mounting the Seat
  61
- Removing the Fuel Tank
  61
- Installing the Fuel Tank
  62
- Removing the Spoiler
  63
- Installing the Spoiler
  63
- Checking the Fuel Pressure
  64
08/Mask, Fender, Decal
65
09/Front Wheel
67
10/Rear Wheel
70
11/Wiring Harness, Battery
75
13/Brake System
80
14/Lighting System, Instruments
88
30/Engine
93
- Removing the Engine
  93
- Installing the Engine
  96
30/Engine Disassembly
101
- Clamping the Engine in the Engine Work Stand
  101
- Draining the Engine Oil
  101
- Removing the Oil Line
  101
- Removing the Starter Motor
  101
- Removing the Oil Filter
  101
- Removing the Valve Cover
  102
- Removing the Spark Plug
  102
- Removing the Generator Cover
  102
- Positioning the Engine at Ignition Top Dead Center (TDC)
  102
- Removing the Timing Chain Tensioner
  103
- Removing the Camshaft
  103
- Removing the Cylinder Head
  104
- Removing the Piston
  104
- Removing the Distance Bushing
  104
- Removing the Rotor
  105
- Removing the Balance Weight
  105
- Removing the Timing Chain Guide Rail
  105
- Removing the Timing Chain Tensioning Rail
  105
- Removing the Timing Chain Securing Guide
  106
- Removing the Timing Chain
  106
- Removing the Ignition Pulse Generator
  106
- Removing the Water Pump Cover
  106
- Removing the Clutch Cover
  106
- Disassembling the Clutch Disks
  107
- Removing the Primary Gear Nut
  107
- Removing the Outer Clutch Hub
  108
- Removing the Balancer Shaft
  108
- Removing the Primary Gear
  108
- Removing the Free Wheel Gear
  109
- Removing the Torque Limiter
  109
- Removing the Starter Idler Gear
  109
- Removing the Oil Pump Gears
  109
- Removing the Oil Pumps
  110
- Removing the Shift Shaft
  110
- Removing the Shift Drum Locating Unit
  110
- Removing the Locking Lever
  110
- Removing the Left Section of the Engine Case
  111
- Removing the Shift Rails
  111
- Removing the Shift Drum
  111
- Removing the Shift Forks
  111
- Removing the Diaphragm
  112
- Removing the Transmission Shafts
  112
- Removing the Crankshaft
  112
30/Engine - Work on the Individual Parts
113
- Working on the Right Section of the Engine Case
  113
- Working on the Left Section of the Engine Case
  114
- Removing the Oil Pressure Regulator Valve
  115
- Checking the Spring Length of the Oil Pressure Regulator Valve
  115
- Installing the Oil Pressure Regulator Valve
  115
- Removing the Crankshaft Seal Ring in the Clutch Cover
  115
- Installing the Crankshaft Seal Ring in the Clutch Cover
  116
- Removing the Water Pump
  116
- Installing the Water Pump
  117
- Checking the Balancer Shaft
  117
- Removing the Timing Chain Sprocket
  118
- Installing the Timing Chain Sprocket
  118
- Removing the Crankshaft Bearing Inner Ring
  118
- Installing the Crankshaft Bearing Inner Ring
  119
- Changing the Conrod Bearing
  119
- Checking the Crankshaft Run-Out at the Bearing Pin
  121
- Measuring the Crankshaft End Play
  121
- Checking/Measuring the Cylinder
  122
- Checking/Measuring the Piston
  122
- Checking the Piston Ring End Gap
  123
- Piston/Cylinder - Determining the Mounting Clearance
  123
- Checking the Oil Pumps for Wear
  124
- Disassembling the Autodecompressor
  124
- Assembling the Autodecompressor
  125
- Checking the Camshaft
  125
- Checking the Timing Assembly
  126
- Preparing the Timing Chain Tensioner for Installation
  126
- Removing the Coolant Temperature Sensor
  127
- Removing the Rocker Arm
  127
- Removing the Valves
  127
- Changing the Camshaft Bearing
  128
- Checking the Valves
  129
- Checking the Valve Springs
  129
- Checking the Valve Spring Seat
  129
- Checking the Cylinder Head
  130
- Installing the Valves
  130
- Installing the Rocker Arm
  131
- Installing the Coolant Temperature Sensor
  131
- Checking the Clutch
  132
- Checking the Shift Mechanism
  133
- Preassembling the Shift Shaft
  134
- Disassembling the Main Shaft
  134
- Assembling the Main Shaft
  134
- Disassembling the Countershaft
  135
- Assembling the Countershaft
  135
- Checking the Transmission
  136
- Checking the Electric Starter Mode
  137
- Removing the Free Wheel
  137
- Installing the Free Wheel
  138
30/Engine Assembly
139
- Installing the Crankshaft
  139
- Installing the Transmission Shafts
  139
- Installing the Diaphragm
  139
- Installing the Shift Fork
  140
- Installing the Shift Drum
  140
- Installing the Shift Rails
  140
- Installing the Left Engine Case
  140
- Installing the Locking Lever
  141
- Installing the Shift Drum Locating Unit
  141
- Installing the Shift Shaft
  141
- Installing the Oil Pumps
  142
- Installing the Oil Pump Gears
  142
- Installing the Starter Idler Gear
  142
- Installing the Torque Limiter
  143
- Installing the Free Wheel Gear
  143
- Installing the Primary Gear
  143
- Installing the Balancer Shaft
  143
- Installing the Outer Clutch Hub
  143
- Installing the Primary Gear Nut
  144
- Installing the Clutch Discs
  144
- Installing the Clutch Cover
  145
- Installing the Water Pump Cover
  145
- Installing the Ignition Pulse Generator
  145
- Installing the Timing Chain
  146
- Installing the Timing Chain Securing Guide
  146
- Installing the Timing Chain Tensioning Rail
  146
- Installing the Timing Chain Guide Rail
  146
- Installing the Balance Weight
  146
- Installing the Rotor
  147
- Installing the Distance Bushing
  147
- Installing the Piston
  147
- Installing the Cylinder Head
  149
- Installing the Camshaft
  150
- Installing the Timing Chain Tensioner
  150
- Checking the Valve Clearance
  150
- Adjusting the Valve Clearance
  151
- Installing the Generator Cover
  151
- Installing the Spark Plug
  152
- Installing the Valve Cover
  152
- Installing the Oil Filter
  152
- Installing the Oil Screen
  152
- Assembling the Starter Motor
  153
- Installing the Oil Line
  153
- Removing the Engine from the Work Stand
  153
32/Clutch
154
- Checking the Fluid Level of the Hydraulic Clutch
  154
- Changing the Hydraulic Clutch Fluid
  154
35/Water Pump, Cooling System
156
- Checking the Coolant Level
  156
- Checking the Antifreeze and Coolant Level
  156
- Draining the Coolant
  157
- Refilling Coolant
  157
38/Lubrication System
158
- Oil Circuit
  158
- Checking the Engine Oil Pressure
  158
- Checking the Engine Oil Level
  160
- Adding Engine Oil
  160
- Changing the Engine Oil and Oil Filter, Cleaning the Engine Oil Screen
  160
- Draining Engine Oil, Cleaning Engine Oil Screen
  160
- Removing the Oil Filter
  161
- Installing the Oil Filter
  162
- Filling up with Engine Oil
  162
41/Throttle Valve Body
163
Fault Code
166
Technical Data - Engine
221
- Capacity - Engine Oil
  221
- Capacity - Coolant
  221
Technical Data - Engine Tolerances, Wear Limits
222
Technical Data - Engine Tightening Torques
224
Technical Data - Chassis
226
- Lighting Equipment
  226
- Tires
  227
- Capacity - Fuel
  227
Technical Data - Fork
228
Technical Data - Shock Absorber
229
Technical Data - Chassis Tightening Torques
230
Cleaning/Protection
231
- Cleaning the Motorcycle
  231
- Protection for Winter Operation
  232
Storage
233
- Putting into Operation after Storage
  233
Service Schedule
234
Wiring Diagram
238
- Of 3 (FE EU)
  238
- Of 3 (FE EU)
  240
- Of 3 (FE EU)
  244
- Of 3 (FE USA)
  248
- Of 3 (FE USA)
  250
- Of 3 (FE USA)
  254
- Of 3 (FE AUS)
  256
- Of 3 (FE AUS)
  258
- Of 3 (FE AUS)
  262
Substances
265
Auxiliary Substances
267
Special Tools
269
Standards
280
Index
281

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HUSABERG FE 450 AUS Owner's Manual

HUSABERG FE 450 AUS Owner's Manual (117 pages)

Motorcycle

Brand: HUSABERG | Category: Motorcycle | Size: 5 MB

Table of Contents

Table of Contents
4
1 Means of Representation

7
- Symbols Used
  7
- Formats Used
  7
2 Safety Advice

8
- Use Definition - Intended Use
  8
- Degrees of Risk and Symbols
  8
- Tampering Warning
  8
- Safe Operation
  9
- Protective Clothing
  9
- Work Rules
  9
- Environment
  9
- Owner's Manual
  10
3 Important Information

11
- Manufacturer and Implied Warranty
  11
- Operating and Auxiliary Substances
  11
- Spare Parts, Accessories
  11
- Service
  11
- Figures
  11
- Customer Service
  11
4 View of Vehicle

12
- View of Vehicle, Front Left (Example)
  12
- View of Vehicle, Rear Right (Example)
  13
5 Serial Numbers

14
- Chassis Number
  14
- Type Label (FE EU, FE AUS)
  14
- Key Number (FE EU, FE AUS)
  14
- Engine Number
  14
- Fork Part Number
  14
- Shock Absorber Part Number
  15
6 Controls

16
- Clutch Lever
  16
- Hand Brake Lever
  16
- Throttle Grip
  16
- Kill Switch (FE EU, FE AUS)
  16
- Kill Switch (FE 501 USA)
  16
- Horn Button (FE EU, FE AUS)
  17
- Light Switch (FE EU, FE AUS)
  17
- Light Switch (FE 501 USA)
  17
- Turn Signal Switch (FE EU, FE AUS)
  17
- Emergency off Switch (FE AUS)
  17
- Electric Starter Button (FE EU, FE 501 USA)
  18
- Electric Starter Button (FE AUS)
  18
- Overview of Indicator Lamps (FE EU, FE AUS)
  18
- Overview of Indicator Lamps (FE 501 USA)
  18
- Opening Filler Cap
  18
- Closing Filler Cap
  19
- Idle Speed Adjusting Screw
  19
- Shift Lever
  20
- Foot Brake Lever
  20
- Side Stand
  20
- Steering Lock (FE EU, FE AUS)
  21
- Locking the Steering (FE EU, FE AUS)
  21
- Unlocking the Steering (FE EU, FE AUS)
  21
7 Speedometer

22
- Overview
  22
- Activation
  22
- Message on the Speedometer
  22
- Setting the Speedometer
  22
- Setting Kilometers or Miles
  23
- Setting the Clock
  24
- Setting the Service Display
  24
- Speed, Time, and DST Distance 1
  25
- Speed, Time, and DST2 Distance 2
  25
- AVG Average Speed, ART Operating Hours, and ODO Total Distance Covered
  25
8 Preparing for Use

26
9 Riding Instructions

30
- Checks and Maintenance Work When Preparing for Use
  30
- Starting
  30
- Starting off
  31
- Shifting, Riding
  31
- Braking
  31
- Stopping, Parking
  32
- Transport
  32
- Refueling
  33
10 Service Schedule

34
- Service Work (as Additional Order)
  35
11 Tuning the Chassis

36
12 Service Work on the Chassis

43
13 Brake System

65
14 Wheels, Tires

74
- Removing the Front Wheel
  74
- Installing the Front Wheel
  74
- Removing the Rear Wheel
  75
- Installing the Rear Wheel
  75
- Checking the Tire Condition
  76
- Checking the Tire Air Pressure
  77
- Checking Spoke Tension
  77
15 Electrical System

79
16 Cooling System

86
17 Tuning the Engine

89
18 Service Work on the Engine

91
19 Cleaning, Care

95
- Cleaning the Motorcycle
  95
- Checks and Maintenance Steps for Winter Operation
  96
20 Storage

97
- Preparing for Use after Storage
  97
21 Troubleshooting

98
22 Blink Code

100
23 Technical Data

102
- Engine
  102
- Engine Tightening Torques
  102
- Capacities
  104
- Engine Oil
  104
- Coolant
  104
- Fuel
  104
- Chassis
  104
- Electrical System
  105
- Tires
  105
- Fork
  105
- Shock Absorber
  106
- Chassis Tightening Torques
  106
24 Substances

108
25 Auxiliary Substances

110
26 Standards

112
- Index
  113

HUSABERG FE 450 AUS Repair Manual

HUSABERG FE 450 AUS Repair Manual (116 pages)

Brand: HUSABERG | Category: Engine | Size: 6 MB

Table of Contents

Table of Contents
5
General Information

6
- Oil Circuit
  6
- Engine Oil
  6
- Checking the Oil Level
  6
- Changing the Engine Oil
  7
- Cleaning the Oil Screen
  7
- Changing the Oil Filter
  8
- Checking the Oil Level in the Hydraulic Clutch
  9
- Bleeding the Clutch
  9
- Cleaning
  10
- Preservation for Winter Operation
  10
- Storage
  10
- Special Tools
  12
Dismounting and Mounting the Engine

14
- Dismounting the Engine
  14
- Mounting the Engine
  18
- Bleeding the Cooling System
  22
- Adjusting the Throttle Cable
  22
Disassembling the Engine

24
- Blocking the Engine
  24
- Removing the Rotor
  25
- Removing the Clutch
  26
- Removing Inner Clutch Hub
  27
- Removing Primary Pinion and the Idler Shaft Gear
  27
- Removing the Oil Pump
  28
- Removing the Chain Tensioner
  29
- Separating the Timing Chain
  29
- Removing the Cylinder Head
  30
- Separating the Housing
  30
- Removing the Crankshaft
  31
- Removing the Transmission
  31
- Removing the Idler Shaft
  32
Servicing the Individual Parts

34
- Important
  34
- Left Housing Half
  34
- Right Housing Half
  35
- Pressure Relief Valve
  36
- Clutch Cover
  36
- Crankshaft
  37
- Press out the Crank Pin
  38
- Press in the Crank Pin
  39
- Outer Dimension of the Crankshaft Webs
  40
- Balancing the Axial Clearance of the Crankshaft
  41
- Nikasil Cylinder Coating
  42
- Measuring the Piston and Cylinder Liner
  42
- Checking the Piston
  43
- Checking the Piston Ring End Gap
  43
- Checking the Oil Pump for Wear
  43
- Cylinder Head Top Section
  44
- Cylinder Head
  45
- Camshaft
  47
- Timing Chain Tensioner
  48
- Timing Train
  48
- Checking the Clutch for Wear
  49
- Checking the Kickstarter for Wear
  50
- Shift Mechanism
  51
- Assembling the Main Shaft (Four-Speed)
  52
- Assembling the Main Shaft (Six-Speed)
  53
- Starter Drive
  55
- Checking the Freewheel
  55
Assembling the Engine

56
- Mounting the Idler Shaft
  56
- Mounting the Crankshaft
  57
- Mounting the Cylinder Head
  59
- Mounting the Timing Chain
  60
- Mounting the Timing Chain Tensioner
  62
- Adjusting the Valve Clearance
  62
- Mounting the Oil Pump
  63
- Mounting the Shift Mechanism
  63
- Mounting the Kickstarter Shaft
  64
- Mounting the Clutch
  64
- Mounting the Clutch Cover
  66
- Mounting the Pressure Relief Valve
  68
Electric System

70
- Checking for Loss of Current
  70
- Dismounting/Mounting the Battery
  70
- Charging the Battery
  70
- Filling the Battery
  71
- Checking the Starter
  71
- Checking the Starter Relay
  72
- Checking the Voltage Regulator
  73
- Troubleshooting in the Ignition System
  74
- CDI Unit
  75
- Checking the Ignition Coil
  75
- Ignition System
  76
- Checking the Stator and Pulse Generator
  76
- Static Ignition Values Kokusan 4K-3A/B
  77
- Static Generator Values Kokusan 4K3B
  79
Fuel System

82
- Keihin Fcr-MX 39/41
  82
- Accelerator Pump
  86
- Jet Needle
  86
- Throttle Slide
  87
- Adjusting the Throttle Sensor Position
  91
- Checking the Throttle Sensor
  92
- Dismounting and Mounting the Throttle Sensor
  92
- Adjusting the Idle
  93
Troubleshooting

96
Technical Specifications

98
- Engine 450, 501
  99
- Chassis
  100
- Tightening Torques
  102
- Mounting Clearances, Engine Wear Limits
  103
Periodic Maintenance Schedule

104
Wiring Diagrams

108
- Cable Colors
  110

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