HUSABERG FE 450 USA Manuals

Manuals and User Guides for HUSABERG FE 450 USA. We have 1 HUSABERG FE 450 USA manual available for free PDF download: Repair Manual

HUSABERG FE 450 USA Repair Manual

HUSABERG FE 450 USA 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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