HUSABERG 2004 FC 450/4 Owner'S Manual Download Page 63

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ENGLISH

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

Loctite 243 + 5 Nm

HH collar screw on cylinder head top section

10 Nm

AH screws on valve cover

6 Nm

HH collar screws on water pump cover

10 Nm

HH screws on cylinder head

M10

50 Nm

HH screw on cylinder head

10 Nm

AH screws on camshaft gear

Loctite 243 + 28 Nm

HH nut on automatic decompression stop

Loctite 2701 + 8 Nm

AH screws on rocker arm shaft silencer cap

Loctite 243 + 6 Nm

Counternut on valve adjusting screw

M6x0,75

11 Nm

HH nut on primary pinion

M16x1

Loctite 2701 + 110 Nm

HH nut on idler shaft gear

M16x1

Loctite 2701 + 110 Nm

HH nut on clutch drive

M18x1,5

Loctite 243 + 120 Nm

HH collar screws on clutch springs

Loctite 243 + 8 Nm

AH screw shift on shift roller lock

Loctite 243 + 10 Nm

HH collar screw on locking lever

Loctite 243 + 10 Nm

HH collar screw on shift roller bearing

Loctite 243 + 10 Nm

HH collar screws on chain tensioner

10 Nm

HH screw chain tensioning rail

Loctite 243 + 6 Nm

HH screw on chain guide rail

Loctite 243 + 6 Nm

HH collar screws on stator FE/FS models

Loctite 243 + 10 Nm

HH collar screws on stator FC models

Loctite 243 + 6 Nm

HH collar screws on pulse generator

Loctite 243 + 6 Nm

HH collar nut on rotor

M12x1

60 Nm

HH collar screw on starter cap, FC models only

10 Nm

HH screw on kickstarter

Loctite 243 + 25 Nm

Phillips screws on kickstarter release plate

Loctite 243 + 6 Nm

HH collar screw on shift lever

10 Nm

Spark plug

M12x1,25

20 Nm

Plug on engine blocking bore

20 Nm

Diaphragm valve

Loctite 243 + 1,5 Nm

Summary of Contents for 2004 FC 450/4

Page 1: ...BEDIENUNGSANLEITUNG OWNERS MANUAL MANUEL D UTILISATION 04 Edition 2004...

Page 2: ...the handlebar position 34 Changing the spring preloading of the shock absorber 34 Check chain tension 35 Correct chain tension 35 Chain maintenance 36 Chain wear 36 General information about Husaberg...

Page 3: ...HE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT PREVIOUS ANNO UNCEMENT AND WITHOUT GIVING REASONS OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTITUTING THEM WITH OTHERS IT SHALL BE ACCEPTAB...

Page 4: ...ubsequent owner in case you decide to sell it The work marked with an in the chapter Servicing the chassis and engine must be performed by an authorized Husaberg dealer If such service work becomes ne...

Page 5: ...conversions to the motorcycle The use of the motorcycle under extreme conditions e g on extremely muddy and wet terrain can lead to higher than average wear on components such as the drive train or t...

Page 6: ...he 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...

Page 7: ...ring the starting procedure The outer end of the lever must provide for a backlash of approx 10 mm 0 4 in at all times Only thereafter may it cause valve motion to be recognized by the stronger resist...

Page 8: ...her switch 3 is a separate unit and is mounted on the left portion of the handlebar The wire harness is designed in a way that whenever you want to use your bike off road you can dismount the entire t...

Page 9: ...ter and ignition circuits are interrupted The E starter cannot be actuated and the engine will not start not even if you attempt to start it with the kickstarter Pushing the black starter button 5 wil...

Page 10: ...O DISPLAY MODE The SPEED ODO mode shows the speed and the total kilometers travled When the front wheel stops turning the display will auto matically change to the SPEED H mode The information will di...

Page 11: ...press and hold the MODE button 3 seconds to reset the MAX figure to 0 SPEED LAP DISPLAY MODE LAP displays the stopped lap time in hours minutes and seconds button Starts and stops the stop watch The...

Page 12: ...ter starts to count as soon as you start the engine The displayed figure cannot be cleared Service intervals are indicated in operating hours for some Husaberg offroad motorcycles making the operating...

Page 13: ...and STP1 figures to 0 SPEED TRP2 TRIP 2 DISPLAY MODE The TRP2 trip meter is always active and counts to 999 9 Contrary to TRP1 the displayed figure can be changed using the and buttons This is a very...

Page 14: ...isplay will return to the SPEED CLK mode button time button time press the MODE button to change to the next digit press and hold the MODE button 3 seconds to store the time and return to the SPEED CL...

Page 15: ...all LAP figures next display mode set clock menu display setup menu resets TRP1 STP1 and AVS1 to 0 resets TRP1 STP1 and AVS1 to 0 resets TRP1 STP1 and AVS1 to 0 resets TRP2 to 0 next display mode sets...

Page 16: ...NOTE The RES function is not available CHOKE If you pull the choke button 2 out as far as possible a bore in the carburetor will be opened through which the engine may take in additional fuel The res...

Page 17: ...ne The upper part is tiltable FOOT BRAKE PEDAL The foot brake pedal is located in front of the right footrest Its basic position can be adjusted to your seat position see mainten ance work SIDE STAND...

Page 18: ...r the relevant type of fork Typ White Power 1445Y728 18 clicks Typ White Power 1445Y729 19 clicks Typ White Power 1445Y730 20 clicks REBOUND DAMPING OF FORK Hydraulic rebound damping determines the re...

Page 19: ...the limit in a clockwise direction using a screwdriver unscrew the respective number of clicks for the specific type of shock absorber in a counterclockwise direction Typ White Power 1245Y721 15 clic...

Page 20: ...p White Power 1245Y722 22 clicks Typ White Power 1245Y723 15 clicks WARNING The damping unit of the shock absorber is fil led with high compression nitrogen Never try to take the shock absorber apart...

Page 21: ...perating hours Besides the engine speed must not exceed 7000 rpm Avoid going full throttle In the following 12 operating hours you may load the engine up to 75 of its capacity Use the motorcycle on va...

Page 22: ...be replaced The tread depth must comply with the legal regulati ons Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving performance 5 Brakes Check correct...

Page 23: ...Wait at least 5 seconds before trying again Don t ride your motorcycle with full load and don t rev up the engine when cold because the piston is warming up faster than the water cooled cylinder and...

Page 24: ...e an adverse effect on the life of your engine We recommend you run the engine in a moderate rpm range for a few miles giving it a chance to warm up After that no further precautions in this respect n...

Page 25: ...SIDE STAND Use your foot to kick side stand forward up to the stop and lean the motorcycle sideways Make sure that the ground is solid and that your motorcycle is standing securely Just in case you ca...

Page 26: ...25 ENGLISH...

Page 27: ...lamp setting Check function of electric systems low high beam brake light indicator lamps speedometer illumination horn emergency OFF switch or button Check brake fluid level lining thickness brake di...

Page 28: ...s Check headlamp setting Check function of electric systems low high beam brake light indicator lamps speedometer illumination horn emergency OFF switch or button Check brake fluid level lining thickn...

Page 29: ...ft bearings Replace the crankshaft main bearings Check the entire transmission including the roller and bearings for wear 60 hours 400 liter 90 hours 600 liter 120 hours 800 liter 180 hours 1200 liter...

Page 30: ...check Check the camshaft for wear visual check Check the camshaft bearings Check the length of the valve springs Check the spring cap for wear Check the eccentricity of the valve disk Check the valve...

Page 31: ...Under no circumstances may used oil be disposed of in the sewage system or in the open countryside 1 liter of used oil contaminates 1 000 000 liters of water CHECKING AND ADJUSTING THE STEERING HEAD B...

Page 32: ...before having the seals replaced CLEANING THE DUST SLEEVES OF THE TELES COPIC FORK The dust protection bellows 2 are to remove dust and coarse dirt particles from the fork tube However after some time...

Page 33: ...ertical distance between the rear wheel axle and a fixed point e g a mark on the side cover and write it down as dimension A Place the motorcycle on the ground again Ask a helper to hold the motorcycl...

Page 34: ...load see WP manual Pretension spacers are available in heights of 1 5 2 5 and 5 mm see spare parts cata log The fork springs may not be pretensioned by more than 20 mm NOTE WP precisely adjusts the sp...

Page 35: ...nd in the rear WARNING The screws 4 must be secured with Loctite 243 CHANGING THE SPRING PRELOADING OF THE SHOCK ABSORBER The spring preload can be changed by turning the adjusting ring 5 For this pur...

Page 36: ...se control of the motorcycle CORRECT CHAIN TENSION Loosen collar nut 1 loosen lock nuts 2 and turn right and left adjusting screws 3 equally far Tighten lock nuts To ensure the correct alignment of th...

Page 37: ...chain masterlink clip the closed side of the masterlink clip must point in running direc tion Also check sprockets and chain guides for wear and replace if necessary CHAIN WEAR To check the chain wear...

Page 38: ...fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not necessary to top up the brake fluid If the brake fluid level drops...

Page 39: ...ress the handbrake lever s outer end forward and at the same time turn the adjusting screw CHECKING THE BRAKE FLUID LEVEL FRONT BRAKE The brake fluid reservoir is linked with the hand brake cylinder a...

Page 40: ...bolts for damage and grease guide bolts if neces sary Mount the right brake pad and fix it with the bolt Mount the left brake pad and insert the bolt until it stops Mount the clips When mounting the b...

Page 41: ...e pads are completely 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 re...

Page 42: ...liper 1 toward the chain wheel in order to move the brake piston into its basic position Remove the clip 2 pull out the bolt 3 and remove the brake pads Thoroughly clean the brake caliper with compres...

Page 43: ...wheel lift it into the fork position and mount the axle shaft 4 Mount the collar nut 2 tighten the clamping screws 3 on the right fork leg axle passage to prevent the axle shaft from turning and tigh...

Page 44: ...dismounted clean the thread of the wheel spindle and collar nut thoroughly and apply a new coat of grease to prevent the thread from jamming The rear wheel is remounted in the reverse order Before tig...

Page 45: ...signs of damage and dirt CAUTION If the shock absorption rubbers are not repla ced in good time the rear sprocket carrier and the rear hub will be damaged Allways replace all 6 absorption rubbers neve...

Page 46: ...cked regularly on a cold tire Proper pressure ensures optimum driving comfort and extends the life of your tires WARNING Do not mount tires which have not been approved by Husaberg Other tires could h...

Page 47: ...GE When preparing the motorcycle for a longer period of standstill remove the battery and recharge it Storage temperature 0 35 C 30 95 F Do not expose to direct sunlight CHARGING THE BATTERY Disconnec...

Page 48: ...ld damage the whole electri cal installation REPLACING HEADLIGHT LAMP PARKING LIGHT LAMP Loosen both rubber bands and tilt headlight mask to the front Pull the parking light lamp with holder 4 careful...

Page 49: ...nt is toxic Keep the coolant out of the reach of children In case coolant is ingested consult a doctor immediately If coolant gets into your eyes rinse them out with water immediately and consult doct...

Page 50: ...out of the silencer Clean the front inner exhaust pipe To facilitate the mounting procedure you can make a mounting tool 7 out of wood plastic or metal Insert the mounting tool into the inner pipe and...

Page 51: ...engine and at idling speed slowly pull the hand decom pression lever until you can feel the thumping of the rocker arm on the lever The backlash until said thumping should be approx 10mm measured at...

Page 52: ...vaila ble from your Husaberg dealer 50ml CAUTION Husaberg uses biodegradable hydraulic oil for the hydraulic clutch control Never mix biodegradable hydraulic oils with mineral oils Never refill with m...

Page 53: ...high increase reduce the idle speed to a normal level and repeat the procedure specified in 4 Serious competitive racers will choose a setting approx 1 4 turn clockwise leaner than this ideal value b...

Page 54: ...pressed air Then mount the plug together with its gasket open the fuel tap and check the float chamber for any leaks NOTE Fuel is easily flammable and toxic When handling fuel be sure to exercise the...

Page 55: ...tch The JASO MA standard responds to these spe cial requirements Only use fully synthetic engine oils that meet the JASO MA quality requirements see information on the can Husaberg recommends Motorex...

Page 56: ...r cover the sealing areas on the O rings and the engine case check the O rings 5 in the oil filter cover for damage and replace if necessary Lay the motorcycle down and fill the oil filter housing app...

Page 57: ...el from the float chamber The engine will immediately start when the float chamber is filled with new fuel Close fuel tap loosen fuel hose at carburetor lead into a basin and open fuel tap if fuel lea...

Page 58: ...evel is too high Engine oil is too thin The voltage regulator is defec tive Fuse in the starter relay is blown Battery is not being charged by the generator REMEDY Disassemble the carburetor and check...

Page 59: ...ther bare or galvanized parts except for brake discs with a wax based anti corrosion agent WARNING Keep the anti corrosion agent from getting into contact with the brake discs otherwise this will sign...

Page 60: ...Z Clutch mult disc clutch in oil bath Transmission clawn shifted 4 Gang 6 Gang Gear ratio 1 Gear 14 33 14 33 2 Gear 17 30 17 30 3 Gear 19 26 19 26 4 Gear 23 25 23 25 5 Gear 24 22 6 Gear 27 20 Ignition...

Page 61: ...mission claw shifted 4 speed 6 speed Gear ratio 1st gear 14 33 14 33 2nd gear 17 30 17 30 3rd gear 19 26 19 26 4th gear 23 25 23 25 5th gear 24 22 6th gear 27 20 Ignition system breakerless transitori...

Page 62: ...7 mm Rear suspension WP Progressive Damping System shock absorber aluminum rear swinging fork Front brake Disk brake perforated 260 mm brake disk floating brake caliper 310 mm Brake disk front minimum...

Page 63: ...HH nut on idler shaft gear M16x1 Loctite 2701 110 Nm HH nut on clutch drive M18x1 5 Loctite 243 120 Nm HH collar screws on clutch springs M6 Loctite 243 8 Nm AH screw shift on shift roller lock M6 Lo...

Page 64: ...indle M20x1 5 80 Nm Hexagon nut swing arm bolt M16x1 5 100 Nm Hexagon collar screw handlebar clamp M8 20 Nm Allan head screw handlebar support M10 Loctite 243 40 Nm Shock absorber top M12 60 Nm Shock...

Page 65: ...k 17 Cooling system 48 Correct chain tension 35 Damping action during compression of shock absorber 18 Determining the riding sag of the shock absorber 32 Determining the static sag of the shock absor...

Page 66: ...X APPENDICE SCHALTPL NE Husaberg FC 04 G 3 red black yellow blue green black generator ignition coil 800 11 075 300 throttle position sensor pick up I D C stop button yellow black black brown red blue...

Page 67: ...left front flasher bl re rear brake switch TPS pick up flasher switch wh gn I D C ye generator ye re cooling fan re bl re wh bl M A starter motor start relay battery 10 24 03 2003 800 11 075 150 main...

Page 68: ...tch cable br LIGHT OFF gn LO P LIGHT high low beam switch wh cable bu wh ye color unpushed START re gn TURN L pi re pi cable brake switch HI ye br bl harness wh cable br bl HORN flasher switch gn OFF...

Page 69: ...stop switch flasher system cooling fan light switch wh wh wh ye bl ye br br ye re br ye ye re wh re bl br br br bl wh ye bl br bu wh re wh re bl gn re bl ye bu bu ye bl re gn re bl re wh ye wh br br w...

Page 70: ...SCHALTPL NE 5 ANHANG APPENDIX APPENDICE re switch cable re start switch wh ye unpushed START...

Page 71: ...ye left front flasher bl re rear brake switch TPS pick up flasher switch wh gn I D C ye ye re re bl re wh bl M A starter motor start relay battery 10 24 03 2003 800 11 075 150 main harness wiring diag...

Page 72: ...FF gn LO P LIGHT high low beam switch wh cable bu wh ye bl br ye LOCKED OFF ON color unpushed START re gn TURN L pi re ignition switch ye pi cable brake switch HI ye br bl harness wh cable br bl HORN...

Page 73: ...uche Light switch Lichtschalter Contacteur d clairage Multi func digital speedometer Multifunktionsdigitaltacho Ordinateur de bord Pick up Impulsgeber Capteur d allumage Position light Begrenzungslich...

Page 74: ...HUSABERG a company of the KTM Group Stallhofner Stra e 3 A 5230 Mattighofen E mail info husaberg cc Internet www husaberg cc Cover B ro 3 Communication Photos Florian Jaenicke 09 2003 ART NR 3802000...

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