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HUSABERG FE 450 AUS, Repair Manual

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INDEX

280

Engine assembly

adjusting the valve clearance . . . . . . . . . . . . . . . . . . 149
balance weight, installing . . . . . . . . . . . . . . . . . . . . 144
balancer shaft, installing . . . . . . . . . . . . . . . . . . . . . 141
camshaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 148
clutch cover, installing . . . . . . . . . . . . . . . . . . . . . . 143
clutch discs, installing

. . . . . . . . . . . . . . . . . . . . . . 142

crankshaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 137
cylinder head, installing

. . . . . . . . . . . . . . . . . . . . . 147

diaphragm, installing

. . . . . . . . . . . . . . . . . . . . . . . 137

distance bushing, installing . . . . . . . . . . . . . . . . . . . 145
engine, removing from work stand . . . . . . . . . . . . . . . 151
free wheel gear, installing . . . . . . . . . . . . . . . . . . . . 141
generator cover, installing . . . . . . . . . . . . . . . . . . . . 149
ignition pulse generator, installing

. . . . . . . . . . . . . . 143

left engine case, installing . . . . . . . . . . . . . . . . . . . . 138
locking lever, installing . . . . . . . . . . . . . . . . . . . . . . 139
oil filter, installing . . . . . . . . . . . . . . . . . . . . . . . . . 150
oil pump gears, installing . . . . . . . . . . . . . . . . . . . . . 140
oil pumps, installing . . . . . . . . . . . . . . . . . . . . . . . . 140
oil screen, installing . . . . . . . . . . . . . . . . . . . . . . . . 150
outer clutch hub, installing . . . . . . . . . . . . . . . . . . . 141
piston, installing

. . . . . . . . . . . . . . . . . . . . . . . . . . 145

primary gear nut, installing . . . . . . . . . . . . . . . . . . . 142
primary gear, installing . . . . . . . . . . . . . . . . . . . . . . 141
rotor, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
shift drum locating unit, installing

. . . . . . . . . . . . . . 139

shift drum, installing . . . . . . . . . . . . . . . . . . . . . . . . 138
shift fork, installing . . . . . . . . . . . . . . . . . . . . . . . . . 138
shift rails, installing . . . . . . . . . . . . . . . . . . . . . . . . 138
shift shaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 139
spark plug, installing . . . . . . . . . . . . . . . . . . . . . . . . 150
starter idler gear, installing . . . . . . . . . . . . . . . . . . . 140
starter motor, assembling

. . . . . . . . . . . . . . . . . . . . 151

timing chain guide rail, installing . . . . . . . . . . . . . . . 144
timing chain securing guide, installing . . . . . . . . . . . . 144
timing chain tensioner, installing . . . . . . . . . . . . . . . 148
timing chain tensioning rail, installing . . . . . . . . . . . . 144
timing chain, installing . . . . . . . . . . . . . . . . . . . . . . 144
torque limiter, installing . . . . . . . . . . . . . . . . . . . . . 141
transmission shafts, installing

. . . . . . . . . . . . . . . . . 137

valve clearance, checking

. . . . . . . . . . . . . . . . . . . . 148

valve cover, installing . . . . . . . . . . . . . . . . . . . . . . . 150
water pump cover, installing

. . . . . . . . . . . . . . . . . . 143

Engine disassembly

balance weight, removing

. . . . . . . . . . . . . . . . . . . . 103

balancer shaft, removing . . . . . . . . . . . . . . . . . . . . . 106
camshaft, removing

. . . . . . . . . . . . . . . . . . . . . . . . 101

clamping engine in engine work stand . . . . . . . . . . . . . 99
clutch cover, removing

. . . . . . . . . . . . . . . . . . . . . . 104

clutch disks, disassembling . . . . . . . . . . . . . . . . . . . 105
crankshaft, removing . . . . . . . . . . . . . . . . . . . . . . . . 110
cylinder head, removing . . . . . . . . . . . . . . . . . . . . . . 102
diaphragm, removing . . . . . . . . . . . . . . . . . . . . . . . . 110
distance bushing, removing . . . . . . . . . . . . . . . . . . . 102
engine oil, draining . . . . . . . . . . . . . . . . . . . . . . . . . . 99
engine, positioning at ignition top dead center . . . . . . 100
free wheel gear, removing . . . . . . . . . . . . . . . . . . . . 107
generator cover, removing . . . . . . . . . . . . . . . . . . . . 100
ignition pulse generator, removing . . . . . . . . . . . . . . . 104
left section of the engine case, removing . . . . . . . . . . 109

locking lever, removing . . . . . . . . . . . . . . . . . . . . . . 108
oil filter, removing

. . . . . . . . . . . . . . . . . . . . . . . . . . 99

oil line, installing . . . . . . . . . . . . . . . . . . . . . . . . . . 151
oil line, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
oil pump gears, removing . . . . . . . . . . . . . . . . . . . . . 107
oil pumps, removing . . . . . . . . . . . . . . . . . . . . . . . . 108
outer clutch hub, removing . . . . . . . . . . . . . . . . . . . 106
piston, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
primary gear nut, removing

. . . . . . . . . . . . . . . . . . . 105

primary gear, removing . . . . . . . . . . . . . . . . . . . . . . 106
rotor, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
shift drum locating unit, removing

. . . . . . . . . . . . . . 108

shift drum, removing . . . . . . . . . . . . . . . . . . . . . . . . 109
shift forks, removing . . . . . . . . . . . . . . . . . . . . . . . . 109
shift rails, removing . . . . . . . . . . . . . . . . . . . . . . . . 109
shift shaft, removing . . . . . . . . . . . . . . . . . . . . . . . . 108
spark plug, removing . . . . . . . . . . . . . . . . . . . . . . . . 100
starter idler gear, removing

. . . . . . . . . . . . . . . . . . . 107

starter motor, removing . . . . . . . . . . . . . . . . . . . . . . . 99
timing chain guide rail, removing . . . . . . . . . . . . . . . 103
timing chain securing guide, removing . . . . . . . . . . . . 104
timing chain tensioner, removing . . . . . . . . . . . . . . . 101
timing chain tensioning rail, removing . . . . . . . . . . . . 103
timing chain, removing . . . . . . . . . . . . . . . . . . . . . . 104
torque limiter, removing

. . . . . . . . . . . . . . . . . . . . . 107

transmission shafts, removing

. . . . . . . . . . . . . . . . . 110

valve cover, removing . . . . . . . . . . . . . . . . . . . . . . . 100
water pump cover, removing . . . . . . . . . . . . . . . . . . . 104

Engine guard

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Engine number

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Engine oil

adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Engine oil level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Engine oil pressure

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Engine oil screens

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Exhaust system

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

F

Fault code

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164-218

Foot brake pedal

basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 82
free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 82

Fork

dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 11

Fork legs

assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
cartridge, assembling . . . . . . . . . . . . . . . . . . . . . . . . 21
cartridge, disassembling . . . . . . . . . . . . . . . . . . . . . . 17

Summary of Contents for FE 450 AUS

Page 1: ...REPAIR MANUAL FE 450 EU FE 450 AUS FE 450 USA FE 570 EU FE 570 AUS FE 570 USA 2009 Article no 3803004en...

Page 2: ......

Page 3: ...n as HUSABERG specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reas...

Page 4: ...Removing the spring 35 Disassembling the shock absorber 36 Disassembling the piston rod 37 Disassembling the seal ring retainer 38 Replacing the pilot bushing 39 Checking the shock absorber 39 Disass...

Page 5: ...106 Removing the primary gear 106 Removing the free wheel gear 107 Removing the torque limiter 107 Removing the starter idler gear 107 Removing the oil pump gears 107 Removing the oil pumps 108 Remov...

Page 6: ...work stand 151 32 CLUTCH 152 Checking the fluid level of the hydraulic clutch 152 Changing the hydraulic clutch fluid 152 35 WATER PUMP COOLING SYSTEM 154 Checking the coolant level 154 Checking the a...

Page 7: ...on Indicates an unexpected reaction e g of a work step or a function Identifies a page reference more information is provided on the specified page Formats used The typographical and other formats use...

Page 8: ...d on screw connections e g Loctite follow the instructions for use from the manufacturer After disassembly clean the parts that are to be reused and check them for damage and wear Replace damaged or w...

Page 9: ...S 100458 10 The type label is fixed to the frame at the front right 3 3 Type label FE USA 100464 10 The type label is fixed to the front of the steering head 3 4 Key number FE EU FE AUS 500125 10 The...

Page 10: ...r is stamped on the inner side of the fork stub 3 7 Shock absorber part number 100419 10 The shock absorber part number is stamped on the upper part of the shock absorber above the adjusting ring The...

Page 11: ...unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in a closed space without an effective exhaust extraction syst...

Page 12: ...e rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior 100376 10 Turn adjusting screws clockwise until they stop Info Adjusting screws are located at...

Page 13: ...egs downwards Info The dust boots should remove dust and coarse dirt particles from the fork tubes Over time dirt can penetrate behind the dust boots If this dirt is not removed the oil seals behind c...

Page 14: ...fork legs Remove the front wheel p 65 FE EU FE AUS Remove the headlight mask with the headlight p 88 FE USA Remove the start number plate p 63 300713 10 Remove screws and take off the clamp 300714 10...

Page 15: ...wheel p 65 FE EU FE AUS Install the headlight mask with the headlight p 88 FE USA Install the start number plate p 64 5 10 Removing the fork protector Remove the fork legs p 12 300716 10 Remove screws...

Page 16: ...he fork legs p 23 5 13 Disassembling the fork legs Info The steps are identical for both fork legs Condition The fork legs are disassembled 200736 10 Remove protective cover Take note of the present s...

Page 17: ...0 Push the outer tube downward Pull the spring downward Place the special tool on the hexagonal part Open end wrench T14032 p 277 Info The preload spacers should be above the special tool 200739 10 Cl...

Page 18: ...drain out 200653 01 Remove the cartridge 200741 10 Remove dust boot Remove fork protector ring Info Disassembly of the fork protector ring is not necessarily required for the fur ther repair 200742 1...

Page 19: ...ring Take off seal ring Take off lock ring Take off dust boot Take out the fork leg 5 14 Cartridge disassembly Info The steps are identical for both fork legs Disassemble the fork legs p 14 200746 10...

Page 20: ...his step is unnecessary for the further disassembly 200697 10 Degrease the piston rod Clamp the piston rod with the special tool Clamping stand T14016S p 276 200698 10 Remove nut Remove shim stack com...

Page 21: ...tack 200704 10 Remove O ring and seal ring from the compression damping fitting Extract the compression damping fitting 5 16 Checking the fork legs Condition The fork legs are disassembled 200728 10 C...

Page 22: ...ing layer Replace the sliding bushing 200666 10 Check the spring length Guideline Spring length with preload spacer s 510 mm 20 08 in If the measured value is greater than the specified value Reduce t...

Page 23: ...ing Extract the compression damping fitting 5 18 Assembling the cartridge Info The steps are identical for both fork legs 200715 10 Clamp in the piston rod Clamping stand T14016S p 276 Mount valve of...

Page 24: ...nut with the collar facing downward Secure the nut by locking 200749 11 Degrease the cartridge and clamp using the special tool Clamping stand T14015S p 276 Mount and tighten screwsleeve Guideline Sc...

Page 25: ...ng downward Slide on lock ring Grease and slide on seal ring Lubricant T511 p 266 Info The sealing lip should face downward and open side upward Slide on support ring Remove the special tool 200670 10...

Page 26: ...ring force The adjustment tube extends more than 7 mm out from the cartridge and can not be pressed inward against the spring force Screw on fluid barrier to the stop Info The fluid barrier must be sc...

Page 27: ...on the hexagonal part Open end wrench T14032 p 277 Remove the special tool Gripping tool T14026S1 p 276 200743 10 Clamp the special tool in the bench vise Grease the threads of the piston rod Lubrica...

Page 28: ...Compression damping Comfort 26 clicks Standard 22 clicks Sport 18 clicks Turn the adjusting screw of the spring preload counterclockwise all the way Turn back clockwise the number of turns correspond...

Page 29: ...otorcycle and its attachments against damage by covering them Do not bend the cables and lines 300718 10 Remove screws Take off the speedometer and connector board and allow them to hang to the side I...

Page 30: ...M20x1 5 10 Nm 7 4 lbf ft 300718 11 Position the speedometer and connector board Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 300717 11 Position the handlebar Mount a...

Page 31: ...g p 29 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range No resting locations should be noticeable If click position...

Page 32: ...00450 10 Remove screw Remove the engine guard 6 2 Installing the engine guard 100450 10 Attach the engine guard on the frame at the rear and swing it up and forward Mount and tighten screw Guideline R...

Page 33: ...t 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping 7 2 Adjusting the low speed compression damping of the shock absorber Danger Danger of accidents Di...

Page 34: ...us pension damping 7 4 Measuring rear wheel sag unloaded Jack up the motorcycle p 9 400520 10 Measure the distance as vertical as possible between the rear axle and a fixed point such as the top edge...

Page 35: ...the shock absorber Danger 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 Info Befor...

Page 36: ...bsorber p 32 7 9 Removing the shock absorber Jack up the motorcycle p 9 100374 10 Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel Fix the re...

Page 37: ...the seal ring retainer p 43 Assemble the piston rod p 43 Assemble the shock absorber p 45 Install the spring p 50 7 12 Removing the spring Condition The shock absorber has been demounted Clamp the sh...

Page 38: ...ng and compres sion damping Remove rubber cap of the reservoir 200754 10 Slowly unscrew screw The pressurized nitrogen is bled off 200755 10 Remove locking cap 200756 10 Press seal ring retainer all t...

Page 39: ...emove nut Info If mount is loosened apply counteractive force Remove rebound damping shim stack Info Guide the rebound damping shim stack onto a screwdriver and put them aside together 200762 10 Remov...

Page 40: ...em aside together 200765 10 Remove rebound damping washer Remove seal ring retainer 200766 10 Remove locking cap and bump rubber 7 15 Disassembling the seal ring retainer Disassemble the piston rod p...

Page 41: ...in T1205 p 274 Support seal ring retainer with the sleeve of the special tool Assembly tool T150S p 277 Press the special tool through the new pilot bushing Calibration pin T1205 p 274 The pilot bushi...

Page 42: ...d wear If there is damage or wear Replace the piston rod 200813 10 Check the piston rings for damage and wear If damage or a bronze colored surface is visible Replace the piston rings 7 18 Disassembli...

Page 43: ...the second heim joint collar bushing with a punch 200800 10 Remove seal ring on both sides 200801 10 Press the heim joint against a lock ring using the special tool Pressing tool T1207S p 275 Remove t...

Page 44: ...le to the point where it is possible to mount the rebound damping adjusting screw Mount rubber plug 200809 10 Lubricate spring balls and O ring Lubricant T159 p 266 Screw in the rebound damping adjust...

Page 45: ...ng Grease the seal ring and mount with the washer facing downward Lubricant T511 p 266 200795 10 Mount centering disk Mount rebound rubber 7 23 Assembling the piston rod Assemble the seal ring retaine...

Page 46: ...ler shims at the top Apply thread locker to the threads of the piston rod Loctite 2701 Screw on mount to the point where the piston can still be turned 200770 10 Mount compression damping shim stack w...

Page 47: ...bricant T158 p 265 Grease the threads Lubricant T159 p 266 Mount and tighten the compression damping adjuster Guideline Compression damping adjuster M31x1 50 Nm 36 9 lbf ft 200759 11 Install adjusting...

Page 48: ...lockwise with a screwdriver up to the last perceptible click Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed Comfort...

Page 49: ...ng and compression damping 200781 10 Remove the screw from the filling port Mount adapter on the shock absorber Info Only tighten hand tight do not use any tools Connect adapter to connection of the v...

Page 50: ...e turn the Damper control lever to Vacuum Guideline 3 bar The pressure gauge drops to the specified value 0 bar 200270 10 As soon as the pressure gauge has attained the specified value turn the Oil re...

Page 51: ...st be set precisely to this position with the piston rod fully extended as otherwise damage could occur when the shock absorber is compressed Remove the special tool 200784 10 Remove adapter from conn...

Page 52: ...asher 200751 11 Measure the overall spring length when not under tension Position the spring Guideline Spring rate Weight of rider 65 75 kg 143 165 lb 69 N mm 394 lb in Weight of rider 75 85 kg 165 18...

Page 53: ...Nm 3 7 lbf ft 7 28 Removing the swingarm with shock absorber and rear wheel Condition The motorcycle is jacked up The fuel tank has been removed 300681 10 Remove chain connecting link Thread the chai...

Page 54: ...is jacked up The fuel tank has been removed 300686 10 Position the swingarm with the shock absorber and rear wheel 300685 11 Mount the swingarm pivot Mount nut but do not tighten it yet Guideline Nut...

Page 55: ...aining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screw Guideline Screw ball joint of push rod on foot brake cylinder M6 10 Nm 7 4 lbf ft 300684 10 Join plug in connector of the brake light...

Page 56: ...main silencer 8 2 Installing the main silencer 100443 11 Mount the main silencer Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Reconnect spring 8 3 Removing the exhau...

Page 57: ...alling the exhaust system 300679 12 Slip in the exhaust pipe Position the engine mounting bracket Mount and tighten screws Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft 300680 11 Mount and t...

Page 58: ...ssis M6 10 Nm 7 4 lbf ft Position the exhaust clamp Tighten screw Guideline Screw exhaust clamp on manifold M8 8 Nm 5 9 lbf ft 300676 11 Plug in connector of the lambda sensor Route the cable so it is...

Page 59: ...lling the air filter 301332 10 Mount the clean air filter onto the air filter support Apply grease to the air filter around area Long life grease p 265 100431 10 Put in both parts together position th...

Page 60: ...y press the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil Oil for foam air filter p 266 Clean the intake flange and check it for damage and tightness In...

Page 61: ...is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fue...

Page 62: ...cle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning F...

Page 63: ...e Remaining screws chassis M6 10 Nm 7 4 lbf ft Check that the intake trumpet and the connection of the engine housing vent are clear Install the air filter p 57 Install the spoiler p 61 Check the fuel...

Page 64: ...start or run the engine in a closed space without an effective exhaust extraction system Start the engine Check the fuel pressure Fuel pressure Under every load condition 3 3 3 7 bar 48 54 psi If the...

Page 65: ...er 300722 11 Ensure that the distance bushings are mounted in the brake line guide Position the fender with the brake line guide Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7...

Page 66: ...A 301333 10 Position the start number plate Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Info Ensure engagement of the holding lugs on the fender Position the brake l...

Page 67: ...ever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged 100412 10 Warning Danger of accidents Reduced braking due to damaged brake discs Always...

Page 68: ...0 bar 15 psi Rear 1 0 bar 15 psi Road tire pressure Front 1 5 bar 22 psi Rear 2 0 bar 29 psi If the tire pressure does not meet specifications Correct the tire pressure Mount the dust cap 12 4 Checki...

Page 69: ...ing Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay A A 400257 10 Check the thickness of the front and rear brake disks at several pl...

Page 70: ...not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged 100414 10 Warning Danger of accidents Reduced braking due to damag...

Page 71: ...e it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check for correct chain tension and adjust if necessary Jack up the motorcycle p 9 100388 10 Pu...

Page 72: ...Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm enables different secondary transmissions with the same chain length Chain adjusters can be turned by 180 Remove the motorcycle...

Page 73: ...If the chain is very dirty Clean the chain p 71 13 8 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning materia...

Page 74: ...loose spoke can cause wheel imbalance which leads to more loose spokes in a short time If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on...

Page 75: ...between battery terminals and cable sockets with the claws facing up 100424 10 Tighten the screw Guideline Screw battery terminal M5 3 Nm 2 2 lbf ft 14 3 Changing the main fuse Warning Fire hazard Th...

Page 76: ...Switch off all power consumers and switch off the engine Remove the seat p 59 100428 10 Open fuse box cover 100429 10 Remove the faulty fuse Guideline Fuse 1 10A EFI control unit Fuse 2 10A fuel pump...

Page 77: ...ff all power consumers and switch off the engine Remove the seat p 59 100422 10 Detach fuse box and swing it to one side Detach connector and swing it to one side with connector Remove screws and swin...

Page 78: ...ner Take the batteries to your HUSABERG dealer or to a collection point for old batteries Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners...

Page 79: ...Charging current charging voltage and charging time may not be exceeded Recharge the battery regularly if the motorcycle is not put into operation 3 months Tip If the vehicle is not ridden for more t...

Page 80: ...heck the free travel of the hand brake lever p 78 Adjust the free travel of the handbrake lever with adjusting screw Info Turn the adjusting screw clockwise to reduce free travel The pressure point mo...

Page 81: ...in the brake system or worn out brake linings Check the brake system and do not continue riding Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and e...

Page 82: ...he brake linings for damage and cracking If damage or cracking is visible Change the front brake linings p 80 15 7 Changing the front brake linings Warning Danger of accident Brake system failure Main...

Page 83: ...lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 100395 10 Move the brake...

Page 84: ...avel does not meet specifications Adjust the basic position of the footbrake lever p 82 Reconnect spring 15 9 Adjusting the basic position of the footbrake lever Warning Danger of accidents Brake syst...

Page 85: ...n on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid gets into your eyes rinse thoroughly with water and con...

Page 86: ...schedule 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 neces...

Page 87: ...e locking split pins withdraw bolt and take out the brake pads Clean the brake caliper and brake caliper support 100407 10 Check that leaf spring in the brake caliper and sliding plate in the brake ca...

Page 88: ...The settings are saved and the Setup menu closed Info If no button is pressed for 20 seconds or if no impulse comes from the wheel speed sensor the settings are automatically saved and the Setup menu...

Page 89: ...ight mask with the headlight p 88 FE USA Remove the start number plate p 63 301287 10 Expose connector CZ 301288 10 Sever brown cable in front of connector CZ PIN 1 Insulate both cable ends FE EU FE A...

Page 90: ...Info The seconds can only be set to zero Press the button for 3 5 seconds The settings are saved and the Setup menu closed Info If no button is pressed for 20 seconds or if no impulse comes from the...

Page 91: ...Adjust the beam width of the headlight p 89 16 9 Adjusting the beam width of the headlight FE EU FE AUS Check the headlight adjustment p 89 100459 10 Adjust the beam width of the headlight by turning...

Page 92: ...ockwise all the way and pull it out Insert a new headlight bulb Headlight S2 socket BA20d p 224 Insert the rubber cap together with the bulb socket into the reflector turn it clock wise all the way In...

Page 93: ...ttle valve body and allow it to hang to the side p 161 Remove the swingarm with shock absorber and rear wheel p 51 300676 10 Unplug connector of the lambda sensor Open the cable binders 300677 10 Remo...

Page 94: ...become kinked Do not actuate the clutch lever while the slave cylinder of the clutch is removed Remove screw Take off the shift lever 300694 10 Push back the rubber cap Remove nut Take off the positiv...

Page 95: ...coolant temperature sensor connector 300696 10 Expose the cable Separate plug in connector of the ignition pulse generator 300697 10 Separate plug in connector of the generator 300698 10 Remove screws...

Page 96: ...frame 300699 11 Mount screw with the sleeves but do not tighten yet 300698 11 Position the engine braces and washers Mount screws with the nuts but do not tighten yet 300679 11 Slip in the exhaust pip...

Page 97: ...garm pivot M16x1 5 100 Nm 73 8 lbf ft 300697 11 Join plug in connector of the generator Route the cable so it is tension free and secure it with cable binders 300696 11 Join plug in connector of the i...

Page 98: ...Mount hose clip and tighten it 300710 10 Mount the radiator hoses Mount and tighten hose clamps 300711 10 Mount the radiator hose Mount hose clip and tighten it Mount the engine breather hose and pos...

Page 99: ...8 4 lbf ft 300678 12 Position the exhaust manifold Mount screw but do not tighten it yet Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 300677 12 Mount and tighten screw Guideline Remaining sc...

Page 100: ...e oil SAE 10W 50 p 263 Mount and tighten screw cap Remove the motorcycle from the work stand p 9 Refill the coolant p 155 Make a short test ride Read out the fault memory using the HUSABERG diagnostic...

Page 101: ...raining the engine oil 300291 10 Remove oil drain plug with the magnet and seal ring Remove the engine oil screen plug Completely drain the engine oil 18 3 Removing the oil line 300292 10 Remove the b...

Page 102: ...the valve cover seal 18 7 Removing the spark plug 300296 10 Remove the spark plug using the special tool Spark plug wrench 75029172000 p 271 18 8 Removing the generator cover 300297 10 Remove screws T...

Page 103: ...ankshaft is visible 300300 10 Screw in special tool Crankshaft locking bolt 113080802 p 267 18 10 Removing the timing chain tensioner 300301 10 Remove screw Take off the seal ring 300302 10 Pull out t...

Page 104: ...8 13 Removing the piston 300307 10 Push the cylinder upward Info Only push the cylinder far enough upward that the piston pin can be taken out Remove the piston pin retainer Remove the piston pin Take...

Page 105: ...2009000 p 268 18 16 Removing the balance weight 300312 10 Bend lock washer Unscrew and remove nut Remove the lock washer Info Ensure that the crankshaft has been blocked Take off the balance weight 18...

Page 106: ...he direction of travel 18 21 Removing the ignition pulse generator 300317 10 Remove screws Pull the cable support sleeve from the engine case Take off the ignition pulse gen erator 18 22 Removing the...

Page 107: ...1 10 Unscrew bolts and remove them with washers and springs Take off the pressure cap 300322 10 Remove pressure piece 300323 10 Completely remove clutch discs 18 25 Removing the primary gear nut 30032...

Page 108: ...clutch hub and washer Info The washer usually adheres to the inner clutch hub Take off outer clutch hub 300328 10 Remove needle bearing and collar sleeve 18 27 Removing the balancer shaft 300327 10 P...

Page 109: ...limiter 300330 10 Remove the screw with the washer Remove torque limiter Remove washer 18 31 Removing the starter idler gear 300331 10 Remove the lock ring Take off the washer Take off starter idler...

Page 110: ...aft 300516 10 Push sliding plate away from the shift drum locating unit Remove shift shaft with the washer 18 35 Removing the shift drum locating unit 300336 10 Remove screw Push away locking lever fr...

Page 111: ...arked with 812 Take off the section of the engine case Info Do not subject the section of the engine case to any stress Remove the special tool Take off the left section of the engine case 18 38 Remov...

Page 112: ...transmission shafts 300342 10 Secure the engine in an upright position Remove lock ring 300343 10 Pull out both transmission shafts together from the bearing seats Info Do not lose the washers 18 43...

Page 113: ...side fac ing outward Info The shaft seal ring must be flush toward the outside Press in the shaft seal ring of the balancer shaft with the open side facing outward Warm up the section of the engine c...

Page 114: ...ide Info Do not press the shaft seal ring from the inside toward the outside as there is a small collar on the outside Press in the shaft seal ring from the inside toward the outside with the open sid...

Page 115: ...f the oil pressure regulator valve Remove the oil pressure regulator valve p 113 200155 10 Measure the spring length of the oil pressure regulator valve Oil pressure regulator valve Minimum length of...

Page 116: ...ter pump 300349 10 Remove nut Remove lock ring Take off the drive wheel 300368 10 Take off the water pump impeller Info If the water pump impeller cannot be detached then the water pump shaft can be p...

Page 117: ...the way in toward spacer 300368 11 Mount water pump shaft Info Be careful not to damage the shaft seal rings Mount water pump impeller 300349 11 Mount the drive wheel Mount lock ring Mount and tighte...

Page 118: ...n such a case the crank web would be squeezed together making the crankshaft unusable 200157 10 Warm up the new timing chain sprocket and immediately push it onto the crankshaft Guideline 150 C 302 F...

Page 119: ...ing device for crankshaft complete 75029047000 p 270 Info Hold the lower crank web Remove the connecting rod and bearing 200210 10 Place connecting rod onto special tool without the bearing Insert for...

Page 120: ...ll the way in Info The press mandrel must be positioned over the crank pin Take the crankshaft out of the special tool and check that the connecting rod can move freely 300609 10 Crankshaft measure th...

Page 121: ...engine case have been mounted tighten them Guideline Screw engine housing M6x75 10 Nm 7 4 lbf ft Mount screw and once all screws of the left section of the engine case have been mounted tighten it Gu...

Page 122: ...0 Using a straightedge and the special tool check the sealing area of the cylinder head for distortion Feeler gauge 59029041100 p 269 Cylinder cylinder head sealing area distortion 0 10 mm 0 0039 in I...

Page 123: ...end gap with a feeler gauge Guideline Piston ring end gap Compression ring 1 00 mm 0 0394 in Oil scraper ring 1 20 mm 0 0472 in If the end gap is greater than the specified measurement Check measure...

Page 124: ...be engine case 300359 10 Use feeler gauge to measure the play between the external rotor and the internal rotor Oil pump External rotor internal rotor clear ance 0 20 mm 0 0079 in If the measured valu...

Page 125: ...ression shaft back to the stop Pre tension the autodecompression spring more or replace it 19 25 Checking the camshaft 200206 10 Check the camshaft for damage and wear If there is damage or wear Chang...

Page 126: ...straight line Replace the timing chain 19 27 Preparing the timing chain tensioner for installation 200171 10 Press the timing chain tensioner together completely Info This requires some some force as...

Page 127: ...Take off rocker arm 19 30 Removing the valves 300372 10 Take the shims from the valve spring retainers and put them aside corresponding to their installation position Pre tension the valve springs us...

Page 128: ...Clamping plate 75029050000 p 271 Remove the camshaft bearing using the special tool Push out drift 75029051000 p 271 300520 10 Remove the small camshaft bearing using the special tool Bearing puller...

Page 129: ...ng the valve springs 200190 10 Check the valve springs for breakage and wear visual check If the valve spring is broken or worn Change the valve spring Measure the length of the valve springs Valve sp...

Page 130: ...of the cylinder for distortion Feeler gauge 59029041100 p 269 Cylinder cylinder head sealing area distortion 0 10 mm 0 0039 in If the measured value does not meet specifications Change the cylinder he...

Page 131: ...insert rocker arm shafts Info Ensure that the threaded hole of the rocker arm shaft is outwardly posi tioned Align the drill holes of the rocker arm shafts with the drill holes of the cylinder head 3...

Page 132: ...disks in outer clutch hub for wear Outer clutch hub clutch facing disks contact surface 0 5 mm 0 02 in If the contact surface exhibits significant wear Change the clutch facing disks and outer clutch...

Page 133: ...the shift roller exhibits surface damage or cracking Change the shift roller Check springs of the shift rails for damage and wear If the spring is damaged or worn Change the spring of the shift rail...

Page 134: ...5 5 0 0 6 6 0 0 7 7 0 0 8 8 0 0 9 9 0 0 bl bl 0 0 bk bk 200177 01 Secure the main shaft with the toothed end facing downward in the bench vise Guideline Use soft jaws Remove stop disk and 2nd gear fix...

Page 135: ...ws Remove stop disk and 1st gear idler gear Remove needle bearing and stop disk Remove 5th gear sliding gear and lock ring Remove stop disk and 3rd gear idler gear Remove needle bearing and 4th gear i...

Page 136: ...Check the pivot points of main shaft and countershaft for damage and wear If there is damage or wear Change the main shaft and or countershaft Check the tooth profiles of main shaft and countershaft f...

Page 137: ...of free wheel gear for damage and wear If there is damage or wear Change the free wheel gear or bearing Check free wheel for damage and wear when it is disassembled If there is damage or wear Change t...

Page 138: ...00184 11 Thoroughly oil all parts Slide free wheel into the primary pinion Info Note the direction of rotation 300457 10 Mount spreader ring 300455 10 Ensure that all lugs of the spreader ring pass th...

Page 139: ...029005100 p 272 Push crankshaft all the way into the bearing seat of the right section of the engine case Remove the special tool 20 2 Installing the transmission shafts 300343 10 Slide both transmiss...

Page 140: ...ershaft Slide on shift rollers 20 5 Installing the shift drum 300340 11 Push shift drum into the bearing seat Put shift forks in the shift drum Info Do not lose the shift rollers 20 6 Installing the s...

Page 141: ...M6x60 10 Nm 7 4 lbf ft 20 8 Installing the locking lever 300364 11 Mount locking lever with the washer sleeve and spring Mount and tighten screw Guideline Screw locking lever M5 6 Nm 4 4 lbf ft Loctit...

Page 142: ...ings are not visible after assembly 300334 11 Position oil pump cover Mount and tighten screws Guideline Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 222 20 12 Installing the oil pump gears 300333...

Page 143: ...el gear 20 16 Installing the primary gear 300448 10 Mount the spring washer Degrease the cone and thinly apply thread locker to it Loctite 648 Mount primary gear Info Turn the free wheel gear back and...

Page 144: ...004000 p 273 Mount and tighten the nut Guideline Nut primary gear M20LHx1 5 120 Nm 88 5 lbf ft Loctite 243 20 20 Installing the clutch discs 400535 10 Thoroughly grease the clutch facing discs Engine...

Page 145: ...M6x65 10 Nm 7 4 lbf ft Position the crankshaft at top dead center TDC and block using the special tool Crankshaft locking bolt 113080802 p 267 20 22 Installing the water pump cover 300318 11 Put the w...

Page 146: ...hain tensioning rail 300314 10 Thread in the timing chain tensioning rail from the top Mount and tighten screw Guideline Screw timing chain ten sioning rail M6 8 Nm 5 9 lbf ft Loctite 243 20 27 Instal...

Page 147: ...ing inward 20 31 Installing the piston 200086 01 Move the joints of the compression ring and oil scraper ring so they are offset by 180 Place the oiled piston on the cylinder Compress the piston rings...

Page 148: ...iston mark faces toward the exhaust side 200091 10 Cover the engine housing opening with a cloth Thread the timing chain through the chain shaft Mount the piston pin Info In order to present them more...

Page 149: ...he cylinder downward letting the dowels engage 20 32 Installing the cylinder head 300306 11 Mount the dowels Put the new cylinder head gasket in place Put the cylinder head in place Put on the cylinde...

Page 150: ...the timing chain tensioner 200074 12 Position timing chain tensioner and insert it with new O ring Mount and tighten plug with new seal ring Guideline Plug timing chain tensioner M24x1 5 30 Nm 22 1 l...

Page 151: ...n in the position in which they were installed Correct the shims according to the findings from checking the valve play Insert the fitting shims Install the camshaft p 148 Install the timing chain ten...

Page 152: ...r 300294 11 Fill oil filter with engine oil and place in the oil filter housing 300360 11 Oil the O ring of the oil filter cover Mount the oil filter cover Mount and tighten screws Guideline Screw oil...

Page 153: ...g the oil line 300292 11 Position oil line Mount and tighten banjo bolt with the engine oil screen and seal rings Guideline Banjo bolt oil line M12 15 Nm 11 1 lbf ft Mount and install banjo bolt with...

Page 154: ...the hydraulic clutch fluid Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applica...

Page 155: ...ws bleeder screw Clean the sealing surfaces of the clutch slave cylinder and engine housing Position the seal and O ring on the clutch slave cylinder and install it Mount and tighten the screws Guidel...

Page 156: ...ternative 2 Coolant mixed ready to use p 263 Refit the radiator cap 22 2 Checking the antifreeze and coolant level Warning Scalding hazard During motorcycle operation the coolant gets very hot and is...

Page 157: ...out of the reach of children Condition The engine is cold 100441 10 Stand the vehicle upright Place a suitable container under the water pump cover Remove screw Remove radiator cap Completely drain t...

Page 158: ...ng the engine oil pressure Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and protective gloves If you get scalded immed...

Page 159: ...ve exhaust extraction system Start the engine and let it warm up Check the engine oil pressure Engine oil pressure Coolant temperature 70 C 158 F Engine speed 1 500 rpm 1 3 2 3 bar 19 33 psi Coolant t...

Page 160: ...ion and do not start or run the engine in a closed space without an effective exhaust extraction system Start the engine and let it run briefly Stop the engine and check that it is oil tight Check the...

Page 161: ...Plug engine oil screen M17x1 5 20 Nm 14 8 lbf ft Mount and tighten the oil drain plug with the magnet and seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft 23 7 Removing the oi...

Page 162: ...il results in premature wear to the engine 100451 10 Remove screw connection and add engine oil Engine oil 1 35 l 1 43 qt Engine oil SAE 10W 50 p 263 Mount and tighten screw cap Danger Danger of poiso...

Page 163: ...d out all the way RPM increase deactivated Idle speed adjusting screw is pushed in all the way 24 2 Taking off the throttle valve body and allowing it to hang to the side Condition The battery has bee...

Page 164: ...d 300690 11 Position the throttle valve body Mount hose clip and tighten it 300688 10 Mount the hose Mount hose clip and tighten it Mount the intake trumpet Mount hose clip and tighten it 300689 10 Co...

Page 165: ...throttle valve body on the left side 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 spee...

Page 166: ...cted and active Select the model type Select ECU Diagnostic Highlight the Engine electronics EXC control unit Press Continue Select actuator test Please enter password Press Continue Select Heating la...

Page 167: ...nsor value is not plausible Condition Th e diagnostic tool is disconnected Lambda sensor is disconnected 400596 10 Heating lambda sensor check the resistance Measure the resistance between the specifi...

Page 168: ...ected 600849 01 Heating lambda sensor check the control line for a short circuit to sensor ground Measure the resistance between the specified points Break Out Box DT Pin 11 Break Out Box DT Pin 24 Re...

Page 169: ...lue does not correspond to the specified value Check the cable from connector DT pin 11 to connector CU pin 4 for a short circuit to ground terminal 31 If the measured value corresponds to the specifi...

Page 170: ...e pressure sensor cylinder 1 voltage PM1AD and deselect the other parameters with Select measured value Manifold absolute pressure sensor voltage PM1AD at 800 mbar 11 6 psi 2 31 V at 850 mbar 12 33 ps...

Page 171: ...cable from connector DX pin 2 to connector DT pin 6 for a short circuit to ground terminal 31 If the measured value corresponds to the specified value Check the next possible cause Manifold absolute...

Page 172: ...d and active The engine is not running Select the model type Select ECU Diagnostic Highlight the Engine electronics EXC control unit Press Continue Select Measurement values Highlight Mixture preparat...

Page 173: ...the wiring harness The manifold absolute pressure sensor is disconnected 600849 01 400595 10 Manifold absolute pressure sensor check the ground line for an open circuit Measure the resistance between...

Page 174: ...the specified points Break Out Box DT Pin 6 Break Out Box DT Pin 1 Resistance If the measured value does not correspond to the specified value Check the cable from connector DT pin 6 to connector DX...

Page 175: ...voltage TAAD 0 196 4 823 V If the displayed value is equal to the setpoint value Delete the fault code Make a test ride Read out the fault code If the displayed value is below the setpoint value Check...

Page 176: ...connector DT pin 25 to connector CM pin 2 for a short circuit to sensor ground Intake air temperature sensor signal line has a short circuit to ground terminal 31 Condition Th e diagnostic tool is di...

Page 177: ...178 Intake air temperature sensor checking the voltage Condition The diagnostic tool is connected and active Select the model type Select ECU Diagnostic Highlight the Engine electronics EXC control un...

Page 178: ...Break Out Box DT Pin 1 Break Out Box DT Pin 25 Resistance If the measured value does not correspond to the specified value Check the cable from connector DT pin 25 to connector CM pin 2 for a short ci...

Page 179: ...o the specified value Check the next possible cause Intake air temperature sensor ground line is open p 177 Intake air temperature sensor ground line is open Condition Th e diagnostic tool is disconne...

Page 180: ...resistance between the specified points Break Out Box DT Pin 24 Break Out Box DT Pin 25 Intake air temperature sensor Resistance at 20 C 4 F 18 80 k Resistance at 20 C 68 F 2 942 k Resistance at 40 C...

Page 181: ...ltage TWAD and deselect the other parameters with Select measured value Coolant temperature sensor cylinder 1 voltage TWAD 0 138 4 784 V If the displayed value is equal to the setpoint value Delete th...

Page 182: ...uring point Ground Resistance If the measured value does not correspond to the specified value Check the cable from connector DT pin 22 to connector AX pin 1 for a short circuit to ground terminal 31...

Page 183: ...tinue Select Measurement values Highlight Mixture preparation general Press Continue Highlight the measured value Coolant temperature sensor cylinder 1 voltage TWAD and deselect the other parameters w...

Page 184: ...ints Break Out Box DT Pin 22 measuring point Ground Voltage 0 1 V If the measured value does not correspond to the specified value Check the cable from connector DT pin 22 to connector AX pin 1 for a...

Page 185: ...next possible cause Coolant temperature sensor signal line is open p 183 Coolant temperature sensor signal line is open Condition Th e diagnostic tool is disconnected The EFI control unit is disconne...

Page 186: ...ed points Break Out Box DT Pin 24 Connector AX Pin 2 Resistance 0 6 If the measured value does not correspond to the specified value Check connector DT pin 24 and connector AX pin 2 Check the cable fr...

Page 187: ...ic Highlight the Engine electronics EXC control unit Press Continue Select Measurement values Highlight Mixture preparation general Press Continue Highlight the measured value Throttle position sensor...

Page 188: ...ort circuit to ground terminal 30 If the measured value corresponds to the specified value Check the next possible cause Throttle position sensor signal line has a short circuit to sensor ground p 186...

Page 189: ...ed points Break Out Box DT Pin 5 Connector EX Pin 1 Resistance 0 6 If the measured value does not correspond to the specified value Check connector DT pin 5 and connector EX pin 1 Check the cable from...

Page 190: ...it Press Continue Select Measurement values Highlight Mixture preparation general Press Continue Highlight the measured value Throttle position sensor circuit A voltage THAD and deselect the other par...

Page 191: ...cuit to ignition plus terminal 15 If the measured value corresponds to the specified value Check the next possible cause Throttle position sensor signal line has a short circuit to the sensor power s...

Page 192: ...d points Break Out Box DT Pin 24 Connector EX Pin 3 Resistance 0 6 If the measured value does not correspond to the specified value Check connector DT pin 24 and connector EX pin 3 Check the cable fro...

Page 193: ...ge Condition The diagnostic tool is connected and active The engine is running at idle speed The engine is at normal operating temperature Select the model type Select ECU Diagnostic Highlight the Eng...

Page 194: ...sconnected 600849 01 Lambda sensor check the signal line for a short circuit to sensor ground Measure the resistance between the specified points Break Out Box DT Pin 7 Break Out Box DT Pin 24 Resista...

Page 195: ...t to ignition plus terminal 15 If the measured value corresponds to the specified value Check the next possible cause Lambda sensor signal line has a short circuit to the sensor power supply p 193 Lam...

Page 196: ...mbda probe ground line is open p 194 Lambda probe ground line is open Condition Th e diagnostic tool is disconnected The EFI control unit is disconnected The breakout box is connected to the wiring ha...

Page 197: ...active Select the model type Select ECU Diagnostic Highlight the Engine electronics EXC control unit Press Continue Select actuator test Please enter password Press Continue Select Injection valve cy...

Page 198: ...ue Check the next possible cause Injection valve control line has a short circuit to plus terminal 30 p 196 Injection valve control line has a short circuit to plus terminal 30 Condition Th e diagnost...

Page 199: ...tool is disconnected The EFI control unit is disconnected The breakout box is connected to the wiring harness The injection valve is disconnected 600849 01 Injection valve check the control line for a...

Page 200: ...oes not correspond to the specified value Check the cable from connector DT pin 16 to connector DQ pin 2 for a short circuit to ground terminal 31 If the measured value corresponds to the specified va...

Page 201: ...l line has a short circuit to the sensor power supply p 202 Ignition pulse generator checking the signal Condition The diagnostic tool is connected and active Select the model type Select ECU Diagnost...

Page 202: ...rt circuit to each other p 200 Ignition pulse generator signal lines have a short circuit to each other Condition Th e diagnostic tool is disconnected The EFI control unit is disconnected The breakout...

Page 203: ...trol unit is disconnected The breakout box is connected to the wiring harness Ignition pulse generator is connected 600849 01 Ignition pulse generator check the signal lines for a short circuit to sen...

Page 204: ...ied points Break Out Box DT Pin 1 Break Out Box DT Pin 3 Resistance If the measured value does not correspond to the specified value Check the cable from connector DT pin 3 to connector AL pin 2 for a...

Page 205: ...FAULT CODE 203 If the measured value corresponds to the specified value Contact customer service...

Page 206: ...ght the Engine electronics EXC control unit Press Continue Select actuator test Please enter password Press Continue Select Ignition cylinder 1 Press Continue Read the information page in the HUSABERG...

Page 207: ...il control line has a short circuit to sensor ground Condition Th e diagnostic tool is disconnected The EFI control unit is disconnected The breakout box is connected to the wiring harness The control...

Page 208: ...t box is connected to the wiring harness The control line of the ignition coil is disconnected 600849 01 Ignition coil check the control line for a short circuit to ignition plus terminal 15 Measure t...

Page 209: ...t points must be loaded with a 12V 21W bulb The value should not vary more than 1V from the battery voltage VBAT If the measured value does not correspond to the specified value Check connector DT pin...

Page 210: ...nics EXC control unit Press Continue Select actuator test Please enter password Press Continue Select Function fuel pump relay Press Continue Read the information page in the HUSABERG diagnostic tool...

Page 211: ...ue Check the next possible cause Fuel pump resistance of ground line is too high p 209 Fuel pump resistance of ground line is too high Condition Th e diagnostic tool is disconnected Fuel pump is disco...

Page 212: ...If the measured value corresponds to the specified value Check the next possible cause Fuel pump control line has a short circuit to sensor ground p 210 Fuel pump control line has a short circuit to s...

Page 213: ...fuel pump relay Press Continue Read the information page in the HUSABERG diagnostic tool and with Continue begin the actuator test Fuel pump Function noise If the specification is attained Delete the...

Page 214: ...Fuel pump check the power supply Measure the voltage between the specified points Break Out Box DT Pin 14 measuring point Ground Info For the measurement the measurement points must be loaded with a...

Page 215: ...nt values Highlight Starter Press Continue Highlight the measured value Rollover sensor voltage RolloverAD and deselect the other parameters with Select measured value Info Deselecting the other param...

Page 216: ...breakout box is connected to the wiring harness The rollover sensor is disconnected 600849 01 Rollover sensor check the signal line for a short circuit to sensor ground Measure the resistance between...

Page 217: ...not correspond to the specified value Check connector AP pin 6 Check the cable from connector AP pin 6 to the next node in the cable harness for an open circuit If the measured value corresponds to th...

Page 218: ...stic Highlight the Engine electronics EXC control unit Press Continue Select Measurement values Highlight Starter Press Continue Highlight the measured value Rollover sensor voltage RolloverAD and des...

Page 219: ...Break Out Box DT Pin 1 Break Out Box DT Pin 2 Resistance If the measured value does not correspond to the specified value Check the cable from connector DT pin 2 to connector AP pin 5 for a short cir...

Page 220: ...If the measured value corresponds to the specified value Check the next possible cause Rollover sensor ground line is open p 218 Rollover sensor ground line is open Condition Th e diagnostic tool is...

Page 221: ...n bearing Not a bearing bush DLC plated piston pins Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with two rotary pu...

Page 222: ...hole diameter All 570 models Size I 100 000 100 012 mm 3 937 3 93747 in Size II 100 012 100 025 mm 3 93747 3 93798 in Piston cylinder mounting clearance All 450 models Size I 0 040 0 082 mm 0 00157 0...

Page 223: ...0 20 mm 0 0079 in External rotor internal rotor clearance 0 20 mm 0 0079 in End play 0 15 mm 0 0059 in Shift fork Sheet thickness 4 85 4 95 mm 0 1909 0 1949 in Shift shaft sliding plate shift quadrant...

Page 224: ...cover M6x30 10 Nm 7 4 lbf ft Screw generator cover M6x50 10 Nm 7 4 lbf ft Screw generator cover chain shaft through hole M6x30 10 Nm 7 4 lbf ft Loctite 243 Screw idler M6 10 Nm 7 4 lbf ft Loctite 243...

Page 225: ...m 44 3 lbf ft Spark plug M12x1 25 15 20 Nm 11 1 14 8 lbf ft Coolant temperature sensor at cylinder head M12x1 5 12 Nm 8 9 lbf ft Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Plug oil pressure...

Page 226: ...heelbase 1 475 10 mm 58 07 0 39 in Seat height unloaded 985 mm 38 78 in Ground clearance unloaded 390 mm 15 35 in Weight without fuel approx FE 450 EU FE 450 AUS 116 5 kg 256 8 lb Weight without fuel...

Page 227: ...TREME 140 80 18 M C 70M M S TT Metzeler MCE 6 DAYS EXTREME FE USA 80 100 21 51M TT Bridgestone M59 110 100 18 64M TT Bridgestone M402 Additional information is available in the Service section under w...

Page 228: ...ng length with preload spacer s 510 mm 20 08 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 2 N mm 24 lb in Weight of rider 75 85 kg 165 187 lb 4 4 N mm 25 1 lb in Weight of rider 85 95 kg 187 2...

Page 229: ...n Rebound damping Comfort 26 clicks Standard 24 clicks Sport 22 clicks Spring preload 10 mm 0 39 in Spring rate Weight of rider 65 75 kg 143 165 lb 69 N mm 394 lb in Weight of rider 75 85 kg 165 187 l...

Page 230: ...p M8 12 Nm 8 9 lbf ft Screw engine brace M8 33 Nm 24 3 lbf ft Screw exhaust clamp on manifold M8 8 Nm 5 9 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loc...

Page 231: ...he intake flange is not closed properly dirt and water can enter into the engine In the worst case this can lead to engine damage When you remove the fuel tank carefully close off the sleeve intake tr...

Page 232: ...e steering lock Universal oil spray p 266 33 2 Protection for winter operation Info If you use the motorcycle in the winter you can expect to encounter salt on the roads Precautions need to be taken a...

Page 233: ...iting times at the start of the new season Clean the motorcycle p 229 Change the engine oil and oil filter clean the engine oil screen p 158 Check the antifreeze and coolant level p 154 Check the tire...

Page 234: ...ch p 152 Clean the air filter p 57 Check the cables for damage and routing without sharp bends Check the functioning of the electrical equipment Adjust the beam width of the headlight FE EU FE AUS p 8...

Page 235: ...ft bearing p 126 Check the valve spring seat p 127 Check the cylinder head p 128 Check the valves p 127 Check the valve springs p 127 Check the radial clearance of the rocker arm rollers Check the tim...

Page 236: ...s Bleed the fork legs p 11 Clean the dust boots of the fork legs p 11 Clean the chain p 71 Check the chain tension p 69 Check the chain wear p 70 Check the rear sprocket engine sprocket for wear p 71...

Page 237: ...235...

Page 238: ...2 D1 1054 3 D5 1077 G 3 G2 EZ 3 EY 3 2 C1 1071 2 D3 1123 BV 2 BS 2 X500 1 2 2 1 2 2 t S3 1 2 M CD 2 BL 2 M3 1 2 5A 1 2 F6 X8 U N1 FA 4 FB 4 1 2 3 4 3 D3 1113 BR 4 BK 4 S8 1 2 3 4 BA 1 X502 AI 2 V1 1 2...

Page 239: ...3 V1 Diode E F4 Cable colors 38 Brown 39 Brown 40 Black 41 Black 54 Black blue 62 White black 68 White red 69 White red 70 White red 71 Blue red 72 Orange 73 Yellow 74 Yellow blue 75 Yellow red 76 Yel...

Page 240: ...071 1 C5 1123 X6 X7 3 C3 1112 X5 1 2 H1 1 D3 1054 DV 2 EL 2 B2 1 2 X11 p DX 3 B4 1 2 3 AL 2 AT 2 L1 1 2 AP 6 B1 4 5 6 CM 2 t B7 1 2 t L CU 4 DY 4 B5 2 3 4 1 EX 3 B3 2 1 3 450 570 FE EU 42 43 44 46 48...

Page 241: ...coil F7 M2 Fuel pump F8 X50 Diagnosis connector A4 X51 Resistance A5 Y1 Injection valve F7 8 Cable colors 42 Orange 43 Yellow red 44 White yellow 45 Black brown 46 Yellow 47 Purple 48 Green red 49 Bro...

Page 242: ...87 Black blue 88 Black blue 89 Orange 90 White black 91 Brown 92 Brown 93 Brown 96 Black 97 Blue 98 Blue 99 Black 100 Orange 101 Black 102 Brown 103 Black 104 Orange 105 Brown 107 Black 112 Orange 11...

Page 243: ...WIRING DIAGRAM 241...

Page 244: ...BV 2 BS 2 H12 1 2 3 1 2 H11 DI 2 1 2 H8 DI 2 BP 4 DG 4 4 3 2 1 H9 X13 BA 1 BF 1 X52 1 2 1 CY 3 CZ 3 DA 4 DB 4 CW 2 CX 2 1 2 1 2 3 1 2 3 4 P1 CW 2 CX 2 H6 1 2 CW 2 CX 2 H5 1 2 X15 X18 G B8 1 2 1 B3 111...

Page 245: ...D8 K3 Turn signal relay E2 P1 Speedometer A B1 S2 Brake light switch front E3 S4 Turn signal switch E3 S5 Horn button light switch short circuit button E4 5 S6 Brake light switch rear E7 Cable colors...

Page 246: ...NG DIAGRAM 244 33 Brown 34 Blue 35 Blue 36 White 37 Green 65 Black yellow 73 Yellow 81 Brown 82 Brown 83 Yellow blue 84 Yellow blue 86 White blue 115 Purple 116 Black 117 Brown 118 Brown 121 Black yel...

Page 247: ...WIRING DIAGRAM 245...

Page 248: ...D1 1041 3 D5 1077 G 3 G2 EZ 3 EY 3 2 C1 1071 2 D3 1123 BV 2 BS 2 X500 1 2 2 1 2 2 t S3 1 2 M CD 2 BL 2 M3 1 2 5A 1 2 F6 X8 U N1 FA 4 FB 4 1 2 3 4 BR 4 BK 4 S8 1 2 3 4 BA 1 X502 1 3 D4 1113 AI 2 V1 1...

Page 249: ...3 V1 Diode E F4 Cable colors 38 Brown 39 Brown 40 Black 41 Black 54 Black blue 62 White black 68 White red 69 White red 70 White red 71 Blue red 72 Orange 73 Yellow 74 Yellow blue 75 Yellow red 76 Yel...

Page 250: ...071 1 C5 1123 X6 X7 3 D3 1112 X5 1 2 H1 1 D3 1041 DV 2 EL 2 B2 1 2 X11 p DX 3 B4 1 2 3 AL 2 AT 2 L1 1 2 AP 6 B1 4 5 6 CM 2 t B7 1 2 t L CU 4 DY 4 B5 2 3 4 1 EX 3 B3 2 1 3 450 570 FE USA 42 43 44 46 48...

Page 251: ...oil F7 M2 Fuel pump F8 X50 Diagnosis connector A4 X51 Resistance A5 Y1 Injection valve F7 8 Cable colors 42 Orange 43 Yellow red 44 White yellow 45 Black brown 46 Yellow 47 Purple 48 Green red 49 Brow...

Page 252: ...87 Black blue 88 Black blue 89 Orange 90 White black 91 Brown 92 Brown 93 Brown 96 Black 97 Blue 98 Blue 99 Black 100 Orange 101 Black 102 Brown 103 Black 104 Orange 105 Brown 107 Black 112 Orange 11...

Page 253: ...WIRING DIAGRAM 251...

Page 254: ...DA 4 DB 4 CW 2 CX 2 1 2 1 2 3 1 2 3 4 P1 X15 X18 G B8 1 2 BP 4 X501 X509 1 2 3 4 AJ 3 X504 1 2 3 AC 6 X503 1 2 3 4 5 6 BA 1 1 BF 1 S9 BA 1 X505 1 BA 1 X506 1 1 B3 1113 AH 2 X507 1 2 AH 2 X508 1 2 450...

Page 255: ...switch front E3 optional X508 Plug in connector for brake light switch rear E7 optional X509 Plug in connector for high beam indicator switch C1 optional Cable colors 15 Yellow blue 16 Yellow 17 Brow...

Page 256: ...D1 1048 3 D5 1077 G 3 G2 EZ 3 EY 3 2 C1 1071 2 D3 1123 BV 2 BS 2 X500 1 2 2 1 2 2 t S3 1 2 M CD 2 BL 2 M3 1 2 5A 1 2 F6 X8 U N1 FA 4 FB 4 1 2 3 4 3 D3 1113 BK 4 BR 4 BF 1 BA 1 S7 1 2 3 4 1 AI 2 V1 1...

Page 257: ...F switch A3 V1 Diode E F4 Cable colors 38 Brown 39 Brown 40 Black 41 Black 54 Black blue 62 White black 68 White red 69 White red 70 White red 71 Blue red 72 Orange 73 Yellow 74 Yellow blue 75 Yellow...

Page 258: ...071 1 C5 1123 X6 X7 3 C3 1112 X5 1 2 H1 1 D3 1048 DV 2 EL 2 B2 1 2 X11 p DX 3 B4 1 2 3 AL 2 AT 2 L1 1 2 AP 6 B1 4 5 6 CM 2 t B7 1 2 t L CU 4 DY 4 B5 2 3 4 1 EX 3 B3 2 1 3 450 570 FE AUS 42 43 44 46 48...

Page 259: ...coil F7 M2 Fuel pump F8 X50 Diagnosis connector A4 X51 Resistance A5 Y1 Injection valve F7 8 Cable colors 42 Orange 43 Yellow red 44 White yellow 45 Black brown 46 Yellow 47 Purple 48 Green red 49 Bro...

Page 260: ...87 Black blue 88 Black blue 89 Orange 90 White black 91 Brown 92 Brown 93 Brown 96 Black 97 Blue 98 Blue 99 Black 100 Orange 101 Black 102 Brown 103 Black 104 Orange 105 Brown 107 Black 112 Orange 11...

Page 261: ...WIRING DIAGRAM 259...

Page 262: ...BV 2 BS 2 H12 1 2 3 1 2 H11 DI 2 1 2 H8 DI 2 BP 4 DG 4 4 3 2 1 H9 X13 BA 1 BF 1 X52 1 2 1 CY 3 CZ 3 DA 4 DB 4 CW 2 CX 2 1 2 1 2 3 1 2 3 4 P1 CW 2 CX 2 H6 1 2 CW 2 CX 2 H5 1 2 X15 X18 G B8 1 2 1 B3 111...

Page 263: ...D8 K3 Turn signal relay E2 P1 Speedometer A B1 S2 Brake light switch front E3 S4 Turn signal switch E3 S5 Horn button light switch short circuit button E4 5 S6 Brake light switch rear E7 Cable colors...

Page 264: ...NG DIAGRAM 262 33 Brown 34 Blue 35 Blue 36 White 37 Green 65 Black yellow 73 Yellow 81 Brown 82 Brown 83 Yellow blue 84 Yellow blue 86 White blue 115 Purple 116 Black 117 Brown 118 Brown 121 Black yel...

Page 265: ...C 40 F Supplier Motorex Anti Freeze Engine oil SAE 10W 50 According to JASO T903 MA p 278 SAE p 278 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specificatio...

Page 266: ...2 5 50180342S1 According to SAE p 278 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Super u...

Page 267: ...otorex products Supplier Motorex Protect Shine 645 Contact spray Specification HUSABERG recommends Motorex products Supplier Motorex Accu Contact High luster polish for paint Specification HUSABERG re...

Page 268: ...52 Specification HUSABERG recommends Bel Ray products Supplier Bel Ray Molylube Anti Seize Motorcycle cleaner Specification HUSABERG recommends Motorex products Supplier Motorex Moto Clean 900 Offroad...

Page 269: ...Art no 00029095000 Crankshaft locking bolt 400035 01 Art no 113080802 Bearing puller 400037 01 Art no 15112017000 Insert for bearing puller 400038 01 Art no 15112018100 Feature 18 23 mm 0 71 0 91 in B...

Page 270: ...00059 01 Art no 51012011000 Clutch holder 400289 01 Art no 51129003000 Extractor 400073 01 Art no 58012009000 Tool for inner bearing race 400082 01 Art no 58429037043 Torque wrench with various access...

Page 271: ...01 01 Art no 59029019000 Limit plug gauge 400104 01 Art no 59029026006 Feeler gauge 25 20 30 15 10 12 5 3 5 400110 01 Art no 59029041100 Piston ring mounting tool 400123 01 Art no 60029015000 Pressure...

Page 272: ...stand 200306 01 Art no 61229001000 Extractor 400157 01 Art no 75029021000 Push in drift 500163 01 Art no 75029044010 Push in drift 500162 01 Art no 75029044020 Pressing device for crankshaft complete...

Page 273: ...xtractor 400162 01 Art no 75029048000 Clamping plate 400163 01 Art no 75029050000 Push out drift 400164 01 Art no 75029051000 Spark plug wrench 400170 01 Art no 75029172000 Limit plug gauge 400104 01...

Page 274: ...77329006000 Insert for piston pin retainer 400160 01 Art no 77329030100 Release device for timing chain tensioner 400181 01 Art no 77329051000 Mounting sleeve 500167 01 Art no 78029005100 Insert for...

Page 275: ...plate 500169 01 Art no 78029009000 Valve spring mounting device 500165 01 Art no 78029060000 Gear segment 500164 01 Art no 80029004000 Fitting for work stand 500281 01 Art no 81229002000 Work stand 5...

Page 276: ...ECIAL TOOLS 274 Pin wrench 200734 10 Art no T103 Hook wrench 301085 01 Art no T106S Depth micrometer 300577 10 Art no T107S Mounting sleeve 200788 10 Art no T1204 Calibration pin 200790 10 Art no T120...

Page 277: ...L TOOLS 275 Pressing tool 200583 10 Art no T1206 Pressing tool 200585 01 Art no T1207S Centering sleeve 200777 10 Art no T1214 Mounting sleeve 300568 10 Art no T1215 Disassembly tool 200816 10 Art no...

Page 278: ...TOOLS 276 Protecting sleeve 200635 10 Art no T1401 Clamping stand 200733 10 Art no T14015S Clamping stand 200688 10 Art no T14016S Gripping tool 200639 10 Art no T14026S1 Assembly tool 200634 10 Art n...

Page 279: ...TOOLS 277 Open end wrench 200640 10 Art no T14032 Clamping stand 200637 10 Art no T1403S Press drift 200789 10 Art no T1504 Assembly tool 200791 10 Art no T150S Nitrogen filling tool 300574 10 Art no...

Page 280: ...ce intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated wi...

Page 281: ...pressor assembling 123 autodecompressor disassembling 122 camshaft checking 123 clutch checking 130 conrod bearing changing 117 coolant temperature sensor installing 129 coolant temperature sensor rem...

Page 282: ...in engine work stand 99 clutch cover removing 104 clutch disks disassembling 105 crankshaft removing 110 cylinder head removing 102 diaphragm removing 110 distance bushing removing 102 engine oil drai...

Page 283: ...ing 158 installing 160 removing 159 Oil pressure regulator valve removing 113 spring length checking 113 P Protection for winter operation 230 Putting into operation after storage 231 R Rear sprocket...

Page 284: ...play adjusting 29 checking 29 Storage 231 Swingarm installing with shock absorber and rear wheel 52 removing with shock absorber and rear wheel 51 T Technical data chassis 224 225 chassis tightening...

Page 285: ...HUSABERG eine Division der KTM SMC AG Stallhofnerstra e 3 5230 Mattighofen Austria www husaberg com 3803004en 3803004en 01 2009 Photo Mitterbauer...

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