HUSABERG FE 450 AUS, Repair Manual

Page: 5 / 285

CONTENTS
3
13/BRAKE SYSTEM........................................................... 78
Checking the free travel of the hand brake lever ............... 78
Adjusting the free travel of the handbrake lever (FE EU,
FE AUS) ....................................................................... 78
Adjusting the basic position of the handbrake lever
(FE USA) ...................................................................... 78
Checking the front brake fluid level ................................. 79
Adding front brake fluid ................................................. 79
Checking the front brake linings...................................... 80
Changing the front brake linings ..................................... 80
Checking the free travel of the foot brake lever ................. 82
Adjusting the basic position of the footbrake lever ............ 82
Checking the rear brake fluid level .................................. 83
Adding rear brake fluid .................................................. 83
Checking the rear brake linings ....................................... 84
Changing the rear brake linings....................................... 84
14/LIGHTING SYSTEM, INSTRUMENTS ............................. 86
Adjusting the speedometer functions............................... 86
Setting kilometers or miles ............................................. 86
Activating the additional functions .................................. 87
Setting the wheel circumference ..................................... 87
Setting the clock ........................................................... 88
Removing the headlight mask with the headlight (FE EU,
FE AUS) ....................................................................... 88
Installing the headlight mask with the headlight (FE EU,
FE AUS) ....................................................................... 88
Checking the headlight adjustment (FE EU, FE AUS)........ 89
Adjusting the beam width of the headlight (FE EU,
FE AUS) ....................................................................... 89
Changing the headlight bulb (FE EU, FE AUS) ................. 89
30/ENGINE....................................................................... 91
Removing the engine ..................................................... 91
Installing the engine ...................................................... 94
30/ENGINE DISASSEMBLY................................................ 99
Clamping the engine in the engine work stand.................. 99
Draining the engine oil................................................... 99
Removing the oil line ..................................................... 99
Removing the starter motor ............................................ 99
Removing the oil filter.................................................... 99
Removing the valve cover ............................................. 100
Removing the spark plug .............................................. 100
Removing the generator cover ....................................... 100
Positioning the engine at ignition top dead center
(TDC) ......................................................................... 100
Removing the timing chain tensioner............................. 101
Removing the camshaft................................................ 101
Removing the cylinder head.......................................... 102
Removing the piston .................................................... 102
Removing the distance bushing .................................... 102
Removing the rotor ...................................................... 103
Removing the balance weight ....................................... 103
Removing the timing chain guide rail ............................ 103
Removing the timing chain tensioning rail...................... 103
Removing the timing chain securing guide ..................... 104
Removing the timing chain........................................... 104
Removing the ignition pulse generator ........................... 104
Removing the water pump cover ................................... 104
Removing the clutch cover ........................................... 104
Disassembling the clutch disks ..................................... 105
Removing the primary gear nut ..................................... 105
Removing the outer clutch hub ..................................... 106
Removing the balancer shaft ........................................ 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
Removing the shift shaft .............................................. 108
Removing the shift drum locating unit ........................... 108
Removing the locking lever........................................... 108
Removing the left section of the engine case.................. 109
Removing the shift rails ............................................... 109
Removing the shift drum .............................................. 109
Removing the shift forks .............................................. 109
Removing the diaphragm.............................................. 110
Removing the transmission shafts ................................. 110
Removing the crankshaft.............................................. 110
30/ENGINE - WORK ON THE INDIVIDUAL PARTS ............. 111
Working on the right section of the engine case .............. 111
Working on the left section of the engine case................ 112
Removing the oil pressure regulator valve....................... 113
Checking the spring length of the oil pressure regulator
valve .......................................................................... 113
Installing the oil pressure regulator valve ....................... 113
Removing the crankshaft seal ring in the clutch cover ..... 113
Installing the crankshaft seal ring in the clutch cover...... 114
Removing the water pump ............................................ 114
Installing the water pump............................................. 115
Checking the balancer shaft ......................................... 115
Removing the timing chain sprocket.............................. 116
Installing the timing chain sprocket............................... 116
Removing the crankshaft bearing inner ring.................... 116
Installing the crankshaft bearing inner ring .................... 117
Changing the conrod bearing ........................................ 117
Checking the crankshaft run-out at the bearing pin ......... 119
Measuring the crankshaft end play ................................ 119
Checking/measuring the cylinder................................... 120
Checking/measuring the piston ..................................... 120
Checking the piston ring end gap .................................. 121
Piston/cylinder - determining the mounting clearance ..... 121
Checking the oil pumps for wear ................................... 122
Disassembling the autodecompressor ............................ 122
Assembling the autodecompressor................................. 123
Checking the camshaft................................................. 123
Checking the timing assembly ...................................... 124
Preparing the timing chain tensioner for installation ....... 124
Removing the coolant temperature sensor ...................... 125
Removing the rocker arm.............................................. 125
Removing the valves .................................................... 125
Changing the camshaft bearing..................................... 126
Checking the valves ..................................................... 127
Checking the valve springs ........................................... 127
Checking the valve spring seat ...................................... 127
Checking the cylinder head .......................................... 128
Installing the valves ..................................................... 128
Installing the rocker arm .............................................. 129
Installing the coolant temperature sensor....................... 129
Checking the clutch..................................................... 130
Checking the shift mechanism ...................................... 131
Preassembling the shift shaft........................................ 132
Disassembling the main shaft ....................................... 132
Assembling the main shaft ........................................... 132
Disassembling the countershaft .................................... 133