Husqvarna 2014 FC 450 EU Owner'S Manual Download

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11 SERVICE WORK ON THE CHASSIS

11.26

Removing the air filter

Note

Engine failure

Unfiltered intake air has a negative effect on the service life of the engine.

–

Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

Warning

Environmental hazard

Hazardous substances cause environmental damage.

–

Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Preparatory work

–

Remove the air filter box lid. (

p. 42)

B01885-11

Main work

–

Push air filter holder

toward the air filter at position

and detach it at end

Swing the air filter holder to one side and remove the air filter with the air filter sup-

port.

–

Remove the air filter from the air filter support.

11.27

Installing the air filter

101351-10

Main work

–

Mount the clean air filter on the air filter support.

–

Grease the air filter in area

B01885-10

–

Insert both parts together, position them, and fasten them using air filter holder

area

The arrow of marking

faces upward.

Info

If the air filter is not correctly mounted, dust and dirt can enter the engine and

cause damage.

Finishing work

–

Install the air filter box lid. (

p. 42)

11.28

Cleaning the air filter and air filter box

Warning

Environmental hazard

Hazardous substances cause environmental damage.

–

Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Do not clean the air filter with fuel or petroleum since these substances attack the foam.

Preparatory work

–

Remove the air filter box lid. (

p. 42)

–

Remove the air filter.

(

p. 43)

Summary of Contents for 2014 FC 450 EU

Page 1: ...OWNER S MANUAL 2014 FC 450 EU Art no 3402004en ...

Page 2: ......

Page 3: ...ifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice Husqvarna accepts no liability for deliv ery options deviations from illustrations and descriptions as well as misprints and other errors The models portrayed partly c...

Page 4: ... Stopping parking 21 8 7 Transport 22 8 8 Refueling 22 9 SERVICE SCHEDULE 24 9 1 Service schedule 24 9 2 Service work as additional order 25 10 TUNING THE CHASSIS 26 10 1 Checking the basic chassis setting with the rider s weight 26 10 2 Compression damping of the shock absorber 26 10 3 Adjusting the low speed compression damping of the shock absorber 26 10 4 Adjusting the high speed compression d...

Page 5: ...ever x 59 12 10 Checking the rear brake fluid level 60 12 11 Adding rear brake fluid x 60 12 12 Checking the rear brake linings 61 12 13 Changing the rear brake linings x 62 13 WHEELS TIRES 64 13 1 Removing the front wheel x 64 13 2 Installing the front wheel x 64 13 3 Removing the rear wheel x 65 13 4 Installing the rear wheel x 65 13 5 Checking the tire condition 66 13 6 Checking the tire air pr...

Page 6: ...cal understanding In the interest of your own safety have these jobs performed by an authorized Husqvarna workshop There your motorcycle will be opti mally cared for by specially trained experts using the special tools required Identifies a page reference more information is provided on the specified page 1 2 Formats used The following typographical formats are used Specific name Identifies a prop...

Page 7: ...er that will lead to environmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new v...

Page 8: ... is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts After you complete the repair or service work check the operating safety of the vehicle 2 8 Environment If you use your motorcycle responsibly you can ensure that problems and conflicts do not occur To protect th...

Page 9: ...y Power parts for your vehicle can be found on the Husqvarna website International Husqvarna website www husqvarna motorcycles com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chas sis is properly carried out as described in the Owner s Manual Incorrect adjustment and tuning of the engine and chassis ca...

Page 10: ...8 4 1 View of vehicle front left example B01920 10 1 Hand brake lever p 11 2 Clutch lever p 11 3 Filler cap 4 Fork rebound adjustment 5 Cold start button p 13 6 Shift lever p 14 7 Air filter box lid 8 Plug in stand p 15 ...

Page 11: ... 10 1 Kill switch p 11 2 Electric starter button p 11 3 Throttle grip p 11 4 Fork compression adjustment 5 Shock absorber rebound adjustment 6 Level viewer for brake fluid rear 7 Shock absorber compression adjustment 8 Level viewer engine oil 9 Foot brake lever p 14 ...

Page 12: ...ring head 5 3 Engine number 401949 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 5 4 Fork part number 401947 10 The fork part number 1 is stamped on the inner side of the axle clamp 5 5 Shock absorber part number 0 0 1 1 401948 10 The shock absorber part number 1 is stamped on the top of the shock absorber above the adjusting ring on the engine side ...

Page 13: ...ndlebar 6 4 Kill switch B01827 10 Kill switch 1 is fitted on the left side of the handlebar Possible states Kill switch in basic position In this position the ignition circuit is closed and the engine can be started Kill switch pressed In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start 6 5 Electric starter button B01828 10 Electric s...

Page 14: ...is restarted 6 8 Overview of indicator lamps B01831 10 Possible states FI warning lamp MIL lights up flashes orange The OBD on board diagnosis has detected an emission or safety critical error 6 9 Opening the filler cap Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt ...

Page 15: ...The cold start button 1 is fitted on the left on the throttle valve body When the engine is cold and outside temperatures are low the injection system extends the injection time To combust the increased amount of fuel the engine is supplied with additional oxygen by pulling the cold start button Possible states The cold start button is activated The cold start button is pulled out all the way The ...

Page 16: ...usted with idle speed adjusting screw 1 Increase the idle speed by turning the idle speed adjusting screw clockwise Decrease the idle speed by turning the idle speed adjusting screw counterclockwise 6 13 Shift lever 401950 10 Shift lever 1 is mounted on the left side of the engine 401950 13 The gear positions can be seen in the photograph The neutral or idle position is between the first and secon...

Page 17: ... 6 15 Plug in stand 0 0 1 1 402001 10 The holder for the plug in stand 1 is the left side of the wheel spindle The plug in stand is used to park the motorcycle Info Remove the plug in stand before starting on a trip ...

Page 18: ...ot off the foot brake lever when you are not braking Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info When using your motorcycle remember that others may feel di...

Page 19: ...erably more rapid wear of components such as the drive train brake system or suspension components For this reason it may be necessary to inspect or replace parts before the next scheduled service Clean the air filter and air filter box x p 43 Info Check the air filter approx every 30 minutes Seal the air filter box x p 44 Additionally secure the rubber grip p 53 Check the electrical connector for...

Page 20: ...eparing for rides on wet sand B00437 01 Fit a rain cover on the air filter Waterproofing device for air filter 77206921100 Info Observe the Husky Power fitting instructions 600868 01 Clean the chain Fit the steel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent radiator fins carefully 7 6 Preparing for rides on wet and muddy surfaces B00437 01 Fit a waterproofing device...

Page 21: ...ns Info The engine oil quickly gets hot if the clutch has to be operated very often due to an excessively high secondary drive Clean the chain Clean radiator fins Straighten bent radiator fins carefully Check the coolant level p 72 7 8 Preparing for rides at low temperatures or in snow B00437 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 77206921100 Info Obser...

Page 22: ...the air filter Check the settings of all controls and ensure that they can be operated smoothly Check all screws nuts and hose clamps regularly for tightness Check the fuel supply 8 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or ru...

Page 23: ... standing for a long time Guideline 1 min Avoid frequent and longer slipping of the clutch This heats the engine oil the engine and the cooling system Ride with a lower engine speed instead of with a high engine speed and a slipping clutch 8 5 Applying the brakes Warning Danger of accidents If you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road condition...

Page 24: ... over 8 8 Refueling Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poi...

Page 25: ...e Open the filler cap p 12 A A 401522 10 Fill the fuel tank with fuel up to measurement A Guideline Measurement of A 35 mm 1 38 in Total fuel tank capacity approx 7 5 l 1 98 US gal Super unleaded ROZ 95 RON 95 PON 91 p 91 Close the filler cap p 13 ...

Page 26: ...cket engine sprocket and chain guide p 50 Check the chain tension p 49 Grease all moving parts e g hand lever chain and check for smooth operation x Check correct the fluid level of the hydraulic clutch p 53 Check the brake fluid level of the front brake p 56 Check the free travel of the hand brake lever p 55 Check the steering head bearing play p 37 Check the valve clearance x Check the clutch x ...

Page 27: ...head bearing x p 38 Service the shock absorber x Change the spark plug and spark plug connector x Change the piston x Check measure the cylinder x Check the cylinder head x Change the valves valve springs and valve spring seats x Check the camshaft and rocker arm x Change the connecting rod conrod bearing and crank pin x Change the shaft seal rings of the water pump x Check the transmission and sh...

Page 28: ...ear wheel suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more slowly These two ranges can be adjusted separately although the transition between high speed and...

Page 29: ...ber of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 10 5 Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with hi...

Page 30: ...ifference between measurements A and B Check the static sag Static sag 30 mm 1 18 in If the static sag is less or more than the specified value Adjust the spring preload of the shock absorber x p 29 10 8 Checking the riding sag of the shock absorber 400990 10 Measure distance A of rear wheel unloaded p 28 With another person holding the motorcycle the rider wearing full protective cloth ing sits o...

Page 31: ... is not under tension Tighten the spring by turning adjusting ring 2 to measurement A Guideline Spring preload 12 mm 0 47 in Info Depending on the static sag and or the riding sag it may be necessary to increase or decrease the spring preload Tighten screw 1 Guideline Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Finishing work Install the shock absorber x p 41 Remove the motorcycle from ...

Page 32: ...ulic compression damping determines the fork suspension behavior B01846 10 Turn adjusting screws 1 clockwise all the way Info Adjusting screws 1 are located at the top end of the fork legs Make the same adjustment on both fork legs Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Info Tur...

Page 33: ...e mounted in the position that is most comfortable for the rider 10 15 Adjusting the handlebar position x B00375 10 Remove screws 1 Take off the handlebar clamps Take off the handlebar and lay it to one side Info Protect the components against damage by covering them Do not bend the cables and lines Remove screws 2 Remove the handlebar supports Place the handlebar supports in the required position...

Page 34: ...tand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 0 0 1 1 402001 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand 1 into the left side of the wheel spin dle Info Remove the plug in stand before riding 11 3 Bleeding the fork legs Preparatory work Raise the motorcy...

Page 35: ... legs Press the dust boots back into their normal position Remove excess oil Finishing work Position the fork protection p 33 Remove the motorcycle from the lift stand p 32 11 5 Loosening the fork protection B01849 10 Remove screws 1 and take off the clamp Remove screws 2 on the left fork leg Push the fork protection downwards Remove the screws on the right fork leg Push the fork protection downwa...

Page 36: ... Main work Position the fork legs Bleeder screws 1 face forward Info Grooves are milled into the side of the upper end of the fork legs The sec ond milled groove from the top must be flush with the top edge of the upper triple clamp B01850 11 Tighten screws 2 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft B00300 11 Pos...

Page 37: ... and tighten the screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the fork legs x p 34 Install the front wheel x p 64 11 11 Removing the lower triple clamp x Preparatory work Raise the motorcycle with a lift stand p 32 Remove the front wheel x p 64 Remove the fork legs x p 33 Remove the start number plate p 38 Remove the front fender p 39 B01864 10 Main work Tak...

Page 38: ...ctly positioned Slide on protective ring 2 and O ring 3 B01867 10 Position the upper triple clamp with the handlebar Mount screw 4 but do not tighten yet B01868 10 Position the fork legs Bleeder screws 5 face forward Info Grooves are milled into the side of the upper end of the fork legs The sec ond milled groove from the top must be flush with the top edge of the upper triple clamp B01869 10 Full...

Page 39: ... cables and brake and clutch lines can move freely and are routed correctly Check the steering head bearing play p 37 Remove the motorcycle from the lift stand p 32 11 13 Checking the steering head bearing play Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play Adjust the steering head bearing play without delay Your authorized Husqvarna workshop will b...

Page 40: ...in work Loosen screw 1 Remove screw 2 Loosen and retighten screw 3 Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Fully tighten screws 1 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw 2 Guideline Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Check the steering head be...

Page 41: ...age Position brake line 2 in the brake line guide 11 18 Removing the front fender Preparatory work Remove the start number plate p 38 B01876 10 Main work Remove screws 1 and 2 Remove the front fender 11 19 Installing the front fender B01876 10 Main work Position the front fender Mount and tighten screws 1 and 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the start...

Page 42: ...se the motorcycle with a lift stand p 32 B01877 10 Main work Remove screw 1 Remove fitting 2 B01878 10 Press angle lever 3 toward the rear Press linkage lever 4 downward B01879 10 Detach springs 5 Spring hooks 50305017000 Remove screw 6 and take off the manifold B01880 10 Raise the swingarm ...

Page 43: ...orber M10 60 Nm 44 3 lbf ft Loctite 2701 B01883 10 Lower the swingarm B01924 11 Position the manifold Attach springs 2 Spring hooks 50305017000 Mount and tighten screw 3 Guideline Screw manifold holder M8 15 Nm 11 1 lbf ft B01877 11 Position the angle lever and linkage lever Mount and tighten fitting 4 Guideline Nut linkage lever to angle lever M14x1 5 80 Nm 59 lbf ft Mount and tighten screw 5 Gui...

Page 44: ...el tank lower it at the rear and simultaneously it push forward Make sure that the seat is correctly locked in Mount and tighten the screw of the seat fixing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 24 Removing the air filter box lid B01938 10 Release catch 1 pull off the air filter box lid sideways in areas A and B and remove toward the rear 11 25 Installing the air filter box li...

Page 45: ...lter sup port Remove the air filter from the air filter support 11 27 Installing the air filter x 101351 10 Main work Mount the clean air filter on the air filter support Grease the air filter in area A B01885 10 Insert both parts together position them and fasten them using air filter holder 1 in area B The arrow of marking UP faces upward Info If the air filter is not correctly mounted dust and ...

Page 46: ...ter box x 401559 01 Seal the air filter box in marked area A 11 30 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components Preparatory work Remove the right side cover p 45 B01886 10 Main work Disconnect spring 1 Remove screws 2 and take off the main silencer 11 31 Installing th...

Page 47: ...main silencer p 44 C00494 10 Main work Remove all screws from the main silencer Remove silencer cap 1 and O ring 2 Remove outer tube 3 and O ring 4 Pull the glass fiber yarn filling 5 from the inner tube 6 Clean the parts that are to be reinstalled Mount the new glass fiber yarn filling 5 on inner tube 6 Slide O ring 4 and outer tube 3 over the glass fiber yarn filling 5 Insert O ring 2 and silenc...

Page 48: ...nto contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel prop erly in a suitable canister and keep away from childr...

Page 49: ...ous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Main work Check the throt...

Page 50: ... for coarse dirt accumulation If the chain is very dirty Clean the chain p 48 11 38 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material 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 b...

Page 51: ...ing work Remove the motorcycle from the lift stand p 32 11 40 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the...

Page 52: ... Guideline Weight chain wear measurement 10 15 kg 22 33 lb Measure distance B of 18 chain rollers on the lower chain section Info Chains do not always wear evenly which is why the measurement should be repeated at several locations on the chain Maximum distance B on the longest part of the chain 272 mm 10 71 in If the distance B is larger than the specified length Change the power set x Info When ...

Page 53: ... found on the front of the chain guide If the light part of the chain guide is worn Change the chain guide x B01928 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the chain guide Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Remove the motorcycle from the lift stand p 32 11 42 Checking the frame x 402015 01 Check the frame for cracking an...

Page 54: ...the fuel tank x p 46 B01929 10 Main work Check the throttle cable routing Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bracket If the throttle cable is not routed as specified Correct the throttle cable routing Finishing work Install the fuel tank x p 47 Mount the seat p 42 11 45 Checking the rubber grip 401197 01 Check t...

Page 55: ...d only and do not apply any force Do not make any adjustments while riding 11 48 Checking correcting the fluid level of the hydraulic clutch Info The fluid level rises with increased wear of the clutch lining discs C00444 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Check the fluid level Fluid level below contai...

Page 56: ...ately with water Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container C00445 10 Inject the liquid into the system until it escapes from openings 6 of the master cylinder without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Tighten the bleeder screw and remove the bleeding syringe ...

Page 57: ...istance between the hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 12 3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due t...

Page 58: ...specified value this is an indication that the brake system is leaking or that the brake linings are completely worn down Check the brake system and do not continue riding Your autho rized Husqvarna workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective cl...

Page 59: ... brake linings for damage and cracking If damage or cracking is visible Change the front brake linings x p 57 12 7 Changing the front brake linings x Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized Husqvarna workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid con...

Page 60: ...tons Ensure that brake fluid does not flow out of the brake fluid reservoir extracting it by suction if it does Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes Remove cotter pins 4 pull out pin 5 and remove the brake linings Clean the brake caliper and brake caliper support B00352 10 Check that leaf spring 6 in the brake caliper and sli...

Page 61: ...just the free travel on foot brake lever according to specifications B01796 10 Disconnect spring 1 Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel A Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the basic position of the foot brake lever x p 59...

Page 62: ...e this is an indication that the brake system is leaking or that the brake linings are completely worn down Check the brake system and do not continue riding Your autho rized Husqvarna workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized Husqva...

Page 63: ... brake 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 Preparatory work Check the rear brake linings p 61 B01903 10 Main work Stand the vehicle upright Remove screw cap 1 with membrane 2 and the O ring Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 91 Mount and tigh...

Page 64: ... fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake 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 B01904 10 Stand the vehicle upright Remove screw cap 1 with...

Page 65: ...te 7 is mounted on the piston side of the brake lining Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point B01903 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 91 Mount and tighten screw cap 1 with membrane 2 and the O ring Info Clean up overflowed or spilt brake fluid immediately with water ...

Page 66: ... front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not damaged L00214 10 Remove spacers 3 13 2 Installing the front wheel x 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...

Page 67: ...en pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut 1 Remove chain adjuster 2 Withdraw wheel spindle 3 only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Info Protect the components against damage by covering them Holding the rear wheel withdraw the wheel ...

Page 68: ...rs 3 can be turned by 180 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 32 13 5 Checking the tire condition Info Only mount tires approved and or recommended by Husqvarna Other tires could have a negative effect on handling characteristics The type condition...

Page 69: ...the tire pressure does not meet specifications Correct the tire pressure Mount the protection cap 13 7 Checking the spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct Your authorized Husqvarna workshop will be glad to help Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes If the spokes a...

Page 70: ...over 1 and disconnect the negative cable from the battery Pull back the positive terminal cover 2 and disconnect the positive cable from the battery Detach rubber band 3 at the bottom Lift the battery up and out 14 2 Installing the battery x B01789 10 Main work Insert the battery into the battery compartment with the terminals facing to the front Battery YTX5L BS p 87 Reconnect rubber band 1 Info ...

Page 71: ...igh charging current shortens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over...

Page 72: ...f all power consumers and switch off the engine Remove the air filter box lid p 42 L01651 10 Main work Take off protection caps 1 Remove the faulty main fuse 2 Info A defective fuse can be identified by the burned out fuse wire A A spare fuse 3 is located in the starter relay Install a new main fuse Fuse 58011109110 p 87 Check that the electrical equipment is functioning properly Tip Insert the sp...

Page 73: ... rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothin...

Page 74: ...evel does not meet specifications Correct the coolant level Alternative 1 Coolant p 91 Alternative 2 Coolant mixed ready to use p 91 Mount the radiator cap 15 4 Draining the coolant x Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the...

Page 75: ... skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of chil dren B01933 10 Make sure that screw 1 is tightened Position the motorcycle upright Pour coolant in up to measurement A above the radiator fins Guideline Dimension A over the radiator fins 10 mm 0 39 in Coolant 1 20 l 1 27 qt Coolant ...

Page 76: ...e the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable x p 74 16 2 Adjusting the play in the throttle cable x Preparatory work Remove the seat p 42 Remove the fuel tank x p 46 Check the throttle cable routing p 52 B01934 10 Main work Move the handlebar to the straight ahead position Push back sleeves ...

Page 77: ...ot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever x p 75 16 5 Adjusting the basic position of the shift lever x 401950 12 Remove screw 1 and take off shift lever 2 401951 10 Clean gear teeth A of the shift lever and shift shaft Mount the shift lever on the shift ...

Page 78: ...5 10 Thoroughly clean plug in connection 1 of the fuel line using compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Pull fuel screen 2 out of the connecting piece Push the new fuel screen all the way into the connecting piece Lubricate the O ring and connect plug in conn...

Page 79: ... stipulated in applicable regulations Info Drain the engine oil only when the engine is warm Preparatory work Park the motorcycle on a level surface B01758 10 Main work Place a suitable container under the engine Remove oil drain plug 1 with the magnet and seal ring B01759 10 Remove screw plug 2 with the short oil screen and the O rings Info Do not remove screw A B01760 10 Remove screw plug 3 with...

Page 80: ...il filter 6 out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing surface B01763 11 Lay the motorcycle on its side and fill the oil filter housing to about full with engine oil Insert the oil filter into the oil filter housing Lubricate the O ring of the oil filter cover and mount it with the oil filter cover 7 Mount...

Page 81: ...emature wear to the engine B01937 10 Remove the oil filler plug 1 with the O ring from the clutch cover Add the same engine oil that was used when the motor was changed Engine oil SAE 10W 50 p 91 Info For optimal performance of the engine oil do not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug with O ring Danger Danger of poisoning ...

Page 82: ...ng First remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner and then clean with a paint brush Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Rem...

Page 83: ...aking the motorcycle out of service add fuel additive Refuel p 22 Clean the motorcycle p 80 Change the engine oil and oil filter and clean the oil screens x p 77 Check the antifreeze and coolant level p 71 Check the tire air pressure p 67 Remove the battery x p 68 Charge the battery x p 69 Guideline Storage temperature of battery without direct sunlight 0 35 C 32 95 F Store the vehicle in a dry lo...

Page 84: ...hange the fuel filter x Defect in fuel injection system Read out the fault memory using the Husqvarna diagnostics tool x Exhaust system leaky deformed or too little glass fiber yarn filling in main silencer Check exhaust system for damage Change the glass fiber yarn filling of the main silencer x p 45 Valve clearance too little Adjust the valve clearance x Engine dies during the trip Lack of fuel ...

Page 85: ...20 TROUBLESHOOTING 83 Faults Possible cause Action Battery is discharged Unwanted power consumer Check the quiescent current x ...

Page 86: ...oo low Engine coolant temperature sensor input signal too high Blink code FI warning lamp MIL 13 FI warning lamp MIL flashes 1x long 3x short Error level condition Intake air temperature sensor input signal to low Intake air temperature sensor input signal too high Blink code FI warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor A D type input si...

Page 87: ...28 4th gear 22 26 5th gear 24 24 Alternator 12 V 75 W Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Spark plug NGK LKAR8AI 9 Spark plug electrode gap 0 9 mm 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter 22 2 Engine tightening torques Screw cable holder in alternator cover M4 4 Nm 3 lbf ft Loc...

Page 88: ...or conrod bearing lubrication M6x0 75 4 Nm 3 lbf ft Plug oil channel M7 9 Nm 6 6 lbf ft Loctite 243 Screw rocker arm bearing M7 15 Nm 11 1 lbf ft Plug timing chain tensioner M8 8 Nm 5 9 lbf ft Screw plug crankshaft location M8 10 Nm 7 4 lbf ft Plug oil channel M10 15 Nm 11 1 lbf ft Loctite 243 Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701 Screw cylinder head M10x1 25 Step 1 10 Nm 7 4 lb...

Page 89: ...Rear 220 mm 8 66 in Brake discs wear limit Front 2 5 mm 0 098 in Rear 3 5 mm 0 138 in Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Secondary ratio 14 50 Chain 5 8 x 1 4 Rear sprockets available 48 50 52 Steering head angle 63 5 Wheelbase 1 495 10 mm 58 86 0 39 in Ground clearance unloaded 374 mm 14 72 in Seat height unloaded 992 mm 39 06 in Weight without fuel approx 107 6 k...

Page 90: ...5 kg 187 209 lb 5 2 N mm 29 7 lb in Gas pressure 1 2 bar 17 psi Fork length 940 mm 37 01 in Oil capacity per cartridge 195 ml 6 59 fl oz Fork oil SAE 4 48601166S1 p 91 Oil capacity fork leg without cartridge 390 ml 13 19 fl oz Fork oil SAE 4 48601166S1 p 91 22 8 Shock absorber Shock absorber part number 18 15 7N 57 Shock absorber WP Suspension 5018 BAVP DCC Compression damping low speed Comfort 17...

Page 91: ...im lock M8 12 Nm 8 9 lbf ft Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw bottom triple clamp M8 12 Nm 8 9 lbf ft Screw chain sliding piece M8 15 Nm 11 1 lbf ft Screw engine brace M8 33 Nm 24 3 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw mani...

Page 92: ...22 TECHNICAL DATA 90 Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft ...

Page 93: ... oils that comply with the specified standards see specifications on the container and that possess the correspond ing properties Synthetic engine oil Fork oil SAE 4 48601166S1 Standard classification SAE p 93 SAE 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Shock absorber oil SAE 2 5 50180342S1...

Page 94: ...24 AUXILIARY SUBSTANCES 92 High viscosity grease Recommended supplier SKF LGHB 2 Rubber grip adhesive 00062030051 Recommended supplier KTM Sportmotorcycle AG GRIP GLUE ...

Page 95: ...vice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils ...

Page 96: ...ng correcting the fluid level 53 fluid changing 53 Clutch lever 11 basic position adjusting 53 Cold start button 13 Compression damping fork adjusting 30 Compression damping high speed shock absorber adjusting 27 Compression damping low speed shock absorber adjusting 26 Coolant draining 72 refilling 73 Coolant level checking 71 72 Cooling system 71 Customer service 7 D Difficult riding conditions ...

Page 97: ... 32 removing from lift stand 32 O Oil filter changing 77 Oil screens cleaning 77 Operating substances 7 Overview of indicator lamps 12 Owner s Manual 6 P Play in throttle cable adjusting 74 Plug in stand 15 Preparing for use advice on first use 16 after storage 81 checks and maintenance work when preparing for use 20 Protective clothing 6 R Rear sprocket checking 50 Rear wheel installing 65 removi...

Page 98: ... 81 Swingarm checking 52 T Technical data capacities 86 chassis 87 chassis tightening torques 89 electrical system 87 engine 85 engine tightening torques 85 fork 88 shock absorber 88 tires 88 Throttle cable play checking 74 Throttle cable routing checking 52 Throttle grip 11 Tire air pressure checking 67 Tire condition checking 66 Transport 22 Troubleshooting 82 83 Type label 10 U Use definition 5...

Page 99: ... 3402004en 3402004en 11 2013 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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Husqvarna 2014 FC 450 EU, Owner'S Manual

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