Husqvarna FE 450 2018 Owner'S Manual Download Page 132

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18 SERVICE WORK ON THE ENGINE

130

Warning

Environmental hazard

Hazardous substances cause environmental damage.

–

Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance
with the applicable regulations.

Info

Drain engine oil with engine at operating temperature.

Preparatory work

–

Remove the engine guard. (

p. 88)

–

Park the motorcycle on a level surface.

F00441-10

Main work

–

Place a suitable container under the engine.

–

Remove oil drain plug

with the magnet and seal ring.

F00442-10

–

Remove screw plug

with the short oil screen and the O-

rings.

Info

Do not remove screw

F00443-10

–

Remove screw plug

with the long oil screen

and the

O-rings.

–

Completely drain the engine oil.

–

Thoroughly clean the parts and sealing surfaces.

F00442-11

–

Mount and tighten screw plug

with the short oil screen

and the O-rings.
Guideline

Screw plug, oil
screen

M20x1.5

15 Nm (11.1 lbf ft)

Summary of Contents for FE 450 2018

Page 1: ...OWNER S MANUAL 2018 FE 450 FE 501 Art no 3402177en ...

Page 2: ......

Page 3: ...ms 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 Motorcycles accepts no liability for delivery options devi ations from illustrations and descriptions as well as misprints and other errors The models portrayed partly contain special eq...

Page 4: ...icator lamps overview 21 6 10 Ignition lock 21 6 11 Opening the filler cap 21 6 12 Closing the filler cap 22 6 13 Cold start button 22 6 14 Idle speed adjusting screw 23 6 15 Shift lever 23 6 16 Foot brake lever 24 6 17 Side stand 24 6 18 Steering lock 24 6 19 Locking the steering 25 6 20 Unlocking the steering 25 7 COMBINATION INSTRUMENT 26 7 1 Combination instrument overview 26 7 2 Activation 26...

Page 5: ... legs 58 12 9 Removing the lower triple clamp 58 12 10 Installing the lower triple clamp 59 12 11 Checking the play of the steering head bearing 61 12 12 Adjusting the steering head bearing play 62 12 13 Lubricating the steering head bearing 63 12 14 Removing front fender 63 12 15 Installing front fender 64 12 16 Removing the shock absorber 64 12 17 Installing the shock absorber 66 12 18 Removing ...

Page 6: ...etting 116 15 11 Adjusting the headlight range 116 15 12 Changing the combination instrument 117 15 13 Diagnostics connector 117 16 COOLING SYSTEM 118 16 1 Cooling system 118 16 2 Checking the antifreeze and coolant level 118 16 3 Checking the coolant level 119 16 4 Draining the coolant 120 16 5 Refilling coolant 120 17 TUNING THE ENGINE 122 17 1 Checking the play in the throttle cable 122 17 2 Ad...

Page 7: ...TABLE OF CONTENTS 5 26 STANDARDS 154 27 INDEX OF SPECIAL TERMS 155 28 LIST OF ABBREVIATIONS 156 29 LIST OF SYMBOLS 157 29 1 Yellow and orange symbols 157 29 2 Green and blue symbols 157 INDEX 158 ...

Page 8: ...l be optimally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Indicates the end of an activity including potential rework 1 2 Formats used The typographical formats used in this document are explained below ...

Page 9: ...ecification for the respective use 2 3 Safety advice A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info The vehicle has various information and warning labels at prominent locations Do not remove informa tion warning labels If the...

Page 10: ... labels E00946 10 1 Canada type label 2 Information on noise emission 3 Information on chain tension 4 Information on starting up 5 Brake fluid information 6 Information on emissions control 7 USA type label E00947 10 Canada type label ...

Page 11: ...FETY ADVICE 9 E00948 10 Information on noise emission F00490 10 Information on chain tension F00491 10 Information on starting up F00489 10 Brake fluid information E00949 10 Information on emissions control ...

Page 12: ... emission standards applicable at the time of sale This warranty extends to the first person who buys this exhaust system for purposes other than resale and to all subsequent buyers Warranty claims should be directed to Husqvarna Motorcycles North America Inc c o KTM North America Inc Customer Support 1119 Milan Ave Amherst OH 44001 USA Phone 440 985 3553 www husqvarna motorcycles com Husqvarna Mo...

Page 13: ...ccidents A rider who is not fit to ride poses a danger to him or herself and others Do not operate the vehicle if you are not fit to ride due to alcohol drugs or medication Do not operate the vehicle if you are physically or mentally impaired Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation...

Page 14: ...ure of the motorcycle sport make sure that you use your motorcycle legally display environmental con sciousness and respect the rights of others When disposing of used oil other operating and auxiliary fluids and used components comply with the laws and regulations of the respective country Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles there are ...

Page 15: ...ccessory products are specified in parentheses in the descriptions Your Husqvarna Motorcycles dealer will be glad to advise you The current Husqvarna Motorcycles accessories for your vehicle can be found on the Husqvarna Motorcycles website International Husqvarna Motorcycles website www husqvarna motorcycles com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is ...

Page 16: ...dealer will be happy to answer any questions you may have regarding your vehicle and Husqvarna Motorcycles A list of authorized Husqvarna Motorcycles dealers can be found on the Husqvarna Motorcycles website International Husqvarna Motorcycles website www husqvarna motorcycles com ...

Page 17: ...4 VIEW OF VEHICLE 15 4 1 View of vehicle front left example M01466 10 1 Filler cap 2 Air filter box cover 3 Side stand p 24 4 Engine number p 18 5 Shift lever p 23 ...

Page 18: ...Horn button p 19 2 Light switch p 20 2 Turn signal switch p 20 3 Clutch lever p 19 4 Emergency OFF switch p 20 4 Electric starter button p 20 5 Throttle grip p 19 6 Hand brake lever p 19 7 Fork compression adjustment 8 Foot brake lever p 24 9 Engine oil level viewer bk Level viewer for brake fluid rear ...

Page 19: ...50 10 The type label 1 is fixed to the front of the steering head The additional type label for Canada 2 is fixed to the front of the front pipe 5 3 Key number H01758 10 Key number 1 for the ignition and steering lock is indicated on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place ...

Page 20: ...e engine behind the shift lever 5 5 Fork part number 401947 10 The fork part number 1 is stamped on the inner side of the fork stub 5 6 Shock absorber article number 0 0 1 1 401948 10 Shock absorber article number 1 is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 21: ...nd brake lever 1 is fitted on the right side of the handle bar The hand brake lever is used to activate the front brake 6 3 Throttle grip S02066 10 The throttle grip 1 is fitted on the right side of the handlebar 6 4 Horn button K00599 12 The horn button 1 is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn button pressed The horn is operated in this po...

Page 22: ...rn signal light right on The turn signal switch is pressed to the right The turn signal switch returns to the middle position after activation To switch off the turn signal press the turn signal switch toward the switch housing 6 7 Emergency OFF switch S02068 10 The emergency OFF switch 1 is fitted on the right side of the handlebar Possible states Ignition off In this position the ignition circui...

Page 23: ...n the ignition circuit is closed and the engine can be started 6 11 Opening the filler cap Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If...

Page 24: ...om of the throttle valve body The injection system extends the injection time if the engine is cold and the outside temperature is low To help the engine burn the increased amount of fuel it must be supplied with additional oxygen by pushing the cold start button After briefly opening up the throttle and then releasing the throttle grip again or turning the throttle grip towards the front the cold...

Page 25: ...idle setting of the throttle valve body has a big influence on the vehicle s starting behavior on stable idling and on vehicle response when the throttle is opened An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly 6 15 Shift lever 401950 10 The shift lever 1 is fitted on the left side of the engine 401950 11 The gear positions can be se...

Page 26: ...e side stand 1 is attached to the left side of the vehicle 401944 10 The side stand is used for parking the motorcycle Info When you are riding side stand 1 must be folded up and secured with rubber band 2 6 18 Steering lock F00268 10 Steering lock 1 is fitted on the left side of the steering head The steering lock is used to lock the steering Steering and therefore riding is no longer possible ...

Page 27: ... regularly Universal oil spray p 153 Insert the key in the steering lock p 24 turn it to the left press it in and turn it to the right Remove the key Steering is no longer possible Info Never leave the key in the steering lock 6 20 Unlocking the steering 400731 01 Insert the key in the steering lock p 24 turn it to the left pull it out and turn it to the right Remove the key You can now steer the ...

Page 28: ...3 Message on the combination instrument 401901 01 Possible states Battery voltage of the combination instrument Bat tery voltage of the combination instrument is too low Change the battery Service A service is due Contact an authorized Husqvarna Motorcycles workshop 7 4 Adjusting the combination instrument Condition The motorcycle is stationary 401909 01 Press both buttons for 3 5 seconds The Setu...

Page 29: ...he left button The value decreases Advancing the time Press the right button The value increases 401913 01 Wait for 5 seconds Combination instrument changes to the next menu item The symbol flashes Set the service Guideline One time service after 1 h Service every 15 h Shortening the service interval Press the left button The value decreases Extending the service interval Press the right button Th...

Page 30: ...peed in kilo meters KM H or miles M H 7 6 Setting the clock Condition The motorcycle is stationary 401911 01 Press both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Wait for the menu of the clock to flash Press one of the buttons to select the 24h or 12h display of the clock 401912 01 Wait for 5 seconds Combination instrument changes to the next menu item The symbol...

Page 31: ...alue increases 401914 01 Switching off the service interval display Press and hold the left button off appears on the display 7 8 Speed time and DST distance 1 401901 01 Press one of the buttons until DST appears on the combina tion instrument KM H or M H shows the speed shows the time DST shows the distance since the last reset such as between two refueling stops Info If the value of 39999 9 is e...

Page 32: ...etween 0 0 and 39999 9 by pressing the buttons Press the right button briefly Next display mode Press the right button for 3 5 sec onds DST2 is reset to 0 0 7 10 AVG average speed ART operating hours and ODO total distance covered 401903 01 Press one of the buttons until AVG ART and ODO appear on the combination instrument AVG shows the average speed since the last reset ART shows the operating ho...

Page 33: ...dapt your riding speed to the road conditions and your riding ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents The brake system fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously Take your foot off the foot brake lever when you are not braking Warni...

Page 34: ...le axle loads Guideline Maximum permissible overall weight 335 kg 739 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible rear axle load 190 kg 419 lb Run in the engine p 32 8 2 Running in the engine During the running in phase do not exceed the specified engine speed and engine performance Guideline Maximum engine speed During the first operating hour 7 000 rpm Maximum engine...

Page 35: ... p 70 Info Check the air filter approx every 30 minutes Seal the air filter box p 71 Check the connector for humidity and corrosion and to ensure it is firmly seated If humidity corrosion or damage is found Clean and dry the connector or change it if necessary Difficult riding conditions are Rides on dry sand p 33 Rides on wet sand p 34 Rides on wet and muddy circuits p 35 Rides at high temperatur...

Page 36: ...d 78932005000 8 6 Preparing for rides on wet sand 102137 01 Fit a rain cover on the air filter Waterproofing device for air filter 79006921000 Info See the Husqvarna Motorcycles accessories fitting instructions 600868 01 Clean the chain Mount the steel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent radiator fins carefully M01459 01 FE 450 US Change the clutch spring C...

Page 37: ...motorcycle p 134 Straighten bent radiator fins carefully M01459 01 FE 450 US Change the clutch spring Clutch spring hard 78932005000 8 8 Preparing for rides at high temperature and slow speed 600868 01 Adjust the secondary drive to the road conditions Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively high sec ondary drive Clean the chain Clean the ra...

Page 38: ...8 9 Preparing for rides at low temperature or in snow 102137 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 79006921000 Info See the Husqvarna Motorcycles accessories fitting instructions ...

Page 39: ... tire condition p 105 Check the tire air pressure p 105 Check the spoke tension p 106 Info The spoke tension must be checked regularly as incorrect spoke tension will strongly impair riding safety Clean the dust boots of the fork legs p 56 Bleed the fork legs p 55 Check the air filter Check the settings of all controls and ensure that they can be operated smoothly Check all screws nuts and hose cl...

Page 40: ...and must be folded up and secured with the rubber band Pull the clutch lever shift into first gear release the clutch lever slowly and at the same time open the throt tle gently 9 4 Shifting riding Warning Danger of accidents If you change down at high engine speed the rear wheel blocks and the engine races Do not change into a low gear at high engine speed Info If unusual noises occur while ridin...

Page 41: ...ed Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Danger of accidents Moisture and dirt impair the brake system Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs On sandy wet or slippery surfaces use the rear brake Braking should always be completed before you go into a bend Change down to a lower gear appropriate to yo...

Page 42: ...ion lock to the position while the engine is idling Info If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock power continues to flow to most power consumers This discharges the battery You should therefore always switch off the engine with the ignition key the emergency OFF switch is intended for emergencies only Park the motorcycle...

Page 43: ...he eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Note Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Refuel only with cle...

Page 44: ...heck the swingarm bearing for play Check the heim joint for play Check the shock absorber linkage Check the tire condition p 105 Check the tire air pressure p 105 Check the wheel bearing for play Check the wheel hubs Check the rim run out Check the spoke tension p 106 Check the chain rear sprocket engine sprocket and chain guide p 81 Check the chain tension p 80 Grease all moving parts e g side st...

Page 45: ...he fork Service the shock absorber Check the screws and nuts for tightness Check the headlight setting p 116 Change the fuel screen p 128 Check the fuel pressure Check idle Check that the radiator fan is functioning properly Check the inlet membrane Final check Check the vehicle is roadworthy and take a test ride Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnos...

Page 46: ...ncluding removing and installing the engine Change the spark plug and spark plug connector Change the piston Check measure the cylinder Check the cylinder head Change the valves valve springs and valve spring seats Check the camshaft rocker arm and rocker arm shafts Change the connecting rod conrod bearing and crank pin Change the shaft seal ring of the water pump Check the transmission and shift ...

Page 47: ...k absorber is divided into two ranges high speed and low speed High speed and low speed refer to the compression speed of the rear 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 com presses quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel s...

Page 48: ...of the shock absorber will fly off if the shock absorber is disassembled incor rectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized Husqvarna Motorcycles workshop will be glad to help Info The effect of the high speed setting can be seen in fast compression of the shock absorber F00270 10 Using an open end wrench turn adjusting ...

Page 49: ...ckwise up to the last perceptible click Turn counterclockwise by the number of clicks correspond ing to the shock absorber type Guideline Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping turn counter clockwise to reduce damping 11 6 Measuring the rear wheel dimension unloaded Preparatory work Raise the motorcycle with a lift stand p 55 40...

Page 50: ...ecified value Adjust the spring preload of the shock absorber p 49 11 8 Checking the riding sag of the shock absorber 402417 10 Measure dimension A of rear wheel unloaded p 47 With another person holding the motorcycle the rider wear ing full protective clothing sits on the seat in a normal sitting position feet on footrests and bounces up and down a few times The rear wheel suspension levels out ...

Page 51: ...5 Remove the shock absorber p 64 After removing the shock absorber clean it thoroughly 402659 10 Main work Loosen screw 1 Turn adjusting ring 2 until the spring is no longer under ten sion Holding wrench 90129051000 Measure the overall spring length while the spring is not under tension Tighten the spring by turning adjusting ring 2 to measure ment A Guideline Spring preload 14 mm 0 55 in Info Dep...

Page 52: ...d Finishing work Install the shock absorber p 66 Check the free travel of the foot brake lever p 94 Remove the motorcycle from the lift stand p 55 Check the static sag of the shock absorber p 48 Check the riding sag of the shock absorber p 48 Adjust the rebound damping of the shock absorber p 47 11 11 Checking the basic setting of the fork Info For various reasons no exact riding sag can be determ...

Page 53: ...deline Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping turn counter clockwise to reduce damping 11 13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior F00352 10 Turn red adjusting screw 1 clockwise as far as it will go Info Adjusting screw 1 is located at the upper e...

Page 54: ...both fork legs Turn the adjusting wings clockwise Guideline Spring preload Preload Adjuster Comfort 0 Standard 0 Sport 3 The adjusting wings engage noticeably at the numerical values Info Adjust the spring preload to the numerical values only as the preload will not engage between the numerical values Turn clockwise to increase the spring preload turn counterclockwise to reduce the spring preload ...

Page 55: ...ndlebar may break as a result Change the handlebar if the handlebar is damaged or bent 101860 10 Remove screws 1 Take off the handlebar clamps Take off the handlebar and lay it to one side Info Cover the components to protect them against dam age Do not bend the cables and lines Remove screws 2 Take off the handlebar supports Place the handlebar supports in the required position Mount and tighten ...

Page 56: ...11 TUNING THE CHASSIS 54 Info Make sure the gap width is even ...

Page 57: ...e The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand 1 to the ground with your foot and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with the rubber band 12 3 Bleeding the fork legs Preparatory w...

Page 58: ...idents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 153 Press the dust boots back into their normal position Remove excess oil Finishing work Install the fork protector p 57 Remove the mot...

Page 59: ...nt and tighten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 7 Removing the fork legs Preparatory work Remove the headlight mask with the headlight p 113 Raise the motorcycle with a lift stand p 55 Remove the front wheel p 101 S02105 10 Main work Remove screws 1 and take off the clamp Remove the cable tie s Remove screws 2 and take off the brake caliper Allow the brake caliper...

Page 60: ...ple clamp M8 17 Nm 12 5 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft S02106 10 Position the brake caliper and mount and tighten screws 4 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount the cable tie s Position the brake line wiring harness and clamp Mount and tighten screws 5 Finishing work Install the front wheel p 102 Install the hea...

Page 61: ... the components to protect them against dam age Do not kink the cables and lines F00278 10 Remove O ring 4 and protective ring 5 Take off the lower triple clamp with the steering stem Remove the upper steering head bearing 12 10 Installing the lower triple clamp 0 0 1 1 0 0 2 2 0 0 3 3 B01632 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 15...

Page 62: ...ht radiator H01672 10 Position the fork legs Bleeder screws 6 are positioned toward the front Info The rebound damping is located in right fork leg REB red adjusting screw The compression damping is located in left fork leg COM white adjusting screw Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the upper edge of the uppe...

Page 63: ... the handlebar cushion Install front fender p 64 Install the front wheel p 102 Install the headlight mask with the headlight p 113 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the play of the steering head bearing p 61 Remove the motorcycle from the lift stand p 55 Check the headlight setting p 116 12 11 Checking the play o...

Page 64: ...sible to move the handlebar easily over the entire steering range There should be no detectable detent positions If detent positions are detected Adjust the steering head bearing play p 62 Check the steering head bearing and replace if neces sary Finishing work Remove the motorcycle from the lift stand p 55 12 12 Adjusting the steering head bearing play Preparatory work Raise the motorcycle with a...

Page 65: ...rom the lift stand p 55 12 13 Lubricating the steering head bearing H02387 01 Remove the lower triple clamp p 58 Install the lower triple clamp p 59 12 14 Removing front fender Preparatory work Remove the headlight mask with the headlight p 113 F00282 10 Main work Remove screws 1 Remove screws 2 Take off the front fender ...

Page 66: ... 4 lbf ft Finishing work Install the headlight mask with the headlight p 113 Check the headlight setting p 116 12 16 Removing the shock absorber Preparatory work Raise the motorcycle with a lift stand p 55 E00939 10 Main work Remove the cable ties Remove screws 1 Remove screws 2 with the washers Remove the frame protectors on the left and right F00284 10 Remove screw 3 Remove fitting 4 Info Raise ...

Page 67: ...downward E00933 10 Disconnect plug in connector 7 S02080 10 Remove screws 8 Pull off foot brake cylinder from the push rod F00294 01 Remove the connecting link of the chain Take off the chain E00935 10 Remove nut 9 and pull out the swingarm pivot Push the swingarm back and secure it against falling over ...

Page 68: ...m Mount and tighten screw 1 Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 F00463 10 Position the swingarm and mount the swingarm pivot Info Pay attention to flat area A Mount and tighten nut 2 Guideline Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft F00294 11 Mount the chain Connect the chain with connecting link 3 Guideline The closed side of the chain joint lock must face ...

Page 69: ...bf ft Info Pay attention to flat area B Mount and tighten screw 8 Guideline Screw bottom shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Info Raise the wheel slightly to be able to mount the screw more easily E00939 11 Position the frame protectors on the left and right Mount and tighten screws 9 Guideline Screw frame pro tector M5 3 Nm 2 2 lbf ft Mount and tighten screws bk with the washers Gui...

Page 70: ...k and lift it off 12 19 Mounting the seat F00297 10 Main work Mount the front of the seat on the collar bushing of the fuel tank lower the seat at the rear and push the seat forward Make sure that the seat is locked in correctly Mount and tighten screw 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the air filter box cover p 69 ...

Page 71: ...er box cover in areas A B and C 12 22 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine Dust and dirt will enter the engine without an air filter Never start to use the vehicle without an air filter Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents b...

Page 72: ...ning tab 3 Retaining pin 2 is secured with retaining tab 3 Info If the air filter is not mounted correctly dust and dirt may enter the engine and result in damage Finishing work Install the air filter box cover p 69 12 24 Cleaning the air filter and air filter box Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake ...

Page 73: ...ter p 153 Clean the air filter box Check the intake flange for damage and looseness Finishing work Install the air filter p 70 Install the air filter box cover p 69 12 25 Sealing the air filter box Preparatory work Remove the air filter box cover p 69 F00248 01 Main work Seal the air filter box in the marked area A Finishing work Install the air filter box cover p 69 12 26 Removing the right side ...

Page 74: ... screw 3 Guideline Remaining screws chassis M5 5 Nm 3 7 lbf ft 12 28 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 before performing any work on the vehicle Preparatory work Remove the right side cover p 71 K00594 10 Main work Detach spring 1 Spring hook 50305017000 Remove screws 2 and take off t...

Page 75: ... 4 lbf ft Finishing work Install the right side cover p 72 12 30 Cleaning the spark arrestor Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Info Soot particles accumulate on the screen of the spark arrestor over time This changes the performance characteristics Preparatory work Remo...

Page 76: ...e eyes and mucuous membranes Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen Clean main silencer housing 3 and filter 4 of the spark arrestor with compressed air Position silencer cap 2 Mount and tighten screws 1 Guideline Screws on the main silencer M5 7 Nm 5 2 lbf ft Finishing work Install the main silencer p 73 Install the right side cover p 72 ...

Page 77: ... 4 Clean the parts that need to be reinstalled and check for damage Mount the new glass fiber yarn filling with connecting cap onto the inner tube Position the inner tube with the connecting cap and glass fiber yarn filling in the outer tube Position the silencer cap with filter in the outer tube Mount and tighten all of the screws Guideline Screws on the main silencer M5 7 Nm 5 2 lbf ft Finishing...

Page 78: ...ister and out of the reach of children Preparatory work Remove the air filter box cover p 69 Remove the seat p 68 V00484 10 Main work Unplug connector 1 of the fuel pump Clean the plug in connection 2 of the fuel line thoroughly with compressed air Info Dirt should not be allowed to get into the fuel line under any circumstances Dirt in the fuel line clogs the injection valve V00485 10 Disconnect ...

Page 79: ...or refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the...

Page 80: ...ten screws 2 with the collar bushings Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft V00484 11 Plug in the connector 3 for the fuel pump Remove the wash cap set Thoroughly clean the plug in connection of the fuel line with an air line Info Dirt should not be allowed to get into the fuel line under any circumstances Dirt in the fuel line clogs the injection valve Lubricate the O ring and co...

Page 81: ...fect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info The service life of the chain depends largely on its maintenance Preparatory w...

Page 82: ... 1 must be taut When the chain guard is mounted it must be possi ble to pull up the chain at least to the point where it makes contact with chain guard B Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 55 58 mm 2 17 2 28 in If the chain tension does not meet the specification Adjust the chain tension p 80 Finishing work Remove the moto...

Page 83: ...e fitted correctly on adjusting screws 3 Tighten nut 1 Guideline Nut rear wheel spin dle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters 4 can be turned by 180 Finishing work Remove the motorcycle from the lift stand p 55 12 38 Checking the chain rear sprocket engine sprocket a...

Page 84: ...1 in If distance B is greater than the specified measurement Change the drivetrain kit Info When a new chain is mounted the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprockets E00944 10 Check the chain sliding guard for wear If the lower edge of the chain pins is in line with or below the chain sliding guard Change the chain sliding guard Check...

Page 85: ...n sliding piece Guideline Screw chain slid ing piece M8 15 Nm 11 1 lbf ft 400985 01 Check the chain guide for wear Info Wear can be seen on the front of the chain guide If the light part of the chain guide is worn Change the chain guide F00322 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the fitting on the chain guide Guideline Remaining screws chassis M6 10 N...

Page 86: ...epair of the frame is not authorized by Husqvarna Motorcycles 12 40 Checking the swingarm 401520 01 Check the swingarm for damage cracking and deformation If the swingarm shows signs of damage cracking or deformation Change the swingarm Info Always change a damaged swingarm Repair of the swingarm is not authorized by Husq varna Motorcycles 12 41 Checking throttle cable routing Preparatory work Rem...

Page 87: ...k p 77 Mount the seat p 68 Install the air filter box cover p 69 12 42 Checking the rubber grip 401197 01 Check the rubber grips on the handlebar for damage wear and looseness Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right The left sleeve is clamped onto the handlebar The rubber grip can only be replaced with the sleeve or ...

Page 88: ...d has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleanin...

Page 89: ...ter in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the ...

Page 90: ...r reservoir to prevent overflow Remove the bleeding syringe Tighten the bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water 12 46 Removing the engine guard H01655 01 Remove screws 1 and engine guard...

Page 91: ... discs Warning Danger of accidents Worn out brake discs reduce the braking effect Make sure that worn out brake discs are replaced immediately Your authorized Husqvarna Motor cycles workshop will be glad to help A A 400257 10 Check the front and rear brake disc thickness at multiple points for the dimension A Info Wear reduces the thickness of the brake disc around the contact surface of the brake...

Page 92: ...An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Skin irritation Brake fluid...

Page 93: ...ion Remove screws 1 Remove cover 2 with membrane 3 Add brake fluid to level A Guideline Level A brake fluid level below reservoir rim 5 mm 0 2 in Brake fluid DOT 4 p 151 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water 13 5 Checking the front brake linings Warning Danger of accidents Worn out brake linings redu...

Page 94: ...Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Warning Danger of accidents Brake linings which have not been approved alter the braking efficiency Not all brake linings are tested and approved for Husqvarna motorcycles The structure and friction coeffi...

Page 95: ...aliper against the spokes when pushing back the brake pis tons Remove cotter pin 4 Push leaf spring 5 upwards and remove pin 6 Remove brake linings Clean the brake caliper and brake caliper support H02377 10 Check that leaf spring 5 in the brake caliper and sliding plate 7 in the brake caliper support are seated correctly K00944 11 Insert the new brake linings Mount pin 6 Leaf spring 5 engages in ...

Page 96: ...ake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification 402026 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 ...

Page 97: ...eline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold screw 3 and tighten nut 2 Guideline Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Hold push rod 5 and tighten nut 4 Guideline Remaining nuts chassis M6 10 Nm 7 4 lbf ft Reconnect spring 1 13 9 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the bra...

Page 98: ...tely if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for ...

Page 99: ...aking effect Ensure that worn out brake linings are replaced immediately Your authorized Husqvarna Motorcy cles workshop will be glad to help H02368 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings p 97 Check the brake linings for damage and cracking If damage or cracking is visible Cha...

Page 100: ...nd grease Clean the brake discs with brake cleaner when necessary Warning Danger of accidents Brake linings which have not been approved alter the braking efficiency Not all brake linings are tested and approved for Husqvarna motorcycles The structure and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original brake linings If brake linings are u...

Page 101: ...against the spokes Remove cotter pin 3 Push leaf spring 4 downwards and remove pin 5 Remove brake linings Clean the brake caliper and brake caliper support H02369 10 Check that leaf spring 4 in the brake caliper and sliding plate 6 in the brake caliper support are seated correctly H02370 10 Insert the new brake linings Mount pin 5 Leaf spring 4 engages in the groove on the pin Info Always change t...

Page 102: ... 10 Add brake fluid to level A Brake fluid DOT 4 p 151 Mount and tighten screw cap 1 with membrane 2 and the shim Info Clean up overflowed or spilled brake fluid immediately with water Mount new cable ties on the frame protector ...

Page 103: ... back the brake pis tons H02371 10 Loosen screw 1 by several rotations Loosen screws 2 Press on screw 1 to push the wheel spindle out of the axle clamp Remove screw 1 V00972 10 Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel ou...

Page 104: ...rt the spacers H02371 11 Clean and grease the wheel spindle Long life grease p 153 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned Mount and tighten screw 2 Guideline Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc Remove the motorcycle...

Page 105: ...ear sprocket Info Cover the components to protect them against dam age Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the rear wheel withdraw the wheel spindle Take the rear wheel out of the swingarm Info Do not operate the foot brake lever when the rear wheel is removed H00936 10 Remove s...

Page 106: ...rrectly positioned H02376 10 Position chain adjuster 3 Mount nut 4 but do not tighten it yet Make sure that chain adjusters 3 are fitted correctly on adjusting screws 5 Check the chain tension p 80 Tighten nut 4 Guideline Nut rear wheel spin dle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length ...

Page 107: ...ck the tread depth Info Adhere to the legally required minimum tread depth Minimum tread depth 2 mm 0 08 in If the tread depth is less than the minimum tread depth Change the tires H01144 01 Check the tire age Info The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT number The first two digits indicate the week of manufacture and ...

Page 108: ...n in the spokes is too low then lateral and radial run out will form in the wheel Other spokes will become looser as a result Check spoke tension regularly and in particular on a new vehicle Your authorized Husqvarna Motorcycles workshop will be glad to help 400694 01 Strike each spoke briefly using a screwdriver blade Info The frequency of the sound depends on the spoke length and spoke diameter ...

Page 109: ...ries if charge is already below the minimum voltage Minimum voltage before the start of the charge 9 V Dispose of batteries with less than the minimum voltage correctly Preparatory work Turn the key in the ignition lock to the position while the engine is idling Remove the air filter box cover p 69 Remove the seat p 68 H01190 10 Main work Pull back the negative terminal cover 1 and disconnect nega...

Page 110: ...ry termi nal M5 2 5 Nm 1 84 lbf ft Info Contact disks A must be mounted under the screw 3 and the cable lug 4 with the claws toward the battery terminal Slide positive terminal cover 6 over the positive terminal Connect negative cable 7 to the battery Guideline Screw battery termi nal M5 2 5 Nm 1 84 lbf ft Info Contact disks A must be mounted under the screw 3 and the cable lug 4 with the claws to...

Page 111: ...ctly and in compliance with the applicable regulations Info Even when there is no load on the battery it discharges steadily The charging level and the method of charging are very important for the service life of the battery Rapid recharging with a high charging current shortens the service life of the battery If the charging current or charging voltage are exceeded the battery will be destroyed ...

Page 112: ...d state for an extended period it will become over discharged and sulfated destroying the battery The battery is maintenance free Never remove cover 1 Switch off the battery charger after charging and disconnect from the battery Finishing work Install the battery p 108 Mount the seat p 68 Install the air filter box cover p 69 15 4 Changing the main fuse Warning Fire hazard Incorrect fuses overload...

Page 113: ...s functioning properly Tip Insert a spare fuse so that it is available if needed Mount the protection caps Mount the starter relay onto the holder and route the cable Finishing work Mount the seat p 68 Install the air filter box cover p 69 15 5 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat Preparatory...

Page 114: ...ght license plate lamp Fuse 3 10 A radiator fan horn brake light turn signal Fuse 4 5 A fuel pump Fuses res 10 A spare fuse Info You can recognize a faulty fuse by a burned out fuse wire A Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 147 ...

Page 115: ...ight Turn the key in the ignition lock to the position while the engine is idling F00479 10 Detach brake line 1 and wiring harness 2 Release rubber bands 3 Slide the headlight mask up and swing it forward F00478 10 Detach plug in connectors 4 and take off the headlight mask with the headlight 15 7 Installing the headlight mask with the headlight F00478 11 Main work Connect plug in connectors 1 ...

Page 116: ...te Damage to reflector Grease on the reflector reduces the brightness Grease on the bulb will evaporate due to the heat and be deposited on the reflector Clean and degrease the bulbs before mounting Do not touch the bulbs with your bare hands Preparatory work Remove the headlight mask with the headlight p 113 K00612 10 Main work Turn protection cap 1 together with the underlying bulb socket counte...

Page 117: ...orate due to the heat and be deposited on the reflector Clean and degrease the bulbs before mounting Do not touch the bulbs with your bare hands E00499 10 Main work Remove the screw and carefully remove diffuser 1 Press the turn signal bulb 2 carefully into the socket turn it counterclockwise by about 30 and take it out of the socket Info Do not touch the reflector with your fingers and keep it fr...

Page 118: ...y between light and dark must be exactly on the lower mark for a motorcycle with rider If the light dark border does not meet specifications Adjust the headlight range p 116 15 11 Adjusting the headlight range Preparatory work Check the headlight setting p 116 F00363 10 Main work Loosen screw 1 Adjust the headlight range by pivoting the headlight Guideline The boundary between light and dark must ...

Page 119: ...facing outward Combination instrument battery CR 2032 p 147 Check the O ring of the protection cap for correct seating F00372 10 Position protection cap 2 and turn all the way clockwise using a coin Press any button on the combination instrument The combination instrument is activated Position the combination instrument in the holder Mount and tighten the screws with washers Finishing work Install...

Page 120: ... and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning D...

Page 121: ...ine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediatel...

Page 122: ...plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold M01471 10 Position the motorcycle upright Place a suitable container under the water pump cover Remove screw 1 Take off radiator cap 2 Completely drain the coolant Moun...

Page 123: ...he screw 1 is tightened Stand the vehicle upright Pour coolant in up to measurement A above the radiator fins Guideline 10 mm 0 39 in Coolant 1 2 l 1 3 qt Coolant p 151 Refit the radiator cap Finishing work Take a short test ride Check the coolant level p 119 ...

Page 124: ...just the play in the throttle cable p 122 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and let it run idle Move the handlebar to and fro over the ...

Page 125: ... there is play in the throttle cable at the throttle grip Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut 2 Slide on sleeve 1 Check the throttle grip for smooth operation Finishing work Check the play in the throttle cable p 122 17 3 Setting the characteristic map of the throttle response Info On the throttle grip the characteristic map of the throttle response is changed by changi...

Page 126: ...ve more slowly The black guide plate opens the throttle valve more quickly The gray guide plate is mounted upon delivery S02098 01 Clean the outside of the handlebar and the inside of the grip tube Mount the grip tube on the handlebar Attach the throttle cables to the guide plate and route cor rectly S02099 10 Position half shells 3 mount and tighten screws 2 Guideline Screw throttle grip M6 5 Nm ...

Page 127: ...xic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Set the idle speed by turning idle speed adjusting screw 1 Guideline Idle speed 1 800 1 900 rpm Tachometer 45129075000 Info Turning counterclockwise lowers the idle ...

Page 128: ...ut leave it running at idle speed until teaching is completed 17 6 Checking the basic position of the shift lever Info When driving the shift lever must not touch the driver s boot when in the basic position When the shift lever keeps touching the boot the transmission will be subject to an excessive load 400692 10 Sit on the vehicle in the riding position and determine the distance A between the ...

Page 129: ... on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during the shift procedure Mount and tighten screw 1 with washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 130: ...ase of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system V00488 10 Clean plug in conn...

Page 131: ...ower edge of level viewer A If the engine oil does not reach the lower edge of the level viewer Add engine oil p 132 Condition The engine is at operating temperature Check the engine oil level Info After switching off the engine wait one minute before checking the level The engine oil is at a level between lower edge A and middle B of the level viewer If the engine oil is not at a level between lo...

Page 132: ...rk the motorcycle on a level surface F00441 10 Main work Place a suitable container under the engine Remove oil drain plug 1 with the magnet and seal ring F00442 10 Remove screw plug 2 with the short oil screen and the O rings Info Do not remove screw A F00443 10 Remove screw plug 3 with the long oil screen 4 and the O rings Completely drain the engine oil Thoroughly clean the parts and sealing su...

Page 133: ... Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft F00440 10 Remove screws 5 Remove the oil filter cover with the O ring F00446 10 Pull oil filter 6 out of the oil filter housing Lock ring plier 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing surface F00440 11 Lay the motorcycle on its side and fill the oil filter housing to about full with engine oi...

Page 134: ...h the O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and check that it is oil tight Finishing work Install the engine guard p 88 Check the en...

Page 135: ... We recommended changing the engine oil when nec essary Install and tighten the oil filler plug with O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the ...

Page 136: ...iod clean it regularly Avoid direct sunshine when cleaning the motorcycle 401061 01 Close off the exhaust system to keep water from entering Remove coarse dirt particles with a gentle water jet Spray dirty parts with a normal commercial engine cleaner and then brush off with a soft brush Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a ...

Page 137: ...road salt If the vehicle was operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 134 Clean the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings in the cooled down and installed state with cold water and dry carefully After riding on salted roads tho...

Page 138: ...uld do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Refuel p 41 Clean the motorcycle p 134 Change the engine oil and oil filter and clean the oil screens p 129 Check the antifreeze and coolant level p ...

Page 139: ...y the water vapor produced during combustion condenses and causes valves and the exhaust system to rust 20 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 55 Install the battery p 108 Perform checks and maintenance measures when preparing for use p 37 Take a test ride ...

Page 140: ...dle speed p 125 Spark plug oily or wet Clean and dry the spark plug or replace if necessary Electrode distance plug gap of spark plug too wide Adjust the plug gap Guideline Spark plug electrode gap 1 0 mm 0 039 in Ignition system defective Check the ignition system Short circuit cable in wiring harness frayed kill switch or emergency OFF switch defec tive Check the wiring harness visual check Chec...

Page 141: ...oolant level p 119 Insufficient airflow Switch off engine when stationary Radiator fins very dirty Clean radiator fins Foam formation in cooling sys tem Drain the coolant p 120 Refill the coolant p 120 Bent radiator hose Change the radiator hose Thermostat defective Check the thermostat Guideline Opening temperature 70 C 158 F Defect in radiator fan system Check fuse 3 Check the radiator fan Malfu...

Page 142: ...nstrument values deleted time stop watch lap times The battery in the combination instrument is discharged Change the combination instrument p 117 The high beam low beam tail light parking light and license plate lamp are not working Fuse 2 blown Change the fuses of individual power consumers p 111 Combination instrument horn brake light turn signal and radiator fan are not working Fuse 3 blown Ch...

Page 143: ...anifold absolute pressure sensor cylinder 1 input signal too low Manifold absolute pressure sensor cylinder 1 input signal too high Blink code for malfunc tion indicator lamp 12 Malfunction indicator lamp flashes 1x long 2x short Error level condition Engine coolant temperature sensor input signal too low Engine coolant temperature sensor input signal too high Blink code for malfunc tion indicator...

Page 144: ...unction indicator lamp flashes 3x long 3x short Error level condition Injector cylinder 1 circuit fault Blink code for malfunc tion indicator lamp 37 Malfunction indicator lamp flashes 3x long 7x short Error level condition Ignition coil 1 cylinder 1 circuit fault Blink code for malfunc tion indicator lamp 41 Malfunction indicator lamp flashes 4x long 1x short Error level condition Fuel pump relay...

Page 145: ... ball bearings Conrod bearing Slide bearing Piston pin 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 Eaton pumps Primary transmission 31 76 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 6 gear claw shifted Transmission ratio First gear...

Page 146: ... cover M5 6 Nm 4 4 lbf ft Loctite 243 Nut water pump impeller M6 6 Nm 4 4 lbf ft Loctite 243 Screw alternator cover M6 10 Nm 7 4 lbf ft Screw bearing bolt torque limiter M6 10 Nm 7 4 lbf ft Loctite 243 Screw camshaft support plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw clutch cover M6 10 Nm 7 4 lbf ft Screw cylinder head M6 10 Nm 7 4 lbf ft Screw engine case M6 10 Nm 7 4 lbf ft Screw EVAP plug M6 1...

Page 147: ... 12 Nm 7 4 8 9 lbf ft Engine coolant temperature sen sor M10x1 25 12 Nm 8 9 lbf ft Screw plug rocker arm shaft M10x1 25 10 Nm 7 4 lbf ft Screw cylinder head M10x1 25 Step 1 10 Nm 7 4 lbf ft Step 2 30 Nm 22 1 lbf ft Step 3 50 Nm 36 9 lbf ft Lubricated with engine oil Nut rotor M12x1 60 Nm 44 3 lbf ft Thread oiled with engine oil cone degreased Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Pl...

Page 148: ...s 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 Road tire pressure front 1 5 bar 22 psi rear 2 0 bar 29 psi Final drive 14 45 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 Seat height unloaded 970 mm 38 19 in Ground clearance unloaded 370 mm 14 57 in Weight w...

Page 149: ...ED License plate lamp LED 23 6 Tires Front tire Rear tire 90 90 21 M C 54S M S TT Continental TKC 80 120 90 18 M C 65R M S TT Continental TKC 80 The tires specified represent one of the possible series production tires Additional information is available in the Service section under www husqvarna motorcycles com 23 7 Fork Fork article number 14 15 8R 69 Fork WP Performance SystemsXplor 48 PA Compr...

Page 150: ...ound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 14 mm 0 55 in Spring rate Weight of rider 65 75 kg 143 165 lb 45 N mm 257 lb in Weight of rider 75 85 kg 165 187 lb 48 N mm 274 lb in Weight of rider 85 95 kg 187 209 lb 51 N mm 291 lb in Spring length 260 mm 10 24 in Gas pressure 10 bar 145 psi Static sag 35 mm 1 38 in Riding sag 110 mm 4 33 in Fitted length 477 mm 1...

Page 151: ...m 3 7 lbf ft Fuel connection on fuel pump M8 10 Nm 7 4 lbf ft Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Nut rear sprocket screw M8 35 Nm 25 8 lbf ft Loctite 2701 Nut rim 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 15 Nm 11 1 lbf ft Screw chain sliding piece M8 15 Nm 11 1 lbf ft Screw engine bra...

Page 152: ...e lever on swingarm M14x1 5 80 Nm 59 lbf ft Nut frame on linkage lever M14x1 5 80 Nm 59 lbf ft Nut linkage lever on angle lever M14x1 5 80 Nm 59 lbf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft Screw SAS valve M16x1 5 15 Nm 11 1 lbf ft Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Screw in noz...

Page 153: ...reeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility compatibility with other coolants Recommended supplier Bel Ray Moto Chill Racing Coolant E...

Page 154: ...and that exhibit the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E1...

Page 155: ...ife grease Recommended supplier Bel Ray Waterproof Grease Offroad chain spray Guideline Recommended supplier Bel Ray Blue Tac Chain Lube Oil for foam air filter Recommended supplier Bel Ray Foam Filter Oil Preserving materials for paints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil spray Recommended supplier Bel Ray 6 in 1 ...

Page 156: ...rvice intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated with the same oil The JASO MA standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to...

Page 157: ...27 INDEX OF SPECIAL TERMS 155 OBD On board diagnosis Vehicle system which monitors the specified param eters of the vehicle electronics ...

Page 158: ...28 LIST OF ABBREVIATIONS 156 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 159: ...shes yellow The OBD has detected an error in the vehicle electronics Come safely to a halt and contact an authorized Husqvarna Motorcy cles workshop The fuel level warning lamp lights up yellow The fuel level has reached the reserve mark 29 2 Green and blue symbols Green and blue symbols reflect information The high beam indicator lamp lights up blue The high beam is switched on Turn signal indica...

Page 160: ... Chain checking 81 cleaning 79 Chain guide checking 81 Chain tension adjusting 80 checking 80 Characteristic map of the throttle response adjusting 123 Chassis number 17 Clutch fluid level checking correcting 86 fluid changing 87 Clutch lever 19 basic position adjusting 86 Cold start button 22 Combination instrument adjusting 26 battery changing 117 message 26 overview 26 setting the clock 28 sett...

Page 161: ...installing 77 removing 75 Fuse individual power consumers changing 111 main fuse changing 110 H Hand brake lever 19 basic position adjusting 89 Handlebar position 53 adjusting 53 Headlight light range adjusting 116 Headlight adjustment checking 116 Headlight bulb changing 114 Headlight mask with headlight installing 113 removing 113 High speed compression damping shock absorber adjusting 46 Horn b...

Page 162: ...moving 68 Service 13 Service schedule 42 44 Shift lever 23 basic position adjusting 126 basic position checking 126 Shock absorber installing 66 removing 64 riding sag checking 48 spring preload adjusting 49 static sag checking 48 Side stand 24 Spare parts 13 Spoke tension checking 106 Starting 37 Starting power of lithium ion batteries at low temperatures 32 Steering locking 25 unlocking 25 Steer...

Page 163: ...oubleshooting 138 140 Turn signal bulb changing 115 Turn signal switch 20 Type label 17 U Use definition 7 V View of vehicle front left 15 rear right 16 W Warranty 13 Winter operation checks and maintenance steps 135 Work rules 12 ...

Page 164: ... 3402177en 3402177en 06 2017 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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Summary of Contents for FE 450 2018

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Husqvarna FE 450 2018, Owner'S Manual

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