Husqvarna FE 450 EU Owner'S Manual Download Page 108

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23 TECHNICAL DATA

106

Oil capacity per fork leg

635 ml (21.47 fl. oz.)

Fork oil (SAE 4) (48601166S1) (

p. 108)

23.8

Shock absorber

Shock absorber part number

18.15.7N.69

Shock absorber

WP Suspension

5018 BAVP DCC

Compression damping, low-speed

Comfort

20 clicks

Standard

18 clicks

Sport

16 clicks

Compression damping, high-speed

Comfort

2.5 turns

Standard

2 turns

Sport

1.5 turns

Rebound damping

Comfort

20 clicks

Standard

18 clicks

Sport

16 clicks

Spring preload

10 mm (0.39 in)

Spring rate

Weight of rider: 65… 75 kg (143… 165 lb.)

54 N/mm (308 lb/in)

Weight of rider: 75… 85 kg (165… 187 lb.)

57 N/mm (325 lb/in)

Weight of rider: 85… 95 kg (187… 209 lb.)

60 N/mm (343 lb/in)

Spring length

260 mm (10.24 in)

Gas pressure

10 bar (145 psi)

Static sag

35 mm (1.38 in)

Riding sag

105 mm (4.13 in)

Fitted length

490 mm (19.29 in)

Shock absorber oil

Shock absorber oil (SAE 2.5) (50180342S1) (

p. 108)

23.9

Chassis tightening torques

Screw, pressure regulator

EJOT PT

3 Nm (2.2 lbf ft)

–

Spoke nipple, front wheel

M4.5

5… 6 Nm (3.7… 4.4 lbf ft)

–

Spoke nipple, rear wheel

M4.5

5… 6 Nm (3.7… 4.4 lbf ft)

–

Screw, battery terminal

2.5 Nm (1.84 lbf ft)

–

Screw, intake air temperature sensor

2 Nm (1.5 lbf ft)

–

Screw, shock absorber adjusting ring

5 Nm (3.7 lbf ft)

–

Screw, spoiler on fuel tank

(FE 501 USA)

M5x12

1.5 Nm (1.11 lbf ft)

–

Nut, cable on starter motor

4 Nm (3 lbf ft)

–

Remaining nuts, chassis

10 Nm (7.4 lbf ft)

–

Remaining screws, chassis

10 Nm (7.4 lbf ft)

–

Screw, ball joint of push rod on foot

brake cylinder

10 Nm (7.4 lbf ft)

Loctite

243™

Screw, chain sliding guard

6 Nm (4.4 lbf ft)

Loctite

243™

Screw, front brake disc

14 Nm (10.3 lbf ft)

Loctite

243™

Screw, rear brake disc

14 Nm (10.3 lbf ft)

Loctite

243™

Screw, throttle grip

5 Nm (3.7 lbf ft)

–

Fuel connection on fuel pump

10 Nm (7.4 lbf ft)

–

Nut, foot brake lever stop

20 Nm (14.8 lbf ft)

–

Nut, rear sprocket screw

35 Nm (25.8 lbf ft)

Loctite

2701™

Nut, rim lock

12 Nm (8.9 lbf ft)

–

Summary of Contents for FE 450 EU

Page 1: ...OWNER S MANUAL 2014 FE 450 EU FE 450 AUS FE 501 EU FE 501 AUS FE 501 USA Art no 3402008en ...

Page 2: ......

Page 3: ...dify or delete technical specifications 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 delivery options deviations from illustrations and descriptions or misprints and other errors The models...

Page 4: ... Setting the service display 22 7 8 Speed time and DST distance 1 23 7 9 Speed time and DST2 distance 2 23 7 10 AVG average speed ART operating hours and ODO total distance covered 23 8 PREPARING FOR USE 24 8 1 Advice on first use 24 8 2 Running in the engine 25 8 3 Preparing the vehicle for difficult riding conditions 25 8 4 Preparing for rides on dry sand 26 8 5 Preparing for rides on wet sand 2...

Page 5: ... hand brake lever FE 501 USA 65 13 4 Checking the brake discs 66 13 5 Checking the front brake fluid level 66 13 6 Adding front brake fluid x 66 13 7 Checking the front brake linings 67 13 8 Changing the front brake linings x 68 13 9 Checking the free travel of foot brake lever 69 13 10 Adjusting the basic position of the foot brake lever x 69 13 11 Checking the rear brake fluid level 70 13 12 Add...

Page 6: ...ine oil 104 23 3 2 Coolant 104 23 3 3 Fuel 104 23 4 Chassis 104 23 5 Electrical system 105 23 6 Tires 105 23 7 Fork 105 23 8 Shock absorber 106 23 9 Chassis tightening torques 106 24 SUBSTANCES 108 25 AUXILIARY SUBSTANCES 110 26 STANDARDS 111 INDEX 112 ...

Page 7: ...anding 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 specialist tools required Identifies a page reference more information is provided on the specified page 1 2 Formats used The typographical formats used in this document are explained below Specific name Id...

Page 8: ...eferred to at the relevant passages Info The vehicle has various information and warning labels at prominent locations Do not remove information warning labels If they are missing you or others may not recognize dangers and may therefore be injured 2 3 Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the approp...

Page 9: ...othing Warning Risk of injury Missing or poor protective clothing presents an increased safety risk Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing that is in good condition and meets the legal requirements In the interest of your own safety Husqvarna recommends that you only operate the vehicle while wea...

Page 10: ... will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as needed If you would like to know more about the vehicle or have questions on the material you read please contact an authorized Husqvarna dealer The Owner s Manual is an important component of the vehicl...

Page 11: ...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 can lead to damage a...

Page 12: ...4 VIEW OF VEHICLE 10 4 1 View of vehicle front left example C00576 10 1 Filler cap 2 Air filter box lid 3 Shift lever p 18 4 Engine number p 12 5 Side stand p 18 ...

Page 13: ... button p 15 2 Light switch p 15 2 Turn signal switch p 15 3 Emergency OFF switch p 15 3 Electric starter button p 16 4 Throttle grip p 14 5 Fork rebound adjustment 6 Shock absorber rebound adjustment 7 Level viewer for brake fluid rear 8 Shock absorber compression adjustment 9 Level viewer engine oil 10 Foot brake lever p 18 ...

Page 14: ... is fixed to the front of the steering head 5 3 Key number FE EU FE AUS 500125 10 The key number 1 for the steering lock is stamped onto the key connector 5 4 Engine number 401949 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 5 5 Fork part number 401947 10 The fork part number 1 is stamped on the inner side of the fork stub ...

Page 15: ...5 SERIAL NUMBERS 13 5 6 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 16: ... is fitted on the left side of the handlebar Possible states Kill switch in basic position the ignition circuit is closed in this position and the engine can be started Kill switch pressed the ignition circuit is open in this position the engine goes out if it was running or does not start if it was off 6 5 Kill switch FE 501 USA C00593 10 Kill switch 1 is fitted on the left side of the handlebar ...

Page 17: ...ft of the speedometer Possible states Light off Light switch is pressed in up to the stop In this position the light is switched off Light on Light switch is pulled out to the stop In this position the low beam and tail light are switched on 6 9 Turn signal switch FE EU FE AUS C00591 10 Turn signal switch 1 is fitted on the left side of the handlebar Possible states Turn signal light off Turn sign...

Page 18: ...ning lamp MIL lights up flashes orange The OBD has detected an emission or safety critical fault The fuel level warning lamp lights up orange The fuel level has reached the reserve mark Turn signal indicator light flashes green Turn signal is switched on 6 14 Overview of indicator lamps FE 501 USA B01648 01 Possible states FI warning lamp MIL lights up flashes orange The OBD has detected an emissi...

Page 19: ...t allow fuel to get into the ground water the ground or the sewage system C00532 10 Press release button 1 turn filler cap counterclockwise and lift it upwards and remove 6 16 Closing filler cap C00532 11 Replace the filler cap and turn clockwise until the release button 1 locks in place Info Route the fuel tank breather hose 2 without kinking 6 17 Idle speed adjusting screw C00533 10 The idle spe...

Page 20: ...t and second gears 6 19 Foot brake lever C00609 10 Foot brake lever 1 is located in front of the right footrest The foot brake lever is used to activate the rear brake 6 20 Side stand C00536 10 The side stand 1 is located on the left side of the vehicle C00537 10 The side stand is used for parking the motorcycle Info When you are riding the side stand 1 must be folded up and secured with rub ber b...

Page 21: ... the vehicle on a firm and even surface 400732 01 Park the vehicle Turn the handlebar as far as possible to the right Insert the key in the steering lock 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 23 Unlocking the steering FE EU FE AUS 400731 01 Insert the key in the steering lock turn it to...

Page 22: ...e speedometer Battery voltage of the speedometer is too low Change the battery Service Service is due Contact an authorized Husqvarna workshop 7 4 Setting the speedometer Condition The motorcycle is stationary 401909 01 Press both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Press one of the buttons to select UNIT for the speed in kilometers KM H or miles M H 401911...

Page 23: ...hortening the service interval Press the left button The value decreases Extending the service interval Press the right button The value increases 401914 01 Switching off the service interval display Press and hold the left button off appears on the display 7 5 Setting kilometers or miles Info If you change the unit of measure the ODO value is retained and converted accordingly Condition The motor...

Page 24: ...value decreases Advancing the time Press the right button The value increases 7 7 Setting the service display Condition The motorcycle is stationary 401913 01 Press both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Wait for the menu of the service display to flash Set the service Guideline One time service after 1 h Service every 15 h Shortening the service interval...

Page 25: ...ince the last reset such as between two refueling stops Info If the value of 39999 9 is exceeded DST2 is automatically reset to 0 0 Press the left but ton briefly Next display mode Press the left but ton for 3 5 sec onds DST2 can be preset to a value between 0 0 and 39999 9 by pressing the buttons Press the right but ton briefly Next display mode Press the right but ton for 3 5 sec onds DST2 is re...

Page 26: ...e rear brake may fail due to overheating Take your foot 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 u...

Page 27: ...tle 8 3 Preparing the vehicle for difficult riding conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can lead to considerably 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 Husqvarna recommends using ...

Page 28: ...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 8 5 Preparing for rides on wet sand B00437 01 Fit a rain cover on the air filter Waterproofing device for air filter 77206921000 Info Observe the Husky Power fitting instructions 600868 01 Clean the chain Fit the s...

Page 29: ... 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 secondary drive Clean the chain Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 87 8 8 Preparing for rides at low temperature or in snow B00437 01 Fi...

Page 30: ... they can be operated smoothly Check all screws nuts and hose clamps regularly for tightness Check the fuel supply 9 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 run the engine in an enclosed space without an effective exhaust ex...

Page 31: ...le opening increases fuel consumption To shift down brake and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time Guideline 2 min Avoid frequent and longer slipping of the clutch This heats the engine oil the engine and the coolin...

Page 32: ...age Damage to or destruction of components due to excessive load The side stand is only designed for the weight of the motorcycle Do no sit on the motorcycle when it is resting on the side stand The side stand or the frame may become damaged and the motorcycle may fall over Brake the motorcycle Shift transmission to neutral FE EU FE AUS Press and hold the kill switch while the engine is idling unt...

Page 33: ...s on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Note Material damage Premature clogging of the fuel filter In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Your authorized Husqvarna workshop will be glad to help Only r...

Page 34: ...ration x Check rectify the fluid level of the hydraulic clutch p 63 Check the front brake fluid level p 66 Check the free travel of the hand brake lever p 65 Check the steering head bearing play p 46 Check the valve clearance x Check the clutch x Change the engine oil and oil filter and clean the oil screens x p 92 Check all hoses e g fuel cooling bleeding drainage and sleeves for cracking leaks a...

Page 35: ...estor x FE 501 USA Perform a fork service x 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 Check the valves valve springs and valve spring seats x Check the camshaft and cam lever x Change the connecting rod conrod bearing and crank pin x Check the transmission and shift mechanism x Check the ...

Page 36: ...he 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 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...

Page 37: ...r 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 11 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 high...

Page 38: ...g is the difference between measurements A and B Check the static sag Static sag 35 mm 1 38 in If the static sag is less or more than the specified value Adjust the spring preload of the shock absorber x p 37 11 8 Checking the riding sag of the shock absorber 400990 10 Measure distance A of rear wheel unloaded p 36 With another person holding the motorcycle the rider wearing full protective cloth ...

Page 39: ...ng 2 until the spring is no longer under tension Hook wrench T106S Measure the overall spring length while the spring is not under tension Tighten the spring by turning adjusting ring 2 to measurement A Guideline Spring preload 10 mm 0 39 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 ab...

Page 40: ...rebound damping of the shock absorber p 35 11 11 Checking basic setting of fork Info For various reasons no exact riding sag can be determined for the forks 401000 01 As with the shock absorber smaller differences in the rider s weight can be compen sated by the spring preload However if the fork is often overloaded hard end stop on compression harder springs must be fit to avoid damage to the for...

Page 41: ...e adjusting screw Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 11 14 Handlebar position 101859 10 On the upper triple clamp there are two holes at a distance of A to each other Hole distance A 15 mm 0 59 in T...

Page 42: ...the handlebar supports Place the handlebar supports in the required position Mount and tighten screws 2 Guideline Screw handlebar holder M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right handlebar holders evenly Position the handlebar Info Make sure the cables and wiring are positioned correctly Position the handlebar clamps Mount and tighten screws 1 evenly Guideline Screw handle...

Page 43: ...ide 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 fork legs Preparatory work Raise the motorcycle with a lift stand p 41 C00562 10 Main work Release bleeder screws 1 Any excess pressure escapes from the interior of the fork Mount and tighten bleeder screws Finishing work Re...

Page 44: ...e fork protector downwards 12 6 Positioning the fork protector C00564 11 Position the fork protector on the left fork leg Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the wiring harness Position the brake line Put the clamp on and mount and tighten screws 2 Position the fork protector on the right fork leg Mount and tighten the screws Guideline Remaini...

Page 45: ...nt C00579 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 15 Nm 11 1 lbf ft C00578 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 cable binder 5 Position the brake line wiring harness and clamp Mount and tighten screws 6 Finishin...

Page 46: ...e fork legs x p 43 Install the front wheel x p 74 Install the headlight mask with the headlight p 82 Check the headlight setting p 84 12 11 Removing the lower triple clamp x Preparatory work Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 82 Raise the motorcycle with a lift stand p 41 Remove the front wheel x p 74 Remove the fork legs p 42 Re...

Page 47: ...ositioned Mount protective ring 2 and O ring 3 C00585 10 Position the upper triple clamp with the steering Mount screw 4 but do not tighten yet Position the clutch line next to the voltage regulator C00598 10 Position the fork legs Info The compression damping is located in the left fork leg COMP white adjust ing screw The rebound damping is located in the right fork leg REB red adjusting screw Gr...

Page 48: ...hten screws bm Finishing work Install the front fender p 48 Install the front wheel x p 74 Install the headlight mask with the headlight p 82 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the steering head bearing play p 46 Remove the motorcycle from the lift stand p 41 Check the headlight setting p 84 12 13 Checking the ste...

Page 49: ... steering head bearing and replace if required Finishing work Remove the motorcycle from the lift stand p 41 12 14 Adjusting the play of the steering head bearing x Preparatory work Raise the motorcycle with a lift stand p 41 C00570 10 Main work Loosen screws 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 ...

Page 50: ...rake line guide C00572 12 Remove screws 3 Take off the fender 12 17 Installing the front fender C00572 11 Main work Position the front fender Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft C00596 11 Position the brake line and wiring harness in the brake line guide Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Connect plug in c...

Page 51: ...m above Finishing work Install the manifold x p 53 Mount the seat p 49 Install the main silencer p 54 Install the right side cover p 56 Remove the motorcycle from the lift stand p 41 12 20 Removing the seat B01819 10 Remove screws 1 in the recessed grips on the left and right Lift up the seat at the rear pull it back and then lift it off 12 21 Mounting the seat B01818 01 Attach the front of the se...

Page 52: ...ilter 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 50 B01816 11 Main work Push air filter holder 1 toward the air filter at position A ...

Page 53: ...ould 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 50 Remove the air filter x p 50 L00189 10 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Info Only press the air filter to dry it never wring it o...

Page 54: ...e the right side cover p 55 Remove the main silencer p 54 Raise the motorcycle with a lift stand p 41 309320 10 Main work Remove fitting 1 Remove screw 2 309321 10 Press angle lever 3 toward the rear Press linkage lever 4 downward 309322 10 Raise the swingarm 309323 10 Remove screw 5 Lower the shock absorber ...

Page 55: ...x 309324 11 Main work Position the manifold and mount springs 1 Spring hooks 50305017000 309325 11 Mount and tighten screw 2 Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft 309326 10 Position the shock absorber Mount and tighten screw 3 Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 309322 11 Lower the swingarm ...

Page 56: ...t touch hot components Preparatory work Remove the right side cover p 55 B01814 11 Main work Disconnect spring 1 Remove screws 2 and take off the main silencer 12 31 Installing the main silencer B01814 10 Main work Mount the main silencer Mount screws 1 but do not tighten yet Reconnect spring 2 Tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the right...

Page 57: ...e screws 5 and silencer cap 6 with O ring 7 Remove screws 8 and insert 9 together with the insulating pad bk Clean the parts that need to be reinstalled and check for damage Mount the new insulating pad bk on insert 9 and secure it with adhesive tape Slide insert 9 with insulating pad bk into the main silencer and secure with screws 8 Mount O ring 3 onto connecting cap 2 Slide the new glass fiber ...

Page 58: ...in 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 children Preparatory work Rem...

Page 59: ... 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 B01809 10 Main work Check the routing of the throttle...

Page 60: ...t accumulation If the chain is very dirty Clean the chain p 58 12 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 brake cleaner wh...

Page 61: ... 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 chain or the countershaft of the transmission to break in extreme cases If the chain is ...

Page 62: ... Measure the distance B of 18 chain links in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance B at the longest chain section 272 mm 10 71 in If the distance B is greater than the specified measurement Change the power set x Info When the chain is replaced the rear sprocket and engine sprocket should also ...

Page 63: ...the chain guide If the light part of the chain guide is worn Change the chain guide x B01634 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 Remaining nuts chassis M6 10 Nm 7 4 lbf ft Finishing work Remove the motorcycle from the lift stand p 41 12 42 Checking the frame x 401799 01 Check the f...

Page 64: ...9 Remove the fuel tank x p 56 C00602 10 Main work Check the routing of the throttle cable Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bearing If the throttle cable is not routed as specified Correct the routing of the throttle cable Finishing work Install the fuel tank x p 57 Mount the seat p 49 12 45 Checking the rubber...

Page 65: ...ted Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 12 48 Checking rectifying the fluid level of the hydraulic clutch Info The fluid level rises with increased wear of the clutch lining discs B01538 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 f...

Page 66: ...nings 6 of the master cylin der without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount and tighten the bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below top edge of container 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws 12 50 Removing the engine guard...

Page 67: ...ee travel of the hand brake lever p 65 Adjust the free travel of the hand brake lever with adjusting screw 1 Info Turn the adjusting screw clockwise to reduce free travel The pressure point moves away from the handlebar Turn the adjusting screw counterclockwise to increase free travel The pres sure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by han...

Page 68: ...rn 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 Husqvarna workshop will be glad to help B01544 10 Move the brake fluid reservoir mounted on the handlebar ...

Page 69: ...linings p 67 B01639 10 Main work Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Add brake fluid to level A Guideline Level A brake fluid level below con tainer rim 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 108 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid...

Page 70: ...ficient of the brake linings and thus their brake power may vary greatly from that of original Husq varna bake linings If brake linings that differ from the original equipment are used it cannot be guaranteed that these are in keeping with the original homologation In this case the vehicle will not correspond to its condition at delivery and the war ranty shall be void Warning Environmental hazard...

Page 71: ...ver Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to overheating Adjust 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 pi...

Page 72: ...m 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 Husqvarna workshop will be glad to help B01795 10 Stand the vehicle upright Check the brake fluid level in level viewer 1 If the brake ...

Page 73: ... fluid from a sealed container Preparatory work Check the rear brake linings p 71 B01794 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 108 Mount the screw cap with the membrane and O ring Info Clean up overflowed or spilt brake fluid immediately with water 13 13 Checking the rear brake linings Warning...

Page 74: ... in Husqvarna vehicles The structure and fiction coefficient of the brake linings and thus their brake power may vary greatly from that of original Husq varna bake linings If brake linings that differ from the original equipment are used it cannot be guaranteed that these are in keeping with the original homologation In this case the vehicle will not correspond to its condition at delivery and the...

Page 75: ... the pin and mount the cotter pin Info Always change the brake linings in pairs Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point B01794 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 108 Mount screw cap 1 with membrane 2 and O ring Info Clean up overflowed or spilt brake fluid immediately with water ...

Page 76: ...e front wheel withdraw the wheel spindle Take the 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 14 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...

Page 77: ...torcycle with a lift stand p 41 B01790 10 Main work Press the brake caliper by hand on to the brake disc in order to press back the brake piston Info Make sure when 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...

Page 78: ... on adjusting screws 5 Check the chain tension p 59 Tighten nut 4 Guideline Nut rear wheel spindle 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 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...

Page 79: ...ve years Change the tire 14 6 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the protection cap Check the tire air pressure when the tires are cold Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Road tire pressure...

Page 80: ...quencies in spokes with the same length and thickness this indicates different spoke tensions You should hear a high note If the spoke tension varies Correct the spoke tension x Check the spoke torque Guideline Spoke nipple front wheel M4 5 5 6 Nm 3 7 4 4 lbf ft Spoke nipple rear wheel M4 5 5 6 Nm 3 7 4 4 lbf ft Torque wrench with various accessories in set 58429094000 ...

Page 81: ...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 15 2 Installing the battery x B01789 10 Main work Insert battery into the battery compartment with the terminals facing to the front Battery YTX5L BS p 105 Reconnect rubber band 1 Info Con...

Page 82: ...gh 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 83: ...y main fuse 2 Info A defective fuse can be identified by the burned out fuse wire A A reserve fuse 3 is located in the starter relay Install a new main fuse Fuse 58011109120 p 105 Check that the electrical equipment is functioning properly Tip Insert the spare fuse so that it is available if needed Mount the protection caps Mount the starter relay onto the holder and lay the cable Finishing work I...

Page 84: ...orrect rating only Fuse 75011088010 p 105 Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover Finishing work Mount the seat p 49 15 6 Removing the headlight mask with the headlight Preparatory work Switch off all power consumers and switch off the engine B01787 10 Main work Open rubber bands 1 o...

Page 85: ...th the bulb socket beneath it all the way counterclockwise and lift it off Pull bulb socket 2 of the parking light out of the reflector L00270 10 Press headlight bulb 3 lightly into the bulb socket turn it all the way counterclock wise and pull it out Insert the new headlight bulb Headlight S2 socket BA20d p 105 Insert the protection cap with the bulb socket into the reflector and turn it all the ...

Page 86: ... of a light wall and make a mark at the height of the center of the low beam headlight Make another mark a distance B under the first mark Guideline Distance B 5 cm 2 in Position the vehicle vertically a distance A away from the wall Guideline Distance A 5 m 16 ft The rider now sits down on the motorcycle Switch on the low beam Check the headlight setting The boundary between light and dark must b...

Page 87: ...se and remove it Remove speedometer battery 3 Insert the new battery with the label facing outward Speedometer battery CR 2032 p 105 Check the O ring of the protection cap for correct seating B01645 10 Position protection cap 2 and turn all the way clockwise using a coin Press any button on the speedometer The speedometer is activated Position the speedometer in the holder Mount and tighten the sc...

Page 88: ...ool down In case of scalding 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 physicia...

Page 89: ...el does not meet specifications Correct the coolant level Alternative 1 Coolant p 108 Alternative 2 Coolant mixed ready to use p 108 Mount the radiator cap 16 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 90: ...on the 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 C00604 10 Main work Make sure that the 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 108 Coolant mixed rea...

Page 91: ...he 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 89 17 2 Adjusting the play in the throttle cable x Preparatory work Remove the seat p 49 Remove the fuel tank x p 56 Check the routing of the throttle cable p 62 C00606 10 Main work Move the handlebar to the straight ahead position Push back slee...

Page 92: ... of your boot and the shift lever Gap between the shift lever and the top of the boot 10 20 mm 0 39 0 79 in If the distance does not meet the specifications Adjust the basic position of the shift lever x p 90 17 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 leve...

Page 93: ...an the plug in connection 1 of the fuel line thoroughly with 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 Insert the new fuel screen all the way into the connecting piece Lubricate the O ring and connect plug in connect...

Page 94: ... in applicable regulations Info Drain the engine oil only when the engine is warm Preparatory work Remove the engine guard p 64 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 gear oil screen and the O rings Info Do not remove screw A B01760 10 Remove ...

Page 95: ...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 Oil the O ring of the oil filter cover and mount it with the oil filter cover 7 Mount and tighten the screws Guideline...

Page 96: ...ture wear to the engine B01766 10 Main work Remove the oil filler plug 1 with the O ring from the clutch cover Fill engine oil to the middle A of the level viewer Engine oil SAE 10W 50 p 108 Alternative 1 Engine oil SAE 10W 60 p 108 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 wi...

Page 97: ... motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust system Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and b...

Page 98: ... the parts are cooled down and while they are installed After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the brake discs with a wax based corrosion inhibitor Info Corrosion inhibitor is not permitted to come in contact with the brake discs as this would greatly reduce the brak...

Page 99: ...efore taking the motorcycle out of service add fuel additive Refuel p 31 Clean the motorcycle p 95 Change the engine oil and oil filter and clean the oil screens x p 92 Check the antifreeze and coolant level p 86 Check the tire air pressure p 77 Remove the battery x p 79 Charge the battery x p 80 Guideline Storage temperature of battery without direct sunlight 0 35 C 32 95 F Store the vehicle in a...

Page 100: ...stem Read out the fault memory using the Husqvarna diagnostics tool x Engine does not speed up Defect in fuel injection system Read out the fault memory using the Husqvarna diagnostics tool x Ignition system defective Ignition coil check the secondary winding x Check the spark plug connector x Check the stator winding of the alternator x Engine has too little power Air filter heavily contaminated ...

Page 101: ...nt hose bent Route the vent hose without bends or replace it if necessary Engine oil level too high Check the engine oil level p 91 Engine oil too thin low viscosity Change the engine oil and oil filter and clean the oil screens x p 92 Piston and cylinder worn Measure the piston cylinder mounting clear ance x Battery discharged Battery is not being charged by alter nator Check the charging voltage...

Page 102: ...arning lamp MIL 13 FI warning lamp MIL flashes 1x long 3x short Error level condition Intake air temperature sensor input signal too 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 signal too low Rollover sensor A D type input signal too high Blink code FI war...

Page 103: ...L 45 FI warning lamp MIL flashes 4x long 5x short Error level condition FE EU FE 501 AUS Lambda sensor heater cylinder 1 sensor 1 short circuit to ground or open circuit FE EU FE 501 AUS Lambda sensor heater cylinder 1 sensor 1 input signal too high ...

Page 104: ...ansmission 32 76 Clutch Multidisc clutch in oil bath hydraulically activated Transmission ratio 1st gear 14 36 2nd gear 17 32 3rd gear 19 28 4th gear 22 26 5th gear 24 23 6th gear 26 21 Alternator 12 V 200 W Ignition Contactless controlled fully electronic ignition with digital ignition adjustment type Kokusan Spark plug NGK LKAR 8AI 9 Spark plug electrode gap 0 9 mm 0 035 in Cooling Water permane...

Page 105: ... ft Loctite 243 Screw timing chain tensioner M6 10 Nm 7 4 lbf ft Screw timing chain tensioning rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw torque governor M6 10 Nm 7 4 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6x25 10 Nm 7 4 lbf ft Screw water pump cover M6x55 10 Nm 7 4 lbf ft Oil jet for balancer shaft lubrication M6x0 75 4 Nm 3 lbf ft Oil nozzle for conrod b...

Page 106: ...approx 1 5 l 1 6 qt 23 4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 4CS Suspension travel Front 300 mm 11 81 in Suspension travel Rear 330 mm 12 99 in Fork offset 20 mm 0 79 in Shock absorber WP Suspension 5018 BAVP DCC Brake system Disc brakes brake calipers on floating bearings Brake discs diameter Front 260 mm 10 24 in Rear 220 m...

Page 107: ... LED License plate lamp FE EU FE AUS W5W socket W2 1x9 5d 12 V 5 W 23 6 Tires Validity Front tires Rear tires FE EU FE AUS 90 90 21 M C 54R TT Michelin ENDURO COMPETITION IV 140 80 18 M C 70R TT Michelin ENDURO COMPETITION IIIe FE 501 USA 80 100 21 M C 51M TT Dunlop GEOMAX MX51 FA 110 100 18 M C 64M TT Dunlop GEOMAX MX51 Additional information is available in the Service section under www husqvarn...

Page 108: ...180342S1 p 108 23 9 Chassis tightening torques Screw pressure regulator EJOT PT 3 Nm 2 2 lbf ft Spoke nipple front wheel M4 5 5 6 Nm 3 7 4 4 lbf ft Spoke nipple rear wheel M4 5 5 6 Nm 3 7 4 4 lbf ft Screw battery terminal M5 2 5 Nm 1 84 lbf ft Screw intake air temperature sensor M5 2 Nm 1 5 lbf ft Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Screw spoiler on fuel tank FE 501 USA M5x12 1 ...

Page 109: ...tite 243 Screw top triple clamp M8 17 Nm 12 5 lbf ft Engine attachment bolt M10 60 Nm 44 3 lbf ft Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw bottom shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Screw handlebar holder M10 40 Nm 29 5 lbf ft Loctite 243 Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Nut fuel pump fixation M12 15 ...

Page 110: ... 111 SAE 10W 60 KTM LC4 2007 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the correspond ing properties Synthetic engine oil Engine oil SAE 10W 50 Standard classification JASO T903 MA p 111 SAE p 111 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container a...

Page 111: ...28 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 E100 ...

Page 112: ...25 AUXILIARY SUBSTANCES 110 High viscosity grease Recommended supplier SKF LGHB 2 Rubber grip adhesive 00062030051 Recommended supplier KTM Sportmotorcycle AG GRIP GLUE ...

Page 113: ...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 114: ...cking 60 Chain tension adjusting 59 checking 59 Chassis number 12 Clutch fluid level checking rectifying 63 fluid changing 63 Clutch lever 14 basic position adjusting 63 Combination instrument overview 20 Compression damping fork adjusting 38 Compression damping high speed shock absorber adjusting 35 Compression damping low speed shock absorber adjusting 34 Coolant draining 87 refilling 88 Coolant...

Page 115: ...5 I Idle speed adjusting 90 Idle speed adjusting screw 17 Implied warranty 9 Intended use 6 K Key number 12 Kill switch 14 L Light switch 15 Lower triple clamp installing 45 removing 44 M Main fuse changing 81 Main silencer glass fiber yarn filling changing 54 installing 54 removing 54 Manifold installing 53 removing 52 Manufacturer warranty 9 Motorcycle cleaning 95 raising with lift stand 41 remo...

Page 116: ...g 19 unlocking 19 Steering head bearing lubricating 47 Steering head bearing play adjusting 47 checking 46 Storage 97 Swingarm checking 62 T Technical data capacities 104 chassis 104 chassis tightening torques 106 electrical system 105 engine 102 engine tightening torques 102 fork 105 shock absorber 106 tires 105 Throttle cable play adjusting 89 Throttle cable routing checking 62 Throttle grip 14 ...

Page 117: ... 3402008en 3402008en 09 2013 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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