Husqvarna FE 450 Owner'S Manual Download Page 51

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12 SERVICE WORK ON THE CHASSIS

F00373-10

–

Secure wiring harness and clutch line with cable holder.

–

Position the voltage regulator, and mount and tighten screws



Guideline

Remaining screws, chassis

10 Nm (7.4 lbf ft)

–

Secure the wiring harness with the cable holder in front of the right radiator.

H01672-10

–

Position the fork legs.

Bleeder screws



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 sec-

ond milled groove (from the top) must be flush with the top edge of the

upper triple clamp.

F00318-11

–

Tighten screws



Guideline

Screw, bottom triple clamp

15 Nm (11.1 lbf ft)

F00281-10

–

Tighten screw



Guideline

Screw, top steering head

M20x1.5

12 Nm (8.9 lbf ft)

F00281-11

–

Mount and tighten screw



Guideline

Screw, top steering stem

17 Nm

(12.5 lbf ft)

Loctite

243™

F00318-10

–

Tighten screws



Guideline

Screw, top triple clamp

17 Nm (12.5 lbf ft)

Summary of Contents for FE 450

Page 1: ...OWNER S MANUAL 2017 FE 450 FE 501 Art no 3402103en ...

Page 2: ......

Page 3: ...erials 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 Motorcy cles accepts no liability for delivery options deviations from illustrations and descriptions as well as misprints and other errors The models portrayed partly contain special equipmen...

Page 4: ...DST2 distance 2 24 7 10 AVG average speed ART operating hours and ODO total distance covered 24 8 PREPARING FOR USE 25 8 1 Advice on first use 25 8 2 Running in the engine 26 8 3 Starting power of lithium ion batteries at low temperatures 26 8 4 Preparing the vehicle for difficult riding conditions 26 8 5 Preparing for rides on dry sand 27 8 6 Preparing for rides on wet sand 27 8 7 Preparing for r...

Page 5: ...justing free travel of hand brake lever 71 13 3 Checking the brake discs 71 13 4 Checking the front brake fluid level 72 13 5 Adding front brake fluid 72 13 6 Checking the front brake linings 73 13 7 Changing the front brake linings 73 13 8 Checking the free travel of foot brake lever 75 13 9 Adjusting the basic position of the foot brake lever 75 13 10 Checking the rear brake fluid level 76 13 11...

Page 6: ...22 3 1 Engine oil 113 22 3 2 Coolant 113 22 3 3 Fuel 113 22 4 Chassis 113 22 5 Electrical system 114 22 6 Tires 114 22 7 Fork 114 22 8 Shock absorber 115 22 9 Chassis tightening torques 115 23 SUBSTANCES 117 24 AUXILIARY SUBSTANCES 118 25 STANDARDS 119 26 INDEX OF SPECIAL TERMS 120 27 LIST OF ABBREVIATIONS 121 28 LIST OF SYMBOLS 122 28 1 Yellow and orange symbols 122 28 2 Green and blue symbols 12...

Page 7: ...shop There your motorcycle will 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 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Indicates a p...

Page 8: ...opriate measures are not taken Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken Note Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning Indicates a dang...

Page 9: ...ch as helmet boots gloves as well as trousers and a jacket with protectors on all rides Always wear protective clothing that is in good condition and meets the legal regulations In the interest of your own safety Husqvarna Motorcycles recommends that you only operate the vehicle while wearing protective clothing 2 7 Work rules Special tools are necessary for certain tasks The tools are not contain...

Page 10: ... 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 Husq varna Motorcycles dealer The Owner s Manual is an important component of th...

Page 11: ...ies 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 that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual Incorrect adjustment and tuning of the engine a...

Page 12: ...IEW OF VEHICLE 10 4 1 View of vehicle front left example H01739 10 1 Hand brake lever p 14 2 Clutch lever p 14 3 Filler cap 4 Air filter box cover 5 Side stand p 19 6 Engine number p 12 7 Shift lever p 18 ...

Page 13: ...button p 14 2 Light switch p 15 2 Turn signal switch p 15 3 Emergency OFF switch p 15 4 Electric starter button p 15 5 Throttle grip p 14 6 Fork rebound adjustment 7 Foot brake lever p 18 8 Level viewer engine oil 9 Shock absorber compression adjustment 10 Shock absorber rebound adjustment 11 Level viewer for brake fluid rear ...

Page 14: ... is fixed to the front of the steering head 5 3 Key number 402247 10 The key number for the steering lock is stamped onto the key connector 5 4 Engine number 0 0 1 1 H00940 01 Engine number is embossed on the left side of the engine behind the shift lever 5 5 Fork part number 401947 10 The fork part number is stamped on the inner side of the fork stub ...

Page 15: ...5 SERIAL NUMBERS 13 5 6 Shock absorber article number 0 0 1 1 401948 10 Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 16: ... on the right side of the handlebar 6 4 Kill switch F00260 10 Kill switch 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 Horn button F00260...

Page 17: ...t turn signal on The turn signal switch is turned to the left Right turn signal on The turn signal switch is turned to the right 6 8 Emergency OFF switch F00262 10 The emergency OFF switch is fitted on the right side of the handlebar Possible states Ignition off In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start Ignition on In this ...

Page 18: ...ts up blue The high beam is switched on Malfunction indicator lamp lights up flashes yellow The OBD has detected an emission or safety critical fault The fuel level warning lamp lights up yellow The fuel level has reached the reserve mark Turn signal indicator lamp flashes green The turn signal is switched on 6 12 Opening the filler cap Danger Fire hazard Fuel is highly flammable The fuel in the f...

Page 19: ...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 turn ing the throttle grip towards the front the cold star...

Page 20: ... 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 16 Shift lever 401950 10 The shift lever is fitted on the left side of the engine 401950 11 The gear positions can be seen in the photograph The neutral or idle position is between the first and sec...

Page 21: ...ck is used to lock the steering Steering and therefore riding is no longer possible 6 20 Locking the steering Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 400732 01 Park the vehicle Turn the handlebar as far as possible to the right Grease the steering lock regularly Universal oil spray p 118 Insert the key in the steering lock p ...

Page 22: ...locking the steering 400731 01 Insert the key in the steering lock p 19 turn it to the left pull it out and turn it to the right Remove the key You can now steer the bike again Info Never leave the key in the steering lock ...

Page 23: ...peedometer Battery voltage of the speedometer is too low Change the battery Service A service is due Contact an authorized Husqvarna Motorcy cles 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 mile...

Page 24: ...h Shortening 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 the kilometers or miles Info If the unit is changed the value ODO is retained and converted accordingly Condition The motorcycl...

Page 25: ...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 26: ... since 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 button briefly Next display mode Press the right button for 3 5 seconds DST2 is res...

Page 27: ...ents 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 Warning Danger of accidents Total weight and axle loads influence the handling characteristic Do not exceed the maximum permissible overall weight or the axle loads Warning Risk of misappropriation Peopl...

Page 28: ... at temperatures over 15 C 60 F At low tempera tures however the starting power of lithium ion batteries drops to below that of lead batteries Multiple starting attempts may be needed Press the electric starter button for 5 sec onds and wait 30 seconds between attempts The pauses are necessary so that the created heat can distribute through the lithium ion battery and the battery is not dam aged I...

Page 29: ...lter Sand cover for air filter 79006922000 Info See the Husqvarna Motorcycles accessories 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 M01459 01 All 450 models Change the clutch spring Clutch spring hard 78932005000 8 6 Preparing for rides on wet sand 102137 01 Fit a waterproofing d...

Page 30: ...pring hard 78932005000 8 7 Preparing for rides on wet and muddy surfaces 102137 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 79006921000 Info See the Husqvarna Motorcycles accessories fitting instructions 600868 01 Fit the steel sprocket Clean the motorcycle p 106 Straighten bent radiator fins carefully M01459 01 All 450 models Change the clutch spring Clutch...

Page 31: ...s 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 95 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 32: ... regularly as incorrect spoke tension will strongly impair riding safety Clean the dust boots of the fork legs p 45 Bleed the fork legs p 45 Check the air filter Check the settings of all controls and ensure that they can be operated smoothly Check all screws nuts and hose clamps regularly for tightness Check the fuel level 9 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhali...

Page 33: ...otorcycle is stationary The engine is running at idle speed Transmission in neutral H01179 10 Press and hold MAP and TC buttons simultaneously FI warning lamp flashes orange rapidly Info Several seconds after the vehicle starts Launch Control is deactivated automatically The Launch Control is deactivated in the following cases FI warning lamp no longer flashes After full throttle the throttle valv...

Page 34: ... open This will barely reduce the speed but fuel consumption will be considerably lower Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption To shift down apply the brakes and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and either open the throttle or shift again S...

Page 35: ...e The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand Note Fire hazard Hot vehicle components pose a fire h...

Page 36: ...ughly 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 clean fuel that ...

Page 37: ...he wheel bearing for play Check the wheel hubs Check the rim run out Check the spoke tension p 84 Check the chain rear sprocket engine sprocket and chain guide p 65 Check the chain tension p 63 Grease all moving parts e g side stand hand lever chain and check for smooth operation Check correct the fluid level of the hydraulic clutch p 68 Check the front brake fluid level p 72 Check the free travel...

Page 38: ... 10 operating hours Change the front brake fluid Change the rear brake fluid Change the hydraulic clutch fluid p 69 Lubricate the steering head bearing p 51 Service the fork Service the shock absorber Perform engine service including 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 valv...

Page 39: ...nd 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 quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses slowly These two ranges can be adjusted separately although the transition between high speed and low speed is gradual Thus chang...

Page 40: ...e number 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 damping 11 5 Adjusting the rebound damping of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectl...

Page 41: ... the motorcycle from the lift stand p 45 11 7 Checking the static sag of the shock absorber 402416 10 Measure dimension of rear wheel unloaded p 39 Hold the motorcycle upright with the aid of an assistant Again measure the distance between the rear axle and marking SAG on the rear fender using the sag gauge Note down the value as dimension Info The static sag is the difference between measurements...

Page 42: ... is disassembled incorrectly 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 Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Preparatory work Raise the motorcycle with a lift stand p 45 Remove the shock absorber...

Page 43: ...r p 53 Check the free travel of the foot brake lever p 75 Remove the motorcycle from the lift stand p 45 Check the static sag of the shock absorber p 39 Check the riding sag of the shock absorber p 40 Adjust the rebound damping of the shock absorber p 38 11 11 Checking the basic setting of the fork Info For various reasons no exact riding sag can be determined for the fork 401000 01 As with the sh...

Page 44: ...F00352 10 Turn red adjusting screw clockwise as far as it will go Info Adjusting screw is located at the upper end of the right fork leg 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 Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping Comfort 1...

Page 45: ...oles on the handlebar supports are placed at a distance of from the center Hole distance 3 5 mm 0 138 in The handlebar supports can be mounted in four different positions 11 16 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk If the handlebar is bent or straightened the material becomes fatigued The handlebar may break as a result Change the han...

Page 46: ...11 TUNING THE CHASSIS 44 Position the handlebar clamps Mount and tighten screws evenly Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure the gap width is even ...

Page 47: ... stand 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 work Raise the motorcycle with a lift stand p 45 402556 10 Main work Release bleeder screws Any excess pressure escapes from the interior of the fork Tighten the bleeder screws Finishing work Remove the ...

Page 48: ...s on the right fork leg and take off the right fork protector 12 6 Installing the fork protector F00316 11 Position the fork protector on the left fork leg Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line wiring harness and clamp Mount and tighten screws Position the fork protector on the right fork leg Mount and tighten screws Guideline Remai...

Page 49: ...deline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft F00276 10 Position the brake caliper and mount and tighten screws 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 Finishing work Install the front wheel p 80 In...

Page 50: ...e Do not kink the cables and lines F00278 10 Remove O ring and protective ring 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 118 Position the lower triple clamp with the steerin...

Page 51: ... 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 sec ond milled groove from the top must be flush with the top edge of the upper triple clamp F00318 11 Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft F00281 10 Tighten screw Guideline Screw to...

Page 52: ...and damages components Correct incorrect steering head bearing play immediately Your authorized Husqvarna Motorcycles workshop will be glad to help Info If the vehicle is operated for a lengthy period with play in the steering head bearing the bearings and the bearing seats in the frame can become damaged over time Preparatory work Raise the motorcycle with a lift stand p 45 400738 11 Main work Mo...

Page 53: ... triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw Guideline Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Finishing work Check the play of the steering head bearing p 50 Remove the motorcycle from the lift stand p 45 12 13 Lubricating the steering head bearing 800010 10 Remove the lower triple clamp p 47 Install the lower triple clamp p 48 12 14 Removing the front fender Prepar...

Page 54: ...ll the headlight mask with the headlight p 90 Check the headlight setting p 91 12 16 Removing the shock absorber Preparatory work Raise the motorcycle with a lift stand p 45 K00589 10 Main work Remove the cable ties Remove screws Remove screws with the washers Remove the frame protectors on the left and right F00284 10 Remove screw Remove fitting Info Raise the wheel slightly to be able to remove ...

Page 55: ... Remove nut and pull out the swingarm pivot Push the swingarm back and secure it against falling over F00461 10 Hold the shock absorber and remove screw Remove the shock absorber carefully at the bottom 12 17 Installing the shock absorber F00462 10 Main work Carefully position the shock absorber into the vehicle from the bottom Mount and tighten screw Guideline Screw top shock absorber M10 60 Nm 4...

Page 56: ...ect plug in connector F00465 10 Position the foot brake cylinder Push rod engages in the foot brake cylinder The dust boot is correctly positioned Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft F00464 10 Position the angle lever and linkage lever Mount and tighten fitting Guideline Nut linkage lever on angle lever M14x1 5 80 Nm 59 lbf ft Info Pay attention to flat ...

Page 57: ...e lever p 75 Remove the motorcycle from the lift stand p 45 12 18 Removing the seat Preparatory work Remove the air filter box cover p 56 F00296 10 Main work Remove screw Pull seat back 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 correct...

Page 58: ...ine 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 brake fluid etc correctly and in compliance with the applicable regulat...

Page 59: ...ard 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 Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the air filter box cover p 56 Remove the air filter p 56 H00277 10 Main work Wash the air filter thor...

Page 60: ...nstall the air filter box cover p 56 12 26 Removing the right side cover K00593 10 Remove screw Pull off the side cover sideways in areas and and remove toward the front 12 27 Installing the right side cover K00592 10 Position the side cover on collar bushings and and push toward the rear Engage the side cover in areas and Mount and tighten screw Guideline Remaining screws chassis M5 5 Nm 3 7 lbf ...

Page 61: ...lencer Mount screws but do not tighten yet Attach spring Spring hook 50305017000 Tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the right side cover p 58 12 30 Changing the glass fiber yarn filling in 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 perfor...

Page 62: ...ot 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 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 co...

Page 63: ...el 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 any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a hea...

Page 64: ...ushings Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft K00596 11 Plug in connector for the fuel pump Remove the wash cap set Thoroughly clean the plug in connection of the fuel line using compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the O ring and connect plug in connection for the fuel line Info R...

Page 65: ...ly on its maintenance Preparatory work Raise the motorcycle with a lift stand p 45 400725 01 Main work Clean the chain regularly and then treat with chain spray Offroad chain spray p 118 Finishing work Remove the motorcycle from the lift stand p 45 12 35 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents If the chain is tensio...

Page 66: ... overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand p 45 Check the chain tension p 63 F00321 10 Main work Loosen nut Loosen nuts Adjust th...

Page 67: ...in rollers in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance at the longest chain section 272 mm 10 71 in If distance is greater than the specified measurement Change the drivetrain kit Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faste...

Page 68: ...he 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 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 45 12 38 Checking the frame F00255 01 C...

Page 69: ...k of the handle bars and above the fuel tank bracket to the throttle valve body Both throttle cables must be secured behind the fuel tank contact area rubber band If the throttle cable routing is not as specified Correct throttle cable routing Finishing work Install the fuel tank p 61 Mount the seat p 55 Install the air filter box cover p 56 12 41 Checking the rubber grip 401197 01 Check the rubbe...

Page 70: ... fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately 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 Environ...

Page 71: ...d It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container F00311 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane F00454 10 Fill bleeding syrin...

Page 72: ... engine guard H01655 01 Remove screws and engine guard 12 46 Installing the engine guard H01655 01 Attach the engine guard on the frame at the rear and swing up at the front Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 73: ...clockwise to increase free travel The pressure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 13 3 Checking the brake discs Warning Danger of accidents Worn out brake discs reduce the braking effect Make sure that worn out brake discs are replaced immediately Your authori...

Page 74: ...nd do not continue riding until the problem is eliminated Your authorized Husqvarna Motorcy cles workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if br...

Page 75: ...mum thickness is less than specified Change the front brake linings p 73 Check the brake linings for damage and cracking If damage or cracking is visible Change the front brake linings p 73 13 7 Changing the front brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail Ensure that service work and repairs are performed professionally Your authorized Husq...

Page 76: ...ake linings approved and recommended by Husqvarna motorcycles 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 Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake ...

Page 77: ...ng 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 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 Guideline Free travel at foot brake lever 3 5 ...

Page 78: ...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 Motorcy cles workshop will be glad to help Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Yo...

Page 79: ... correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container Preparatory work Check the rear brake linings p 77 F00331 10 Main work ...

Page 80: ... 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 coefficient of the brake linings and thus their...

Page 81: ... leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly The arrow on the leaf spring points in the rotation direction of the brake disc F00355 10 Insert the new brake linings insert pin and mount cotter pins Info Always change the brake linings in pairs Make sure that decoupling plate is mounted on the piston side brake lining Operate the foot brake le...

Page 82: ...educe 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 out of the fork Info Do not pull the hand brake lever when the front wheel is removed H00934 10 Remove spacers 14 2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effe...

Page 83: ...stand p 45 F00338 10 Main work Press the brake caliper onto the brake disc by hand in order to push 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 Remove chain adjuster Withdraw wheel spindle only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove th...

Page 84: ...sition the rear wheel and insert wheel spindle Mount the chain The brake linings are correctly positioned F00321 11 Position chain adjuster Mount nut but do not tighten it yet Make sure that chain adjusters are fitted correctly on adjusting screws Check the chain tension p 63 Tighten nut Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters ...

Page 85: ...pth 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 the last two digits the year of manu facture Husqvarna Motorcycles recommends that the tires be changed after 5 years at the latest regardless of the actual sta...

Page 86: ...r 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 If you hear different tone frequencies from different spokes of equal length and diameter this is an indication of different spoke tensions You should hear a high note If t...

Page 87: ...nd switch off the engine Remove the air filter box cover p 56 Remove the seat p 55 H01190 10 Main work Pull back the negative terminal cover and disconnect negative cable from the battery Pull back the positive terminal cover and disconnect positive cable from the battery Remove screw Pull holding bracket forward and remove battery toward the top 15 2 Installing the battery H00388 10 Main work Ins...

Page 88: ...tion point for used batteries 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 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 ba...

Page 89: ...harger to the battery Switch on the battery charger Battery charger 81229074000 The charging time may be longer at low temperatures This battery charger is not suitable for the trickle charging of lithium ion batteries Switch off the battery charger after charging and disconnect from the battery Finishing work Install the battery p 85 Mount the seat p 55 Install the air filter box cover p 56 15 4 ...

Page 90: ...idual power consumers is located under the seat Preparatory work Switch off all power consumers and switch off the engine Remove the air filter box cover p 56 Remove the seat p 55 F00359 10 Main work Pull EFI control unit from the holder and hang it to one side F00360 10 Open fuse box cover Remove the defective fuse Guideline FE EU Fuse 1 10 A EFI control unit lambda sensor speedometer combination...

Page 91: ...e power consumer is functioning properly Close the fuse box cover F00359 10 Mount EFI control unit on the holder Finishing work Mount the seat p 55 Install the air filter box cover p 56 15 6 Removing the headlight mask with the headlight Preparatory work Switch off all power consumers and switch off the engine F00339 10 Main work Detach brake line and wiring harness Release rubber straps Slide the...

Page 92: ...t setting p 91 15 8 Changing the headlight bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 89 F00343 10 Main work Turn protection cap to...

Page 93: ...rn it counterclockwise by about 30 and take it out of the socket Info Do not touch the reflector with your fingers and keep it free from grease Press the new turn signal bulb carefully into the socket and turn it clockwise until it stops Turn signal R10W socket BA15s p 114 Mount the orange cap Position the diffuser Insert the screw and first turn counterclockwise until it engages in the thread wit...

Page 94: ...ork Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 89 F00370 10 Main work Remove screws with the washers Pull the speedometer upward out of the holder F00371 10 Using a coin turn protection cap all the way counterclockwise and remove it Remove speedometer battery Insert the new battery with the label facing outward Speedometer battery CR 203...

Page 95: ...15 ELECTRICAL SYSTEM 93 15 13 Diagnostics connector H00933 12 Diagnostics connector is located under the seat ...

Page 96: ...before you open the radiator the radiator hoses or other compo nents 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 immediately if coolant is ...

Page 97: ...orcycle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level above the radiator fins 10 mm 0 39 in If the coolant level does not match the specified value Correct the coolant level Coolant p 117 Mount the radiator cap 16 4 Draining the coolant Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under press...

Page 98: ...e into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with 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 F00452 10 Main work Make sure that the screw is tigh...

Page 99: ...action 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 entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 97 17 2 Adjusting the play in the throttle cable Info If the correct routing of the throttle cables has already been secured the fuel ...

Page 100: ... on the grip tube Guideline The label OUTSIDE must be visible Marking must be positioned at mark ing Alternative 1 Grey guide plate 79002014000 Alternative 2 Black guide plate 79002014100 Info The gray guide plate opens the throttle valve more slowly The black guide plate opens the throttle valve more quickly The gray guide plate is mounted upon delivery F00348 01 Clean the outside of the handleba...

Page 101: ...ed 4 000 rpm STANDARD balanced response H01180 11 Activating ADVANCED mapping Press button MAP until LED 2 lights up Guideline Engine speed 4 000 rpm ADVANCED direct response 17 5 Adjusting the idle speed Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low Set the idle speed to the specified value Your authorized Husqvarna Motorcycles workshop will be g...

Page 102: ...ve it running at idle speed until teaching is completed 17 7 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 between the upper ed...

Page 103: ...17 TUNING THE ENGINE 101 Mount and tighten screw with the washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 104: ...azard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system F00447 10 Clean plug in connection 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 Info Remaining fu...

Page 105: ...ng rinse the area affected immediately with lukewarm water 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 70 Park the motorcycle on a level ...

Page 106: ...t Mount and tighten oil drain plug with the magnet and a new seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft F00440 10 Remove screws Remove the oil filter cover with the O ring F00446 10 Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing surface F00440 11 Lay the motorcycle...

Page 107: ... guard p 70 Check the engine oil level p 102 18 4 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear of the engine F00439 10 Main work Remove oil filler plug with the O ring from the clutch cover Fill engine oil to the middle of the level viewer Engine oil SAE 10W 50 p 117 Info For optimal performance of the engine oil do not mix different types of en...

Page 108: ...ng 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 dry vehicle always rinse the vehicle with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly...

Page 109: ...torcycle p 106 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 thoroughly wash the vehicle 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 ba...

Page 110: ...ing the motorcycle out of service add fuel additive Refuel p 34 Clean the motorcycle p 106 Change the engine oil and oil filter and clean the oil screens p 103 Check the antifreeze and coolant level p 94 Check the tire air pressure p 83 Remove the battery p 85 Recharge the battery p 86 Guideline Storage temperature of battery with out direct sunshine 0 35 C 32 95 F Store the vehicle in a dry locat...

Page 111: ...ction system Read out the fault memory using the Husq varna Motorcycles diagnostics tool Engine does not speed up Defect in fuel injection system Read out the fault memory using the Husq varna Motorcycles diagnostics tool Ignition system defective Ignition coil check the secondary winding Check the spark plug connector Check the stator winding of the alternator Engine has too little power Air filt...

Page 112: ...oute the vent hose without bends or replace it if necessary Engine oil level too high Check the engine oil level p 102 Engine oil too thin low viscosity Change the engine oil and oil filter and clean the oil screens p 103 Piston and cylinder worn Measure the piston cylinder mounting clear ance Battery discharged Battery is not being charged by alter nator Check the charging voltage Check the stato...

Page 113: ...ch in oil bath hydraulically activated Transmission ratio First gear 14 36 Second gear 17 32 Third gear 19 28 Fourth gear 22 26 Fifth gear 23 24 Sixth gear 26 21 Alternator 12 V 168 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spark plug NGK LKAR9AI 10 Spark plug electrode gap 1 0 mm 0 039 in Cooling Water cooling permanent circulation of coolant by...

Page 114: ...Nm 7 4 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Oil nozzle for conrod bearing lubrica tion M6x0 75 4 Nm 3 lbf ft Loctite 243 Plug oil channel M7 9 Nm 6 6 lbf ft Loctite 243 Screw rocker arm bearing M7 15 Nm 11 1 lbf ft Plug timing chain tensioner M8 8 Nm 5 9 lbf ft Screw plug crankshaft location M8 10 Nm 7 4 lbf ft Plug oil channel M10 15 ...

Page 115: ... bearings Brake discs diameter Front 260 mm 10 24 in Rear 220 mm 8 66 in Brake discs wear limit Front 2 5 mm 0 098 in Rear 3 5 mm 0 138 in Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Road tire pressure Front 1 5 bar 22 psi Rear 1 5 bar 22 psi Final drive All 450 models 14 52 13 52 Final drive All 501 models 14 50 13 50 Chain 5 8 x 1 4 Rear sprockets available 48 50 52 Steer...

Page 116: ...tires specified represent one of the possible series production tires Additional information is available in the Service section under www husqvarna motorcycles com 22 7 Fork Fork article number 14 15 8Q 69 Fork WP Performance SystemsXplor 48 Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload ...

Page 117: ... 18 78 in Shock absorber oil Shock absorber fluid SAE 2 5 50180751S1 p 117 22 9 Chassis tightening torques Screw intake air temperature sensor EJOT PT K50x18 1 Nm 0 7 lbf ft Screw pressure regulator EJOT PT K60x25 Z 3 Nm 2 2 lbf ft Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Remaining nuts chassis M5 5 N...

Page 118: ...2 1 lbf ft Loctite 2701 Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 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 ab...

Page 119: ...rds see specifications on the container and that possess the corre sponding properties Synthetic engine oil Recommended supplier Bel Ray Works Thumper Racing Synthetic Ester 4T Fork oil SAE 4 48601166S1 Standard classification SAE p 119 SAE 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Shock abso...

Page 120: ...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 121: ...rvice 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 Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils ...

Page 122: ...26 INDEX OF SPECIAL TERMS 120 OBD On board diagnosis Vehicle system that monitors emission and safety related val ues ...

Page 123: ...27 LIST OF ABBREVIATIONS 121 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 124: ...alfunction indicator lamp lights up flashes yellow The OBD has detected an emission or safety critical fault The fuel level warning lamp lights up yellow The fuel level has reached the reserve mark 28 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 indicator lamp flashes green The turn signal i...

Page 125: ... 63 Characteristic map of the throttle response adjusting 98 Chassis number 12 Clutch fluid level checking correcting 68 fluid changing 69 Clutch lever 14 basic position adjusting 68 Cold start button 17 Compression damping fork adjusting 41 Compression damping high speed shock absorber adjusting 38 Compression damping low speed shock absorber adjusting 37 Coolant antifreeze and coolant level chec...

Page 126: ...removing 89 Horn button 14 I Idle speed adjusting 99 Idle speed adjusting screw 18 Implied warranty 9 Indicator lamps overview 16 Intended use 6 K Key number 12 Kill switch 14 L Launch Control activating 31 Light switch 15 Lower triple clamp installing 48 removing 47 M Main fuse changing 87 Main silencer changing the glass fiber yarn filling 59 installing 59 removing 59 Mapping changing 99 Motorcy...

Page 127: ...locking 20 Steering head bearing lubricating 51 Steering head bearing play adjusting 51 checking 50 Storage 108 Swingarm checking 67 T Technical data capacities 113 chassis 113 chassis tightening torques 115 electrical system 114 engine 111 engine tightening torques 111 fork 114 shock absorber 115 tires 114 Throttle cable play adjusting 97 checking 97 Throttle cable routing checking 67 Throttle gr...

Page 128: ... 3402103en 3402103en 07 2016 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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Husqvarna FE 450, Owner'S Manual

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