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HUSABERG FE 450 AUS, Руководство по ремонту

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CONTENTS

4

Assembling the countershaft......................................... 133
Checking the transmission............................................ 134
Checking the electric starter mode ................................ 135
Removing the free wheel .............................................. 135
Installing the free wheel............................................... 136

30/ENGINE ASSEMBLY ................................................... 137

Installing the crankshaft............................................... 137
Installing the transmission shafts .................................. 137
Installing the diaphragm .............................................. 137
Installing the shift fork................................................. 138
Installing the shift drum............................................... 138
Installing the shift rails ................................................ 138
Installing the left engine case ....................................... 138
Installing the locking lever............................................ 139
Installing the shift drum locating unit............................ 139
Installing the shift shaft ............................................... 139
Installing the oil pumps ............................................... 140
Installing the oil pump gears ........................................ 140
Installing the starter idler gear ...................................... 140
Installing the torque limiter .......................................... 141
Installing the free wheel gear........................................ 141
Installing the primary gear............................................ 141
Installing the balancer shaft ......................................... 141
Installing the outer clutch hub...................................... 141
Installing the primary gear nut ...................................... 142
Installing the clutch discs ............................................ 142
Installing the clutch cover ............................................ 143
Installing the water pump cover .................................... 143
Installing the ignition pulse generator............................ 143
Installing the timing chain............................................ 144
Installing the timing chain securing guide...................... 144
Installing the timing chain tensioning rail ...................... 144
Installing the timing chain guide rail ............................. 144
Installing the balance weight ........................................ 144
Installing the rotor ....................................................... 145
Installing the distance bushing ..................................... 145
Installing the piston..................................................... 145
Installing the cylinder head .......................................... 147
Installing the camshaft ................................................ 148
Installing the timing chain tensioner ............................. 148
Checking the valve clearance ........................................ 148
Adjusting the valve clearance........................................ 149
Installing the generator cover........................................ 149
Installing the spark plug............................................... 150
Installing the valve cover .............................................. 150
Installing the oil filter .................................................. 150
Installing the oil screen................................................ 150
Assembling the starter motor ........................................ 151
Installing the oil line.................................................... 151
Removing the engine from the work stand...................... 151

32/CLUTCH .................................................................... 152

Checking the fluid level of the hydraulic clutch .............. 152
Changing the hydraulic clutch fluid............................... 152

35/WATER PUMP, COOLING SYSTEM .............................. 154

Checking the coolant level............................................ 154
Checking the antifreeze and coolant level ...................... 154
Draining the coolant .................................................... 155
Refilling coolant .......................................................... 155

38/LUBRICATION SYSTEM .............................................. 156

Oil circuit ................................................................... 156
Checking the engine oil pressure................................... 156

Checking the engine oil level ........................................ 158
Adding engine oil ........................................................ 158
Changing the engine oil and oil filter, cleaning the
engine oil screen ......................................................... 158
Draining engine oil, cleaning engine oil screen ............... 158
Removing the oil filter.................................................. 159
Installing the oil filter .................................................. 160
Filling up with engine oil.............................................. 160

41/THROTTLE VALVE BODY............................................. 161

Idle speed adjusting screw ........................................... 161
Taking off the throttle valve body and allowing it to
hang to the side .......................................................... 161
Installing the throttle valve body ................................... 162
Adjusting the idle speed............................................... 163

FAULT CODE .................................................................. 164
TECHNICAL DATA - ENGINE............................................ 219

Capacity - engine oil .................................................... 219
Capacity - coolant........................................................ 219

TECHNICAL DATA - ENGINE TOLERANCES, WEAR
LIMITS ........................................................................... 220
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 222
TECHNICAL DATA - CHASSIS .......................................... 224

Lighting equipment ..................................................... 224
Tires .......................................................................... 225
Capacity - fuel............................................................. 225

TECHNICAL DATA - FORK................................................ 226
TECHNICAL DATA - SHOCK ABSORBER ........................... 227
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 228
CLEANING/PROTECTION ................................................. 229

Cleaning the motorcycle ............................................... 229
Protection for winter operation ...................................... 230

STORAGE ....................................................................... 231

Storage....................................................................... 231
Putting into operation after storage ............................... 231

SERVICE SCHEDULE....................................................... 232

Important maintenance work to be carried out by an
authorized HUSABERG workshop.................................. 232
Important maintenance work to be carried out by an
authorized HUSABERG workshop. (as additional order) ... 233
Important checks and maintenance work to be carried
out by the rider ........................................................... 234

WIRING DIAGRAM .......................................................... 236

1 of 3 (FE EU) ............................................................ 236
2 of 3 (FE EU) ............................................................ 238
3 of 3 (FE EU) ............................................................ 242
1 of 3 (FE USA) .......................................................... 246
2 of 3 (FE USA) .......................................................... 248
3 of 3 (FE USA) .......................................................... 252
1 of 3 (FE AUS) .......................................................... 254
2 of 3 (FE AUS) .......................................................... 256
3 of 3 (FE AUS) .......................................................... 260

SUBSTANCES................................................................. 263
AUXILIARY SUBSTANCES................................................ 265
SPECIAL TOOLS.............................................................. 267
STANDARDS................................................................... 278
INDEX ............................................................................ 279

Содержание FE 450 AUS

Страница 1: ...REPAIR MANUAL FE 450 EU FE 450 AUS FE 450 USA FE 570 EU FE 570 AUS FE 570 USA 2009 Article no 3803004en...

Страница 2: ......

Страница 3: ...n as HUSABERG specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reas...

Страница 4: ...Removing the spring 35 Disassembling the shock absorber 36 Disassembling the piston rod 37 Disassembling the seal ring retainer 38 Replacing the pilot bushing 39 Checking the shock absorber 39 Disass...

Страница 5: ...106 Removing the primary gear 106 Removing the free wheel gear 107 Removing the torque limiter 107 Removing the starter idler gear 107 Removing the oil pump gears 107 Removing the oil pumps 108 Remov...

Страница 6: ...work stand 151 32 CLUTCH 152 Checking the fluid level of the hydraulic clutch 152 Changing the hydraulic clutch fluid 152 35 WATER PUMP COOLING SYSTEM 154 Checking the coolant level 154 Checking the a...

Страница 7: ...on Indicates an unexpected reaction e g of a work step or a function Identifies a page reference more information is provided on the specified page Formats used The typographical and other formats use...

Страница 8: ...d on screw connections e g Loctite follow the instructions for use from the manufacturer After disassembly clean the parts that are to be reused and check them for damage and wear Replace damaged or w...

Страница 9: ...S 100458 10 The type label is fixed to the frame at the front right 3 3 Type label FE USA 100464 10 The type label is fixed to the front of the steering head 3 4 Key number FE EU FE AUS 500125 10 The...

Страница 10: ...r is stamped on the inner side of the fork stub 3 7 Shock absorber part number 100419 10 The shock absorber part number is stamped on the upper part of the shock absorber above the adjusting ring The...

Страница 11: ...unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in a closed space without an effective exhaust extraction syst...

Страница 12: ...e rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior 100376 10 Turn adjusting screws clockwise until they stop Info Adjusting screws are located at...

Страница 13: ...egs downwards Info The dust boots should remove dust and coarse dirt particles from the fork tubes Over time dirt can penetrate behind the dust boots If this dirt is not removed the oil seals behind c...

Страница 14: ...fork legs Remove the front wheel p 65 FE EU FE AUS Remove the headlight mask with the headlight p 88 FE USA Remove the start number plate p 63 300713 10 Remove screws and take off the clamp 300714 10...

Страница 15: ...wheel p 65 FE EU FE AUS Install the headlight mask with the headlight p 88 FE USA Install the start number plate p 64 5 10 Removing the fork protector Remove the fork legs p 12 300716 10 Remove screws...

Страница 16: ...he fork legs p 23 5 13 Disassembling the fork legs Info The steps are identical for both fork legs Condition The fork legs are disassembled 200736 10 Remove protective cover Take note of the present s...

Страница 17: ...0 Push the outer tube downward Pull the spring downward Place the special tool on the hexagonal part Open end wrench T14032 p 277 Info The preload spacers should be above the special tool 200739 10 Cl...

Страница 18: ...drain out 200653 01 Remove the cartridge 200741 10 Remove dust boot Remove fork protector ring Info Disassembly of the fork protector ring is not necessarily required for the fur ther repair 200742 1...

Страница 19: ...ring Take off seal ring Take off lock ring Take off dust boot Take out the fork leg 5 14 Cartridge disassembly Info The steps are identical for both fork legs Disassemble the fork legs p 14 200746 10...

Страница 20: ...his step is unnecessary for the further disassembly 200697 10 Degrease the piston rod Clamp the piston rod with the special tool Clamping stand T14016S p 276 200698 10 Remove nut Remove shim stack com...

Страница 21: ...tack 200704 10 Remove O ring and seal ring from the compression damping fitting Extract the compression damping fitting 5 16 Checking the fork legs Condition The fork legs are disassembled 200728 10 C...

Страница 22: ...ing layer Replace the sliding bushing 200666 10 Check the spring length Guideline Spring length with preload spacer s 510 mm 20 08 in If the measured value is greater than the specified value Reduce t...

Страница 23: ...ing Extract the compression damping fitting 5 18 Assembling the cartridge Info The steps are identical for both fork legs 200715 10 Clamp in the piston rod Clamping stand T14016S p 276 Mount valve of...

Страница 24: ...nut with the collar facing downward Secure the nut by locking 200749 11 Degrease the cartridge and clamp using the special tool Clamping stand T14015S p 276 Mount and tighten screwsleeve Guideline Sc...

Страница 25: ...ng downward Slide on lock ring Grease and slide on seal ring Lubricant T511 p 266 Info The sealing lip should face downward and open side upward Slide on support ring Remove the special tool 200670 10...

Страница 26: ...ring force The adjustment tube extends more than 7 mm out from the cartridge and can not be pressed inward against the spring force Screw on fluid barrier to the stop Info The fluid barrier must be sc...

Страница 27: ...on the hexagonal part Open end wrench T14032 p 277 Remove the special tool Gripping tool T14026S1 p 276 200743 10 Clamp the special tool in the bench vise Grease the threads of the piston rod Lubrica...

Страница 28: ...Compression damping Comfort 26 clicks Standard 22 clicks Sport 18 clicks Turn the adjusting screw of the spring preload counterclockwise all the way Turn back clockwise the number of turns correspond...

Страница 29: ...otorcycle and its attachments against damage by covering them Do not bend the cables and lines 300718 10 Remove screws Take off the speedometer and connector board and allow them to hang to the side I...

Страница 30: ...M20x1 5 10 Nm 7 4 lbf ft 300718 11 Position the speedometer and connector board Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 300717 11 Position the handlebar Mount a...

Страница 31: ...g p 29 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range No resting locations should be noticeable If click position...

Страница 32: ...00450 10 Remove screw Remove the engine guard 6 2 Installing the engine guard 100450 10 Attach the engine guard on the frame at the rear and swing it up and forward Mount and tighten screw Guideline R...

Страница 33: ...t 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping 7 2 Adjusting the low speed compression damping of the shock absorber Danger Danger of accidents Di...

Страница 34: ...us pension damping 7 4 Measuring rear wheel sag unloaded Jack up the motorcycle p 9 400520 10 Measure the distance as vertical as possible between the rear axle and a fixed point such as the top edge...

Страница 35: ...the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Info Befor...

Страница 36: ...bsorber p 32 7 9 Removing the shock absorber Jack up the motorcycle p 9 100374 10 Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel Fix the re...

Страница 37: ...the seal ring retainer p 43 Assemble the piston rod p 43 Assemble the shock absorber p 45 Install the spring p 50 7 12 Removing the spring Condition The shock absorber has been demounted Clamp the sh...

Страница 38: ...ng and compres sion damping Remove rubber cap of the reservoir 200754 10 Slowly unscrew screw The pressurized nitrogen is bled off 200755 10 Remove locking cap 200756 10 Press seal ring retainer all t...

Страница 39: ...emove nut Info If mount is loosened apply counteractive force Remove rebound damping shim stack Info Guide the rebound damping shim stack onto a screwdriver and put them aside together 200762 10 Remov...

Страница 40: ...em aside together 200765 10 Remove rebound damping washer Remove seal ring retainer 200766 10 Remove locking cap and bump rubber 7 15 Disassembling the seal ring retainer Disassemble the piston rod p...

Страница 41: ...in T1205 p 274 Support seal ring retainer with the sleeve of the special tool Assembly tool T150S p 277 Press the special tool through the new pilot bushing Calibration pin T1205 p 274 The pilot bushi...

Страница 42: ...d wear If there is damage or wear Replace the piston rod 200813 10 Check the piston rings for damage and wear If damage or a bronze colored surface is visible Replace the piston rings 7 18 Disassembli...

Страница 43: ...the second heim joint collar bushing with a punch 200800 10 Remove seal ring on both sides 200801 10 Press the heim joint against a lock ring using the special tool Pressing tool T1207S p 275 Remove t...

Страница 44: ...le to the point where it is possible to mount the rebound damping adjusting screw Mount rubber plug 200809 10 Lubricate spring balls and O ring Lubricant T159 p 266 Screw in the rebound damping adjust...

Страница 45: ...ng Grease the seal ring and mount with the washer facing downward Lubricant T511 p 266 200795 10 Mount centering disk Mount rebound rubber 7 23 Assembling the piston rod Assemble the seal ring retaine...

Страница 46: ...ler shims at the top Apply thread locker to the threads of the piston rod Loctite 2701 Screw on mount to the point where the piston can still be turned 200770 10 Mount compression damping shim stack w...

Страница 47: ...bricant T158 p 265 Grease the threads Lubricant T159 p 266 Mount and tighten the compression damping adjuster Guideline Compression damping adjuster M31x1 50 Nm 36 9 lbf ft 200759 11 Install adjusting...

Страница 48: ...lockwise with a screwdriver up to the last perceptible click Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed Comfort...

Страница 49: ...ng and compression damping 200781 10 Remove the screw from the filling port Mount adapter on the shock absorber Info Only tighten hand tight do not use any tools Connect adapter to connection of the v...

Страница 50: ...e turn the Damper control lever to Vacuum Guideline 3 bar The pressure gauge drops to the specified value 0 bar 200270 10 As soon as the pressure gauge has attained the specified value turn the Oil re...

Страница 51: ...st be set precisely to this position with the piston rod fully extended as otherwise damage could occur when the shock absorber is compressed Remove the special tool 200784 10 Remove adapter from conn...

Страница 52: ...asher 200751 11 Measure the overall spring length when not under tension Position the spring Guideline Spring rate Weight of rider 65 75 kg 143 165 lb 69 N mm 394 lb in Weight of rider 75 85 kg 165 18...

Страница 53: ...Nm 3 7 lbf ft 7 28 Removing the swingarm with shock absorber and rear wheel Condition The motorcycle is jacked up The fuel tank has been removed 300681 10 Remove chain connecting link Thread the chai...

Страница 54: ...is jacked up The fuel tank has been removed 300686 10 Position the swingarm with the shock absorber and rear wheel 300685 11 Mount the swingarm pivot Mount nut but do not tighten it yet Guideline Nut...

Страница 55: ...aining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screw Guideline Screw ball joint of push rod on foot brake cylinder M6 10 Nm 7 4 lbf ft 300684 10 Join plug in connector of the brake light...

Страница 56: ...main silencer 8 2 Installing the main silencer 100443 11 Mount the main silencer Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Reconnect spring 8 3 Removing the exhau...

Страница 57: ...alling the exhaust system 300679 12 Slip in the exhaust pipe Position the engine mounting bracket Mount and tighten screws Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft 300680 11 Mount and t...

Страница 58: ...ssis M6 10 Nm 7 4 lbf ft Position the exhaust clamp Tighten screw Guideline Screw exhaust clamp on manifold M8 8 Nm 5 9 lbf ft 300676 11 Plug in connector of the lambda sensor Route the cable so it is...

Страница 59: ...lling the air filter 301332 10 Mount the clean air filter onto the air filter support Apply grease to the air filter around area Long life grease p 265 100431 10 Put in both parts together position th...

Страница 60: ...y press the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil Oil for foam air filter p 266 Clean the intake flange and check it for damage and tightness In...

Страница 61: ...is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fue...

Страница 62: ...cle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning F...

Страница 63: ...e Remaining screws chassis M6 10 Nm 7 4 lbf ft Check that the intake trumpet and the connection of the engine housing vent are clear Install the air filter p 57 Install the spoiler p 61 Check the fuel...

Страница 64: ...start or run the engine in a closed space without an effective exhaust extraction system Start the engine Check the fuel pressure Fuel pressure Under every load condition 3 3 3 7 bar 48 54 psi If the...

Страница 65: ...er 300722 11 Ensure that the distance bushings are mounted in the brake line guide Position the fender with the brake line guide Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7...

Страница 66: ...A 301333 10 Position the start number plate Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Info Ensure engagement of the holding lugs on the fender Position the brake l...

Страница 67: ...ever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged 100412 10 Warning Danger of accidents Reduced braking due to damaged brake discs Always...

Страница 68: ...0 bar 15 psi Rear 1 0 bar 15 psi Road tire pressure Front 1 5 bar 22 psi Rear 2 0 bar 29 psi If the tire pressure does not meet specifications Correct the tire pressure Mount the dust cap 12 4 Checki...

Страница 69: ...ing Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay A A 400257 10 Check the thickness of the front and rear brake disks at several pl...

Страница 70: ...not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged 100414 10 Warning Danger of accidents Reduced braking due to damag...

Страница 71: ...e it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check for correct chain tension and adjust if necessary Jack up the motorcycle p 9 100388 10 Pu...

Страница 72: ...Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm enables different secondary transmissions with the same chain length Chain adjusters can be turned by 180 Remove the motorcycle...

Страница 73: ...If the chain is very dirty Clean the chain p 71 13 8 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning materia...

Страница 74: ...loose spoke can cause wheel imbalance which leads to more loose spokes in a short time If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on...

Страница 75: ...between battery terminals and cable sockets with the claws facing up 100424 10 Tighten the screw Guideline Screw battery terminal M5 3 Nm 2 2 lbf ft 14 3 Changing the main fuse Warning Fire hazard Th...

Страница 76: ...Switch off all power consumers and switch off the engine Remove the seat p 59 100428 10 Open fuse box cover 100429 10 Remove the faulty fuse Guideline Fuse 1 10A EFI control unit Fuse 2 10A fuel pump...

Страница 77: ...ff all power consumers and switch off the engine Remove the seat p 59 100422 10 Detach fuse box and swing it to one side Detach connector and swing it to one side with connector Remove screws and swin...

Страница 78: ...ner Take the batteries to your HUSABERG dealer or to a collection point for old batteries Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners...

Страница 79: ...Charging current charging voltage and charging time may not be exceeded Recharge the battery regularly if the motorcycle is not put into operation 3 months Tip If the vehicle is not ridden for more t...

Страница 80: ...heck the free travel of the hand brake lever p 78 Adjust the free travel of the handbrake lever with adjusting screw Info Turn the adjusting screw clockwise to reduce free travel The pressure point mo...

Страница 81: ...in the brake system or worn out brake linings Check the brake system and do not continue riding Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and e...

Страница 82: ...he brake linings for damage and cracking If damage or cracking is visible Change the front brake linings p 80 15 7 Changing the front brake linings Warning Danger of accident Brake system failure Main...

Страница 83: ...lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 100395 10 Move the brake...

Страница 84: ...avel does not meet specifications Adjust the basic position of the footbrake lever p 82 Reconnect spring 15 9 Adjusting the basic position of the footbrake lever Warning Danger of accidents Brake syst...

Страница 85: ...n on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid gets into your eyes rinse thoroughly with water and con...

Страница 86: ...schedule 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 when neces...

Страница 87: ...e locking split pins withdraw bolt and take out the brake pads Clean the brake caliper and brake caliper support 100407 10 Check that leaf spring in the brake caliper and sliding plate in the brake ca...

Страница 88: ...The settings are saved and the Setup menu closed Info If no button is pressed for 20 seconds or if no impulse comes from the wheel speed sensor the settings are automatically saved and the Setup menu...

Страница 89: ...ight mask with the headlight p 88 FE USA Remove the start number plate p 63 301287 10 Expose connector CZ 301288 10 Sever brown cable in front of connector CZ PIN 1 Insulate both cable ends FE EU FE A...

Страница 90: ...Info The seconds can only be set to zero Press the button for 3 5 seconds The settings are saved and the Setup menu closed Info If no button is pressed for 20 seconds or if no impulse comes from the...

Страница 91: ...Adjust the beam width of the headlight p 89 16 9 Adjusting the beam width of the headlight FE EU FE AUS Check the headlight adjustment p 89 100459 10 Adjust the beam width of the headlight by turning...

Страница 92: ...ockwise all the way and pull it out Insert a new headlight bulb Headlight S2 socket BA20d p 224 Insert the rubber cap together with the bulb socket into the reflector turn it clock wise all the way In...

Страница 93: ...ttle valve body and allow it to hang to the side p 161 Remove the swingarm with shock absorber and rear wheel p 51 300676 10 Unplug connector of the lambda sensor Open the cable binders 300677 10 Remo...

Страница 94: ...become kinked Do not actuate the clutch lever while the slave cylinder of the clutch is removed Remove screw Take off the shift lever 300694 10 Push back the rubber cap Remove nut Take off the positiv...

Страница 95: ...coolant temperature sensor connector 300696 10 Expose the cable Separate plug in connector of the ignition pulse generator 300697 10 Separate plug in connector of the generator 300698 10 Remove screws...

Страница 96: ...frame 300699 11 Mount screw with the sleeves but do not tighten yet 300698 11 Position the engine braces and washers Mount screws with the nuts but do not tighten yet 300679 11 Slip in the exhaust pip...

Страница 97: ...garm pivot M16x1 5 100 Nm 73 8 lbf ft 300697 11 Join plug in connector of the generator Route the cable so it is tension free and secure it with cable binders 300696 11 Join plug in connector of the i...

Страница 98: ...Mount hose clip and tighten it 300710 10 Mount the radiator hoses Mount and tighten hose clamps 300711 10 Mount the radiator hose Mount hose clip and tighten it Mount the engine breather hose and pos...

Страница 99: ...8 4 lbf ft 300678 12 Position the exhaust manifold Mount screw but do not tighten it yet Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 300677 12 Mount and tighten screw Guideline Remaining sc...

Страница 100: ...e oil SAE 10W 50 p 263 Mount and tighten screw cap Remove the motorcycle from the work stand p 9 Refill the coolant p 155 Make a short test ride Read out the fault memory using the HUSABERG diagnostic...

Страница 101: ...raining the engine oil 300291 10 Remove oil drain plug with the magnet and seal ring Remove the engine oil screen plug Completely drain the engine oil 18 3 Removing the oil line 300292 10 Remove the b...

Страница 102: ...the valve cover seal 18 7 Removing the spark plug 300296 10 Remove the spark plug using the special tool Spark plug wrench 75029172000 p 271 18 8 Removing the generator cover 300297 10 Remove screws T...

Страница 103: ...ankshaft is visible 300300 10 Screw in special tool Crankshaft locking bolt 113080802 p 267 18 10 Removing the timing chain tensioner 300301 10 Remove screw Take off the seal ring 300302 10 Pull out t...

Страница 104: ...8 13 Removing the piston 300307 10 Push the cylinder upward Info Only push the cylinder far enough upward that the piston pin can be taken out Remove the piston pin retainer Remove the piston pin Take...

Страница 105: ...2009000 p 268 18 16 Removing the balance weight 300312 10 Bend lock washer Unscrew and remove nut Remove the lock washer Info Ensure that the crankshaft has been blocked Take off the balance weight 18...

Страница 106: ...he direction of travel 18 21 Removing the ignition pulse generator 300317 10 Remove screws Pull the cable support sleeve from the engine case Take off the ignition pulse gen erator 18 22 Removing the...

Страница 107: ...1 10 Unscrew bolts and remove them with washers and springs Take off the pressure cap 300322 10 Remove pressure piece 300323 10 Completely remove clutch discs 18 25 Removing the primary gear nut 30032...

Страница 108: ...clutch hub and washer Info The washer usually adheres to the inner clutch hub Take off outer clutch hub 300328 10 Remove needle bearing and collar sleeve 18 27 Removing the balancer shaft 300327 10 P...

Страница 109: ...limiter 300330 10 Remove the screw with the washer Remove torque limiter Remove washer 18 31 Removing the starter idler gear 300331 10 Remove the lock ring Take off the washer Take off starter idler...

Страница 110: ...aft 300516 10 Push sliding plate away from the shift drum locating unit Remove shift shaft with the washer 18 35 Removing the shift drum locating unit 300336 10 Remove screw Push away locking lever fr...

Страница 111: ...arked with 812 Take off the section of the engine case Info Do not subject the section of the engine case to any stress Remove the special tool Take off the left section of the engine case 18 38 Remov...

Страница 112: ...transmission shafts 300342 10 Secure the engine in an upright position Remove lock ring 300343 10 Pull out both transmission shafts together from the bearing seats Info Do not lose the washers 18 43...

Страница 113: ...side fac ing outward Info The shaft seal ring must be flush toward the outside Press in the shaft seal ring of the balancer shaft with the open side facing outward Warm up the section of the engine c...

Страница 114: ...ide Info Do not press the shaft seal ring from the inside toward the outside as there is a small collar on the outside Press in the shaft seal ring from the inside toward the outside with the open sid...

Страница 115: ...f the oil pressure regulator valve Remove the oil pressure regulator valve p 113 200155 10 Measure the spring length of the oil pressure regulator valve Oil pressure regulator valve Minimum length of...

Страница 116: ...ter pump 300349 10 Remove nut Remove lock ring Take off the drive wheel 300368 10 Take off the water pump impeller Info If the water pump impeller cannot be detached then the water pump shaft can be p...

Страница 117: ...the way in toward spacer 300368 11 Mount water pump shaft Info Be careful not to damage the shaft seal rings Mount water pump impeller 300349 11 Mount the drive wheel Mount lock ring Mount and tighte...

Страница 118: ...n such a case the crank web would be squeezed together making the crankshaft unusable 200157 10 Warm up the new timing chain sprocket and immediately push it onto the crankshaft Guideline 150 C 302 F...

Страница 119: ...ing device for crankshaft complete 75029047000 p 270 Info Hold the lower crank web Remove the connecting rod and bearing 200210 10 Place connecting rod onto special tool without the bearing Insert for...

Страница 120: ...ll the way in Info The press mandrel must be positioned over the crank pin Take the crankshaft out of the special tool and check that the connecting rod can move freely 300609 10 Crankshaft measure th...

Страница 121: ...engine case have been mounted tighten them Guideline Screw engine housing M6x75 10 Nm 7 4 lbf ft Mount screw and once all screws of the left section of the engine case have been mounted tighten it Gu...

Страница 122: ...0 Using a straightedge and the special tool check the sealing area of the cylinder head for distortion Feeler gauge 59029041100 p 269 Cylinder cylinder head sealing area distortion 0 10 mm 0 0039 in I...

Страница 123: ...end gap with a feeler gauge Guideline Piston ring end gap Compression ring 1 00 mm 0 0394 in Oil scraper ring 1 20 mm 0 0472 in If the end gap is greater than the specified measurement Check measure...

Страница 124: ...be engine case 300359 10 Use feeler gauge to measure the play between the external rotor and the internal rotor Oil pump External rotor internal rotor clear ance 0 20 mm 0 0079 in If the measured valu...

Страница 125: ...ression shaft back to the stop Pre tension the autodecompression spring more or replace it 19 25 Checking the camshaft 200206 10 Check the camshaft for damage and wear If there is damage or wear Chang...

Страница 126: ...straight line Replace the timing chain 19 27 Preparing the timing chain tensioner for installation 200171 10 Press the timing chain tensioner together completely Info This requires some some force as...

Страница 127: ...Take off rocker arm 19 30 Removing the valves 300372 10 Take the shims from the valve spring retainers and put them aside corresponding to their installation position Pre tension the valve springs us...

Страница 128: ...Clamping plate 75029050000 p 271 Remove the camshaft bearing using the special tool Push out drift 75029051000 p 271 300520 10 Remove the small camshaft bearing using the special tool Bearing puller...

Страница 129: ...ng the valve springs 200190 10 Check the valve springs for breakage and wear visual check If the valve spring is broken or worn Change the valve spring Measure the length of the valve springs Valve sp...

Страница 130: ...of the cylinder for distortion Feeler gauge 59029041100 p 269 Cylinder cylinder head sealing area distortion 0 10 mm 0 0039 in If the measured value does not meet specifications Change the cylinder he...

Страница 131: ...insert rocker arm shafts Info Ensure that the threaded hole of the rocker arm shaft is outwardly posi tioned Align the drill holes of the rocker arm shafts with the drill holes of the cylinder head 3...

Страница 132: ...disks in outer clutch hub for wear Outer clutch hub clutch facing disks contact surface 0 5 mm 0 02 in If the contact surface exhibits significant wear Change the clutch facing disks and outer clutch...

Страница 133: ...the shift roller exhibits surface damage or cracking Change the shift roller Check springs of the shift rails for damage and wear If the spring is damaged or worn Change the spring of the shift rail...

Страница 134: ...5 5 0 0 6 6 0 0 7 7 0 0 8 8 0 0 9 9 0 0 bl bl 0 0 bk bk 200177 01 Secure the main shaft with the toothed end facing downward in the bench vise Guideline Use soft jaws Remove stop disk and 2nd gear fix...

Страница 135: ...ws Remove stop disk and 1st gear idler gear Remove needle bearing and stop disk Remove 5th gear sliding gear and lock ring Remove stop disk and 3rd gear idler gear Remove needle bearing and 4th gear i...

Страница 136: ...Check the pivot points of main shaft and countershaft for damage and wear If there is damage or wear Change the main shaft and or countershaft Check the tooth profiles of main shaft and countershaft f...

Страница 137: ...of free wheel gear for damage and wear If there is damage or wear Change the free wheel gear or bearing Check free wheel for damage and wear when it is disassembled If there is damage or wear Change t...

Страница 138: ...00184 11 Thoroughly oil all parts Slide free wheel into the primary pinion Info Note the direction of rotation 300457 10 Mount spreader ring 300455 10 Ensure that all lugs of the spreader ring pass th...

Страница 139: ...029005100 p 272 Push crankshaft all the way into the bearing seat of the right section of the engine case Remove the special tool 20 2 Installing the transmission shafts 300343 10 Slide both transmiss...

Страница 140: ...ershaft Slide on shift rollers 20 5 Installing the shift drum 300340 11 Push shift drum into the bearing seat Put shift forks in the shift drum Info Do not lose the shift rollers 20 6 Installing the s...

Страница 141: ...M6x60 10 Nm 7 4 lbf ft 20 8 Installing the locking lever 300364 11 Mount locking lever with the washer sleeve and spring Mount and tighten screw Guideline Screw locking lever M5 6 Nm 4 4 lbf ft Loctit...

Страница 142: ...ings are not visible after assembly 300334 11 Position oil pump cover Mount and tighten screws Guideline Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 222 20 12 Installing the oil pump gears 300333...

Страница 143: ...el gear 20 16 Installing the primary gear 300448 10 Mount the spring washer Degrease the cone and thinly apply thread locker to it Loctite 648 Mount primary gear Info Turn the free wheel gear back and...

Страница 144: ...004000 p 273 Mount and tighten the nut Guideline Nut primary gear M20LHx1 5 120 Nm 88 5 lbf ft Loctite 243 20 20 Installing the clutch discs 400535 10 Thoroughly grease the clutch facing discs Engine...

Страница 145: ...M6x65 10 Nm 7 4 lbf ft Position the crankshaft at top dead center TDC and block using the special tool Crankshaft locking bolt 113080802 p 267 20 22 Installing the water pump cover 300318 11 Put the w...

Страница 146: ...hain tensioning rail 300314 10 Thread in the timing chain tensioning rail from the top Mount and tighten screw Guideline Screw timing chain ten sioning rail M6 8 Nm 5 9 lbf ft Loctite 243 20 27 Instal...

Страница 147: ...ing inward 20 31 Installing the piston 200086 01 Move the joints of the compression ring and oil scraper ring so they are offset by 180 Place the oiled piston on the cylinder Compress the piston rings...

Страница 148: ...iston mark faces toward the exhaust side 200091 10 Cover the engine housing opening with a cloth Thread the timing chain through the chain shaft Mount the piston pin Info In order to present them more...

Страница 149: ...he cylinder downward letting the dowels engage 20 32 Installing the cylinder head 300306 11 Mount the dowels Put the new cylinder head gasket in place Put the cylinder head in place Put on the cylinde...

Страница 150: ...the timing chain tensioner 200074 12 Position timing chain tensioner and insert it with new O ring Mount and tighten plug with new seal ring Guideline Plug timing chain tensioner M24x1 5 30 Nm 22 1 l...

Страница 151: ...n in the position in which they were installed Correct the shims according to the findings from checking the valve play Insert the fitting shims Install the camshaft p 148 Install the timing chain ten...

Страница 152: ...r 300294 11 Fill oil filter with engine oil and place in the oil filter housing 300360 11 Oil the O ring of the oil filter cover Mount the oil filter cover Mount and tighten screws Guideline Screw oil...

Страница 153: ...g the oil line 300292 11 Position oil line Mount and tighten banjo bolt with the engine oil screen and seal rings Guideline Banjo bolt oil line M12 15 Nm 11 1 lbf ft Mount and install banjo bolt with...

Страница 154: ...the hydraulic clutch fluid Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applica...

Страница 155: ...ws bleeder screw Clean the sealing surfaces of the clutch slave cylinder and engine housing Position the seal and O ring on the clutch slave cylinder and install it Mount and tighten the screws Guidel...

Страница 156: ...ternative 2 Coolant mixed ready to use p 263 Refit the radiator cap 22 2 Checking the antifreeze and coolant level Warning Scalding hazard During motorcycle operation the coolant gets very hot and is...

Страница 157: ...out of the reach of children Condition The engine is cold 100441 10 Stand the vehicle upright Place a suitable container under the water pump cover Remove screw Remove radiator cap Completely drain t...

Страница 158: ...ng the engine oil pressure Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and protective gloves If you get scalded immed...

Страница 159: ...ve exhaust extraction system Start the engine and let it warm up Check the engine oil pressure Engine oil pressure Coolant temperature 70 C 158 F Engine speed 1 500 rpm 1 3 2 3 bar 19 33 psi Coolant t...

Страница 160: ...ion and do not start or run the engine in a closed space without an effective exhaust extraction system Start the engine and let it run briefly Stop the engine and check that it is oil tight Check the...

Страница 161: ...Plug engine oil screen M17x1 5 20 Nm 14 8 lbf ft Mount and tighten the oil drain plug with the magnet and seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft 23 7 Removing the oi...

Страница 162: ...il results in premature wear to the engine 100451 10 Remove screw connection and add engine oil Engine oil 1 35 l 1 43 qt Engine oil SAE 10W 50 p 263 Mount and tighten screw cap Danger Danger of poiso...

Страница 163: ...d out all the way RPM increase deactivated Idle speed adjusting screw is pushed in all the way 24 2 Taking off the throttle valve body and allowing it to hang to the side Condition The battery has bee...

Страница 164: ...d 300690 11 Position the throttle valve body Mount hose clip and tighten it 300688 10 Mount the hose Mount hose clip and tighten it Mount the intake trumpet Mount hose clip and tighten it 300689 10 Co...

Страница 165: ...throttle valve body on the left side Run the engine warm and push the idle speed adjusting screw all the way in Set the desired idle speed by turning the idle speed adjusting screw Guideline Idle spee...

Страница 166: ...cted and active Select the model type Select ECU Diagnostic Highlight the Engine electronics EXC control unit Press Continue Select actuator test Please enter password Press Continue Select Heating la...

Страница 167: ...nsor value is not plausible Condition Th e diagnostic tool is disconnected Lambda sensor is disconnected 400596 10 Heating lambda sensor check the resistance Measure the resistance between the specifi...

Страница 168: ...ected 600849 01 Heating lambda sensor check the control line for a short circuit to sensor ground Measure the resistance between the specified points Break Out Box DT Pin 11 Break Out Box DT Pin 24 Re...

Страница 169: ...lue does not correspond to the specified value Check the cable from connector DT pin 11 to connector CU pin 4 for a short circuit to ground terminal 31 If the measured value corresponds to the specifi...

Страница 170: ...e pressure sensor cylinder 1 voltage PM1AD and deselect the other parameters with Select measured value Manifold absolute pressure sensor voltage PM1AD at 800 mbar 11 6 psi 2 31 V at 850 mbar 12 33 ps...

Страница 171: ...cable from connector DX pin 2 to connector DT pin 6 for a short circuit to ground terminal 31 If the measured value corresponds to the specified value Check the next possible cause Manifold absolute...

Страница 172: ...d and active The engine is not running Select the model type Select ECU Diagnostic Highlight the Engine electronics EXC control unit Press Continue Select Measurement values Highlight Mixture preparat...

Страница 173: ...the wiring harness The manifold absolute pressure sensor is disconnected 600849 01 400595 10 Manifold absolute pressure sensor check the ground line for an open circuit Measure the resistance between...

Страница 174: ...the specified points Break Out Box DT Pin 6 Break Out Box DT Pin 1 Resistance If the measured value does not correspond to the specified value Check the cable from connector DT pin 6 to connector DX...

Страница 175: ...voltage TAAD 0 196 4 823 V If the displayed value is equal to the setpoint value Delete the fault code Make a test ride Read out the fault code If the displayed value is below the setpoint value Check...

Страница 176: ...connector DT pin 25 to connector CM pin 2 for a short circuit to sensor ground Intake air temperature sensor signal line has a short circuit to ground terminal 31 Condition Th e diagnostic tool is di...

Страница 177: ...178 Intake air temperature sensor checking the voltage Condition The diagnostic tool is connected and active Select the model type Select ECU Diagnostic Highlight the Engine electronics EXC control un...

Страница 178: ...Break Out Box DT Pin 1 Break Out Box DT Pin 25 Resistance If the measured value does not correspond to the specified value Check the cable from connector DT pin 25 to connector CM pin 2 for a short ci...

Страница 179: ...o the specified value Check the next possible cause Intake air temperature sensor ground line is open p 177 Intake air temperature sensor ground line is open Condition Th e diagnostic tool is disconne...

Страница 180: ...resistance between the specified points Break Out Box DT Pin 24 Break Out Box DT Pin 25 Intake air temperature sensor Resistance at 20 C 4 F 18 80 k Resistance at 20 C 68 F 2 942 k Resistance at 40 C...

Страница 181: ...ltage TWAD and deselect the other parameters with Select measured value Coolant temperature sensor cylinder 1 voltage TWAD 0 138 4 784 V If the displayed value is equal to the setpoint value Delete th...

Страница 182: ...uring point Ground Resistance If the measured value does not correspond to the specified value Check the cable from connector DT pin 22 to connector AX pin 1 for a short circuit to ground terminal 31...

Страница 183: ...tinue Select Measurement values Highlight Mixture preparation general Press Continue Highlight the measured value Coolant temperature sensor cylinder 1 voltage TWAD and deselect the other parameters w...

Страница 184: ...ints Break Out Box DT Pin 22 measuring point Ground Voltage 0 1 V If the measured value does not correspond to the specified value Check the cable from connector DT pin 22 to connector AX pin 1 for a...

Страница 185: ...next possible cause Coolant temperature sensor signal line is open p 183 Coolant temperature sensor signal line is open Condition Th e diagnostic tool is disconnected The EFI control unit is disconne...

Страница 186: ...ed points Break Out Box DT Pin 24 Connector AX Pin 2 Resistance 0 6 If the measured value does not correspond to the specified value Check connector DT pin 24 and connector AX pin 2 Check the cable fr...

Страница 187: ...ic Highlight the Engine electronics EXC control unit Press Continue Select Measurement values Highlight Mixture preparation general Press Continue Highlight the measured value Throttle position sensor...

Страница 188: ...ort circuit to ground terminal 30 If the measured value corresponds to the specified value Check the next possible cause Throttle position sensor signal line has a short circuit to sensor ground p 186...

Страница 189: ...ed points Break Out Box DT Pin 5 Connector EX Pin 1 Resistance 0 6 If the measured value does not correspond to the specified value Check connector DT pin 5 and connector EX pin 1 Check the cable from...

Страница 190: ...it Press Continue Select Measurement values Highlight Mixture preparation general Press Continue Highlight the measured value Throttle position sensor circuit A voltage THAD and deselect the other par...

Страница 191: ...cuit to ignition plus terminal 15 If the measured value corresponds to the specified value Check the next possible cause Throttle position sensor signal line has a short circuit to the sensor power s...

Страница 192: ...d points Break Out Box DT Pin 24 Connector EX Pin 3 Resistance 0 6 If the measured value does not correspond to the specified value Check connector DT pin 24 and connector EX pin 3 Check the cable fro...

Страница 193: ...ge Condition The diagnostic tool is connected and active The engine is running at idle speed The engine is at normal operating temperature Select the model type Select ECU Diagnostic Highlight the Eng...

Страница 194: ...sconnected 600849 01 Lambda sensor check the signal line for a short circuit to sensor ground Measure the resistance between the specified points Break Out Box DT Pin 7 Break Out Box DT Pin 24 Resista...

Страница 195: ...t to ignition plus terminal 15 If the measured value corresponds to the specified value Check the next possible cause Lambda sensor signal line has a short circuit to the sensor power supply p 193 Lam...

Страница 196: ...mbda probe ground line is open p 194 Lambda probe ground line is open Condition Th e diagnostic tool is disconnected The EFI control unit is disconnected The breakout box is connected to the wiring ha...

Страница 197: ...active Select the model type Select ECU Diagnostic Highlight the Engine electronics EXC control unit Press Continue Select actuator test Please enter password Press Continue Select Injection valve cy...

Страница 198: ...ue Check the next possible cause Injection valve control line has a short circuit to plus terminal 30 p 196 Injection valve control line has a short circuit to plus terminal 30 Condition Th e diagnost...

Страница 199: ...tool is disconnected The EFI control unit is disconnected The breakout box is connected to the wiring harness The injection valve is disconnected 600849 01 Injection valve check the control line for a...

Страница 200: ...oes not correspond to the specified value Check the cable from connector DT pin 16 to connector DQ pin 2 for a short circuit to ground terminal 31 If the measured value corresponds to the specified va...

Страница 201: ...l line has a short circuit to the sensor power supply p 202 Ignition pulse generator checking the signal Condition The diagnostic tool is connected and active Select the model type Select ECU Diagnost...

Страница 202: ...rt circuit to each other p 200 Ignition pulse generator signal lines have a short circuit to each other Condition Th e diagnostic tool is disconnected The EFI control unit is disconnected The breakout...

Страница 203: ...trol unit is disconnected The breakout box is connected to the wiring harness Ignition pulse generator is connected 600849 01 Ignition pulse generator check the signal lines for a short circuit to sen...

Страница 204: ...ied points Break Out Box DT Pin 1 Break Out Box DT Pin 3 Resistance If the measured value does not correspond to the specified value Check the cable from connector DT pin 3 to connector AL pin 2 for a...

Страница 205: ...FAULT CODE 203 If the measured value corresponds to the specified value Contact customer service...

Страница 206: ...ght the Engine electronics EXC control unit Press Continue Select actuator test Please enter password Press Continue Select Ignition cylinder 1 Press Continue Read the information page in the HUSABERG...

Страница 207: ...il control line has a short circuit to sensor ground Condition Th e diagnostic tool is disconnected The EFI control unit is disconnected The breakout box is connected to the wiring harness The control...

Страница 208: ...t box is connected to the wiring harness The control line of the ignition coil is disconnected 600849 01 Ignition coil check the control line for a short circuit to ignition plus terminal 15 Measure t...

Страница 209: ...t points must be loaded with a 12V 21W bulb The value should not vary more than 1V from the battery voltage VBAT If the measured value does not correspond to the specified value Check connector DT pin...

Страница 210: ...nics EXC control unit Press Continue Select actuator test Please enter password Press Continue Select Function fuel pump relay Press Continue Read the information page in the HUSABERG diagnostic tool...

Страница 211: ...ue Check the next possible cause Fuel pump resistance of ground line is too high p 209 Fuel pump resistance of ground line is too high Condition Th e diagnostic tool is disconnected Fuel pump is disco...

Страница 212: ...If the measured value corresponds to the specified value Check the next possible cause Fuel pump control line has a short circuit to sensor ground p 210 Fuel pump control line has a short circuit to s...

Страница 213: ...fuel pump relay Press Continue Read the information page in the HUSABERG diagnostic tool and with Continue begin the actuator test Fuel pump Function noise If the specification is attained Delete the...

Страница 214: ...Fuel pump check the power supply Measure the voltage between the specified points Break Out Box DT Pin 14 measuring point Ground Info For the measurement the measurement points must be loaded with a...

Страница 215: ...nt values Highlight Starter Press Continue Highlight the measured value Rollover sensor voltage RolloverAD and deselect the other parameters with Select measured value Info Deselecting the other param...

Страница 216: ...breakout box is connected to the wiring harness The rollover sensor is disconnected 600849 01 Rollover sensor check the signal line for a short circuit to sensor ground Measure the resistance between...

Страница 217: ...not correspond to the specified value Check connector AP pin 6 Check the cable from connector AP pin 6 to the next node in the cable harness for an open circuit If the measured value corresponds to th...

Страница 218: ...stic Highlight the Engine electronics EXC control unit Press Continue Select Measurement values Highlight Starter Press Continue Highlight the measured value Rollover sensor voltage RolloverAD and des...

Страница 219: ...Break Out Box DT Pin 1 Break Out Box DT Pin 2 Resistance If the measured value does not correspond to the specified value Check the cable from connector DT pin 2 to connector AP pin 5 for a short cir...

Страница 220: ...If the measured value corresponds to the specified value Check the next possible cause Rollover sensor ground line is open p 218 Rollover sensor ground line is open Condition Th e diagnostic tool is...

Страница 221: ...n bearing Not a bearing bush DLC plated piston pins Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with two rotary pu...

Страница 222: ...hole diameter All 570 models Size I 100 000 100 012 mm 3 937 3 93747 in Size II 100 012 100 025 mm 3 93747 3 93798 in Piston cylinder mounting clearance All 450 models Size I 0 040 0 082 mm 0 00157 0...

Страница 223: ...0 20 mm 0 0079 in External rotor internal rotor clearance 0 20 mm 0 0079 in End play 0 15 mm 0 0059 in Shift fork Sheet thickness 4 85 4 95 mm 0 1909 0 1949 in Shift shaft sliding plate shift quadrant...

Страница 224: ...cover M6x30 10 Nm 7 4 lbf ft Screw generator cover M6x50 10 Nm 7 4 lbf ft Screw generator cover chain shaft through hole M6x30 10 Nm 7 4 lbf ft Loctite 243 Screw idler M6 10 Nm 7 4 lbf ft Loctite 243...

Страница 225: ...m 44 3 lbf ft Spark plug M12x1 25 15 20 Nm 11 1 14 8 lbf ft Coolant temperature sensor at cylinder head M12x1 5 12 Nm 8 9 lbf ft Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Plug oil pressure...

Страница 226: ...heelbase 1 475 10 mm 58 07 0 39 in Seat height unloaded 985 mm 38 78 in Ground clearance unloaded 390 mm 15 35 in Weight without fuel approx FE 450 EU FE 450 AUS 116 5 kg 256 8 lb Weight without fuel...

Страница 227: ...TREME 140 80 18 M C 70M M S TT Metzeler MCE 6 DAYS EXTREME FE USA 80 100 21 51M TT Bridgestone M59 110 100 18 64M TT Bridgestone M402 Additional information is available in the Service section under w...

Страница 228: ...ng length with preload spacer s 510 mm 20 08 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 2 N mm 24 lb in Weight of rider 75 85 kg 165 187 lb 4 4 N mm 25 1 lb in Weight of rider 85 95 kg 187 2...

Страница 229: ...n Rebound damping Comfort 26 clicks Standard 24 clicks Sport 22 clicks Spring preload 10 mm 0 39 in Spring rate Weight of rider 65 75 kg 143 165 lb 69 N mm 394 lb in Weight of rider 75 85 kg 165 187 l...

Страница 230: ...p M8 12 Nm 8 9 lbf ft Screw engine brace M8 33 Nm 24 3 lbf ft Screw exhaust clamp on manifold M8 8 Nm 5 9 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loc...

Страница 231: ...he intake flange is not closed properly dirt and water can enter into the engine In the worst case this can lead to engine damage When you remove the fuel tank carefully close off the sleeve intake tr...

Страница 232: ...e steering lock Universal oil spray p 266 33 2 Protection for winter operation Info If you use the motorcycle in the winter you can expect to encounter salt on the roads Precautions need to be taken a...

Страница 233: ...iting times at the start of the new season Clean the motorcycle p 229 Change the engine oil and oil filter clean the engine oil screen p 158 Check the antifreeze and coolant level p 154 Check the tire...

Страница 234: ...ch p 152 Clean the air filter p 57 Check the cables for damage and routing without sharp bends Check the functioning of the electrical equipment Adjust the beam width of the headlight FE EU FE AUS p 8...

Страница 235: ...ft bearing p 126 Check the valve spring seat p 127 Check the cylinder head p 128 Check the valves p 127 Check the valve springs p 127 Check the radial clearance of the rocker arm rollers Check the tim...

Страница 236: ...s Bleed the fork legs p 11 Clean the dust boots of the fork legs p 11 Clean the chain p 71 Check the chain tension p 69 Check the chain wear p 70 Check the rear sprocket engine sprocket for wear p 71...

Страница 237: ...235...

Страница 238: ...2 D1 1054 3 D5 1077 G 3 G2 EZ 3 EY 3 2 C1 1071 2 D3 1123 BV 2 BS 2 X500 1 2 2 1 2 2 t S3 1 2 M CD 2 BL 2 M3 1 2 5A 1 2 F6 X8 U N1 FA 4 FB 4 1 2 3 4 3 D3 1113 BR 4 BK 4 S8 1 2 3 4 BA 1 X502 AI 2 V1 1 2...

Страница 239: ...3 V1 Diode E F4 Cable colors 38 Brown 39 Brown 40 Black 41 Black 54 Black blue 62 White black 68 White red 69 White red 70 White red 71 Blue red 72 Orange 73 Yellow 74 Yellow blue 75 Yellow red 76 Yel...

Страница 240: ...071 1 C5 1123 X6 X7 3 C3 1112 X5 1 2 H1 1 D3 1054 DV 2 EL 2 B2 1 2 X11 p DX 3 B4 1 2 3 AL 2 AT 2 L1 1 2 AP 6 B1 4 5 6 CM 2 t B7 1 2 t L CU 4 DY 4 B5 2 3 4 1 EX 3 B3 2 1 3 450 570 FE EU 42 43 44 46 48...

Страница 241: ...coil F7 M2 Fuel pump F8 X50 Diagnosis connector A4 X51 Resistance A5 Y1 Injection valve F7 8 Cable colors 42 Orange 43 Yellow red 44 White yellow 45 Black brown 46 Yellow 47 Purple 48 Green red 49 Bro...

Страница 242: ...87 Black blue 88 Black blue 89 Orange 90 White black 91 Brown 92 Brown 93 Brown 96 Black 97 Blue 98 Blue 99 Black 100 Orange 101 Black 102 Brown 103 Black 104 Orange 105 Brown 107 Black 112 Orange 11...

Страница 243: ...WIRING DIAGRAM 241...

Страница 244: ...BV 2 BS 2 H12 1 2 3 1 2 H11 DI 2 1 2 H8 DI 2 BP 4 DG 4 4 3 2 1 H9 X13 BA 1 BF 1 X52 1 2 1 CY 3 CZ 3 DA 4 DB 4 CW 2 CX 2 1 2 1 2 3 1 2 3 4 P1 CW 2 CX 2 H6 1 2 CW 2 CX 2 H5 1 2 X15 X18 G B8 1 2 1 B3 111...

Страница 245: ...D8 K3 Turn signal relay E2 P1 Speedometer A B1 S2 Brake light switch front E3 S4 Turn signal switch E3 S5 Horn button light switch short circuit button E4 5 S6 Brake light switch rear E7 Cable colors...

Страница 246: ...NG DIAGRAM 244 33 Brown 34 Blue 35 Blue 36 White 37 Green 65 Black yellow 73 Yellow 81 Brown 82 Brown 83 Yellow blue 84 Yellow blue 86 White blue 115 Purple 116 Black 117 Brown 118 Brown 121 Black yel...

Страница 247: ...WIRING DIAGRAM 245...

Страница 248: ...D1 1041 3 D5 1077 G 3 G2 EZ 3 EY 3 2 C1 1071 2 D3 1123 BV 2 BS 2 X500 1 2 2 1 2 2 t S3 1 2 M CD 2 BL 2 M3 1 2 5A 1 2 F6 X8 U N1 FA 4 FB 4 1 2 3 4 BR 4 BK 4 S8 1 2 3 4 BA 1 X502 1 3 D4 1113 AI 2 V1 1...

Страница 249: ...3 V1 Diode E F4 Cable colors 38 Brown 39 Brown 40 Black 41 Black 54 Black blue 62 White black 68 White red 69 White red 70 White red 71 Blue red 72 Orange 73 Yellow 74 Yellow blue 75 Yellow red 76 Yel...

Страница 250: ...071 1 C5 1123 X6 X7 3 D3 1112 X5 1 2 H1 1 D3 1041 DV 2 EL 2 B2 1 2 X11 p DX 3 B4 1 2 3 AL 2 AT 2 L1 1 2 AP 6 B1 4 5 6 CM 2 t B7 1 2 t L CU 4 DY 4 B5 2 3 4 1 EX 3 B3 2 1 3 450 570 FE USA 42 43 44 46 48...

Страница 251: ...oil F7 M2 Fuel pump F8 X50 Diagnosis connector A4 X51 Resistance A5 Y1 Injection valve F7 8 Cable colors 42 Orange 43 Yellow red 44 White yellow 45 Black brown 46 Yellow 47 Purple 48 Green red 49 Brow...

Страница 252: ...87 Black blue 88 Black blue 89 Orange 90 White black 91 Brown 92 Brown 93 Brown 96 Black 97 Blue 98 Blue 99 Black 100 Orange 101 Black 102 Brown 103 Black 104 Orange 105 Brown 107 Black 112 Orange 11...

Страница 253: ...WIRING DIAGRAM 251...

Страница 254: ...DA 4 DB 4 CW 2 CX 2 1 2 1 2 3 1 2 3 4 P1 X15 X18 G B8 1 2 BP 4 X501 X509 1 2 3 4 AJ 3 X504 1 2 3 AC 6 X503 1 2 3 4 5 6 BA 1 1 BF 1 S9 BA 1 X505 1 BA 1 X506 1 1 B3 1113 AH 2 X507 1 2 AH 2 X508 1 2 450...

Страница 255: ...switch front E3 optional X508 Plug in connector for brake light switch rear E7 optional X509 Plug in connector for high beam indicator switch C1 optional Cable colors 15 Yellow blue 16 Yellow 17 Brow...

Страница 256: ...D1 1048 3 D5 1077 G 3 G2 EZ 3 EY 3 2 C1 1071 2 D3 1123 BV 2 BS 2 X500 1 2 2 1 2 2 t S3 1 2 M CD 2 BL 2 M3 1 2 5A 1 2 F6 X8 U N1 FA 4 FB 4 1 2 3 4 3 D3 1113 BK 4 BR 4 BF 1 BA 1 S7 1 2 3 4 1 AI 2 V1 1...

Страница 257: ...F switch A3 V1 Diode E F4 Cable colors 38 Brown 39 Brown 40 Black 41 Black 54 Black blue 62 White black 68 White red 69 White red 70 White red 71 Blue red 72 Orange 73 Yellow 74 Yellow blue 75 Yellow...

Страница 258: ...071 1 C5 1123 X6 X7 3 C3 1112 X5 1 2 H1 1 D3 1048 DV 2 EL 2 B2 1 2 X11 p DX 3 B4 1 2 3 AL 2 AT 2 L1 1 2 AP 6 B1 4 5 6 CM 2 t B7 1 2 t L CU 4 DY 4 B5 2 3 4 1 EX 3 B3 2 1 3 450 570 FE AUS 42 43 44 46 48...

Страница 259: ...coil F7 M2 Fuel pump F8 X50 Diagnosis connector A4 X51 Resistance A5 Y1 Injection valve F7 8 Cable colors 42 Orange 43 Yellow red 44 White yellow 45 Black brown 46 Yellow 47 Purple 48 Green red 49 Bro...

Страница 260: ...87 Black blue 88 Black blue 89 Orange 90 White black 91 Brown 92 Brown 93 Brown 96 Black 97 Blue 98 Blue 99 Black 100 Orange 101 Black 102 Brown 103 Black 104 Orange 105 Brown 107 Black 112 Orange 11...

Страница 261: ...WIRING DIAGRAM 259...

Страница 262: ...BV 2 BS 2 H12 1 2 3 1 2 H11 DI 2 1 2 H8 DI 2 BP 4 DG 4 4 3 2 1 H9 X13 BA 1 BF 1 X52 1 2 1 CY 3 CZ 3 DA 4 DB 4 CW 2 CX 2 1 2 1 2 3 1 2 3 4 P1 CW 2 CX 2 H6 1 2 CW 2 CX 2 H5 1 2 X15 X18 G B8 1 2 1 B3 111...

Страница 263: ...D8 K3 Turn signal relay E2 P1 Speedometer A B1 S2 Brake light switch front E3 S4 Turn signal switch E3 S5 Horn button light switch short circuit button E4 5 S6 Brake light switch rear E7 Cable colors...

Страница 264: ...NG DIAGRAM 262 33 Brown 34 Blue 35 Blue 36 White 37 Green 65 Black yellow 73 Yellow 81 Brown 82 Brown 83 Yellow blue 84 Yellow blue 86 White blue 115 Purple 116 Black 117 Brown 118 Brown 121 Black yel...

Страница 265: ...C 40 F Supplier Motorex Anti Freeze Engine oil SAE 10W 50 According to JASO T903 MA p 278 SAE p 278 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specificatio...

Страница 266: ...2 5 50180342S1 According to SAE p 278 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Super u...

Страница 267: ...otorex products Supplier Motorex Protect Shine 645 Contact spray Specification HUSABERG recommends Motorex products Supplier Motorex Accu Contact High luster polish for paint Specification HUSABERG re...

Страница 268: ...52 Specification HUSABERG recommends Bel Ray products Supplier Bel Ray Molylube Anti Seize Motorcycle cleaner Specification HUSABERG recommends Motorex products Supplier Motorex Moto Clean 900 Offroad...

Страница 269: ...Art no 00029095000 Crankshaft locking bolt 400035 01 Art no 113080802 Bearing puller 400037 01 Art no 15112017000 Insert for bearing puller 400038 01 Art no 15112018100 Feature 18 23 mm 0 71 0 91 in B...

Страница 270: ...00059 01 Art no 51012011000 Clutch holder 400289 01 Art no 51129003000 Extractor 400073 01 Art no 58012009000 Tool for inner bearing race 400082 01 Art no 58429037043 Torque wrench with various access...

Страница 271: ...01 01 Art no 59029019000 Limit plug gauge 400104 01 Art no 59029026006 Feeler gauge 25 20 30 15 10 12 5 3 5 400110 01 Art no 59029041100 Piston ring mounting tool 400123 01 Art no 60029015000 Pressure...

Страница 272: ...stand 200306 01 Art no 61229001000 Extractor 400157 01 Art no 75029021000 Push in drift 500163 01 Art no 75029044010 Push in drift 500162 01 Art no 75029044020 Pressing device for crankshaft complete...

Страница 273: ...xtractor 400162 01 Art no 75029048000 Clamping plate 400163 01 Art no 75029050000 Push out drift 400164 01 Art no 75029051000 Spark plug wrench 400170 01 Art no 75029172000 Limit plug gauge 400104 01...

Страница 274: ...77329006000 Insert for piston pin retainer 400160 01 Art no 77329030100 Release device for timing chain tensioner 400181 01 Art no 77329051000 Mounting sleeve 500167 01 Art no 78029005100 Insert for...

Страница 275: ...plate 500169 01 Art no 78029009000 Valve spring mounting device 500165 01 Art no 78029060000 Gear segment 500164 01 Art no 80029004000 Fitting for work stand 500281 01 Art no 81229002000 Work stand 5...

Страница 276: ...ECIAL TOOLS 274 Pin wrench 200734 10 Art no T103 Hook wrench 301085 01 Art no T106S Depth micrometer 300577 10 Art no T107S Mounting sleeve 200788 10 Art no T1204 Calibration pin 200790 10 Art no T120...

Страница 277: ...L TOOLS 275 Pressing tool 200583 10 Art no T1206 Pressing tool 200585 01 Art no T1207S Centering sleeve 200777 10 Art no T1214 Mounting sleeve 300568 10 Art no T1215 Disassembly tool 200816 10 Art no...

Страница 278: ...TOOLS 276 Protecting sleeve 200635 10 Art no T1401 Clamping stand 200733 10 Art no T14015S Clamping stand 200688 10 Art no T14016S Gripping tool 200639 10 Art no T14026S1 Assembly tool 200634 10 Art n...

Страница 279: ...TOOLS 277 Open end wrench 200640 10 Art no T14032 Clamping stand 200637 10 Art no T1403S Press drift 200789 10 Art no T1504 Assembly tool 200791 10 Art no T150S Nitrogen filling tool 300574 10 Art no...

Страница 280: ...ce intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated wi...

Страница 281: ...pressor assembling 123 autodecompressor disassembling 122 camshaft checking 123 clutch checking 130 conrod bearing changing 117 coolant temperature sensor installing 129 coolant temperature sensor rem...

Страница 282: ...in engine work stand 99 clutch cover removing 104 clutch disks disassembling 105 crankshaft removing 110 cylinder head removing 102 diaphragm removing 110 distance bushing removing 102 engine oil drai...

Страница 283: ...ing 158 installing 160 removing 159 Oil pressure regulator valve removing 113 spring length checking 113 P Protection for winter operation 230 Putting into operation after storage 231 R Rear sprocket...

Страница 284: ...play adjusting 29 checking 29 Storage 231 Swingarm installing with shock absorber and rear wheel 52 removing with shock absorber and rear wheel 51 T Technical data chassis 224 225 chassis tightening...

Страница 285: ...HUSABERG eine Division der KTM SMC AG Stallhofnerstra e 3 5230 Mattighofen Austria www husaberg com 3803004en 3803004en 01 2009 Photo Mitterbauer...

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