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BEDIENUNGSANLEITUNG OWNERS MANUAL

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1. 10 clicks Standard high speed setting turn the adjusting screw 2 to the limit in a clockwise direction using a box wrench unscrew the respective number of turns for the specific type of shock absorber in a counterclockwise direction Typ White Power 1245Y721 2 turns Typ White Power 1245Y722 2 turns Typ White Power 1245Y723 2 turns WARNING The damping unit of the shock absorber is fil led with high compression nitrogen Never try to take the shock absorber apart or to do any maintenance work yourself Severe injuries could be the result Never unscrew the black screw connection 3 24mm 18 REBOUND DAMPING OF SHOCK ABSORBER By using the adiusting screvv 1 the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during rebo unding STANDARD ADJUSTMENT turn the adjusting screw clockwise to the stop then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the respective type of shock absorber Typ White Power 1245Y721 22 clicks Typ White Power 1245Y722 22 clicks Typ White Power 1245Y723 15 clicks WARNING The damping unit of the shock absorber is fil led with high compression nitrogen Never try to take the shock absorber apart or to do any maintenance work yourself Severe injuries could be the result
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3. button time press the MODE button to change to the next digit press and hold the MODE button 3 seconds to store the time and return to the SPEED CLK mode ACTIVATING DEACTIVATING THE DISPLAY MODES It may not be necessary to display all of the display modes func tions at the same time It is possible to conceal any information not currently required By deactivating certain functions the MODE button will only allow you to select from the activated modes In the SPEED H mode press and hold the MODE button for 3 seconds to access the SETUP menu The blinking function can be activated by pressing the button and deactivated by pressing the button If no button is pressed for 20 seconds the setting will be stored automatically and the display will return to the SPEED H mode button activates the blinking display button deactivates the blinking display press the MODE button to change to the next display without changing any settings press and hold the MODE button 3 seconds to store the settings and change to the SPEED H mode 13 TRP m N61 SPI 000 gt WAS UP CLK A ur o c LLI OPERATION INSTRUMENTS KILOMETERS OR MILES The unit kilometers or miles can also be changed The ODO figure vvill be retained and converted accordingly The TRP1 AVS1 TRP STP1 TRP2 and AVS2 figures will be cleared To select the unit select the SPEED H mode and hold the MODE button for 3 seconds to
4. ehe e 54 Stopping and parking NEE 24 Cleaning the oil screen EE 54 RUC M T 24 Changing the oil filter 55 PERIODIC MAINTENANCE SCHEDULE 2004 26 TROUBLESHOOTING EE 56 MAINTENANCE WORK ON CHASSIS AND ENGINE 30 CLEANING CONSERVATION STORAGE 58 Checking and adjusting the steering head bearing 30 Breather plug front fork 31 TECHNICAL DATA ENGINE 59 Cleaning the dust sleeves of the telescopic fork 31 Basic suspension setup for the weight of the driver 32 TECHNICAL DATA CHASSIS duri ar ean pea s 61 Checking the shock absorber and spring 32 Determining the static sag of the shock absorber 32 HEAD WORD INDEX 64 Determining the riding sag of the shock absorber 32 Checking the basic setup of the telescopic fork 33 WIRING DIAGRAMM Appendix Changing the spring preload on the telescopic fork 33 LL Z A un L INTRODUCTION IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COM PLETELY BEFORE GOING ON YOUR FIRST RIDE IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY IN YOUR OWN INTEREST PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS CH WARNING IGNORING THESE INSTRUCTIONS CAN ENDANGER YOUR BODY AND YOUR LIFE N CAUTION IGNORING THESE INSTRUCTIONS COULD CAUSE DAM
5. d 1 OO e 49 MAINTENANCE WORK ON CHASSIS AND ENGINE CLEANING THE AIR FILTER The air filter must be cleaned prior to every race or depending on the accumulation of dust To clean remove the seat unscrew the wing screw and remove the air filter together with the filter support CAUTION Do not clean air filter with fuel or petroleum since these damage the foam Husaberg recommends the products of the company Motorex for air filter mainte nance Motorex Bio Dirt Remover Motorex Liquid Bio Popwer Never operate your motorcycle without air filter Otherwise dust and dirt may get into the engine and lead to increased wear Thoroughly wash the air filter with special cleaning fluid and allow to dry Press out the water from the air filter but do not wring Lubricate the dry air filter with high grade filter oil Check the car buretor connection boot for damage and a good fit Mount the air filter on the filter support Attach the air filter and fil ter support to the frame making sure it is centered and fix with the wing screw m c A un L CHECKING THE ADJUSTMENT OF THE HAND DECOMPRESSION RELEASE CABLE Start the engine and at idling speed slowly pull the hand decom pression lever until you can feel the thumping of the rocker arm on the lever The backlash until said thumping should be approx 10mm measured at the lever s outer end If necessary correct this backlash
6. 59 TECHNICAL DATA ENGINE Design Liquid cooled 1 eylinder 4 stroke Otto engine vvith balancer vveight RIVE Displacement 550 cm 644 cm Bore Stroke Compression ratio 100 70 mm 100 82 mm 11 8 1 11 5 1 Keihin carburetor FCR MX 41 Fuel Timing unleaded fuel with at least RON 95 USA Premium RON 91 4 valves controlled over rocker arm and 1 camshaft camshaft drive with single chain Valve diameter intake 35 mm Valve diameter exhaust Valve clearance intake cold 30 mm 0 12 mm Valve clearance exhaust cold 0 12 mm Crankcase bearing Conrod bearing 2 roller bearings needle bearing Piston pin bearing bronze bush Piston Piston rings Light allow forged 1 compression ring 1 oil scraper ring Engine lubrication pressure lubrication with trochoid rotor pump Engine oill Quantity of engine oil fully synthetic engine oil Motorex Power Synt 4T SAE 10W50 1 0 liter Primary drive straight toothed spur wheels 29 78t Clutch Transmission claw shifted multi disk clutch in oil bath Gear ratio 1st gear 2nd gear 3rd gear 4th gear 5th gear 24 22 th gear 27 20 Ignition system Generator breakerless transitorized DC CDI ignition system with digital ignition advance type KOKUSAN 12V 150W Spark plug NGK DCPR 8 E Electrode distance Cooling system 0 6 mm liquid cool
7. ENGLISH Have the ignition system checked Clean and check the fuel system and carburetor Check the rubber sleeve and carburetor for a tight fit Add cooling liquid see maintenance work check the cooling system for tightness Continue driving speedily Ventilate the cooling system Clean the radiator fins with a water jet Replace the cooling liquid use brand name antifreeze Shorten or replace the radiator hose Install the ventilation hose without kinks or replace Check the engine oil level and correct if necessary Use a thicker engine oil see Engine oil chapter viscosity Have the voltage regulator checked in the starter relay is Renew the fuse blown Check the connections on the voltage regulator have the vol tage regulator checked at an authorized workshop LL Z A un L CLEANING CONSERVATION STORAGE Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces The best manner would be to use warm water that has been mixed with a normal brand name washing detergent and a sponge The hard dirt can be removed before washing with the help of a soft water jet CAUTION Never clean your motorcycle with a high pressured cleaner or a high pressured water jet The water could otherwise run into the electrical components connectors sheathed cables bearings carburetor etc and cause disturbances or lead to a premature destruction of these parts You should use normal b
8. The telescopic forks for these models must be partly disassembled to adjust the spring preload see WP manual Pretension spacers are available in heights of 1 5 2 5 and 5 mm see spare parts cata log The fork springs may not be pretensioned by more than 20 mm E NOTE WP precisely adjusts the spring pressure by inser ting pretension spacers Fluctuations in production are compensated with pretension spacers in various heights This can cause the fork springs in the fork legs to have different degrees of pretension Fork springs and preten sion spacers should always stay together REPLACING FORK SPRINGS If you weigh less than 70 kg or more than 80 kg you should install the respective fork springs The correct spring rate is shown in the illustrations The standard spring is shown in bold print The type number of the telescopic fork is embossed on the caps on the top of the telescopic fork If you are uncertain which spring to use contact your Husaberg workshop According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increa sed by a few clicks for a harder spring 33 1245Y7229 i6 86 260 71 5 90 5 260 81 99 5 260 FE 450 501 550 650 FS 450 650 ENGLISH OSD SU KXT LTKT LILT XX for example FC 450 550 4 6 N mm 4 4 N mm 4 2 N mm 60 65 70 75 80 85 90 RIDERS WEIGH
9. 2 INTRODUCTION We would like to congratulate you on your purchase of a Husaberg motorcycle You are now the owner of a state of the art sport motorcycle that guarantees to bring you lots of fun and enjoyment provided that you clean and maintain it appro priately Before you go for your first ride be sure to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new motorcycle and with its characteristics even if this means that you will have to dedicate some of your valuable time to this task Only by doing so will you learn how to tune your motorcycle to your specific needs and how to protect yourself against injury Besides this manual contains important information on motorcycle maintenance At the time this manual was typeset it was up to date with the latest state of this production series Please note that motorcycle features may vary according to the effective legal provisions It cannot be completely ruled out however that minor discrepancies may exist resulting from further design upgrades of these motorcycles This manual is an important part of your motorcycle and should be passed on to any subsequent owner in case you decide to sell it L CL ur o c LLI The work marked with an in the chapter Servicing the chassis and engine must be performed by an authorized Husaberg dealer If such service work becomes necessary during a competition it must be performed by a trained m
10. HH screw chain tensioning rail HH screw on chain guide rail HH collar screws on stator FE FS models Loctite 243 6Nm Loctite 243 6Nm Loctite 243 10 Nm HH collar screws on stator FC models HH collar screws on pulse generator Loctite 243 6Nm Loctite 243 6Nm HH collar nut on rotor 60 Nm HH collar screw on starter cap FC models only HH screw on kickstarter 10 Nm Loctite 243 25 Nm Phillios screws on kickstarter release plate Loctite 243 6Nm HH collar screw on shift lever Spark plug M12x1 25 10Nm 20Nm Plug on engine blocking bore M8 20 Nm Diaphragm valve 2862 M4 Loctite 243 1 5 Nm TECHNICAL DATA CHASSIS TIGHTENING TORQUES CHASSIS Collar screw front wheel spindle Brake caliper front M24x1 5 M8 40 Nm Loctite 243 25 Nm Collar screw brake pads front F5 models only Brake discs Clamping screws upper fork bridge M6 M M8 10 Nm Loctite 243 10 Nm 20 Nm Clamping screws lower fork bridge Klemmutter Gabelbr cke Clamping screws fork stubs M8 M22x1 M8 15 Nm 20 Nm 10 Nm Collar nut rear wheel spindle Hexagon nut swing arm bolt Hexagon collar screw handlebar clamp M20x1 5 M16x1 5 M8 80 Nm 100 Nm 20 Nm Allan head screw handlebar support Shock absorber top Shock absorber bottom M10 M12 M10 Loctite 243 40 Nm 60 Nm 40 Nm Sprocket screws Ball joint for push rod Engine
11. To adjust move back the protective cover 1 loosen the counter nut 2 and correct the adjustment screw 3 accordingly Tighten counter nut and push back protective cover N CAUTION The setting of the decompression cable should be checked regulary If there is no play in the deko lever this can result in engine damage NOTE No adjustment need be made to the automatic J decompressor ADJUSTING THE THROTTLE CABLES The throttle grip should always provide for a backlash of 3 5 mm Besides with the engine running the idling speed must not change if you turn the handlebar all the way to the left or right To adjust the throttle cables dismount the seat and the tank together with spoilers Slide back the protection cover 4 Loosen the counternut 5 and turn the adjusting screw bk accordingly Turning the adjusting screw 6 counterclockwise will reduce the backlash turning the adjusting screw clockwise will increase the backlash Tighten the counternut and check whether the throttle grip can be actuated smoothly Mount tank and seat 50 MAINTENANCE VVORK ON CHASSIS AND ENGINE CHANGING THE ORIGINAL POSITION OF THE CLUTCH LEVER The adjusting screw 1 can be used for individual adjustment of the original position of the clutch lever thus allowing adjustment to an optimal position for every hand size Turning the adjusting screw clockwise reduces the distance bet ween the clutch lever and the handlebar Tur
12. pull the hand decom pression lever fully rev up the engine actuate the kickstarter 5 to 10 times or actuate the E starter 2 times for 5 seconds each Then start the engine as described above If the engine fails to start unscrew the spark plug and dry it Clean and dry the spark plug or exchange it respectively Adjust spark plug electrode gap to 0 6 mm Dismount spark plug connect ignition cable hold to ground blank place on engine and actuate starter a strong spark must be produced at the spark plug If no spark is created replace the spark plug If the new spark plug doesn t produce a spark either dis connect the spark plug connector from the ignition cable hold it a distance of approx 5 mm from ground and start If a spark now occurs replace spark plug cap If no spark is produced control ignition system Dismount the fuel tank disconnect the black yellow cable from the cable of the emergency OFF switch and the short circuit button respectively and check the ignition spark If a spark is generated look for the problem in the short cir cuit circuit Remove the seat and the fuel tank Clean the plug connec tion and treat it with contact spray Dismount and clean the carburetor Disassemble the carburetor and clean the jets Have the carburetor adjusted Replace the spark plug Have the ignition system checked 56 Engine won t rev up Engine does not have enough power Engin
13. 1 Swing up the side stand or center stand Put the gear in neutral Operate the choke 2 Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E starter Cn A Co N WARNING If you want to start the engine make sure that you always put on sturdy motorcycle boots in order to avoid injuries You might slip off the kickstarter or the engine may kick back and propel your foot upward with great force Always kick the kickstarter briskly all the way without opening the throttle If you do not Kick hard enought with an open throttle grip the kick back hazard will be higher Do not start the engine and allow it to idle in a closed area Exhaust fumes are poisonous and can cause loss of consciousness and death Always provide adequate venti lation while the engine is running Always verify that the transmission has been set to idle neutral before actuating the starter button If you start the motorcycle with a gear engaged the motorcycle will move forward N CAUTION Be sure to kick up the side stand before you start the engine to avoid any damage Maximal period for continuous starting 5 seconds Wait at least 5 seconds before trying again Don t ride your motorcycle with full load and don t rev up the engine when cold because the piston is warming up faster than the water cooled cylinder and can cause engine damage STARTING WHEN THE ENGINE IS WARM 1 Open the fuel tap 1 2 Swi
14. Never unscrew the black screw connection 2 15mm STEERING LOCK The lock mounted on the steering head locks the steering system To lock turn the handlebar all the way to the left insert the key turn to the left press in turn to the right and pull off the key CAUTION Never leave the key inserted in the steering lock If you turn the handlebar to the right the key could get damaged 19 ENGLISH LL Z A un L TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE INSTRUCTIONS FOR INITIAL OPERATION Verify that your Husaberg dealer performed the PREPA RATION OF VEHICLE jobs see Customer Service Manual Read these operating instructions carefully before your first ride Familiarize yourself with the operating elements Set the clutch lever the handbrake lever and the foot brake pedal to the positions that are most convenient for you Get used to handling the motorcycle on an empty par king lot or open space before starting on a longer drive Also try to drive as slowly as possible and in a standing position to improve your feeling for the vehicle Do not drive along off road tracks which go beyond your abitily and experience Hold the handlebars with both hands and leave your feet on the foot rests while driving Remove your foot from the foot brake lever when you are not braking If the foot brake lever is not released the brake pads rub continuously and the braking
15. The displayed figure cannot be cleared Service intervals are indicated in operating hours for some Husaberg offroad motorcycles making the operating hour counter a very practical function button no function button no function press the MODE button to change to the next mode press and hold the MODE button 3 seconds to change to the SETUP mode see REVEALING CONCEALING functions SPEED TRP1 TRIP 1 DISPLAY MODE The TRP1 trio meter is always active and counts to 999 9 It is used to measure the length of a trip or the distance between 2 refueling stops TRP1 is linked to AVS1 and STP1 The calculation of these figures is activated by the first impulse received from the wheel sensor when the front wheel starts to turn and stops 3 seconds after the last impulse is received when the front wheel has stop ped The TRP1 AVS1 and STP1 figures are automatically reset to 0 after passing 999 9 button no function button no function press the MODE button to change to the next mode press and hold the MODE button 3 seconds to automatically reset the TRP1 AVS1 and STP1 figures to 11 e ay a HG 20 LI 20 UP pE LI EE Li n d pa E a I CLK ENGLISH OPERATION INSTRUMENTS SPEED AVS1 AVERAGE SPEED 1 DISPLAY MODE AVS1 is alvvays active and shovvs the average speed based on the TRP1 and STP1 figures The calculation of this figure is activated by the first impulse received
16. and minus WARNING Do not try to change the mode or read the settings while driving Your attention will be distracted from the traffic which can easily lead to an accident ELECTRONIC SPEEDOMETER FUNCTIONS PRO VIDED BY THE TRIPMASTER SWITCH The display modes on the electronic speedometer will change in the following order If not please read the chapter ACTIVATING AND DEACTIVATING THE DISPLAY MODE ENGLISH JC LILIL LI LI 000 OPERATION INSTRUMENTS SPEED ODO DISPLAY MODE SPEED displays the speed in KPH or MPH The displayed figure cannot be cleared ODO displays the kilometers or miles traveled The displayed JE x figure cannot be cleared button no function Wi IL M oe MODE 7 7U7v to the next mode MUM C T NI press and hold the MODE button 3 seconds to change to the next 000 mode LL SPEED MAX DISPLAY MODE G MAX displays the maximum speed It is always active Un button no function ua Dutton no function press the MODE button to change to the next mode press and hold the MODE button 3 seconds to reset the MAX figure to 0 SPEED LAP DISPLAY MODE LAP displays the stopped lap time in hours minutes and seconds button Starts and stops the stop watch The lap time is not reset to O button Stops the running stop vvatch stores the lap time and restarts the stop watch The time is reset to 0 A total of 10 lap times can be stored and read
17. pads are completely worn In this case consult an authorized Husaberg dealer immediately m c A un L REFILLING THE REAR BRAKE FLUID RESERVOIR When the brake fluid level has dropped to the MIN mark you need to refill the brake fluid reservoir For easier access to the brake fluid reservoir it is recommended to remove the hexagon screw Then move the container outwards as indicated in the illustration Remove plug 3 with rubber boot 4 and add brake fluid DOT 5 1 Motorex Brake Fluid DOT 5 1 up to the MAX mark Replace rubber boot and plug Overflown or spil led brake liquid must be rinsed off with water Mount the screw and fix the brake fluid reservoir to the frame always making sure to pre vent kinks in the connecting hose CH VVARNING Never use DOT5 brake fluidl It is based on silicone oil and of a purple color Seals and brake hoses must be especially adapted to it Store brake fluid out of reach of children Brake fluid can cause skin irritation Avoid contact vvith skin and eyes f you get brake fluid in your eyes rinse vvith plenty of vvater and consult a doctor N CAUTION Don t let brake fluid get in contact with paint it is an effective paint remover Use only clean brake fluid taken from a tightly sealed container 40 MAINTENANCE WORK ON CHASSIS AND ENGINE CHECKING THE REAR BRAKE PADS The brake pads can be inspected from the rear The thickness of the linings may not be l
18. res The calculation of this figure is activated by the first impulse received trom the wheel sensor and stops 3 seconds after the last impulse is received The displayed figure will deviate from the actual average speed if TRP2 was changed manually or if STP2 was not stopped after the trip button no function button no function press the MODE button to change to the next mode press and hold the MODE button 3 seconds to change to the next mode 12 OPERATION INSTRUMENTS SPEED STP2 STOP 2 DISPLAY MODE STP2 is a manual stop vvatch Start the stop vvatch by pressing the button press again to hold Press again to continue timing Press the MODE button to change to the next mode The STP2 dis play will blink in the other modes if STP2 continues to run in the background To stop STP2 return to the SPEED STP2 mode and press the button button starts and stops the stop vvatch button no function press the MODE button to change to the next mode press and hold the MODE button 3 seconds to reset STP2 figures to0 SETTING THE CLOCK To set the clock svvitch the ignition off and select the SPEED CLK mode Press and hold the MODE button for 3 seconds The blin king digits can be changed using the and buttons Press the MODE button to move to the next digit If no button is pressed for 20 seconds the settings vvill be stored automatically and the display will return to the SPEED CLK mode button time
19. A and a maximum of 14 4 V off load voltage charging level chrging time charging voltage Volt 9 5 100 75 50 Caution To avoid damage do not remove the locking bar Always connect the battery to the charging unit before turning the charging unit on When recharging the battery in closed rooms there is suf ficient venti lation Explosive gases are released during the battery charging process Charging time and charging voltage should not exceed the stated values Otherwise electrolyte will be released through the safety valves Avoid quick charging if possible 46 MAINTENANCE WORK ON CHASSIS AND ENGINE FUSE FE FS The fuse 1 is located in the electric starter relay 2 above the bat tery The fuse can be seen after removing the protection cover A The following loads are connected to it E starter system Horn Speedometer Flasher light The starter relay also contains a 10 amp spare fuse 3 Replace a blown fuse only with an equivalent one If a new fuse that has just been installed gets blown again you are strongly advi sed to have it inspected by a Husaberg dealer The fuse capacity is 10 Ampere N CAUTION Under no circumstances is a stronger fuse allo wed to be installed or a fuse allowed to be repaired An improper treatment could damage the whole electri cal installation L N O Z TT REPLACING HEADLIGHT LAMP PARKING LIGHT LAMP L
20. Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regularly Remove and clean fork dust bellows regularly Clean and lubricate chain check tension and adjust if necessary Clean air filter and filter box Check tires for pressure and wear Check cooling fluid level Check fuel lines for leaks Drain and clean float chamber Check all control elements for smooth operation Check brake performance Treat blank metal parts with the exception of brake and exhaust system with wax based anti corrosion agent Treat ignition and steering locks and light switches with contact spray Check tightness of screws nuts and hose clamps regularly RIVE RECOMMENDED INSPECTION OF THE HUSABERG ENGINES USED FOR HOBBY ENDURO COMPETITIONS BY YOUR HUSABERG WORKSHOP ADDITIONAL ORDER FOR THE HUSABERG WORKSHOP a 100 liter fuel consumption is equivalent to approx 15 operating hours 30 hours 200 liter 60 hours 400 liter 90 hours 600 liter 120 hours 800 liter 180 hours 1200 liter 240 hours 1600 liter 270 hours 1800 liter Check the clutch disks for wear Check the length of the clutch springs Check the cylinder and piston for wear Check the groove on the piston pin retainer for wear visual check Check the camshaft for wear visual check Check the camshaft bearings Check the length of the valve spri
21. On the downward movement of the piston engine oil is pressed from the crankcase through the diaphragm valve not depicted to the transmission and shift mechanism 53 AL c A un L MAINTENANCE WORK ON CHASSIS AND ENGINE CHECKING THE ENGINE OIL LEVEL The engine oil level can be checked with the engine either warm or cold Place the motorcycle in an upright position and on a horizon tal surface not on the side stand If the engine is cold the engine oil must be visible at the lower edge of the inspection glass A If the engine is warm the engine oil must be visible up to the upper edge of the inspection glass B Replenish the engine oil if necessary CAUTION Insufficient amounts of or low grade engine oil lead to premature wear in the engine ENGINE OIL Automobile engine oil used to be used for four stroke motorcycles before there were separate motorcycle specifications Different technical developments made it necessary to have a separate spe cification for four stroke motorcycles the JASO T903 MA standard Whereas car engines require long changing intervals motorcycle engines require a higher power output at higher speeds Most motorcycle engines also use the same oil to lubricate the transmis sion and the clutch The JASO MA standard responds to these spe cial requirements Only use fully synthetic engine oils t
22. access the SETUP menu Press the MODE button 10 times until the KMH MPH function blinks Press the button to move to the 77 Press the button for KMH or the P button for MPH If no button is pressed for 20 seconds the set ting vvill be stored automatically and the display vvill return to the NEI SPEED H mode The setting can be stored immediately by holding the MODE but 9iPf 000 MAX UP CLK ton for a fevv seconds until the display returns to the SPEED H mode button to access the menu to activate the KMH setting button to activate the MPH setting press the MODE button to change to the next mode press and hold the MODE button 3 seconds to store the setting and return to the SETUP menu LL Z A un L OVERVIEW OF TRIPMASTER FUNCTIONS X X starts stops LAP stops LAP stores LAP next display mode NN SPEED LAP figure LAP remains figure resets LAP to 0 XIX SPEED no function no function next display mode resets TRP1 STP1 and TRP1 AVS1 to XIX SPEED no function no function next display mode resets TRP1 STP1 and AVS1 AVS1 to 0 XIX SPEED no function no function next display mode resets TRP1 STP1 and STP1 AVS1 to X EH gt O 4 CH E D E CH 5 N Driving motorcycle E increases TRP2 figure decreases TRP2 figure next display mode resets TRP2 to O Ge starts stops STP2 next display mode sets STP2 to 14 X IL OPER
23. anti corrosion agent WARNING Keep the anti corrosion agent from getting into contact with the brake discs otherwise this will significantly reduce the braking power CAUTION After rides on salted roads clean motorcycle thoroughly with cold water and let it dry well STORAGE Should you wish to make a pause over a longer space of time please observe the following instructions Clean motorcycle thoroughly see chapter CLEANING Change engine oil short and long oil filters old engine oil contains aggressive contaminants Check antifreeze and amount of cooling liquid Warm up the engine once again close the fuel cock and wait until the engine dies Then open the drain plug of the float chamber to remove the remaining fuel Remove spark plug and fill in approx 5 ccm of engine oil into the cylinder through the opening Actuate kick starter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug Set piston to compression so that the valves will be closed slowly operate the kickstarter until you can hear the automa tic decompressor click release Let fuel flow out of tank into an appropriate container Correct tire pressure Lubricate pivot points of the control levers foot rests etc as well as the chain Service the shock absorber linkage Disassemble and charge battery see chapter BATTERY The storage place should be dry and not subjected
24. by a Husaberg dealer as soon as possible A loose axle may lead to an unstable driving behavior of your motorcycle After mounting the front wheel keep operating the hand brake until the pressure point returns It is very important to keep the brake disk free from oil and fatty matters otherwise the braking effect would be strongly reduced 42 MAINTENANCE WORK ON CHASSIS AND ENGINE DISMOUNTING AND MOUNTING THE REAR WHEEL Jack the motorcycle up on its frame so that the rear wheel no lon ger touches the ground Loosen the collar nut 1 remove chain tensioner 2 hold the rear wheel and pull out the wheel spindle 3 until the rear wheel is free but the brake caliper support is still held Push the rear wheel as far forward as possible take the chain from the chain wheel and carefully take the rear wheel out of the swing arm CAUTION Do not operate the rear brake when the rear wheel has been dismounted Make sure the brake disc is always on top when you lay down the wheel otherwise the brake disc can be dama ged If the axle is dismounted clean the thread of the wheel spindle and collar nut thoroughly and apply a new coat of grease to prevent the thread from jamming L N O Z TT The rear wheel is remounted in the reverse order Before tightening the collar nut to 80 Nm push the rear wheel forwards so that the chain tensioners lie on the tension screws CH WARNING If you don t happen to
25. have a torque wrench at hand make sure you have the tightening torque cor rected by a Husaberg dealer as soon as possible A loose axle may lead to an unstable driving behavior of your motorcycle After mounting the rear wheel keep operating the rear brake until the pressure point returns It is very important to keep the brake disk free from oil and fatty matters eitherwise the braking effects would be strongly reduced Tighten the collar nut with the required torque A loose wheel spindle may lead to an unstable behavior of your motorcycle 43 MAINTENANCE WORK ON CHASSIS AND ENGINE CHECKING THE SHOCK ABSORPTION RUBBERS IN THE REAR HUB The FS models have a damped rear wheel hub For this purpose the engine power is conveyed from the rear sprocket via 6 shock absorption rubbers 1 to the rear wheel These 6 absorption rub bers wear with increasing operation time and should be checked for wear whenever the rear wheel is dismounted For this purpose lie the rear wheel on a work bench with the rear sprocket upwards and put the wheel spindle in the hub Now hold the rear wheel firmly and try to turn the rear sprocket The rear sprocket may not turn more than maximum 5 mm 0 2 in measured on the outside If the play in the chain wheel is larger all 6 shock absorption rubbers are to be replaced Check the shock absorption rubbers for signs of damage and dirt CAUTION If the shock absorption rubbers are not rep
26. in such a way that even if the brake pads are worn it is not necessary to top up the brake fluid If the brake fluid level drops below the minimum level either the brake system has a leak or the brake pads are completely worn In this case consult an aut horized Husaberg dealer immediately BRAKE FLUID Husaberg fills the brake systems with Motorex Brake Fluid DOT 5 1 brake fluid one of the best brake currently available We recom mend that you continue to use it DOT 5 1 brake fluid is based on glycol ether and of an amber color If you do not have any DOT 5 1 for refilling you may use DOT 4 brake fluid However you should replace it as soon as possible with DOT 5 1 Never use brake fluid DOT 5 The color of this silicon oil based pro duct is purple red The gaskets and brake hoses of Husaberg motorcycles are not designed for DOT 5 brake fluid WARNING Have the brake fluid changed at least once annually If you wash your motorcycle often the brake fluid should be changed even more frequently Brake fluid tends to absorb water Therefore vapor pockets may form in old brake fluids even at low temperatures causing the brake system to fail ER uu EL 100 E Ee Aim i d x de i 1 22021 yd o d x F hb i 8 T 7 v i yer gt p S d p A ur o c LLI aum aum AL c A un L CHANGING THE BASIC POSITION THE HAND BRAKE LEVER FC FE Free travel at the hand brake lev
27. so much and the brakes will not overheat WARNING In case of rain after washing the motorcycle after rides through water and in case of rides on wet off road tracks humid or dirty brake discs can delay the braking effect The bra kes must be pulled until they are dry or clean Rides on salt strewed or dirty roads can also delay the braking effect The brakes must be pulled until they are clean Dirty brake discs cause increased tear of brake pads and brake discs When you brake the brake discs brake pads brake caliper and brake fluid heat up The hotter these parts get the weaker the breaking effect In extreme cases the entire braking system can fail If the resistance in the hand brake lever or foot brake pedal feels spongy too much play this is an indication that something is wrong with the brake system Don t ride your motorcycle any more without first having the brake system looked over by a Husaberg dealer 23 L CL ur o c LLI AL c A un L STOPPING AND PARKING Decelerate and switch the engine into neutral To switch off the engine at idling speed press the short circuit switch or the emer gency off switch until the engine is off or switch off the ignition Close the fuel taps park the motorcycle on a firm surface and lock WARNING Motorcycle engines produce a great amount of heat while running The engine exhaust pipe muffler brake rotors and shock absorbers can becom
28. system is over heated Do not make any alterations to the motorcycle and always use ORIGINAL HUSABERG SPARE PARTS Spare parts from other manufacturers can impair the safety of the motorcycle Motorcycles are sensitive to alterations in the distribution of weight If you are taking luggage with you this should be secured as close as possible to the middle of the vehicle distribute the weight evenly between the front and rear wheel Never exceed the maximum permissible laden weight and the axle weights The maximum per missible laden weight is comprised of the following com ponents Motorcycle ready for operation and tank full Luggage Driver with protective clothing and helmet Pay attention to the running in procedure RUNNING IN THE HUSABERG MODELS Even very precisely machined sections of engine compo nents have rougher surfaces than components which have been sliding across one another for quite some time Therefore every engine needs to be broken in For this reason do not load the engine more than 50 of its capacity during the first 3 operating hours Besides the engine speed must not exceed 7000 rpm Avoid going full throttle In the following 12 operating hours you may load the engine up to 75 of its capacity Use the motorcycle on various types of terrain road easy off road trails CAUTION The Husaberg models were uncompro misingly designed for off road competition purpo ses only
29. the glassfiber yarn packing of the silencer 49 Rebound damping offork 17 Cleaning the spark arrester 49 Damping action during compression of shock absorber 18 Cleaning the air filter 50 Rebound damping of shock absorber 19 Checking the adiustment of the hand decompression SICCIING Xm 19 Le 50 Adjusting the throttle cables 50 TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE 20 Changing the original position of the clutch lever Ai Instructions for initial operation 20 Checking the oil level of the hydraulic clutch 51 Running in the Husaberg models 20 Bleeding of the hydraulic clutch 51 Carburetor Adjust idling 52 DRIVING INSTRUCTIONS 21 Basic information on carburetor wear 52 Check the following before each start 21 Adjusting the mixture control screw 52 Starting when the engine is cold 22 Checking the float level float height 53 Starting when the engine is warm 22 Draining the float chamber of the carburetor 53 What to do when the engine is flooded 22 OCCU m w 53 Elle SE ER Checking the engine oil level 54 Shifting Riding 23 Engine EE 54 Braking EE 23 Changing the engine oil
30. the starting procedure The outer end of the lever must provide for a backlash of approx 10 mm 0 4 in at all times Only thereafter may it cause valve motion to be recognized by the stronger resistance which the hand decompression lever encounters LL c A GA L HAND BRAKE LEVER The hand brake lever 3 is located on the right side of the hand lebar and actuates the front brake The basic setting of the hand brake lever can be adjusted see maintenance work SHORT CIRCUIT BUTTON The short circuit button 4 turns off the engine When pressing this button the ignition circuit is short circuited OPERATION INSTRUMENTS COMBINATION SVVITCH The light svvitch has 2 respectively 3 svvitch positions A Light off this function is not available in all models B Low beam on C High beam on You may use button 1 to actuate the horn The red short circuit button 2 serves to switch off the engine Leave the switch pressed until the engine stops FLASHER SWITCH The flasher switch 3 is a separate unit and is mounted on the left portion of the handlebar The wire harness is designed in a way that whenever you want to use your bike off road you can dismount the entire turn indicator system without affecting the function of the remaining electrical system ENGLISH qn Flasher left gt Flasher right IGNITION LOCK Switch positions of ignition lock Ignition off light off engine can t be st
31. 4 Charging the EE 46 Chassisnumber EN e EN AE 5 Check chain tehsion saca E 35 Check the following before each start 21 Check the rear brake fluid level 40 Check set distance of the magnetic sensor 45 Checking and adjusting the steering head bearing 30 Checking spoke tension as 44 Checking the adiustment of the hand decompression ll 50 Checking the basic setup of the telescopic fork 33 Checking the brake fluid level front brake 38 Checking the coolant level 48 Checking the engine oil level z vv os ta daaa 54 Checking the float level float height 53 Checking the front brake pads 39 Checking the oil level of the hydraulic clutch 51 Checking the rear brake pads 41 Checking the shock absorber and spring 32 Checking the shock absorption rubbers in the rear hub A4 Eee 15 Cleaning the air filter 50 Cleaning the dust sleeves of the telescopic fork 31 Cleaning theoil screen 2442644 SE 32 54 Cleaning the spark arrester 49 Cleaning conservation storage 58 Cute eve EE 6 Combination switch uestes serve te tense te at 7 Compression damping of fork 17 Coolins sy stemi xus 63 ot m cut S E 48 COMECE CHAIN TENSION Ee 3G eic Ee 35 Damping action during comp
32. AGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR CYCLE IS NOT ROAD SAFE ANYMORE E NOTE USEFUL INFORMATION ON HANDLING AND SERVICING YOUR MOTORCYCLE Please insert the serial numbers of your motorcycle in the boxes below Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY The exhaust system on this vehicle has no owner serviceable parts Should there be an increase in noise or damage to any component relating to the noise reduction system replacement parts should be fitted by an Authorised dealer Tampering with noise control system prohibited Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorpora ted into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and bjthe use of the vehicle after such device or element of design has been removed or rendered inoperative by any person HUSABERG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATIONS COLORS MATERIALS SERVI CES OFFERED AND RENDERED AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT PREVIOUS ANNO UNCEMENT AND WITHOUT GIVING REASONS OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTITUTING THEM WITH OTHERS IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS ANNOUNCEMENT
33. ANCE WORK DONE BY HUSABERG AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER 26 PERIODIC MAINTENANCE SCHEDULE 2004 FE 450 501 550 650 E 6 FS 450 650 E 6 MODEL 2004 1 service after A clean motorcycle can be checked more quickly which saves money 3 hours after every 15 hours or 20 fuel or 100 fuel Change engine oil and oil filter Clean oil screen and drain plug magnet Replace spark plug after 30 hours Check and adjust valve clearance Check engine mounting bolts for tightness Check carburetor connection boot for cracks and leaks Check idle speed setting Check vent hoses for damage or bends Check cooling system for leaks check quantity of antifreeze CARBURETOR ENGINE Check exhaust system for leaks and fitment Check cables for damage smooth operation and bends adjust and lubricate Check fluid level of the clutch master cylinder Clean air filter and filter box CL ur o c LLI Check electric wires for damage and bends Check headlamp setting ADD ON PARTS Check function of electric systems low high beam brake light indicator lamps speedometer illumination horn emergency OFF switch or button Check brake fluid level lining thickness brake discs Check brake lines for damage and leaks Check function smooth operation and adjust free travel of handbrake foot brake lever Check tightness of brake system sc
34. ATION INSTRUMENTS FILLER CAP To open the filler cap Turn the filler cap counter clockvvise To close the filler cap Put the filler cap on and tighten it by turning it clockwise Install the tank breather hose 1 without kinks FUEL TAPS OFF In this position the fuel taps are closed No fuel can flow to the carburetor ON RES The knob is in the ON or RES position when the motorcy cle is running Fuel is conveyed to the carburetor in this position and the tank will drain completely NOTE The RES function is not available L N Z TT CHOKE If you pull the choke button 2 out as far as possible a bore in the carburetor will be opened through which the engine may take in additional fuel The result is a fat fuel air mixture of the type nee ded for cold starts To deactivate the choke push the choke button back into its basic position HOT START DEVICE If you pull the hot start device 3 out as far as possible a bore in the carburetor will be opened through which the engine may take in additional air The result is a lean fuel air mixture of the type needed for hot starts To deactivate the hot start device push the hot start button back into its basic position 15 OPERATION INSTRUMENTS SHIFT LEVER The shift lever is mounted on the left side of the engine The posi tion of the gears is shovvn in the illustration Neutral or the idle speed is located between first and second
35. DO MAX UP UK M m L L mn OC iL i ib re 1 ih M OPERATION INSTRUMENTS VVS VVHEEL SIZE The display will change and briefly show the diameter of the front wheel in millimeters If the front wheel does not turn the display will automatically change to the SPEED H mode If the front wheel turns the display will automatically change to the SPEED ODO mode SPEED H HOURS DISPLAY MODE When you stop driving and no impulses are sent from the wheel sensor the display mode will automatically change from SPEED ODO to SPEED H H shows the operating hours The ope rating hour counter starts to count as soon as you start the engine The displayed figure cannot be cleared Service intervals are indicated in operating hours for some Husaberg offroad motorcycles making the operating hour counter a very practical function SPEED ODO DISPLAY MODE The SPEED ODO mode shows the speed and the total kilometers travled When the front wheel stops turning the display will auto matically change to the SPEED H mode The information will disap pear in the display when the front wheel stops turning for 1 minute NOTE A Tripmaster switch is available as an accessory and enhances the electronic speedometer by providing the following functions 2x ripmaster 2x chronometer for the lap time Average speed Maximum speed Clock Display in miles TRIPMASTER SWITCH The switch has three buttons MODE plus
36. Edition 2004 PEL 4 4 STROKE FORCE FORCE TABLE OF CONTENTS Page Page INTRODUCTION 2 Replacing fork springs 33 mportant limited vvarranty and limited guarantee Hovv to change the handlebar position 34 information e EE Ne 4 Changing the spring preloading of the shock absorber 34 Check chain tension ows m na an Sob e edu 35 SER AL NUMBER LOCATIONS 5 Correct chain TENSION EEN 35 Chassis DUE 23 en oboe de E EE 5 36 Engine Number EE 5 We 30 General information about Husaberg disc brakes 37 OPERATION INSTRUMENTS 6 Changing the basic position the hand brake lever FC FE 38 Cl teh lever ct eet ee e ee dow ee 6 Changing the basic position the hand brake lever FS 38 Hand decompression lever 6 Checking the brake fluid level front brake 38 Hand brake lever i e e stewed dad 6 Refilling the front brake fluid reservoir 38 Short circuit button sons osm nna ee dor a d oe or e dedos 6 Checking the front brake pads 39 Combination switch 7 Replacing the front brake pads FC FE 39 Flasher switch 7 Replacing the front brake pads FS 39 T Ignition lock 7 Changing the basic position of the foot brake pedal 40 H
37. Loctite 243 WARNING It is very important to keep the brake disk free from oil and fatty matters Otherwise the braking effect would be strongly reduced After working on the braking system always actuate the hand brake lever or foot brake lever respectively to ensure that the brake pads will lie against the brake disk and the pressure point is established 39 L N O Z TT MAINTENANCE WORK ON CHASSIS AND ENGINE CHANGING THE BASIC POSITION OF THE FOOT BRAKE PEDAL The basic position of the foot brake pedal can be altered by tur ning the stop screw 1 The free play at the foot brake pedal must then be adjusted by means of the piston rod 2 Measured on the outside the foot brake pedal must have 3 5 mm 0 12 0 20 in of free play before the piston rod can move the piston in the brake cylinder to be recognised from the resistance on the foot brake pedal CAUTION If this free play is not present then pressure can build up in the brake system when driving causing the rear wheel to brake The braking system overheats and may even fail completely in extreme cases CHECK THE REAR BRAKE FLUID LEVEL The reservoir for the rear disc brake is located above the main brake cylinder The level of brake fluid may not fall below the MIN mark when the vehicle has been left standing upright WARNING If the brake fluid level drops below the mini mum either the brake system has a leak or the brake
38. NE DISMOUNTING AND MOUNTING THE FRONT WHEEL To remove the front wheel jack the motorcycle up on its frame so that the front wheel no longer touches the ground Loosen the 2 clamping screws 1 on the left side of the fork fists Loosen and remove the collar nut 2 loosen the clamping screws 3 on the right side of the fork fist Hold the front wheel pull out the wheel spindle 4 CAUTION Do not operate the hand brake when the front wheel has been dismounted Make sure the brake disc is always on top when you lay down the wheel otherwise the brake disc can be dama ged Before remounting the front wheel clean and grease the shaft seal rings A and the bearing surface B of the distance bushings and mount the distance bushings LL 2 A GA L To install the front wheel lift it into the fork position and mount the axle shaft 4 Mount the collar nut 2 tighten the clamping screws 3 on the right fork leg axle passage to prevent the axle shaft from turning and tighten the collar nut to 40 Nm Loosen the clamp screws on the right fork leg Take the motorcycle down from its stand Press the front wheel brakes and push down on the fork a few times vigorously so that the fork legs come into alignment Only after this has been accomplished tighten the clamp screws on both fork legs with 10 Nm WARNING If you don t happen to have a torque wrench at hand make sure you have the tightening torque cor rected
39. On the road approved models FC FE are only allowed on public roads in the original homologated throttled version Avoid extended on road rides at full throttle 20 WARNING Wear suitable clothing when driving a motorcycle Clever Husaberg drivers always wear a helmet boots gloves and a jacket regardless of whether driving all day or just for a short trip The protective clothing should be brightly colored so that other vehicles can see you as early as possi ble Always turn on the light to make sure that other drivers become aware of you as early as possible Do not drive after having consumed alcohol Only use accessories recommended by Husaberg For example front panelling can impair the dri ving properties of the motorcycle Cases extra tanks etc can alter the weight distribution and thus also impair the vehicles driving properties The front and rear wheel may only be fitted with tires that have the same profile type The Husaberg models are designed and dimensio ned for 1 person only Never take another rider along Observe the traffic regulations drive defensively and try to look ahead as far as possible so that any hazards can be recognized as early as possi ble Adjust your driving speed according to the condi tions and your driving skills Drive carefully on unknown roads or on unfamiliar trials When driving off road always have a friend on a second motorcycle to keep you company so that y
40. S IN KILOGRAM Lu 4 O 2 a m N 32 MAINTENANCE WORK ON CHASSIS AND ENGINE MODELL SOFTER STANDARD HARDER 1245Y721 66 86 260 76 95 260 81 99 5 260 FC 450 550 The riding sag should lie between 90 and 105 mm If the riding sag is less than 90 mm the spring is too hard the spring rate is too high If the riding sag is more than 105 mm the spring is too soft the spring rate is too low The spring rate is written on the outside of the spring e g 88 250 The type number of the shock absorber is embossed on the bot tom of the tank The illustrations show which spring should be installed The standard spring is shown in bold print After installing a different spring readjust the static sag to 35 mm 2 mm According to our experience the damping rate of the com pression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder spring CHECKING THE BASIC SETUP OF THE TELESCO PIC FORK The precise riding sag of the telescopic fork cannot be determined for various reasons Similar to the shock absorber smaller deviati ons in your weight can be compensated by adjusting the spring preload However if your telescopic fork bumps frequently hard end stop during compression you should install harder fork springs to avoid damaging the telescopic fork and frame CHANGING THE SPRING PRELOAD ON THE TELESCOPIC FORK
41. T INCLUSIVE GEARS IN KILOGRAM SPRING RATE MODELL SOFTER STANDARD HARDER 4 2 N mm 4 4 N mm 4 6 N mm FC 450 550 4 0 N mm 4 2 N mm 4 4 N mm FE 450 501 550 650 1445Y730 FS 450 650 4 4 N mm 4 6 N mm MAINTENANCE WORK ON CHASSIS AND ENGINE HOW TO CHANGE THE HANDLEBAR POSITION The handlebar position can be readjusted by 22 mm Thus you can put the handlebar in the position that is the most convenient for you The upper triple clamp 1 includes 2 bores arranged at a distance of 15 mm 0 6 in from one another The bores at the handlebar support 2 are offset from the center by 3 5 mm 0 13 in Accordingly you can mount the handlebar in 4 different positi ons For this purpose remove screws 3 of the handlebar clamps and screws 4 of the handlebar support Position the handlebar sup port and tighten screws 4 to 40 Nm Mount handlebar and hana lebar clamps and tighten screws 3 to 20 Nm The gap between the handlebar support and the handlebar clamps should be the same in the front and in the rear WARNING The screws 4 must be secured with Loctite 243 m c A GA L CHANGING THE SPRING PRELOADING OF THE SHOCK ABSORBER The spring preload can be changed by turning the adjusting ring 5 For this purpose you should dismount the shock absorber and clean it thoroughly NOTE Before changing the spring preload note down the basic setting e g how many threads are visible abov
42. TENANCE WORK ON CHASSIS AND ENGINE CHAIN MAINTENANCE For a long chain life good maintenance is very important Chains without X rings should be cleaned in fireproof solvent regularly and afterwards treated with hot grease or chain spray e g Motorex Chainlube 622 X ring chains on the other hand are very simple to clean The best way is to use lots of water but never use brushes or cleaning liquids After letting the chain dry you can use a special X ring chain spray e g Motorex Chainlube 622 CH WARNING No lubrication is allovved to reach the rear tire or the brake disks othervvise the road adherence and the rear wheel braking effects would be strongly reduced and the motorcycle could easily lose control N CAUTION mounting the chain masterlink clip the closed side of the masterlink clip must point in running direc tion Also check sprockets and chain guides for wear and replace if necessary CHAIN WEAR To check the chain wear observe the following indications Shift the gear into idling and pull the upper chain strand with approx 10 15 Kilograms 33 b upwards see figure Now one can measure a space of 18 chain reels at the lower chain strand The chain should be replaced at the latest when a space of 272 mm 10 70 in is measured Chains do not always wear off evenly there fore repeat the measurement at different places on the chain ER NOTE If you mount a new chain the sprockets should also be repl
43. TPLANE ENGLISCH DEUTSCH FRANZOSISCH Battery Batterie Batterie Cooling fan Luftermotor Ventilateur Driving light lamp Fernlichtkontrollampe temoin feu route Flasher control lamp Blinkerkontrollampe temoin de clignoteur Flasher relay Blinkerrelais Relais de clignotants Flasher svvitch Blinkerschalter Bouton de clignotants Flasher system Blinksystem Systeme de clignotants Front brake switch vorderer Bremslichtschalter Contacteur de frein avant Generator Generator Alternateur Handle bar switch for multi func digital speedometer Lenkerschalter f r Multifunkt Digitaltacho Contacteur au guidon pour ordinateur de bord Headlight Scheinwerfer Phare High low beam switch Auf Abblendschalter Contacteur code phare Horn Hupe Avertisseur sonore Horn switch Hornschalter Bouton d avertisseur sonore Ignition coil Z ndspule Bobine d allumage Ignition switch Z ndschloss Contacteur d allumage Left front flasher linker vorderer Blinker Clignotant avant gauche Left rear flasher linker hinterer Blinker Clignotant arri re gauche Light switch Lichtschalter Contacteur d clairage Multi func digital speedometer Multifunktionsdigitaltacho Ordinateur de bord Pick up Impulsgeber Capteur d allumage Position light Begrenzungslicht feu de position Rear brake switch hinterer Bremslichtschalter Contacteur de frein arri re Rear light brakelight hinteres Begrenzungslicht Bremslicht Feu rouge stop Regulator rectifier Regelgleichrichter R gulateur redresseur Righ
44. aced New chains wear faster if used on old used sprockets N CAUTION Secure the screvvs of the chain vvheel by app lying Loctite and fasten them in a crossvvise order Tightening torque for nuts 35 Nm Tightening torque for screvvs 50 Nm 36 max 272 mm 16 17 18 COC MAINTENANCE VVORK ON CHASSIS AND ENGINE GENERAL INFORMATION ABOUT HUSABERG DISC BRAKES BRAKE CALIPERS Secure the screws of the caliper support with Loctite 243 and tigh ten to 25 Nm BRAKE PADS The brake pads are fitted with TOSHIBA TT 2701 FC FE BERINGER 1100S FS sintered lining at the front and ID450 sinte red lining at the back These linings provide an optimal combina tion of dosing brake performance and life cycle The lining type is stated on the back of the brake pad and also recorded in the homologation papers Other brake pads are available for competition sports BRAKE DISCS Wear will reduce the thickness of the brake disk around the moun ting face 1 of the brake pads Brake disks with less than the minimum thickness are a safety risk Have the brake disk replaced as soon as it reaches the wear limit Always have repairs to the brake system performed by an authorized Husaberg shop WEAR LIMIT A BRAKE DISKS front PG FE Aerer sues 2 5 mm front FS ee Ee 5 mm rear FC FE FS 3 5 mm BRAKE FLUID RESERVOIRS The brake fluid reservoirs on the front and rear wheel brakes have been designed
45. arted Ignition on light off engine can be started HEADLAMP SWITCH USA In this model the headlamp is switched on with the pull switch 4 LL c A GA L OPERATION INSTRUMENTS INDICATOR LAMPS The green control lamp 1 flashes in the same rhythm as the flashing indicator when the indicator is working The blue control lamp 2 lights up when the high beam is on STARTER BUTTON 5 Pushing the black starter button 3 vvill actuate the E starter EMERGENCY OFF SWITCH AUSTRALIA The red emergency OFF svvitch 4 is arranged adjacent to the throttle grip n this position the E starter is operational and the JL engine can be started In this position the E starter and ignition circuits are 2 E interrupted The E starter cannot be actuated and the engine will not start not even if you attempt to start it with the kickstarter Pushing the black starter button 5 will actuate the E starter ELECTRONIC SPEEDOMETER The electronic speedometer display is activated as soon as the engine is switched on and the motorcycle starts to move The engine must be started in order for the speedometer to be supplied with electricity from the generator An impulse must be received from the wheel sensor to activate the display the front wheel must turn at least one time TEST All of the display elements will light up for 1 second for the func tion test m L CICIC WO jr Ww m CI TID DEU O
46. ate engine 2 Warm up the engine 3 Use the adjusting wheel 1 to set the normal idle speed 1400 1500 rom 4 Turn mixture control screw 2 slowly clockwise until idling speed starts to decrease Memorize this position and turn mixture con trol screw slowly counterclockwise until the idling soeed decrea ses again Adjust the point of the highest idling speed between these two positions If in the course of this procedure the speed undergoes a relatively high increase reduce the idle speed to a normal level and repeat the procedure specified in 4 Serious competitive racers will choose a setting approx 1 4 turn clockwise leaner than this ideal value because their engine will heat up more when used in competitions m c A GA L E NOTE If you fail to obtain a satisfying result by following the procedure described above an incorrectly dimensio ned idling nozzle may be the cause If a the mixture control screw has been screwed in up to the stop without causing any change in rotational speed a smaller idling jet has to be installed b the engine dies when the mixture control screw is still open by 2 turns a larger idling jet needs to be selected Naturally in cases of jet changes you have to start your adjusting work from the beginning 5 Then use the adjusting wheel to set the desired idle speed 6 n cases of greater changes in the outside temperature and extremely different altitudes the idling sp
47. bi qe ANHANG APPENDIX APPENDICE Berl 1uBippeeu sce Jejeujopeeds JejBip ounj ninu SCHALTPLANE start svvitch cable re Switch nl APPENDICE x Q Z LLI D D 4 o Z 4 Z lt 00c 0 vc Jeuse 1 l SCHALTPLANE 1uiexe1qAuBi see mm UollNs eyeJq e El 000 ZZ0 1 1008 GL 9L0 11008 Uw uD Jeuse juu TH Jeol A neq sseuJeu U lAS uoniufi ssousey uleuJ eleJ ues uuueJbeip Hum c oO UEL 6ullooo woyoq pes YOUMS lloo uonlubi B M youms uoniubi ANHANG APPENDIX APPENDICE GO 54 Bs qesnu uoynq 0015 uojs uJou LOS uieeq MOUUDI BEI WUuOU YO SES dwe UOHAS exeJq UOJ qul uonisod 1U6llpeeU m Jejeulopeeds JeiBip ounj ninuu SCHALTPLANE light svvitch high lovv beam svvitch horn svvitch flasher svvitch cable brake switch harness or pu gr br cable gn ye cable gn bu bu br harness wh switch br re bl pi cable switch www en www ignition switch start switch cable re ye switch wh re unpushed oc le APPENDICE x lt a Z LLI D D 4 Ai 2 4 Z lt gt gt gt U2 ma 2p mZ x SCHAL
48. by imparing the braking effect and destroying the brake disc REPLACING THE FRONT BRAKE PADS FC FE Press the brake caliper tovvard the brake disk to put the brake piston in its basic position Remove clips 1 and pull out bolt 2 Remove brake pads from the brake caliper Clean the brake caliper and the brake caliper support with compressed air Check the slee ves of the guide bolts for damage and grease guide bolts if neces sary Mount the right brake pad and fix it with the bolt Mount the left brake pad and insert the bolt until it stops Mount the clips When mounting the brake pads be sure to check for correct fit of the sliding metal sheet in the caliper support and of the leaf spring WARNING It is very important to keep the brake disk free from oil and fatty matters Otherwise the braking effect would be strongly reduced After assembly check if circlips have been fitted correc tly After working on the braking system always actuate the hand brake lever or foot brake lever respectively to ensure that the brake pads will lie against the brake disk and the pressure point is established REPLACING THE FRONT BRAKE PADS FS Remove the screw 3 Use a screwdriver to carefully press against the brake pads to move them into the basic position Remove the brake pads from the brake caliper and thoroughly clean the brake caliper with compressed air Mount the brake pads and the screw 3 and tighten to 10 Nm
49. chain tensioner tooting for damage visual check Check the eccentricity of the crankshaft journal Replace the conrod bearings Check piston pin bearing Replace the balancer shaft bearings Replace the crankshaft main bearings Check the entire transmission including the roller and bearings for wear NOTE IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED THE RESPECTIVE COMPONENTS MUST BE REPLACED CL ur o c LLI 29 MAINTENANCE WORK ON CHASSIS AND ENGINE WARNING Maintenance and adjusting work marked with an asterisk requires expert skills and technical know how For your own safety always have such work performed by a specialized Husaberg dealer where your motorcycle will be optimally serviced by appropriately qualified skilled staff m CAUTION When cleaning the motorcycle do not use a high pressure cleaning unit if possible otherwise water will penetrate the bearings carburetor electric connectors etc When transporting your Husaberg ensure that it is held upright with restraining straps or other mechanical fastening devices and that the fuel tap is in the OFF position if the motorcycle should fall over no fuel can leak from the carburetor or fuel tank Do not use toothed washers or spring rings with the engine fastening screws as these work into the frame parts and keep working loose Instead use self locking nuts Let your motorcycle cool dow
50. d damping of shock absorber 19 Refilling the front brake fluid reservoir 38 Refilling the rear brake fluid reservoir 40 Replacing fork springs wae a b Sa ee we 33 Replacing headlight lamp parking light lamp 47 Replacing the front brake pads FC FE 39 Replacing the glassfiber yarn packing of the silencer 49 Replacing the rear brake pads 41 Running in the Husaberg models 20 Serial number locations EE 5 Setimg ME ClOCK d De OE 13 SR NEE EE 16 SHIKONI wee ee ip eee ee 23 Short circuit DUON YAR x IRE Eae edi d 6 SIGE Stan 22 30 c4 de roteare pn es le ens 16 Se 8 Staring E EE ER Starting when the engine is cold 22 Starting vvhen the engine is vvarm 22 STECKING 19 Stopping and parking 392 200 24 Eee 1 Technical data chassis EE 61 Technical data engine seats hus act a icem cio tae det 59 Tips and warnings for starting the motorcycle 20 Tresan NESSUS Ge 45 sezona n b bo cate 00 dong 9 HT n 56 What to do when the engine is flooded 22 Wiring diagramm 0000 ee eee appendix SCHALTPLANE 32140 344 XIGNdddV ONVHNV DOC 320 LL 009 vO 24 BseqesnyH Deegen dn y rd lod uoniui Josues uonisod L Ot e O TE TL UO0
51. does not overflow The bleeder syringe can be purchased from your Husaberg dealer Having com pleted the bleeding procedure you have to verify that the oil level in the master cylinder is correct lf necessary fill up with biodegradable hydraulic oil SAE 10 e g Motorex Kupplungs Fluid 75 Biodegradable hydraulic oil is available from your Husaberg dealer bOml CAUTION Husaberg uses biodegradable hydraulic oil for the hydraulic clutch control Never mix biodegradable hydraulic oils with mineral oils Never refill with mineral hydraulic oil or brake fluid 51 MAINTENANCE WORK ON CHASSIS AND ENGINE CARBURETOR ADJUST IDLING Idling adjustment of the carburetor strongly affects the engine s starting behavior That is an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly The idle speed is controlled by means of the adjusting wheel 1 and the mixture control screw 2 The adjusting wheel is used to adjust the basic setting of the slide The mixture control screw is used to control the idle mixture which arrives at the engine by way of the idle system Clockwise turning reduces the fuel quantity lean mixture counterclockwise turning increases the fuel quantity rich mixture TO ADJUST IDLING CORRECTLY PROCEED AS FOLLOWS 1 Turn in mixture control screw 2 up to the stop and turn it back out to the basic position see technical d
52. e a rag to cover the cap and open slowly to release pressure Caution scalding hazard Do not detach any radiator hoses while the engine is hot The escaping hot coolant and the steam may cause serious burns In case you get burnt hold the affected part of your body under running cold water right away Coolant is toxic Keep the coolant out of the reach of children In case coolant is ingested consult a doctor immediately m c A GA L If coolant gets into your eyes rinse them out with water immediately and consult doctor A mixture of 40 antifreeze liquid and 60 water is used as coo lant However the antifreeze protection must be at least 25 C 13 F This mixture offers antifreeze protection but also good cor rosion protection and should therefore not be replaced by pure water CAUTION If the coolant has been drained it will be absolutely necessary to bleed the cooling system during filling For the cooling system use only high grade antifreeze e g Motorex Anti Freeze Using lower grade antifreeze agents can cause corrosion and coolant foaming Extreme climate conditions or stop and go Traffic may cause overheating problems CHECKING THE COOLANT LEVEL The coolant should be 10 mm 0 4 in above the radiator fins when the engine is cold see diagram In the event of the coolant being drained always fill and bleed the system CAUTION If the coolant has been drained it will be absolu
53. e stops or backfires in the carburetor Engine gets too hot High oil consumption All of the switched on lights are burned out Horn turn signal and star ter do not work Battery is dead TROUBLESHOOTING Carburetor overflows because the float needle is soiled or worn Loose carburetor jets Electronic ignition advance is defective Fuel supply is interrupted or the carburetor soiled Air filter is heavily soiled Exhaust system is not tight deformed or there is not enough glass fiber yarn in the silencer Valve clearance is too small Compression loss due since hand decompression lever is inadequately adjusted Electronic ignition advance is defective Shortage of fuel Engine drawns in unmetered air Not enough cooling liquid in the cooling system Not enough air stream Cooling system not ventilated Radiator fins are heavily soiled Foam has formed in the coo ling system Bent radiator hose Bent engine ventilation hose Engine oil level is too high Engine oil is too thin The voltage regulator is defec tive Fuse Battery is not being charged by the generator Disassemble the carburetor and check for wear Tighten the jets Have the ignition system checked Clean and check the fuel system and carburetor Clean or replace the air filter Check the exhaust system for damage replace the glass fiber yarn in the main silencer Adjust the valve clearance Adjust the hand decompression cable
54. e the adjusting ring One rotation of the adjusting ring 5 changes the spring preten sion by approximately 1 75 mm 0 07 in Loosen the clamping screw 6 and use the hook wrench contained in the vehicle tool set to turn the adjusting ring as desired Turning it counterclockwise will reduce the preload turning it clockwise will increasethe preload After readjusting the clamping screw 6 tighten it to 8 Nm ADJUSTMENT VALUES SPRING PRELOAD A MmU prola NEE 4 mm STANDARD PRELOAD FC 450 550 mm STANDARD PRELOAD FE 450 501 550 650 8 mm STANDARD PRELOAD FS 450 650 leen 5 mm qaz ten o 10mm 34 MAINTENANCE WORK ON CHASSIS AND ENGINE CHECK CHAIN TENSION Jack the motorcycle up on its frame so that the rear wheel no lon ger touches the ground Press the chain upward at the end of the chain sliding component The distance between the chain and the swing arm should be approx 8 10 mm 0 31 0 39 in In the course of this procedure the upper chain portion A must be taut see drawing If necessary correct the chain tension CH WARNING Excessive tensioning of the chain will put additional load on the components of the secondary dri vetrain chain bearings of transmission and rear wheel Aside from resulting premature wear if worst comes to worst the chain may rupture or the countershaft of the transmission may break Too much slack in the chain o
55. e very hot Do not touch any of these parts after operating the motorcycle and take care to park it where pedestrians are not likely to touch it and get burned N CAUTION Do not use the hand decompressor lever to switch off the engine Always use the short circuit switch the emergency off switch or the ignition switch Close the fuel tap when leaving your vehicle Otherwise the carburettor can flood and fuel will enter the engine Never park your motorcycle in places where there are fire hazards due to dry grass or other easily flammable materials NOTE REGARDING THE SIDE STAND Use your foot to kick side stand forward up to the stop and lean the motorcycle sideways Make sure that the ground is solid and that your motorcycle is standing securely Just in case you can shift into first gear N CAUTION The side stand is designed to bear only the load of the motorcycle The side stand and or the frame can be damaged and the motorcycle can fall over if you mount the motor cycle thus putting an additional load on the side stand FUEL The engine needs unleaded fuel with at least RON 95 USA Premium RON 91 CAUTION Use leaded or unleaded premium grade gaso line 95 octanes Never use gasoline having less than 95 octanes because it may damage the engine CH WARNING Gasoline is highly flammable and poisonous Extreme caution should be used when handling gasoline Do not refuel the motoreycle near open flames or bur ni
56. eadlamp switch USA 7 Check the rear brake fluid level 222 40 N Ca 8 Refilling the rear brake fluid reservoir 40 GEES bbe EE do on ddr 8 Checking the rear brake pads 41 w Emergency OFF switch Australia 8 Replacing the rear brake pads 41 z Electronic speedometer 8 Dismounting and mounting the front vvheel 42 TT Tripmasterswitch y l epee ane 9 Paene xab 9 Dismounting and mounting the rear wheel 43 Seting hE er Ee BE 13 Checking the shock absorption rubbers in the rear hub 44 Activating deactivating the display modes 13 Checking spoke tension 44 Kilometers or miles 14 Tires air pressure 45 q l r 7 77 15 Check set distance of the magnetic sensor 45 15 000 EE 46 SI dC 15 Charging the battery 46 Hotstartdevite ewe shod oe ad chad Basa 15 Fuse FE FS 0 bab adina Pa e RR e 47 El c v wm 16 Replacing headlight lamp parking light lamp 47 Wein a VC 16 Cooling system 4 5 2n dokn d 33e edd 48 Footbrake pedal te EE heehee ee aids 16 Checking the coolant level 48 Side stand uma nam Rama ee ee ed 16 Bleeding the cooling system 49 Compression damping offork 17 Replacing
57. ebound can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during rebounding L N O Z TT STANDARD ADJUSTMENT turn adjusting screw clockwise as far as it will go turn it back by as many clicks as are specified for the relevant type of fork Typ White Power 1445Y728 19 clicks Typ White Power 1445Y729 21 clicks Typ White Power 1445Y730 15 clicks 17 m c A GA L DAMPING ACTION DURING COMPRESSION OF SHOCK ABSORBER The shock absorber can synchronize the compression damping in the low and high speed range separately Dual Compression Control Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle The low and high speed technology overlaps The low speed setting is primarily for slow to normal shock absor ber compression rates The high speed setting is effective at fast compression rates Turning in a clockwise direction will increase the damping turning counterclockwise will decrease the damping Standard low speed setting turn the adjusting screw 1 to the limit in a clockwise direction using a screwdriver unscrew the respective number of clicks for the specific type of shock absorber in a counterclockwise direction Typ White Power 1245Y721 15 clicks Typ White Power 1245Y722 15 clicks Typ White Power 1245Y723
58. echanic For your own safety use Husaberg approved parts and accessories only Husaberg is not liable for damage that arises in connection with the use of other products Take special care to follow the recommended run in inspection and maintenance intervals Heeding these guidelines will significantly increase the life of your motorcycle Be sure to have your motorcycle serviced by an authorized Husaberg dealer to maintain the validity of your warranty Off road Supermoto motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full It may however involve potential problems for the environment or lead to conflicts with others These problems or conflicts can be avoided if the motorcycle is used responsibly To safeguard the future of motorcycle sports make sure that you use the motorcycle in accordance with the law show that you are environmentally conscious and respect the rights of others We wish you a lot of fun when driving HUSABERG 5230 MATTIGHOFEN AUSTRIA ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL O by HUSABERG Alle Rechte vorbehalten INTRODUCTION IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION Husaberg sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associati
59. ed permanent circulation of cooling liquid through water pump Cooling liquid 1 0 liters mixing ratio 40 antifreeze 60 vvater at least 25 C Starting aid kickstarter kickstarter electric starter BASIC CARBURETOR SETTING Type of carburetor Carburetor ID number Main jet FC 550 4 FE FS 550e 6 FE FS 650e 6 EU AUS USA green EU AUS USA green Keihin FCR MX 41 Keihin FCR MX 41 Keihin FCR MX 41 4125B 4125B 4138C 182 182 160 Jet needle Idling jet Main air jet OBDVR OBDVT OBDVR OBDVT OBEKR 40 38 40 38 45 200 200 200 Idle air jet Needle position Starting jet 100 100 100 5th from top 5th from top 2nd 6th from top 85 85 85 Mixture control screw open Slide Restriction 1 5 1 5 0 5 1 5 15 15 15 slide stop slide stop Pump diaphragm stop Hot start knob 858 2 15 mm 858 2 15 mm 858 2 15 mm diameter 2 5 mm diameter 2 5 mm diameter 2 5 mm TECHNICAL DATA CHASSIS FC 450 4 550 4 FE 450 501 550 650e 6 FS 450e 6 650e 6 tubular chrome molybdenum steel frame powder coated WP Up Side Down 4860 MXMA Spring travel front rear 295 320 mm 260 287 mm Rear suspension WP Progressive Damping System shock absorber aluminum rear swinging fork Front brake Disk brake perforated 260 mm brake disk floating brake caliper 310 mm Brake disk front minimum thickness 2 5 mm minimum thickness 5 0 mm Rear brake Disk brake perforated 220 mm b
60. ediately REFILLING THE FRONT BRAKE FLUID RESERVOIR Loosen screws 4 and remove lid 5 and membrane 6 Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm 0 2 in below the rim with clean brake fluid DOT 5 1 e g Motorex Brake Fluid DOT 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water WARNING Never use DOT5 brake fluid It is based on silicone oil and of a purple color Seals and brake hoses must be especially adapted to it Store brake fluid out of reach of children 38 CH WARNING Brake fluid can cause skin irritation Avoid contact with skin and eyes If you get brake fluid in your eyes rinse with plenty of water and consult a doctor CAUTION Don t let brake fluid get in contact with paint it is an effective paint remover gt Use only clean brake fluid taken from a tightly sealed container CHECKING THE FRONT BRAKE PADS The brake pads can be seen from the bottom FS from the rear The lining thickness should not be less than 1 mm WARNING At their most worn point brake pad linings should not be thinner than 1 mm otherwise they could lead to brake failure For your own safety don t put off having your brake pads changed d CAUTION If the brake pads are replaced too late so that the lining is Partly or entirely vvorn the steel components of the brake pad will rub against the brake disc there
61. eed should be readju sted BASIC INFORMATION ON CARBURETOR WEAR As a result of engine vibrations the throttle valve jet needle and needle jet are subjected to increased wear This wear may cause the carburetor to malfunction e g overly rich mixture Therefore these parts should be replaced after 200 hours ADJUSTING THE MIXTURE CONTROL SCREW The mixture control screw is used to adjust the idle mixture Turning the mixture control screw in a clockwise direction will reduce the idle mixture turning it in a counterclockwise direction will increase the idle mixture 52 MAINTENANCE WORK ON CHASSIS AND ENGINE CHECKING THE FLOAT LEVEL FLOAT HEIGHT For this purpose dismount the carburetor and remove the float chamber Hold the carburetor in a slanted position such that the float will abut the float needle valve but not compress it In this position the edge of the float should be parallel with the float chamber sealing surface see illustration If the float height does not correspond to the desired value check the float needle valve and if necessary replace it If the float needle valve is o k you can adjust the float height by bending the float lever 1 Mount the float chamber install the carburetor and adjust the idle speed DRAINING THE FLOAT CHAMBER OF THE CARBURETOR Following every wet cleaning procedure the float chamber of the carburetor should be drained in order to remove any wa
62. el or to add vvater Merely keep the battery poles clean and grease slightly vvith acid free grease if required WARNING If electrolyte sulphuric acid leaks from the battery proceed with great care The electrolyte can cause severe burns In the case of skin contact rinse thoroughly with water In the case of contact with the eyes thoroughly rinse eyes with water for at least 15 minutes Immediately con sult a doctor The battery is a closed model but can nevertheless emit explosive gases Avoid sparks and open fire near the bat tery Defective batteries must be stored out of the reach of children Ensure proper disposal of discarded batteries N CAUTION To avoid damage do not remove the locking bar 2 Never disconnect the battery while the engine is running This will destroy the rectifier regulator m c A GA L BATTERY STORAGE When preparing the motorcycle for a longer period of standstill remove the battery and recharge it Storage temperature 0 35 C 30 95 F Do not expose to direct sunlight CHARGING THE BATTERY Disconnect the negative pole and check the charging level Use a voltmeter to measure the voltage between the battery poles off load voltage Accurate results can only be obtained if the battery has neither been charged nor discharged during a period of 30 minutes preceding the measuring If the battery is empty it can be recharged for a maximum period of 10 hours at 0 4
63. er may be readjusted by using adjustment screw 1 In this way the position of the point of pres sure e g the resistance you feel on the hand brake lever when the brake pads are pressed against the brake disc can be adjusted for any hand size When you press the hand brake lever forwards you should have at least 3 mm free travel Turn the adjusting screw 1 if necessary CAUTION At the hand brake lever free travel must at least be 3 mm 0 1 in Only then may the piston in the hand brake cylinder be moved to be recognized by the greater resistance of the hand brake lever If this free travel is not provided pressure will build up in the bra king system and the front wheel brake may fail due to overheating CHANGING THE BASIC POSITION THE HAND BRAKE LEVER FS The adjusting screw 2 allows you to change the basic position of the handbrake lever 3 Press the handbrake lever s outer end forward and at the same time turn the adjusting screw CHECKING THE BRAKE FLUID LEVEL FRONT BRAKE The brake fluid reservoir is linked with the hand brake cylinder at the handlebar and the reservoir is provided with an inspection glass With the reservoir in a horizontal position the brake fluid level should not drop below the middle of the glass WARNING If the brake fluid level drops below the mini mum either the brake system has a leak or the brake pads are completely worn In this case consult an autho rized Husaberg dealer imm
64. ese models are only allowed to be driven off road and not on public roads The FE models are designed for off road sports endurance competiti ons enduro and not suitable for predominant motocross use MODELS FS The FS models are only allowed on public roads in the original homologated thrott led version Without this performance restriction i e dethrottled these models are only allowed to be driven in Supermoto competitions but not on public roads No warranty will be assumed if the bike is used in races or competitions In accordance with the international quality management ISO 9001 standard Husaberg uses quality assurance pro cesses that lead to the highest possible product quality REG NO 12 100 6061 SERIAL NUMBER LOCATIONS CHASSIS NUMBER The chassis number is stamped on the right side of the steering head tube Enter this number in the field on page no 2 ENGINE NUMBER The engine number is embossed in the engine case on the left side of the engine under the radiator hose L N O Z TT OPERATION INSTRUMENTS CLUTCH LEVER The clutch lever 1 is located on the left side of the handlebar The adjusting screw A is used to change the original position of the clutch lever see maintenance work on chassis and engine HAND DECOMPRESSION LEVER The hand decompression lever 2 is needed only if the carburetor overflows after a fall To pump the engine free pull the hand decompression lever during
65. ess than 1 mm 0 04 in WARNING At their most worn point brake pad linings should not be thinner than 1 mm otherwise they could lead to brake failure For your own safety don t put off having your brake pads changed N CAUTION If the brake pads are replaced too late so that the lining is partly or entirely worn the steel components of the brake pad will rub against the brake disc thereby imparing the braking effect and destroying the brake disc REPLACING THE REAR BRAKE PADS Push the brake caliper 1 toward the chain wheel in order to move the brake piston into its basic position Remove the clip 2 pull out the bolt 3 and remove the brake pads Thoroughly clean the brake caliper with compressed air and check the sleeves of the guide bolts for damage L N O Z TT Insert the left brake pad into the brake caliper and secure it with the bolt Insert the right brake pad and push the bolt 3 into the brake caliper up to the stop Reattach clip 2 WARNING It is very important to keep the brake disk free from oil and fatty matters Otherwise the braking effect would be strongly reduced After assembly check if the clip has been fitted correctly After working on the braking system always actuate the hand brake lever or foot brake lever respectively to ensure that the brake pads will lie against the brake disk and the pressure point is established 41 MAINTENANCE WORK ON CHASSIS AND ENGI
66. from the vvheel sensor and stops 3 seconds after the last impulse is received button no function button no function press the MODE button to change to the next mode press and hold the MODE button 3 seconds to reset the TRP1 AVS1 and STP1 figures to 0 SPEED STP1 STOP 1 DISPLAY MODE STP1 shows the traveling time based on TRP1 and continues to count whenever it receives impulses from the wheel sensor The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received LL Z A L button no function button no function press the MODE button to change to the next mode press and hold the MODE button 3 seconds to reset the TRP1 AVS1 and STP1 figures to 0 SPEED TRP2 TRIP 2 DISPLAY MODE The TRP2 trio meter is always active and counts to 999 9 Contrary to TRP1 the displayed figure can be changed using the and buttons This is a very useful function for trips taken according to a roadbook TRP2 is activated by the first impulse received trom the wheel sen sor and stops automatically 3 seconds after the last impulse is received button increases the TRP2 figure button decreases the TRP2 figure press the MODE button to change to the next mode press and hold the MODE button 3 seconds to reset TRP2 to 0 SPEED AVS2 AVERAGE SPEED 2 DISPLAY MODE AVS2 shows the average speed based on the TRP2 and STP2 figu
67. gear KICKSTARTER The kickstarter is located on the left side of the engine The upper part is tiltable LL c A GA L FOOT BRAKE PEDAL The foot brake pedal is located in front of the right footrest Its basic position can be adjusted to your seat position see mainten ance work SIDE STAND Push the side stand to the ground with your foot and load it with the motorcycle Make sure that you put your bike on solid ground and in a secure position WARNING The side stand swings up rapidly when the load is released Make sure you are not standing in the way 16 OPERATION INSTRUMENTS COMPRESSION DAMPING OF FORK Hydraulic compression damping determines the reaction when the fork is compressed The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs Remove the protecting cap 1 Turn the adjusting screws 2 clockwise to increase damping turn it counterclockwise to reduce damping during compression STANDARD ADJUSTMENT turn adjusting screw clockwise as far as it will go turn it back by as many clicks as are specified for the relevant type of fork Typ White Power 1445Y728 18 clicks Typ White Power 1445Y729 19 clicks Typ White Power 1445Y730 20 clicks REBOUND DAMPING OF FORK Hydraulic rebound damping determines the reaction when the fork is rebound By turning the adjusting screw 3 REB the degree of damping of the r
68. gine Sooty or wet spark plug Electrode gap too large Spark plug connector or spark plug faulty Short circuit cable scored in wiring harness emergency OFF switch or short circuit button faulty The plug connection of the CDI unit the pulse generator or the ignition coil has oxydized Water in blocked carburetor or jets Engine fails to idle Glogged idling jet Incorrect adjustment of adjusting screws on carburetor Defective spark plug Defective ignition system REMEDY Turn on the emergency OFF switch Australia only Dismount the left paneling and the filter box cover and replace the fuse in the starter relay Recharge the battery and investigate the causes for discharging contact a Husaberg dealer Start the engine with the kickstarter Open fuel tap tank fuel actuate choke Pay attention to starting information see driving instructions The easily inflammable components of the new fuels evapo rate during longer periods of standing still When the motorcycle has been out of operation for more than a week it is therefore recommended to drain the old fuel from the float chamber The engine will immediately start when the float chamber is filled with new fuel Close fuel tap loosen fuel hose at carburetor lead into a basin and open fuel tap if fuel leaks out the carburetor may need cleaning if no fuel leaks out check tank ventilation i e clean fuel tap In order to pump the engine free
69. hat meet the JASO MA quality requirements see information on the can Husaberg recommends Motorex Power Synt 4T in the 10W 50 viscosity for temperatures over 0 C 32 F or 5VV 40 for temperatures under 0 C 32 F CAUTION Insufficient amounts of or low grade engine oil lead to premature wear in the engine CHANGING THE ENGINE OIL E NOTE When changing the engine oil it is necessary to clean the short and long oil screens and to replace both oil filters WARNING An engine at operating temperature and the engine oil it contains are very hot do not burn or scald yourself Place the motorcycle on a horizontal surface remove the plug 1 and allow the oil to drain into a receptacle Clean plug with magnet thoroughly Once the entire oil has been drained clean the sealing surface mount the plug together with the sealing ring and tighten it to 20 Nm CLEANING THE OIL SCREEN Dismount the plug 2 with the oil screen thoroughly clean the parts and blow clean with compressed air Check the O rings 4 for damage and replace if necessary Insert the oil screen in the plug 2 mount and tighten the plug to 15 Nm 54 JASO T903 MA TEMPERATUR 0 C 32 F 5W 40 10W 50 MAINTENANCE WORK ON CHASSIS AND ENGINE CHANGING THE OIL FILTER Place a suitable vessel under the engine to allow the oil to drain Remove both screws 1 and screw an M6 screw in the center hole 2 of the oil filter co
70. ight have become embedded in them Refer to the specific regulations in your country for minimum tire tread requirements We recommend you replace the tires at the latest when the tread is down to 2 mm 0 08 in Tire pressure should be checked regularly on a cold tire Proper pressure ensures optimum driving comfort and extends the life of your tires WARNING Do not mount tires which have not been approved by Husaberg Other tires could have adverse effects on the way your motorcycle behaves Front and rear wheels may only be fitted with tires having the same tread layout Use homologated tires Off road FC FE For your own safety replace damaged tires immediately Worn tires can have a negative effect on how your Road FE motorcycle performs especially on wet surfaces If air pressure is too low abnormal wear and overheating of the tire can result TIRES PRESSURE ENGLISH CHECK SET DISTANCE OF THE MAGNETIC SENSOR The distance between magnet 2 and sensor 1 must be 2 4 mm 0 08 0 16 in otherwise malfunctions on the speedometer might occur This distance can be corrected by screwing in or off the sensor 1 45 MAINTENANCE WORK ON CHASSIS AND ENGINE BATTERY The battery 1 is located in front of the shock absorber and is main tenance free t is not necessary to check the electrolyte lev
71. imension A Place the motorcycle on the ground again Ask a helper to hold the motorcycle in vertical position Measure the distance between the rear axle and the fixed point again to establish dimension B The static sag is the difference between dimensions A and B Ke 19 SONS LL Z A un L EXAMPLE Motorcycle jacked up dimension A 600 mm Motorcycle on ground unloaded dimension B 565 mm So EE 7 toate ew de eed a 35 mm If the static sag is lower the spring preload of the shock absorber must be reduced if the static sag is higher the spring preload must be increased See chapter Changing the spring preload of the shock absorber DETERMINING THE RIDING SAG OF THE SHOCK ABSORBER Have a helper hold the motorcycle while you sit on the bike in a normal seating position feet on the footrests wearing full pro tective clothing and bounce up and down a few times to allow the rear wheel suspension to become level Stay on the bike and have another person measure the distance between the same two points and write it down as dimension C The riding sag is the difference between dimensions A and C EXAMPLE f FC 450 550 Motorcycle jacked up dimension A 600 mm Motorcycle on ground loaded dimension C 510 mm je 90 mm 81 99 5 260 76 95 260 66 86 260 60 65 70 75 80 85 90 RIDERS WEIGHT INCLUSIVE GEAR
72. in the SPEED LAP display mode To clear all of the stored lap times hold the MODE button for 3 seconds in the SPEED LAP mode press the MODE button to change to the next mode If no lap time LAP is stored or the motorcycle is driving the LAP LAP mode will be skipped press and hold the MODE button 3 seconds to reset the LAP figure and all stored lap times to 0 10 OPERATION INSTRUMENTS LAP LAP DISPLAY MODE The lap number is shovvn at the top and the lap time in hours minutes and seconds at the bottom of the display If no lap time is stored or the motorcycle is driving the LAP LAP mode will be skipped Hold the MODE button for 3 seconds in the SPEED LAP mode to clear the stored lap times button changes to the next lap time button no function press the MODE button to change to the next mode press and hold the MODE button 3 seconds to change to the next mode SPEED CLK CLOCK DISPLAY MODE CLK will display time in hours minutes and seconds button no function button no function press the MODE button to change to the next mode press and hold the MODE button 3 seconds to set the time in the menu see SETTING THE CLOCK SPEED H HOURS DISPLAY MODE When you stop driving and no impulses are sent from the wheel sensor the display mode will automatically change from SPEED ODO to SPEED H H shows the operating hours The ope rating hour counter starts to count as soon as you start the engine
73. is would considerably reduce the tire s road grip and the braking effect of the front brake 31 MAINTENANCE WORK ON CHASSIS AND ENGINE BASIC SUSPENSION SETUP FOR THE WEIGHT OF THE DRIVER To achieve maximum handling performance and to prevent the fork shock absorber swing arm and frame from being damaged the basic setup of the suspension components must be suitable for your weight At delivery Husaberg s offroad motorcycles are set to accommodate a driver weighing 70 80 kg wearing full protective clothing If your weight exceeds or falls short of this range you will need to adjust the basic setup for the suspension components accordingly Minor deviations in weight can be compensated by adjusting the spring preload Different springs must be installed for larger deviations CHECKING THE SHOCK ABSORBER AND SPRING You can establish whether or not the shock absorber spring is suita ble for your weight by checking the riding sag The static slag must be correctly adjusted before the riding sag can be determined DETERMINING THE STATIC SAG OF THE SHOCK ABSORBER The static sag should be as close as possible to 35 mm Deviations of more than 2 mm can strongly influence the motorcycle s perfor mance Procedure Jack up the motorcycle until the rear wheel no longer touches the ground Measure the vertical distance between the rear wheel axle and a fixed point e g a mark on the side cover and write it down as d
74. k all functions thoroughly before starting up operations again A twisted handlebar must always be replaced Do not adjust the handlebar it will lose stability CAUTION High rpm rates when the engine is cold have an adverse effect on the life of your engine We recommend you run the engine in a moderate rpm range for a few miles giving it a chance to warm up After that no further precautions in this respect need to be taken The engine has reached its operating temperature as soon as the radiators become warm Never have the throttle wide open when changing down to a lower gear The engine will over rev damaging the valves In addition the rear wheel locks so that the motorcycle can easily get out of control If any abnormal vibrations occur while driving check that the engine fastening bolts are tight In the event that while riding on your motorcycle you notice any unusual operation related noise stop immediately turn the engine off and contact an authorized Husaberg dealer BRAKING Close throttle and apply the hand and foot brakes at the same time When driving on sandy wet or slippery ground use mainly the rear wheel brake Always brake with feeling blocking wheels can cause you to skid or fall Also change down to lower gears depending on your speed When driving down hill use the braking effect of the engine Change down one or two gears but do not over speed the engine In this way you will not need to brake
75. l Piston rings 1 compression ring 1 oil scraper ring Engine lubrication pressure circulation lubrication vvith tvvo rotor pumps L Eingine oil full synthetic oil Motorex Power Synt 4T SAE 10W50 LLI Quantity of engine oil 1 0 Liter Clutch mult disc clutch in oil bath Transmission clawn shifted 4 Gang Gang Gear ratio 1 Gear 2 Gear 3 Gear 19 26 19 26 4 Gear 23 25 23 25 5 Gear 24 22 27 20 Ignition system contactless DC CDI ignition with digital advanced system Tyo KOKUSAN Generator 12V 150VV Spark plug NGK DCPR 8 E Spark plug gap 0 6 mm Cooling system liquid cooled permanent rotation through mechanically driven vvater pump Cooling iquid 1 3 liter 40 antifreeze 60 water at least 25 C Starting equipment kickstarter kick electric starter BASIC CARBURATOR SETTING E FC 450 4 FE FS 450e 6 FE 501e 6 EU AUS USA green EU AUS Keihin FCR MX 41 Keihin FCR MX 39 Keihin FCR MX 39 Carburator setting number 4125B 3925B 3925A Main jet 178 178 Jet needle OBDVT OBDVR OBDVT OBDVR Idling jet 38 40 38 42 Main air jet 200 200 200 Idling air jet 100 100 100 Needle position 6 rd from top 2 6 rd from top 3 rd from top Starting jet Mixture control screw open Slide Performance restrictor Slide stop Slide stop Stop pump membrane 858 2 15 mm 858 2 15 mm 858 2 15 mm Hot start device 25mm diameter 25 mm diameter 25mm diameter
76. la ced in good time the rear sprocket carrier and the rear hub will be damaged Allways replace all 6 absorption rubbers never single rubbers m c A GA L CHECKING SPOKE TENSION The correct spoke tension is very important for the stability of the wheels and thus for riding safety A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose Check spoke tension especially on a new motorcycle at regular intervals For checking tap on each spoke with the blade of a screwdriver see photo A clear tone must be the result Dull tones are indicators of loose spokes If necessary have the spokes retightened and the wheel centered by a Husaberg dealer WARNING Spokes can tear if you continue to ride with them loose This may lead to an unstable handling of your motorcycle Excessively tensioned spokes may rupture due to local overloading The spokes must be tensioned to 5 Nm 44 MAINTENANCE WORK ON CHASSIS AND ENGINE TIRES AIR PRESSURE Tire type tire condition and air pressure level affect the way your motor cycle rides and must therefore be checked whenever you are getting ready to go anywhere on your motorcycle Tire size can be found in the technical specifications and in the homologation certificate Tire condition has to be checked every time you want to ride your motorcycle Before leaving check tires for punctures and nails or other sharp objects that m
77. low speed 2 HS high speed 2 HS high speed 2 HS high speed Rebound adjuster 22 22 15 Spring 76 95 260 71 90 260 84 250 Spring preload 6mm 8mm 5mm LL Z A m Un L TECHNICAL DATA ENGINE TIGHTENING TORQUES HH collar screws on housing clutch cover ignition cover M Oil drain plug M12x1 5 HH plug oil screen AH collar screw on oil filter cover M20x1 5 M5 6 Nm Plug on pressure relief valve M12x1 5 20 Nm HH screws on oil pump cover HH collar screw on cylinder head top section M4 Loctite 243 5 Nm AH screws on valve cover HH collar screws on water pump cover HH screws on cylinder head 50 Nm HH screw on cylinder head 10 Nm AH screws on camshaft gear HH nut on automatic decompression stop M5 Loctite 243 28 Nm Loctite 2701 8 Nm AH screws on rocker arm shaft silencer cap M5 Loctite 243 6Nm Counternut on valve adjusting screw HH nut on primary pinion 0 75 M16x1 11 Nm Loctite 2701 110 Nm HH nut on idler shaft gear M16x1 Loctite 2701 110 Nm HH nut on clutch drive HH collar screws on clutch springs M18x1 5 Loctite 243 120 Nm Loctite 243 8 Nm AH screvv shift on shift roller lock Loctite 243 10 Nm HH collar screw on locking lever HH collar screw on shift roller bearing Loctite 243 10 Nm Loctite 243 10 Nm HH collar screws on chain tensioner 10 Nm
78. may break ENGLISH 4 Tires Check for damaged tires Tires showing cuts or dents must be replaced The tread depth must comply with the legal regulati ons Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving performance 5 Brakes Check correct functioning of the braking system Check for suffi cient brake fluid in the reservoir The reservoirs have been desi gned in such a way that brake fluid does not need to be refilled even when the brake pads are worn If the level of brake fluid falls below the minimum value this indicates a leak in the bra king system or completely worn out brake pads Arrange for the braking system to be checked by a Husaberg specialist as com plete failure of the braking system can be avoided Also check the state of the brake hose and the thickness of the brake linings Check free travel at the hand brake lever and foot brake lever 6 Cables Check correct setting and easy running of all control cables 7 Cooling fluid Check the level of the cooling fluid when the engine is cold 8 Electrical system Check correct functioning of headlamps tail lights brake lights indicators control lamps and horn while the engine is running 9 Luggage If you are taking luggage with you check that this is securely fastened 10 Rear mirror Checking the rear mirror setting 21 AL c A un L STARTING WHEN THE ENGINE IS COLD Open the fuel taps
79. mounting bolt M8 M M8 Loctite 243 35 Nm Loctite 243 10 Nm 25 Nm Side stand Rim lock Screw adjusting ring spring preload shock abs M8 M8 M 20 Nm Nm 8 Nm Spoke nipple Other screvvs on chassis Other collar nuts on chassis 63 4 5 M5 M M8 M10 M M8 M10 5 Nm 10 Nm 25 Nm 45 Nm 15 Nm 30 Nm 50 Nm CL QO c LLI LL Z A 5 un I HEAD WORD INDEX Page Activating deactivating the display modes 13 Adiusting the mixture control screw 52 Adjusting the throttle cables sss vs Eia ERES 50 Basic information on carburetor wear 52 Basic suspension setup for the weight of the driver 32 ET 46 Bleeding of the hydraulic clutch 51 Bleeding the cooling system sau Seo anadan Ad 49 sc dec pt 23 Breather plug front fork E balaq 31 Carburetor adjust idling 52 Chaim maintenance 424 244 4455 tite 2505 26054345 36 LIVE 36 Changing the basic position of the foot brake pedal 40 Changing the basic position the hand brake lever FC FE 38 Changing the basic position the hand brake lever FS 38 Changing the engine oil 3 2 93 6 RS SERES 54 Changing the oil filter 55 Changing the original position of the clutch lever 51 Changing the spring preload on the telescopic fork 27 Changing the spring preloading of the shock absorber 3
80. n before beginning any maintenance work in order to avoid getting burned Dispose oils fatty matters filters fuels washing detergents etc properly Under no circumstances may used oil be disposed of in the sewage system or in the open countryside 1 liter of used oil contaminates 1 000 000 liters of water AL c A un L CHECKING AND ADJUSTING THE STEERING HEAD BEARING The steering head bearing should be checked regularly for play For this purpose jack up the motorcycle by the frame so that the front wheel is in the air Now try to move the fork forward and back ward There should be no clearance For readjustment release the 4 clamp screws 1 of the top triple clamp and the steering head nut 2 Turn the adjusting nut 3 until almost no play is left Do not tighten the adjusting nut Tightening the adjusting nut can damage the bearings Keep in mind that tightening the steering head nut 2 reduces the play of the bearing Slightly tap the top triple clamp with a rubber hammer to prevent jamming Then tighten the 4 clamp screws with 20 Nm CH WARNING If the steering head bearing is not adjusted to be free of play the motorcycle will exhibit unsteady driving characteristics and can get out of control N CAUTION If you drive with play in the steering head bearing for longer periods the bearings and subse quently the bearing seats in the frame will be destroyed The steering head bearings should be reg
81. n the other hand can result in the chain jumping off the chain wheels If this happens the chain could also block the rear wheel or damage the engine In either case the operator is likely to lose control of the motorcycle L N Z TT CORRECT CHAIN TENSION Loosen collar nut 1 loosen lock nuts 2 and turn right and left adjusting screws 3 equally far Tighten lock nuts To ensure the correct alignment of the rear wheel the marks at the left and right chain adjusters must be positioned identically in rela tion to the reference marks B Tighten the counter nut of the adju sting screws Before tightening thr collar nut verify that the chain adjusters 4 are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut 1 to 80 Nm WARNING If you don t happen to have a torque wrench at hand make sure you have the tightening torque cor rected by a Husaberg dealer as soon as possible A loose axle may lead to an unstable driving behavior of your motorcycle Tighten the collar nut with the required torque A loose wheel spindle may lead to an unstable behavior of your motorcycle NOTE The large adjusting range of the chain adjusters 32mm allovvs you to use different secondary ratios in combination vvith the same chain length The chain adiu sters 4 can be rotated by 180 35 LL Z A L MAIN
82. ng cigarettes Alvvays svvitch off the engine before refu elling Be careful not to spill gasoline on the engine or exhaust pipe vvhile the engine is hot VVipe up spills promptly If gasoline is swallowed or splashed in the eyes seek a doctor s advice immediately Fuel expands when its temperature rises Therefore do not fill the tank to the top see fig 24 vv x xak EE y AS HSIIONSA 25 PERIODIC MAINTENANCE SCHEDULE 2004 FC 450 4 FC 550 4 MODEL 2004 1 service after after every A clean motorcycle can be checked more quickly which saves money 2 hours 10 hours or or 15 fuel 60 fuel Change engine oil and oil filter Clean oil screen and drain plug magnet Replace spark plug after 30 hours Check and adjust valve clearance Check engine mounting bolts for tightness Check carburetor connection boot for cracks and leaks Check idle speed setting Check vent hoses for damage or bends ENGINE CARBURETOR Check cooling system for leaks check quantity of antifreeze Check exhaust system for leaks and fitment Check cables for damage smooth operation and bends adjust and lubricate Check fluid level of the clutch master cylinder Clean air filter and filter box Check electric wires for damage and bends Check headlamp setting Check function of electric systems low high beam brake light indicator lamps speedome
83. ng up the side stand 3 Put the gear in neutral 4 Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E starter NOTE Pull the hot start knob if the engine won t start WHAT TO DO WHEN THE ENGINE IS FLOODED In the event of a fall more fuel than necessary may get into the engine In order to pump the engine free pull the hand decom pression lever fully rev up the engine actuate the kickstarter 5 to 10 times or actuate the E starter 2 times for 5 seconds each Then start the engine as described above If the engine fails to start unscrew the spark plug and dry it NOTE The carburetor has an accelerator pump Every time you open the throttle fuel will be injected into the intake passage When starting be sure that you open the throttle completely only once STARTING OFF Pull the clutch lever Put the engine into first gear slowly release the clutch lever and open the throttle at the same time WARNING Before you start off check that the side stand has been swung up fully If the stand drags on the ground the motorcycle can go out of control 22 SHIFTING RIDING You are novv in first gear refered to as the drive or uphill gear Depending on the conditions traffic hill size etc you can shift to a higher gear Close throttle at the same time pull clutch lever in and shift to the next higher gear Let clutch lever go again and accelerate If you turned on the ch
84. ngs Check the spring cap for wear Check the eccentricity of the valve disk Check the valve guides for wear Check the radial clearance of the rocker arm rollers Check the elongation of the timing chain Check the chain tensioner tooting for damage visual check Check the eccentricity of the crankshaft journal Replace the conrod bearings Check piston pin bearing Replace the balancer shaft bearings Replace the crankshaft main bearings Check the entire transmission including the roller and bearings for wear 28 PERIODIC MAINTENANCE SCHEDULE 2004 RECOMMENDED INSPECTION OF THE HUSABERG ENGINES USED FOR ENDURO COMPETITIONS BY YOUR HUSABERG WORKSHOP ADDITIONAL ORDER FOR THE HUSABERG WORKSHOP a 100 liter fuel consumption is equivalent to approx 15 operating hours 15 hours 100 liter 30 hours 200 liter 300 liter 400 liter 90 hours 600 liter 120 hours 800 liter 135 hours 900 liter Check the clutch disks for wear Check the length of the clutch springs Check the cylinder and piston for wear Check the groove on the piston pin retainer for wear visual check Check the camshaft for wear visual check Check the camshaft bearings Check the length of the valve springs Check the spring cap for wear Check the eccentricity of the valve disk Check the valve guides for wear Check the radial clearance of the rocker arm rollers Check the elongation of the timing chain Check the
85. ning the adjusting screw counterclockwise increases the distance between the clutch lever and the handlebar N CAUTION Adjustment of the clutch lever position is only possible within certain limits Only turn the adjusting screw manually and never apply excessive force CHECKING THE OIL LEVEL OF THE HYDRAULIC CLUTCH To check the oil level in the master cylinder of the clutch remove the cover For this purpose remove screws 2 and cover 3 together with the rubber boot 4 The oil level in the horizontal standing master cylinder should be 4 mm below the upper edge If necessary fill up with biodegradable hydraulic oil SAE 10 e g Motorex Kupplungs Fluid 75 Biodegradable hydraulic oil is availa ble from your Husaberg dealer bOml CAUTION Husaberg uses biodegradable hydraulic oil for the hydraulic clutch control Never mix biodegradable hydraulic oils with mineral oils Never refill with mineral hydraulic oil or brake fluid A ur J c LU BLEEDING OF THE HYDRAULIC CLUTCH To bleed the cover of the master cylinder of the clutch needs to be removed For this purpose remove screvvs 2 and take off cover 3 together vvith rubber bellovvs 4 At the slave eylinder of the clutch remove the bleeder nipple 5 In its place mount the bleeder syringe 6 which is filled with SAE 10 hydraulic oil Refill oil until oil is discharged from the bore 7 of the master cylinder in a bubble free state Make sure that the oil
86. oke make sure you turn it off again as soon as engine is warm When you reach full soeed through opening the throttle all the way turn throttle back to 3 4 the speed hardly decrea ses although the engine will use less gas Only give as much gas as the engine can handle Through quick and high revving of the throttle the fuel usage increases By shifting down use the brakes if necessary and close the throttle at the same time Pull the clutch lever and shift down to the next gear Let clutch lever go slowly and open the throttle or shift down again ES NOTE Dedicated to nothing but offroad racing Husaberg models make no compromises in their design As such they do not include any radiator fan and the size of the radiator is dimensioned for optimum ergonomics n normal racing the cooling system is sufficient If you use your motorbike in other conditions please note that the E starter allovvs you to start FC FS models again at any time Therefore turn off the engine if you intend to run your motorcycle in idle or at a standstill for longer periods of time more than 2 minutes Avoid letting the clutch slip frequently and for extended periods This vvould cause the engine oil to heat up thereby heating up the coo ling system You should drive at lovv speeds 4 stroke style letting the engine pull you and not at high speeds not by letting the clutch slip 2 stroke style WARNING After falling with the motorcycle chec
87. ons Observance of the service maintenance and tuning instructions for the engine and chassis specitied in the Owner s Manual is a prerequisite for faultless operation and the avoidance of premature wear An improperly tuned chassis can lead to damage and breakage of the chassis components see chapter on checking the basic chassis setting The service work described in the Lubrication and maintenance chart must be car ried out and confirmed by an authorized Husaberg dealer otherwise your warranty will become void LL Z A un L The fuels and lubricants specified in the Owner s Manual or fluids with equivalent specifications must be used in accordance with the maintenance schedule No claims can be filed under the warranty for damage or consequential damage caused by manipulations or conversions to the motorcycle The use of the motorcycle under extreme conditions e g on extremely muddy and wet terrain can lead to higher than average wear on components such as the drive train or the brakes In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been rea ched MODELS FC FC and other competition only labeled models are prohibited on public roads MODELS FE On the road approved models are only allowed on public roads in the original homologated throttled version Without this performance restriction i e de throttled th
88. oosen both rubber bands and tilt headlight mask to the front Pull the parking light lamp with holder 4 carefully out of the reflector Pull connector 5 off the headlamp and remove rubber cap 6 Disengage retaining clip and take bulb out of reflector When chan ging the parking light lamp simply pull it out of the holder Insert the new lamp such that the noses 7 engage in the recesses 8 When doing so do not touch the glass body of the lamp so that it remains free from fat Engage retaining clip mount rubber cap and connector If the parking light lamp is to be replaced simply insert it in the holder Reinsert the parking light lamp together with the holder Engage the bottom end of the headlamp mask at the retaining pins and fix the mask by means of the rubber bands 47 MAINTENANCE WORK ON CHASSIS AND ENGINE COOLING SYSTEM Coolant is circulated by a water pump 1 located in the engine Air blowing in through the radiators cools the coolant The slower the speed of the motorcycle the less the coolant is cooled down Dirty radiators also reduce the cooling efficiency Pressure induced by heating of the coolant in the system is control led by a valve in the radiator cap 2 a water temperature rising up to 120 C 248 F is admissible without fear of problems WARNING If possible always check level of cooling liquid when the engine is cold If you have to open the radiator cap 2 when the engine is hot us
89. ou can help each other should difficulties arise Replace the helmet visor or goggle lens when scratched or damaged if bright light shines through a scratched visor or lens the operator will be blinded Never leave your motorcycle without supervision if the engine is running The FC models are not approved for use on public roads and freeways When riding your motorcycle please bear in mind that other people may feel molested by excessive noise DRIVING INSTRUCTIONS CHECK THE FOLLOWING BEFORE EACH START When you start off the motorcycle must be in perfect technical condition For safety reasons you should make a habit of perfor ming an overall check of your motorcycle before each start The following checks should be performed 1 Check the oil level Insufficient oil results in premature wear and consequently to engine damage 2 Fuel Check that there is sufficient fuel in the tank when closing the fil ler cap check that the tank venting hose is free of kinks 3 Chain A loose chain can fall from the chain wheels an extremely worn chain can tear and insufficient lubrication can result in unneces sary wear to the chain and chain wheels Excessive tensioning of the chain will put additional load on the components of the secondary drivetrain chain bearings of transmission and rear wheel Aside from resulting in premature wear if worst comes to worst the chain may rupture or the countershaft of the transmis sion
90. rake disk floating brake caliper Brake disk rear minimum thickness 3 5 mm Front tire 80 100 21 90 90 21 120 60 17 Air pressure off road 1 0 bar 1 0 bar Air pressure on road alone 1 5 bar 1 5 bar Rear tire 110 100 19 140 80 18 150 60 17 Air pressure off road 1 0 bar 1 0 bar Air pressure on road alone 2 0 bar 2 0 bar Fuel tank capacity 9 liters Gear ratio rear wheel 450 501 14 48 550 15 48 650 15 45 450 15 42 650 15 40 Chain X Ring 520 Available rear sprockets 382 407 42Z 45Z 487 50Z 522 Lighting Headlight HS1 12V 35 35W Parking light 12V 5W Socket W2 1x9 5d3 Brake light 12V 21 5W Sockel Bav bd Turn signal 12V 10W Sockel Ba15s License plate illumination 12V 1 2W Sockel 1x4 6d Battery maintenance free battery 12V 7Ah ENGLISH Steering head angle Wheel base 1490 10 mm Seat height unloaded Ground clearance unloaded STANDARD ADJUSTMENT FORK FC 450 4 550 4 FE 450 501 550 650e 6 FS 450e 6 650e 6 WP4860MXMA WP4860MXMA WP4860MXMA 14 45Y7 28 14 45Y7 29 14 45Y7 30 Compression adjuster 18 19 20 Rebound adjuster Spring Spring preload Airchamber lenght 100 mm Fork oil SAE 5 STANDARD ADJUSTMENT SHOCK ABSORBER FC 450 4 550 4 FE 450 501 550 650e 6 FS 450e 6 650e 6 WP 5018 PDS DCC WP 5018 PDS DCC WP 5018 PDS DCC 12 45 Y7 21 12 45 Y7 22 12 45 Y7 23 Compression adjuster 15 LS low speed 15 LS low speed 10 LS
91. rand name detergents to clean the motorcycle Especially dirty parts should also be cleaned with the help of a paint brush Before cleaning with water plug the exhaust pipe to prevent water ingress After the motorcycle has been rinsed with a soft water jet it should be dried by air pressure and a cloth Drain the float chamber of the carburetor Then take a short drive until the engine has reached the working temperature and also use the brakes By warming these components the residual water can evaporate from inaccessable parts of the engine and the brakes Slide back the protective covers on the handlebar mounted instruments so that any water that may have seeped into this part of the motorcycle is allowed to evaporate Once the motorcycle has cooled down oil or grease all sliding and bearing points Treat the chain with a chain spray Also oil the fuel tap To avoid any failures in of the electric system you should treat the emergency OFF switch short circuit button light switch and socket connectors with a contact spray CONSERVATION FOR WINTER OPERATION In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying you will have to take precautions against the aggressive road salt clean the motorcycle thoroughly and let it dry after each ride treat the engine carburetor swing arm and all other bare or galvanized parts except for brake discs with a wax based
92. reased at least once a year e g Motorex Long Therm 2000 30 MAINTENANCE WORK ON CHASSIS AND ENGINE BREATHER PLUG FRONT FORK After every 5 hours of use for competitive racing slacken the breat her plugs 1 a few turns in order to relieve excess pressure from the inside of the fork To do this place the motorcycle on a stand with the front wheel lifted off the ground When riding the motorcy cle mainly on the road it will suffice to have this job performed in the course of the periodical maintenance service N CAUTION Excessive pressure in the interior of the fork can cause leaks in the fork If your fork is leaking it is recommended to open the breather plugs before having the seals replaced CLEANING THE DUST SLEEVES OF THE TELES COPIC FORK The dust protection bellows 2 are to remove dust and coarse dirt particles from the fork tube However after some time dirt may also get in behind the dust protection bellows If this dirt is not removed the oil sealing rings located behind it may start to leak Use a screwdriver to lift the dust protection bellows out of the outer tubes and slide them downward A ur o c LU Clean the dust protection bellovvs outer tubes and fork tubes thoroughly and oil them thoroughly with silicone spray or engine oil Then push the dust protection bellows into the outer tubes by hand WARNING No silicone oil may reach the front tire or the brake disks since th
93. ression of shock absorber 18 Determining the riding sag of the shock absorber 32 Determining the static sag of the shock absorber eZ Dismounting and mounting the front wheel 42 Dismounting and mounting the rear wheel 43 Draining the float chamber of the carburetor 53 Driving Weg tee 21 64 Page Electronic speedometer 8 Emergency off switch australia suns 8 Breil Rae PD Mone EDUC 54 Enginen DEF r 5 15 Flasher E EE 7 FOOt Drake Pedal AE I D M UNS RE 16 0012700 6000020000 070017 24 PUCITADS orara tnt a cae Sete bs eh a es 15 PUSEN NEE 47 General information about Husaberg disc brakes 37 eV 6 Hand decompression lever 6 4 Headlamp switch USA 7 Hotstart re EE ake a daa bl 15 How to change the handlebar position 34 ea xa ax ar n exu A ades 7 Important limited warranty and limited guarantee information 4 INGICALON ere ws Sys de Bea D b oe hes 8 Instructions for initial operation 20 ee 2 Micketartef e Ee 16 Kilometers OF Mies esse saobo b se cele his ae ke 14 Maintenance work on chassis and engine 30 EE 53 GDeration iRstTUmenis eE ng EE EEN A 6 Periodic maintenance schedule 2004 26 Rebound damping Are ee 17 Reboun
94. rews Check shock absorber and fork for leaks and function Clean fork dust bellows BRAKES Bleed fork legs Check adjust steering head bearings Check tightness of chassis screws triple clamps fork leg axle passage Check swing arm bearings CHASSIS Check spoke tension and rim joint Check tires and air pressure Check chain chain joint rear sprockets and chain guides for wear fit and tension WHEELS Lubricate chain Check clearance of wheel bearings IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED QUT BY EXTRA ORDER at least once a year Complete maintenance of fork Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Clean and adjust carburetor Replace glass fibre yarn filling of the exhaust main silencer Treat electric contacts and switches with contact spray Treat battery connections with contact grease Change hydraulic clutch fluid Change brake fluid IF MOTORCYCLE IS USED FOR COMPETITION 15 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE SERVICE INTERVALLS SHOULD NEVER BE EXCEEDED BY MORE THAN 2 HOURS OR 15 LITERS OF FUEL MAINTENANCE WORK DONE BY HUSABERG AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER 27 PERIODIC MAINTENANCE SCHEDULE 2004 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER start cleaning country use Check oil level
95. t front flasher rechter vorderer Blinker Clignotant avant droit Right rear flasher Rechter hinterer Blinker Clignotant arri re droit Speed sensor Geschwindigkeitssensor Capteur de vitesse Start relay Startrelais Relais de d marreur Start stop button Start Stop schalter Contacteur start stop Starter motor Startermotor D marreur Temperature switch Temperaturschalter Contacteur de temp rature Throttle position sensor TPS Vergaserpotentiometer Capteur d ouverture de carburateur Cable colours Kabelfarben Couleur de cable bl black bl schwarz bl noir ye yellow ye gelb ye jaune bu blue bu blau bu bleu gn green gn gr n gn vert re red re rot re rouge wh white wh weil3 wh blanc br brown br braun br brun or orange or orange or orange pi pink pi rosa pi rose gr grey gr grau gr gris pu purple pu violett pu violet LATUM m H Sub dt vun h Mo r 7 F Y EI TERT GR y 2 5 2 7 77 5 72777 TUR 4 STROKE FURCE 7
96. tely necessary to bleed the cooling system during filling 10 mm by cold engine Kai E Ka P F i x a E EH RH p zc E E E EH E _ Ps Fa Pu Kl E LA E EH E Fa LI LI E EH aos EH EH EH CH E E E E Es E E E EH E E al E rn E LI LI am E Ca Fa ov E LL E Ka E E E E E E E kal E Fa Foz mam 48 MAINTENANCE VVORK ON CHASSIS AND ENGINE BLEEDING THE COOLING SYSTEM The cooling liquid is drained by removing the hose 1 from the vvater pump To bleed the cooling system fill in approx 1 liter 0 26 US gallons of coolant and remove the bleeder screw 2 Do not reinstall the bleeder screvv until coolant escapes at the bore vvithout any bub bles Then fill in the coolant until it reaches a level about 10mm above the radiator fins After a short ride check the coolant level once more REPLACING THE GLASSFIBER YARN PACKING OF THE SILENCER Aluminum silencers are filled with glassfiber yarn to muffle noise The effect of heat causes the glassfiber yarn to become loose This may lead to a loss of performance and reduce the silencer s muf fling power By experience the front glasstiber yarn packing 3 needs to be replaced more often than the rear silencing mat 4 For this purpose remove the silencer from the vehicle and dismo unt the front cap 5 Pull the front glassfiber yarn packing toge
97. ter illumination horn emergency OFF switch or button Check brake fluid level lining thickness brake discs Check brake lines for damage and leaks Check function and smooth operation and adjust free travel of handbrake foot brake lever LL Z Q 5 un L ADD ON PARTS BRAKES Check tightness of brake system screws Check shock absorber and fork for leaks and function Clean fork dust bellows Bleed fork legs Check swing arm bearings Check adjust steering head bearings Check tightness of chassis screws triple clamps fork leg axle passage Check spoke tension and rim joint CHASSIS Check tires and air pressure Check chain chain joint rear sprockets and chain guides for wear fit and tension Lubricate chain WHEELS Check clearance of wheel bearings at least once a year Complete maintenance of fork Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Clean and adjust carburetor Replace glass fibre yarn filling of the exhaust main silencer Treat electric contacts and switches with contact spray Treat battery connections with contact grease Change hydraulic clutch fluid Change brake fluid IF MOTORCYCLE IS USED FOR COMPETITION 10 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE SERVICE INTERVALLS SHOULD NEVER BE EXCEEDED BY MORE THAN 2 HOURS OR 15 LITERS OF FUEL MAINTEN
98. ter that may have penetrated into it Water in the float chamber causes engine malfunction Perform this task on a cold engine Close the fuel tap and place a cloth underneath the carburetor which is able to absorb any esca ping fuel Unscrew the plug 2 and clean it with compressed air Then mount the plug together with its gasket open the fuel tap and check the float chamber for any leaks ENGLISH NOTE Fuel is easily flammable and toxic When handling ZJ fuel be sure to exercise the utmost caution Never per form any work on the fuel system near open flames or burning cigarettes Always allow the engine to cool off first Immediately clean up any fuel which may have been spilled Materials saturated with fuel are also easily flammable In case you ingested fuel or fuel splashed into your eyes consult a doctor immediately Dispose of the fuel properly OIL CIRCUIT The oil pump 3 draws the engine oil from the oil sump through the oil screen 4 and pumps it past the pressure relief valve 5 to the oil filter 6 It continues to the crankshaft 7 partly branching off through a hole to lubricate and cool the piston 8 and the piston pin bearing Once through the crankshaft the engine oil is pumped to the conrod bearing 9 and branches off again to the bearings in the balance weight 10 The camshaft 11 is lubricated by the engine oil which is transpor ted to the cylinder head by the timing chain 12
99. ther with the inner exhaust pipe 6 out of the silencer Clean the front inner exhaust pipe To facilitate the mounting procedure you can make a mounting tool 7 out of wood plastic or metal Insert the mounting tool into the inner pipe and mount the glassfiber packing Push the inner pipe containing the packing into the silencer such that the slot engages the web A Use a blunt ended object to stuff the glassfi ber yarn packing all the way into the silencer and mount the front cap C A o c LLI To change the rear silencing mat start by removing the front packing and the inner exhaust pipe Then drill open the rivets and remove the end cap NOTE In every exhaust repair procedure the O rings ZJ must be replaced by new ones Glass fiber yarn packings are available from your licensed Husaberg mechanic CH VVARNING The exhaust system becomes very hot while the motoreycle is running to avoid burns do not start vvork on the exhaust system until it has properly cooled dovvn CLEANING THE SPARK ARRESTER The spark arrester should be cleaned every time the glassfiber yarn filling is changed or at least once annually For this purpose dismount the silencer cap and remove any depo sits that might exist in region B Renew the O ring and mount the silencer cap EE e be Ge FS ee
100. to excessive temperature fluctuations Cover the motorcycle with an air permeated tarpaulin or blanket Do not use airtight materials as a possible humidity might not be able to escape and could cause corrosion CAUTION It would be very bad to let the engine run for a short time during the storage period The engine would not get warmed up enough and the thus developed steam would condense during the combustion process and cause the valves and exhaust to rust USE AFTER A PERIOD OF STORAGE Mount the charged battery regard polarity Fill up tank with fresh fuel Check motorcycle as before each start see driving instructions Take a short careful test ride first 58 TECHNICAL DATA ENGINE Engine FC 450 4 FE 450e 6 FS 450e 6 FE 501e 6 Design 1 cylinder 4 stroke engine with balancer shaft liquid cooled Displacement 449 cm Bore Stroke 100 57 2 mm 95 70 7 mm Ratio 12 751 11 6 1 Carburetor Keihin FCR MX 41 FCR MX 39 Fuel unleaded fuel with at least RON 95 USA Premium RON91 Valve timing 4 valves over rocker arm and 1 overhead camshaft camshaft drive through single chain Valve diameter Intake 35 mm Valve diameter Exhaust 30 mm Valve clearence cold Intake 0 12 mm Valve clearence cold Exhaust 0 12 mm Crank shadt bearing 2 cylinder roller bearing Connecting rod bearing needle bearing L Top end bearing bronze bushing N Piston alluminium alloy forged wl
101. ver NOTE only tighten the screvv by hand otherwise you will damage the oil filter cover Pull the oil filter cover 3 out of the hole with the screw M and remove the screvv Use pliers to pull the oil filter element 4 from the housing Clean the oil filter cover the sealing areas on the O rings and the engine case check the O rings 5 in the oil filter cover for damage and replace if necessary L N Z TT Lay the motorcycle down and fill the oil filter housing approx half full with engine oil Insert the oil filter in the housing Grease the O rings in the oil filter cover and mount the cover Mount the screws and tighten to 6 Nm Place the motorcycle in an upright position again Unscrew the oil filler plug 6 and add 1 liter of fully synthetic engine oil e g Motorex Power Synt 4T Start the engine and check all of the plugs and the oil filter cover for leakage Finally check the engine oil level and correct if necessary LAGINESIUIN 55 RIVE TROUBLESHOOTING TROUBLE CAUSE Engine doesn t E starter crank Operating errror Blown fuse Discharged battery Low outside temperature Engine cranks but doesn t start E starter Engine vvill not Kickstarter Operating error start The motoreycle has been out of operation for a longer period of time Therefore old fuel has accu mulated in the float chamber Fuel supply interrupted Flooded en

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