Home

BEDIENUNGSANLEITUNG OWNERS MANUAL MANUEL D

1. 7 Replacing the front brake pads FS 38 dy Indicatorlamps 7 Changing the basic position of the foot brake pedal 39 oa Starter button 8 Check the rear brake fluid level 39 l Emergency OFF switch Australia 8 Refilling the rear brake fluid reservoir 39 5 Electronic speedometer 8 Checking the rear brake pads 40 L Kilometers or miles 13 Replacing the rear brake pads 40 LLI Setting the clock 13 Dismounting and mounting the front wheel 41 Fler ee EE 14 Dismounting and mounting the rear wheel 42 RUC TANS 24 425 2m eae Se GATOS e eee aao sa 14 Checking the shock absorption rubbers in the rear hub 43 ne 14 Checking spoke tension 43 Hot start device 14 Tires airpressure 44 SHINMMIGVE 623 354 kee Bee E asses 15 Check set distance of the magnetic sensor 44 lee cna Sapu t O inet fee tiie kao Tass 15 DANGLY ge cee t EA E e eege 45 Foot brake pedal 15 Charging the battery 45 Side stand ei EE E hee pe taa Dua ga 15 FUSO Sow S candied Samana EE 46 Pluginstand 16 Replacing
2. 51 Starting when the engine iswarm 21 Checking the float level float height 52 What to do when the engine is flooded 21 Draining the float chamber of the carburetor 52 Sar die Ke WEE ER Re EE 52 SHMING RIGING WEE ER Checking the engine oillevel 53 Braking EE 22 Fie OUI S Stes u cSt dds mwa kus arth sau ate oh qua eg 53 Stopping and parking 23 Changing the engine oil 53 ST peat ton ce a Ws u ate en ee a ed Bee min Se 23 Cleaning the oil Screen 53 Changing the oil filter 54 C Un ee ane eet T VX saus sss SS TROUBLESHOOTING 23204 23462 Gee hae A eee ees 55 MAINTENANCE WORK ON eg ICUEANING CONSERVATION STORAGE ste 57 Checking and adjusting the steering head bearing 27 Breather plug front fork 28 TECHNICAL DATA ENGINE LLL LLL LLL 58 Cleaning the dust sleeves of the telescopic fork 28 Basic suspension setup for the weight of the driver 29 TECHNICAL DATA CHASSIS 61 Checking the shock absorber and spring 29 Determining the static sag of the shock absorber 29 HEAD WORDINDEX eee 63 Determining the riding sag of the shock absorber 29 Checking the basic setup of the telescopic fork 30 WIRING DIAGRAM 0 Appendix
3. 35 Chainwear 35 Changing the basic position of the foot brake pedal 39 Changing the basic position the hand brake lever FE 37 Changing the basic position the hand brake lever FS 37 Changing the engine oil 53 Changing the fork offset caster 31 Changing the oil filter __ 54 Changing the original position of the clutch lever 50 Changing the spring preload on the telescopic fork 16 Changing the spring preloading of the shock absorber 33 Charging the battery 88 45 Chassis number 5 Check chain tension 34 Check the following before each start 20 Check the rear brake fluid level 39 Check set distance of the magnetic sensor 44 Checking and adjusting the steering head bearing 27 Checking spokeiension 000 eee eee 43 Checking the adjustment of the hand decompression release cable 49 Checking the basic setup of the telescopic fork 30 Checking the brake fluid level front brake 37 Checking the coolantlevel 47 Checking the engine oillevel 53 Checking the float level float height 52 Checking the front brake pads 38 Checking the oil level of the hydraulic clutch
4. D Z G E U I 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 18 TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE INSTRUCTIONS FOR INITIAL OPERATION Verify that your Husaberg dealer performed the PREPARATION 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 footbrake pedal to the positions that are most convenient for you Get used to handling the motorcycle on an empty parking 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 Donotdrive 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 system is over heated Donot make any alterations to the motorcyc
5. The easily inflammable components of the new fuels eva porate 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 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 Ifthe 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 t
6. BEDIENUNGSANLEITUNG OWNERS MANUAL MANUEL D UTILISATION Husazerg 4 STROKE FORCE TABLE OF CONTENTS Page Page INTRODUCTION ois Z Ls U S Su ne eee us g a a 2 Replacing fork springs 30 Important limited warranty and limited guarantee Changing the fork offset caster 31 INTOLMAION NEE 4 How to change the handlebar position 33 Changing the spring preloading of the shock absorber 33 SERIAL NUMBER LOCATIONS aaaaaanannanaaa annaa 5 Check chain tension 34 Chassis NUMDET LG eg eege Eat 5 Correct chain tension 34 Engine Number roc uuu ss un uu e eee 5 Chain maintenance 35 CHAIN WEINE X z coat Gerda NEEN e 35 OPERATION INSTRUMENTS 6 General information about Husaberg disc brakes 36 Een ever ute 222 ei ena Moen ook tea eQ 6 Changing the basic position the hand brake lever FE 37 Hand decompression lever 6 Changing the basic position the hand brake lever FS 37 Hand brake lever EE 6 Checking the brake fluid level front brake 37 Short circuit button 6 Refilling the front brake fluid reservoir 37 Combination switch T Checking the front brake pads 38 Flasher Le NEE 7 Replacing the front brake pads FE 38 TC Headlamp switch USA
7. briefly press O button Changes to the next display mode lf no lap time is stored or the motorcycle is driving the LAP LAP mode will be skipped hold O button 3 secs Clears all LAP figures 10 OPERATION INSTRUMENTS LAP LAP DISPLAY MODE TO VIEW LAP TIMES The LAP LAP display mode will only be shown if lap times have been sto red and the front wheel has stopped It will display the lap number and the stopped lap time in hours minutes and seconds Press the button to access the next lap time To clear all of the stored lap times hold the O button for 3 seconds in the SPEED LAP mode button changes to the next lap time button no function briefly press O button changes to the next display mode hold O button 3 secs changes to the next display mode SPEED MAX DISPLAY MODE MAXIMUM SPEED MAX displays the maximum speed traveled and is always active button no function button no function briefly press O button changes to the next display mode hold O button 3 secs clears the MAX figure SPEED TR1 DISPLAY MODE TRIPMASTER 1 The TR1 tripmaster 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 TR1 is linked to A1 average speed 1 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 th
8. fuel air mixture of the type needed 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 additio nal 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 14 OPERATION INSTRUMENTS SHIFT LEVER The shift lever is mounted on the left side of the engine The position of the gears is shown in the illustration Neutral or the idle speed is located between first and second gear KICKSTARTER The kickstarter is located on the left side of the engine The upper part is tiltable cl N O lt Tr 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 maintenance work SIDE STAND Push the side stand to the ground with your foot and load it with the motor cycle 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 15 OPERATION INSTRUMENTS PLUG IN STAND The plug in stand can be attached to the wheel spindle on the left side of the motorcycle COMPRESSION DAMPIN
9. 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 38 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 turning the stop screw 1 The free play at the foot brake pedal must then be adjus ted 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 cylin der 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 minimum either the brake system has a leak or the brake pads are com pletely worn In this case consult an authorized Husaberg dealer immediately cl Hi O lt Tr REFILLING THE REAR BRAKE FLUID RESERVOIR When the brake fluid level
10. ENGINE OIL Automobile engine oil used to be used for four stroke motorcycles before there were separate motorcycle specifications Different technical deve lopments made it necessary to have a separate specification for four stroke motorcycles the JASO T903 MA standard Whereas car engines require JASO T903 MA long changing intervals motorcycle engines require a higher power out put at higher speeds Most motorcycle engines also use the same oil to lubricate the transmission and the clutch The JASO MA standard res TEMPERATURE ponds to these special requirements ENGLISH Only use fully synthetic engine oils that meet the JASO MA quality requi 0 C 32 F rements see information on the can Husaberg recommends Motorex 5W 40 10W 50 Power Synt 4T in the 10W 50 viscosity for temperatures over 0 C 32 F or 5W 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 lt NOTE When changing the engine oil it is necessary to clean the short and long oil screens and to replace both oil filters CN 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
11. 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 bet ween the same two points and write it down as dimension C The riding sag is the difference between dimensions A and C EXAMPLE Motorcycle jacked up dimension A 600 mm Motorcycle on ground loaded dimension C 500 mm Riding Sag WEE 100 mm for example FE 450 550 650 88 250 84 250 80 250 65 70 15 80 85 90 95 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM u lt D X A Wa 29 MAINTENANCE WORK ON CHASSIS AND ENGINE If the riding sag is less than 95 mm FE or 85 mm FS the spring is too hard the spring rate is too high If the riding sag is more than 105 mm 12457D02 80 250 84 250 88 250 FE or 95 mm FS the spring is too soft the spring rate is too low FE 450 990 650 The spring rate is written on the outside of the spring e g 88 250 The 12457D03 type number of the shock absorber is embossed on the bottom of the tank FS 450 650 84 250 88 250 92 250 The illustrations show which spring should be installed The standard spring is shown in bold print After installing a different spring readjust the sta tic sag to 35 mm 2 mm FE or 20 mm 2 mm FS According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage c
12. m Z G m Q I INTRODUCTION IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLE TELY BEFORE GOING ON YOUR FIRST RIDE IT CONTAINS A GREAT DEAL OF INFOR MATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PRO PERLY IN YOUR OWN INTEREST PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS WARNING IGNORING THESE INSTRUCTIONS CAN ENDANGER YOUR BODY AND YOUR LIFE CAUTION IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR CYCLE IS NOT ROAD SAFE ANYMORE 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 incorporated 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 b the use of the vehicle after such devi
13. 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 advised to have it inspected by a Husaberg dealer The fuse capacity is 10 Ampere CAUTION Under no circumstances is a stronger fuse allo wed to be installed or a fuse allowed to be repaired An impro per treatment could damage the whole electrical installation om Z Q r I REPLACING HEADLIGHT LAMP PARKING LIGHT LAMP Loosen both rubber bands and tilt headlight mask to the front Pull the parking light lamp with holder 4 carefully out of the reflector Pull con nector 5 off the headlamp and remove rubber cap 6 Disengage retai ning clip and take bulb out of reflector When changing 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 Rein sert 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 46 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 c
14. 10 Nm 14 Nm 17 Nm Clamping screws lower fork bridge FS FE 12 Nm Clamping nut fork bridge Clamping screws fork stubs M8 20 Nm Collar nut rear wheel spindle Hexagon nut swing arm bolt Hexagon collar screw handlebar clamp M20x1 5 M16x1 5 M 15 Nm 80 Nm 100 Nm Allan head screw handlebar support Shock absorber top M10 M12 20 Nm Loctite 243 40 Nm Shock absorber bottom Sprocket screws Ball joint for push rod 8 M10 M8 6 Loctite 243 70 Nm 40 Nm Loctite 243 10 Nm Engine mounting bolt Side stand M M8 25 Nm 20 Nm Rim lock 10 Nm Screw adjusting ring spring preload shock abs Spoke nipple M4 5 M5 8 Nm Other screws on chassis Other collar nuts on chassis 62 M6 HEAD WORD INDEX Page Activating and deactivating display modes 10 Adjusting the mixture control screw 51 Adjusting the throttle cables 49 Basic information on carburetor wear 51 Basic suspension setup for the weight of the driver 29 BAO Iy X aus pus Sasa waya he eae eee es 45 Bleeding of the hydraulic clutch 50 Bleeding the cooling system 48 PIGRIn Sean suu test Mth bik nob kuqa C Sr Gea ea de E Leica stl 22 Breather plug front fork 28 Carburetor Adjust idling o n naa aaa aaa 51 Chain maintenance
15. 50 Checking the rear brake pads 40 Checking the shock absorber and spring 29 Checking the shock absorption rubbers in the rear hub 43 EE te ul eebe Se eee e Gak 14 Cleaning the air filter _ 49 Cleaning the dust sleeves of the telescopic fork 28 Cleaning the oil Screen 53 Cleaning the spark arrester 48 Cleaning Conservation Storage 57 Clutch lever 6 Combination switch 7 Compression damping of fork 16 Cooling System uu y 2 ied ne a eo eee u S utu 47 Correct chain tension 34 Damping action during compression of shock absorber 17 Determining the riding sag of the shock absorber 29 Determining the static sag of the shock absorber 29 Dismounting and mounting the front wheel 41 63 Page Dismounting and mounting the rear wheel 42 Draining the float chamber of the carburetor 52 Driving IN SUMUICTIONNS EE 20 Electronic speedometer 8 Emergency OFF switch Australia 8 EDGING OW sie isa tre ae urn te ee Bey uu a a Rae 53 Siwe Ve te 5 PGW CAD EE 14 Flasher switch 7 Foot brake pedal 15 LEE 23 PUCUTADS EE 14 G 2 2 ZZ ee 46 General information about Husaberg di
16. CLUTCH LEVER The clutch lever 1 is located on the left side of the handlebar The adjust ing 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 over flows after a fall To pump the engine free pull the hand decompression lever during 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 recog nized by the stronger resistance which the hand decompression lever encounters om Z Q m r I HAND BRAKE LEVER The hand brake lever 3 is located on the right side of the handlebar 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 but ton the ignition circuit is short circuited OPERATION INSTRUMENTS COMBINATION SWITCH The light switch has 2 respectively 3 switch 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 a
17. ENGINE GENERAL INFORMATION ABOUT HUSABERG DISC BRAKES BRAKE CALIPERS Tighten the screws on the brake caliper support or the brake caliper to 25 Nm Loctite 243 FE or to 40 Nm FS BRAKE PADS The brake pads are fitted with TOSHIBA TT 2701 FE BERINGER 1100S FS sintered lining at the front and ID450 sintered lining at the back These pike BER ations 100 linings provide an optimal combination of dosing brake performance and a o oe e re H Saa Cs CU 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 mounting face 1 of the brake pads WARNING Brake disks with less than the minimum thickn ess are a safety risk Have the brake disk replaced as soon as it reaches the wear limit mn Z r I Always have repairs to the brake system performed by an aut horized Husaberg shop WEAR LIMIT A BRAKE DISKS front FE 2 5 mm ONT FS een 4 5 mm rear FE 3 5 mm rearFS 4 5 mm BRAKE FLUID RESERVOIRS The brake fluid reservoirs on the front and rear wheel brakes have been designed 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 lea
18. 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 pres sure will build up in the braking 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 handle bar and the reservoir is provided with an inspection glass With the reser voir 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 minimum either the brake system has a leak or the brake pads are com pletely worn In this case consult an authorized Husaberg dealer immediately 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 screw
19. Turning in a clockwise direction will increase the prestress turning in a counterclockwise direction will decrease the prestress Changing the spring preload will not affect the rebound damping adjust ment Generally if the spring preload is higher the rebound damping should also be set higher NOTE Always turn the adjusting screws the same distance on both fork legs Different spring preloads on the fork legs will reduce the telescopic fork s response 16 OPERATION INSTRUMENTS 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 absorber 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 cl O lt Tr Typ WP Suspension 12457D02 18 clicks Typ WP Suspension 12457D0
20. ak alee wie Soe ed ee eg 22 Starting when the engine is cold 21 Starting when the engine is warm 21 Steering lock 18 Stopping and parking 23 Technical data chassis 61 Technical data engine 59 Tips and warnings for starting the motorcycle 19 Tires air pressure 44 TROUBDIESMOOTING EE 55 What to do when the engine is flooded 21 Winna Bel Let aris sered i wearer eck ve eae ee A appendix cl N O lt Tr ENGLISH 64 multi func digital speedometer SCHALTPLAN WIRING DIAGRAM 3OIGNdddV XIQGNAddV ONVHNV high low beam switch horn switch stop button flasher switch CN start relay battery handle bar switch Q F E g optional flasher relay starter motor ttt D O kag KERSE BR s start button e re e re O regulator rectifier brake switch OO i in speed sensor C K 3 TI F amp o Cell SI Ku J 8 n driving light lamp L S front brake switch Gel m WS rear light brakelight headlight left rear flasher position light left front flasher ignition coil AUSRBERG Husaberg FE FS 06 08 wiring diagram main harness 800 11 075 500 25 02 2005 gt lt gt gt KE m
21. 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 FE or 20 mm FS Deviations of more than 2 mm can strongly influence the motorcy cle s performance 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 dimension 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 ENGLISH EXAMPLE Motorcycle jacked up dimensionA 600 mm Motorcycle on ground unloaded dimension B 565 mm Static sag 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 incre ased 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 protective
22. 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 spilled brake liquid must be rinsed off with water Mount the screw and fix the brake fluid reservoir to the frame always making sure to prevent kinks in the connecting hose WARNING Never use DOTS 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 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 N CAUTION Don t let brake fluid get in contact with paint it is an effective paint remover Use only clean brake fluid not older than six months taken from a tightly sealed container 39 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 less 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
23. headlight lamp parking light lamp 46 Compression damping of fork 16 C oling Syst m ues ee Se dete ee ed ene 47 Rebound damping of fork 16 Checking the coolant level nananana anaana aaa 47 Changing the spring preload on the telescopic fork 16 Bleeding the cooling system 48 Damping action during compression of shock absorber 17 Replacing the glassfiber yarn packing of the silencer 48 Rebound damping of shock absorber 18 Cleaning the spark arrester 48 Steering OCK arros E be Stews et t 18 Cleaning the air filter _ 49 Instructions for initial operation 19 Checking the adjustment of the hand decompression Running in the Husaberg models 19 release cable 49 Adjusting the throttle cables n anana a anaana 49 TIPS AND WARNINGS FOR STARTING THE Changing the original position of the clutch lever 50 MOTORCYCLE EE 19 Checking the oil level of the hydraulic clutch 50 Bleeding of the hydraulic clutch 50 DRIVINGINSTRUCTIONS 20 Carburetor Adjust idliing 51 Check the following before each start 20 Basic information on carburetor wear 51 Starting when the engine is cold 21 Adjusting the mixture control screw
24. 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 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 d CAUTION The setting ofthe 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 decom pressor ADJUSTING THE THROTTLE CABLES The throttle grip should always provide for a backlash of 3 5 mm Besi des 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 49 MAINTENANCE WORK ON CHASSIS AND ENGINE CHANGING THE ORIGINAL POSITION OF THE CLUTCH LEVER The adjusting screw 1 can be used for individual adjustment of the ori ginal positio
25. 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 cali per support with compressed air Check the sleeves of the guide bolts for damage and grease guide bolts if necessary 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 sli ding 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 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 REPLACING THE FRONT BRAKE PADS FS Remove the screw 3 Carefully press against the brake pads with a screw driver to move the brake pistons in their basic position Remove the brake pads from the brake caliper and clean the brake caliper thoroughly with compressed air Mount the brake pads mount the screw 3 and hold in place with the securing clip WARNING It is very important to keep the brake disk free from oil and fatty matters Otherwise the braking effect would be strongly reduced
26. spoke tension is very important for the stability of the wheels and thus for riding safety Aloose spoke causes the wheel to become unbal anced and before long other spokes will have come loose Check spoke tension especially on anew 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 Hus aberg 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 over loading The spokes must be tensioned to 5 Nm 43 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 homo logation certificate Tire condition has to be checked every time you want to ride your motor cycle Before leaving check tires for punctures and nails or other sharp objects that might 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
27. triple clamp with a rubber hammer to loosen the steering stem 5 out of the bearing seat Take the lower triple clamp with the steering stem out of the steering head 31 MAINTENANCE WORK ON CHASSIS AND ENGINE Remove the collar screw from the lower triple clamp and pull out the stee ring stem Thoroughly clean all parts Turn the steering stem 180 and insert it in the triple clamp Apply Loctite 243 to the thread of the collar screw 2 and turn all the way in WARNING Be sure to lock the thread on the collar screw 2 with Loctite 243 Grease the steering head bearing and sealing elements Mount the lower triple clamp protection ring adjusting nut upper triple clamp and the end screw Tighten the collar screw on the lower triple clamp to 60 Nm Mount the fork legs and tighten the clamp screws on the lower triple clamp to 12 Nm in 3 stages D Z G E U I Adjust the steering head bearing without clearance see Checking and adjusting the steering head support and tighten the clamp screws on the upper triple clamp to 17 Nm in 3 stages Mount the front wheel fender and tighten the screws to 10 Nm Mount the hand brake cylinder and tighten the screws to 10 Nm Connect the plug connector for the brake light switch and speedometer sensor and mount the headlight mask Mount the front wheel see Dismounting and mounting the front wheel AAAS 32 MAINTENANCE WORK ON CHASSIS AND ENGINE HOW TO CHA
28. you intend to run your motorcycle in idle or at a stand still for longer periods of time more than 2 minutes Avoid letting the clutch slip frequently and for exten ded periods This would cause the engine oil to heat up thereby heating up the cooling system You should drive at low 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 check 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 tem perature as soon as the radiators become warm A Never have the throttle wide open when changing down to a lower gear The engine will over rev dama ging 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 imme diately turn the engine off and contact an auth
29. 2 mm 0 08 in Tire pressure should be checked regularly on a cold tire Proper pres sure ensures optimum driving comfort and extends the life of your tires WARNING Do not mount tires which have not been appro ved 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 TIRES AIR PRESSURE same tread layout Use homologated tires For your own safety replace damaged tires immediately Offroad FE Worn tires can have a negative effect on how your motorcy cle performs especially on wet surfaces Road FE 1 5 bar 2 0 bar If air pressure is too low abnormal wear and overheating of Road FS 1 5 bar 2 0 bar the tire can result D Z G E U I 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 44 MAINTENANCE WORK ON CHASSIS AND ENGINE BATTERY The battery 1 is located in front of the shock absorber and is mainte nance free It is not necessary to check the electrolyte level or to add water Merely keep the battery poles clean and grease slightly with acid free grease if required WARNING If electrolyte sulphur
30. 3 12 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 WP Suspension 12457D02 2 turns Typ WP Suspension 12457D03 2 turns WARNING The damping unit of the shock absorber is filled with high compression nitrogen Never try to take the shock absorber apart or to do any maintenance work yours elf Severe injuries could be the result Never unscrew the black screw connection 3 24mm 17 OPERATION INSTRUMENTS REBOUND DAMPING OF SHOCK ABSORBER By using the adjusting screw 1 the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it coun terclockwise to reduce damping during rebounding 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 WP Suspension 12457D02 20 clicks Typ WP Suspension 12457D03 10 clicks WARNING The damping unit of the shock absorber is filled 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 2 15mm
31. 6 38 15 40 16 38 15 40 Chain 5 8x1 4 Available rear sprockets 38t 40t 42t 45t 48t 49t 50t 51t 52t Lighting Headlight HS1 12V 35 35W Parking light 12V 5W socket W2 1x9 5d Brake light 12V 21 5W socket BaY15d Turn signal 12V 10W socket Ba15s maintenance free battery 12V 7Ah Steering head angle 63 63 5 Wheel base 1490 10 mm 1481 10 mm Seat height unloaded 930 mm 870 mm Ground clearance unloaded 380 mm 320 mm ENGLISH STANDARD ADJUSTMENT FORK FE 450 550 650e 6 FS 450e 6 650e 6 650c 6 WP 4860 MXMA PA WP 4860 MXMA PA 14 45 7D 02 14 45 7D 03 19 20 Rebound adjuster 20 15 Spring 4 4 N mm 4 6 N mm Spring preload 2 turns 5 turns Airchamber lenght 105 mm 100 mm 4860 0401 Motorex 4860 0401 Motorex STANDARD ADJUSTMENT SHOCK ABSORBER FE 450 550 650e 6 FS 450e 6 650e 6 650c 6 WP 5018 PDS DCC WP 5018 PDS DCC 12 45 7D 02 12 45 7D 03 Compression adjuster 18 LS low speed 12 LS low speed 2 HS high speed 2 HS high speed Rebound adjuster 20 10 Spring 84 250 88 250 61 m Z G m r I TECHNICAL DATA CHASSIS TIGHTENING TORQUES CHASSIS Collar screw front wheel spindle M24x1 5 40 Nm Brake caliper front FE M8 Loctite 243 25 Nm Brake caliper front FS Collar screw brake pads front FS models only M10 40 Nm Brake discs Clamping screws upper fork bridge FS FE M6 M6
32. DE ODOMETER The SPEED ODO mode displays the speed and the total distance trave led The display automatically changes to the SPEED H display mode when the front wheel stops turning button no function button no function briefly press O button changes to the next display mode hold O button 3 secs changes to the next display mode The electronic speedometer has a number of display modes functions that you can also activate reveal see Activating and deactivating dis play modes OPERATION INSTRUMENTS ACTIVATING AND DEACTIVATING DISPLAY MODES In the display mode SPEED H press and hold the O button for 3 seconds to access the SETUP menu The active functions will be displayed The blinking function can be activated by pressing the button and deacti l vated by pressing the button Km h Mph ODOSMAX lt LAP CLK H Press and hold the O button 3 seconds to store the settings ZA If no button is pressed for 20 seconds the setting will be stored automa tically and the display will return to the SPEED H mode T TR2 Al A2 St 82 button activates the blinking display button deactivates the blinking display briefly press O button changes to the next display without changing any settings hold O button 3 secs starts the SETUP stores the settings and changes to the SPEED H mode T The following display modes can be activated O TR1 tripmaster 1 TR2 tripmaster 2 IT A1 average speed 1 dy A2 av
33. Engine stops or backfires in the car buretor Engine gets too hot High oil consumption Shortage of fuel Engine drawns in unmetered air Not enough cooling liquid in the cooling system Incorrect carburetor jetting Not enough air stream Cooling system not ventilated Radiator fins are heavily soiled Foam has formed in the cooling system Bent radiator hose Bent engine ventilation hose Engine oil level is too high Engine oil is too thin 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 coo ling system for tightness Check the carburetor jetting and correct if necessary see Basic Carburetor Setting 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 All of the switched on lights are bur ned out The voltage regulator is defective Have the voltage regulator checked Horn turn signal and starter do not work Fuse in the starter relay is blown Renew the fuse Battery is dead Battery is not being charged by the Check the connections on the voltage regulator have the generator volta
34. FE 450e 6 FE 450e 6 FS 450e 6 EU AUS UK USA EU Type of carburetor Keihin FCR MX 39 Keihin FCR MX 39 Keihin FCR MX 41 Carburetor ID number 3925C 3925C 4125D Main jet 178 OBDVT OBDVR OBDVT OBDVT 38 38 Jet needle Idling jet Main air jet 200 200 Idle air jet 100 100 Needle 2nd from top 6th from top 2nd from top 2nd from top Starting jet 85 8 l Sp Mixture control screw open 1 5 2 1 5 Slide 15 15 Restriction slide stop slide stop Pump diaphragm stop 858 2 15 mm 858 2 15 mm 858 2 15 mm Hot start knob 2 2 5 mm TECHNICAL DATA ENGINE Design Liquid cooled 1 cylinder 4 stroke Otto engine with balancer weight Displacement 549 8 cc 628 3 cc Bore Stroke 100 70 mm 100 80 mm Ratio 11 8 1 11 8 1 Fuel unleaded fuel with at least RON 95 USA Premium PON 91 Valve timing 4 valves controlled over rocker arm and 1 camshaft camshaft drive with single chain Valve diameter Intake 35 mm Valve diameter Exhaust 30 mm Valve clearence cold Exhaust 0 12 mm Crank shadt bearing 2 roller bearings Connecting rod bearing needle bearing L Top end bearing bronze bush dp Piston rings 1 compression ring 1 oil scraper ring D Engine lubrication pressure lubrication with trochoid rotor pump Za Engine oil fully synthetic engine oil Motorex Power Synt 4T SAE 10W50 LLI Primary ratio straight toothed spur wheels 29 78t Clutch multi disk clutch in oil ba
35. G OF FORK Hydraulic compression damping determines the reaction when the fork is compressed The degree of compression can be adjusted with adjus ting screws at the bottom of the fork legs Remove the protecting cap 1 Turn the adjusting screws 2 clockwise to increase damping turn it coun terclockwise to reduce damping during compression mn Z G m r I 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 WP Suspension 14457D02 19 clicks Typ WP Suspension 14457D03 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 rebound can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during rebounding 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 WP Suspension 14457D02 20 clicks Typ WP Suspension 14457D03 15 clicks CHANGING THE SPRING PRELOAD ON THE TELESCOPIC FORK The telescopic forks of these models come with a preload adjuster for easy adjustment of the spring preload You can adjust the spring preload 9 mm by turning the adjusting screws basic position middle position
36. NGE 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 handle bar in 4 different positions For this purpose remove screws 3 of the handlebar clamps and screws 4 of the handlebar support Position the handlebar support and tighten screws 4 to 40 Nm Mount handlebar and handlebar clamps and tigh ten 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 CN WARNING The screws 4 must be secured with Loctite 243 ENGLISH 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 above the adjusting ring One rotation of the adjusting ring 5 changes the spring pretension by approximately 1 mm 0 04 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 counter clockwise
37. RES Check for damaged tires Tires showing cuts or dents must be repla ced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure deterio rate the driving performance 5 BRAKES Check correct functioning of the braking system Check for sufficient 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 braking system or com pletely worn out brake pads Arrange for the braking system to be che cked by a Husaberg specialist as complete failure of the braking sys tem 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 faste ned 10 REAR MIRROR Checking the rear mirror setting 20 DRIVING INSTRUCTIONS STARTING WHEN THE ENGINE IS COLD Open the fuel taps 1 Swing up the si
38. S models HH collar screws on pulse generator M5 Loctite 243 10 Nm Loctite 243 6 Nm HH collar nut on rotor M12x1 60 Nm HH screw on kickstarter Loctite 243 25 Nm Phillips screws on kickstarter release plate Loctite 243 6 Nm HH collar screw on shift lever M6 10 Nm Spark plug M12x1 25 20 Nm Plug on engine blocking bore 20 Nm Diaphragm valve Loctite 243 1 5 Nm 60 TECHNICAL DATA CHASSIS CHASSIS FE 450 550 650e 6 FS 450 650e 6 FS 650c 6 Frame tubular chrome molybdenum steel frame powder coated Fork WP Up Side Down 4860 MXMA PA Spring travel front rear 295 320 mm 275 288 mm Rear suspension WP Progressive Damping System shock absorber aluminum rear swinging fork Front brake 260 mm brake disk floating brake caliper 310 mm radial brake caliper Brake disk front minimum thickness 2 5 mm minimum thickness 4 5 mm Rear brake Disk brake perforated 220 mm brake disk floating brake caliper Brake disk rear minimum thickness 3 5 mm minimum thickness 4 5 mm Front tire 90 90 21 120 70 17 12 60 17 Air pressure off road 1 0 bar Air pressure on road alone 1 5 bar 1 5 bar 1 5 bar Rear tire 140 80 18 150 60 17 16 63 17 Air pressure off road 1 0 bar Air pressure on road alone 2 0 bar 2 0 bar 2 0 bar Fuel tank capacity FE 9 liters 7 5 liters EU FS 7 5 liters Gear ratio rear wheel 16 40 14 48 15 48 15 45 1
39. S1 no function no function next display mode clears TR1 S1 A1 SPEED S2 starts stops S2 no function X X X X X next display mode clears S2 If the CLK LAP MAX TR1 TR2 A1 A2 S1 and S2 figures are suddenly cleared the battery in the electronic speedometer is empty and must be replaced see Replacing the battery in the electronic speedometer A tripmaster switch is available as an accessory that lets you control the electronic soeedometer functions from the handlebar 13 O lt Tr OPERATION INSTRUMENTS FILLER CAP To open the filler cap Turn the filler cap counter clockwise 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 The fuel tap is closed in this position No fuel can flow to the carburetor ON Turn the twist grip in the ON position to operate the motorcycle Now fuel can flow to the carburetor The tank will drain completely in this position mn Z Q r I A threaded fuel tap 1 is also located on the left side No fuel can flow to the carburetor if it is screwed in Fuel will flow to the carburetor if the fuel tap is screwed out NOTE No RES function is available 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 additio nal fuel The result is a fat
40. SABERG 5230 MATTIGHOFEN AUSTRIA ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL by HUSABERG cl N O lt Tr 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 associations Observance of the service maintenance and tuning instructions for the engine and chassis specified 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 chas sis components see chapter on checking the basic chassis setting The service work described in the Lubrication and maintenance chart must be carried out and confirmed by an authorized Husaberg dealer otherwise your warranty will become void The fuels and lubricants specified in the Owner s Manual or fluids with equivalent specificati ons must be used in accordance with the maintenance schedule m Z G m Q I 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 ter rain can lead to higher than average wear on components su
41. age speed based on the TR2 tripmaster 2 and S2 stop watch 2 figures The displayed figure can deviate from the actual average speed if the TR2 figure was changed manually or if S2 was not stopped after the trip mn Z r I button no function button no function briefly press O button changes to the next display mode hold O button 3 secs changes to the next display mode SPEED S1 DISPLAY MODE STOP WATCH 1 S1 shows the traveling time based on TR1 and continues to run whene _ S ER ver it receives impulses from the wheel sensor The calculation of this figure WI H i IH ed is activated by the first impulse received from the wheel sensor and stops gt lt a lt a 3 seconds after the last impulse is received SPEED Km h button no function button no function briefly press O button changes to the next display mode hold O button 3 secs clears the TR1 S1 A1 figures SPEED S2 DISPLAY MODE STOP WATCH 2 S2 is a manual stop watch Start the stop watch by pressing the but ton press again to hold Press again to continue timing Press the O button to change to the next mode The S2 display will blink in the other modes if S2 continues to run in the background To stop S2 return to the SPEED S2 mode and press the button button starts and stops the stop watch button no function briefly press O button changes to the next display mode hold O button 3 se
42. an 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 TELESCOPIC FORK The precise riding sag of the telescopic fork cannot be determined for various reasons Similar to the shock absorber smaller deviations 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 m Z G m Q I CHANGING THE SPRING PRELOAD ON THE TELESCOPIC FORK see page 16 LLII LTKT i ll lla REPLACING FORK SPRINGS If you weigh less than 75 kg or more than 85 kg you should install the for example FE 450 550 650 respective fork springs The correct spring rate is shown in the illustra tions 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 C O According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be gt reduced by a few clicks for a softer spring or increased by a few clicks for 65 70 75 80 85 90 95 a harder spring RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM MODELL SOFTER STANDARD HARDER 14457D02 FE 450 550 650 4 2 Nmm 4 4N
43. ared if no button is pressed for 1 minute or no impulse is received from the wheel sensor The O button is used to change between display modes The and buttons are used to control various functions LI lt SED mn OPERATION INSTRUMENTS Mel m TR2 M M St 2 All of the display segments briefly light up for the display function test LAP g Pata tate a HL OO OO 00 SPEED WS Km h Mph Miles ODO MAX LAP CLK H WS WHEEL SIZE The display changes and the circumference of the front wheel is briefly displayed in millimeters 2205 mm corresponds to a front wheel circum ference of 21 with production tires Afterwards the display will return to the previous display mode ENGLISH SPEED DISPLAY MODE H SERVICE HOURS Only the SPEED H and SPEED ODO display modes are activated in Z the condition at delivery SPEED H is displayed whenever the display is N I H d activated and the front wheel is not turning It automatically changes to SPEED ad ea ee the SPEED ODO display mode as soon as the front wheel starts turning Km h H SPEED displays the speed H displays the engine s service hours The service hour counter starts to count as soon as you start the engine The displayed figure cannot be changed Service intervals are indicated in service hours for some Husaberg offroad motorcycles making the service hour counter a very practical function SPEED ODO DISPLAY MO
44. arz ye gelb bu blau gn grun re rot wh wei br braun or orange pi rosa gr grau pu violett bl noir ye jaune bu bleu gn vert re rouge wh blanc br brun or orange pi rose gr gris pu violet munication Photos Joachim Sauer 06 2007 ART NR 3802013 ELUA 4 4 STROKE FORCE FORCE HUSABERG a part of the KTM Group Stallhofner Stra e 3 A 5230 Mattighofena E mail info husaberg cc Internet www husaberg cc
45. bolts for tightness Check carburetor connection boot for cracks and leaks Check idle speed setting E A E E E Check cooling system for leaks check quantity ofantteeze T e e Check exhaust system for leaks and fitment e E S e Check fluid level of the clutch master cylinder E asss Check electro wires fordamageandbends e Check headlamp setting CARBURETOR 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 BRAKES Check function and smooth operation and adjust free travel of handbrake foot brake lever Check tightness of brake system screws Check shock absorber and fork for leaks and function Clean fork dust bellows lt Check swing arm bearings iss EE Check tightness of chassis screws triple clamps fork leg axle passage Check okt tension and rim joint a Checktresandairpresue OOOO O e e m Check chain chain joint rear sprockets and chain guides for wear fit and tension Lubricate chain Check clearance of wheel bearings o IMPORTANT MAINTENANCE WORK THAT MUST BE CARRIED OUT BY EXTRA ORDER at least once a year Complete maintenance of fork e Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Clean and adjus
46. ce or element of design has been removed or rendered ino perative by any person HUSABERG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATIONS COLORS MATERIALS SERVICES OFFERED AND RENDERED AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT PREVIOUS ANNOUNCE MENT 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 ae 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 appropriately Before you go for your first ride be sure to read this manual carefully and thoroughly in order to fami liarize 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 impor tant 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 ru
47. ces and that the fuel tap is in the OFF position if the motorcycle should fall over no fuel can leak from the car buretor 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 down 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 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 backward 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 Tighten the steering head nut to 20 Nm and the 4 clamping screws to 17 Nm 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 If the steering head nut is not tightened to
48. ch as the drive train or the bra kes In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached 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 these models are only allowed to be driven off road and not on public roads The FE models are desi gned for off road sports endurance competitions enduro and not suitable for predominant motocross use MODELS FS The FS models are only allowed on public roads in the original homologated throttled ver sion Without this performance restriction i e dethrottled these models are only allo wed 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 e h In accordance with the international quality management ISO 9001 stan TUV dard Husaberg uses quality assurance processes that lead to the hig leger best 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 cl O lt Tr OPERATION INSTRUMENTS
49. ck all of the plugs and the oil filter cover for leakage Finally check the engine oil level and correct if necessary 54 TROUBLE TROUBLESHOOTING CAUSE REMEDY Engine doesn t crank E starter Engine cranks but doesn t start E starter Engine will not start Kickstarter Engine fails to idle Operating errror Blown fuse Discharged battery Low outside temperature Operating error The motorcycle has been out of operation for a longer period of time Therefore old fuel has accumulated in the float chamber Fuel supply interrupted Flooded engine 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 igni tion coil has oxydized Water in carburetor or jets blocked Glogged idling jet Incorrect adjustment of adjusting screws on carburetor Defective spark plug Defective ignition system 55 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 discharg ing contact a Husaberg dealer Start the engine with the kickstarter Open fuel tap tank fuel actuate choke Pay attention to start ing information see driving instructions
50. cs clears the S2 figure 12 OPERATION INSTRUMENTS KILOMETERS OR MILES The unit kilometers or miles can also be changed The ODO figure will be retained and converted accordingly The TR1 A1 S1 TR2 andA2 figu res will be cleared To select the unit select the SPEED H mode and hold the O button for 3 seconds to access the SETUP menu Press the O button until the KMH MPH function blinks Press the button briefly to move to the options Press the button for KMH or the button for MPH To set briefly press the O button 1 x and hold for 3 seconds until the dis play returns to the SPEED H mode If no button is pressed for 20 seconds the setting will be stored automa tically and the display will return to the SPEED H mode button to access the menu to activate the KMH display button to activate the MPH display briefly press O button changes to the next mode changes from the menu to the SETUP menu hold O button 3 secs stores and closes the SETUP menu SETTING THE CLOCK To set the clock switch the ignition off and select the SPEED CLK mode Press and hold the O button for 3 seconds The blinking digits can be changed using the and buttons Press the O button to move to the next digit 0 12 will show the time in the 12 hour mode 0 24 in the 24 hour mode Press and hold the O button for 3 seconds to store the settings If no button is pressed for 20 seconds the settings will be stored auto matically an
51. d the display will return to the SPEED CLK mode time time changes to the next digit starts the SETUP menu stores the time and changes to the SPEED CLK display mode button button briefly press O button hold O button 3 secs TRI TR2 Al A2 St 82 o e Gm Mph lt ANNAN UDO MAX LAP CLK H OVERVIEW OF THE ELECTRONIC SPEEDOMETER FUNCTIONS Motorcycle is driving display briefly press button briefly press button briefly press O button hold O button 3 secs gt lt Motorcycle is standing SPEED H no function no function gt x SPEED starts stops LAP without LAP clearing LAP figure SPEED ODO no function no function next display mode displays the SETUP menu X X SPEED CLK no function no function next display mode Setting the clock menu stops LAP stores LAP figure resets LAP to 0 LAP LAP next figure no function next display mode next display mode X SPEED MAX no function no function next display mode next display mode clears all LAP figures clears MAX next display mode next display mode SPEED TR1 no function no function next display mode clears TR1 S1 A1 SPEED TR2 A A A increases the TR2 figure A SPEED A2 no function no function reduces the TR2 figure SPEED A1 no function no function next display mode clears TR1 S1 A1 next display mode clears TR2 next display mode next display mode SPEED
52. de 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 OO Q N WARNING If you want to start the engine make sure that you always put on sturdy motorcycle boots in order to avoid inju ries 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 ope ning 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 cons ciousness and death Always provide adequate ventilation while the engine is running Always verify that the transmission has been set to idle neu tral before actuating the starter button If you start the motorcycle with a gear engaged the motorcycle will move forward cl N O lt Tr 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 lt NOTE If it is difficult to start the engine this co
53. djust the idle speed DRAINING THE FLOAT CHAMBER OF THE CARBURETOR Following every wet cleaning procedure the float chamber of the carbu retor should be drained in order to remove any water that may have pene trated 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 escaping fuel Unscrew the plug 2 and clean it with compressed air Mount the plug and gasket and tighten to 4 Nm open the fuel tap and check the float chamber for any leaks D Z G E U I lt NOTE Fuel is easily flammable and toxic When handling fuel be sure to exercise the utmost caution Never perform 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 satura ted 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 INTERCEPTING TANK FOR THE CARBURETOR VENTILATION To prevent fuel from running out after a fall mount the intercepting tank included for racing purposes Screw the intercepting tank 3 to the bot tom of the frame crossrail using the clamp and HH collar screws A drain plug is located on the bottom to drain the tank OIL CIRCUIT The oil pump 4 draws the en
54. don t put off having your brake pads changed 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 om Z Q r I 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 40 MAINTENANCE WORK ON CHASSIS AND ENGINE 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 clamp
55. e 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 does not overflow The bleeder syringe can be purchased from your Husaberg dealer Having completed the bleeding procedure you have to verify that the oil level in the master cylinder is correct If necessary fill up with biodegradable hydraulic oil SAE 10 e g Motorex Kupplungs Fluid 75 Biodegradable hydraulic oil is available from your Husaberg dealer 50ml 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 50 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 t
56. e front wheel has stopped The TR1 A1 and S1 figures are automatically cleared after passing 999 9 button no function button no function briefly press O button changes to the next display mode hold O button 3 secs clears the TR1 S1 A1 figures SPEED TR2 DISPLAY MODE TRIPMASTER 2 The tripmaster 2 is always active and counts to 999 9 Contrary to TR1 the displayed figure can be changed using the and buttons This is a very useful function for trips taken according to a roadbook button increases the TR2 figure button decreases the TR2 figure briefly press O button changes to the next display mode hold O button 3 secs clears the TR2 figure 11 LAP SPEED SPEED W CU LIT 200 L LU 27 LAP e gt E Li I m I Km h MAX _ e TRI Lt 20 3 CX I 3 3 Km h Fa TR el 07 L LA 20 Km h cl Hi O lt Tr OPERATION INSTRUMENTS SPEED A1 DISPLAY MODE AVERAGE SPEED 1 A1 shows the average speed based on the TR1 tripmaster 1 and S1 stop watch 1 figures 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 button no function button no function briefly press O button changes to the next display mode hold O button 3 secs clears the TR1 S1 A1 figures SPEED A2 DISPLAY MODE AVERAGE SPEED 2 A2 shows the aver
57. e 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 chain tensioner tooting for damage visual check Check the eccentricity of the crankshaft journal e Replace the conrod bearings e e e 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 26 PERIODIC MAINTENANCE SCHEDULE 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 SPECIA LIZED HUSABERG DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUA LIFIED SKILLED STAFF d CAUTION If using a power washer do not point the water jet at the electric components plugs cables bearings car buretor etc The high pressure will cause water to penetrate into the components and can cause them to malfunc tion or lead to premature wear When transporting your Husaberg ensure that it is held upright with restraining straps or other mechanical fastening devi
58. e sure the side stand is folded all the way up before driving off The motorcycle can go out of control if the side stand touches the ground SHIFTING RIDING You are now in first gear refered to as the drive or uphill gear Depen ding on the conditions traffic hill size etc you can shift to a hig her gear Close throttle at the same time pull clutch lever in and shift to the next higher gear Let clutch lever go again and acce lerate If you turned on the choke make sure you turn it off again as soon as engine is warm When you reach full speed through opening the throttle all the way turn throttle back to 3 4 the speed hardly decreases 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 NOTE Dedicated to nothing but offroad racing Hus aberg 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 ergo nomics In normal racing the cooling system is suffi cient If you use your motorbike in other conditions please note that the E starter allows you to start FS models again at any time Therefore turn off the engine if
59. em looked over by a Husaberg dealer 22 DRIVING INSTRUCTIONS 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 emergency off switch until the engine is off 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 become 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 d CAUTION Do not use the hand decompressor lever to switch off the engine Always use the short circuit switch the emer gency off 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 ES 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 For off road riding you can use the rubber band to additionally secure the center stand in its folded up position ENGLISH J CAUTION The side stand is designed to bear only t
60. erage speed 2 T S1 stop watch 1 S2 stop watch 2 CLK clock LAP lap time MAX maximum speed KMH MPH display in kilometers or miles see Kilometers or miles If you have activated all of the display modes they will be displayed in the following order SPEED H SPEED CLK SPEED LAP LAP LAP SPEED MAX SPEED ODO SPEED TR1 SPEED TR2 SPEED A1 SPEED A2 SPEED S1 SPEED S2 SPEED CLK TIME DISPLAY MODE _ CLK displays the time in hours minutes and seconds CC Dafa a fad button no function SPEED lt a LUC A button no function Km h CLK briefly press O button changes to the next display mode hold O button 3 secs set the clock menu To set the clock see Setting the clock SPEED LAP LAP TIME DISPLAY MODE You can use the manual stop watch to stop and store up to 10 lap times mm lt which you can view in the LAP LAP display mode see below H IS JH RI LAP displays the lap times in hours minutes and seconds mm Se lt lt e LIP button Starts and stops the stop watch lap time is not reset to 0 button Stops the stop watch stores the lap time and restarts the stop watch again The time is reset to 0 Atotal of 10 lap times can be stored If the lap time continues to run after you press the button all 10 memory locations are occupied To clear all of the stored lap times hold the O but ton for 3 seconds in the SPEED LAP mode Up to 10 lap times can be stored in this way
61. ge regulator checked at an authorized workshop 56 CLEANING CONSERVATION STORAGE CLEANING 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 If using a power washer do not point the water jet at the electric components plugs cables bearings carburetor etc The high pressure will cause water to penetrate into the components and can cause them to mal function or lead to premature wear You should use normal brand 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 war ming 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 g
62. gine oil from the oil sump through the oil screen 5 and pumps it past the pressure relief valve 6 to the oil filter 7 It continues to the crankshaft 8 partly branching off through a hole to lubricate and cool the piston 9 and the piston pin bearing Once through the crankshaft the engine oil is pumped to the conrod bearing 10 and branches off again to the bearings in the balance weight 11 The camshaft 12 is lubricated by the engine oil which is transported to the cylinder head by the timing chain 13 On the downward movement of the piston engine oil is pressed from the crankcase through the diaphragm valve not depicted to the transmis sion and shift mechanism 52 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 horizontal 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
63. he 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 connection 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 ENGLISH om Z Q m r I Engine won t rev up TROUBLESHOOTING Carburetor overflows because the float needle is soiled or worn Loose carburetor jets Electronic ignition advance is defective Disassemble the carburetor and check for wear Tighten the jets Have the ignition system checked Engine does not have enough power Fuel supply is interrupted or the car buretor soiled Air filter is heavily soiled Exhaust system is not tight defor med or there is not enough glass fiber yarn in the silencer Valve clearance is too small Compression loss due since hand decompression lever is inadequa tely adjusted Electronic ignition advance is defective 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 Have the ignition system checked
64. he 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 date engine 2 Warm up the engine 3 Use the adjusting wheel 1 to set the normal idle speed 1400 1500 rpm 4 Turn mixture control screw 2 slowly clockwise until idling speed starts to decrease Memorize this position and turn mixture control screw slowly counterclockwise until the idling speed decreases again Adjust the point of the highest idling speed between these two posi tions If in the course of this procedure the speed undergoes a rela tively 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 cl O lt Tr lt NOTE If you fail to obtain a satisfying result by following the procedure described above an incorrectly dimensioned 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 smal ler 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 adju sting
65. he 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 PON 91 CAUTION Use leaded or unleaded premium grade gasoline 95 octanes Never use gasoline having less than 95 octa nes because it may damage the engine WARNING Gasoline is highly flammable and poisonous Extreme caution should be used when handling gasoline Do not refuel the motorcycle near open flames or burning ciga rettes Always switch off the engine before refuelling Be careful not to spill gasoline on the engine or exhaust pipe while the engine is hot Wipe up spills promptly If gasoline is swal lowed or splashed in the eyes seek a doctor s advice imme Wi diately SA SSS NJ ee Ro Fuel expands when its temperature rises Therefore do not fill the tank to EXE AN the top see fig 23 m Z Q E U I v lt lt 7 Q el st PERIODIC MAINTENANCE SCHEDULE FE 450 550 650 FS 450 650 1 service after after every A clean motorcycle can be checked more quickly which saves money 3 hours or 15 hours 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 ENGINE Check engine mounting
66. ic acid leaks from the bat tery 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 consult a doctor The battery is a closed model but can nevertheless emit explosive gases Avoid sparks and open fire near the battery Defective batteries must be stored out of the reach of child ren Ensure proper disposal of discarded batteries d 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 cl N O lt Tr 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 Charge the battery every 3 months CHARGING THE BATTERY The battery discharges every day even if it is not used Always disconnectthe battery when charging Charge the battery as des cribed in the instructions 3 on the battery housing Do not exceed the amperage and charging time Quick charging at a high amperage has an adverse effect on the service life Always use special charging devices to charge maintenance free batte ries e g the charging device item no 58429074000 You can also use this charging device to test the off load vo
67. ing 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 damaged 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 cl N O lt Tr 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 tigh ten 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 15 Nm WARNING If you don t happen to have a torque wrench at hand make sure you have the tightening torque corrected 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 press
68. is changed or at least once annually For this purpose dismount the silencer cap and remove any deposits that might exist in region B Renew the O ring and mount the silencer cap AKA KAT ORF SOR ee d Se SST T ee ee RRIS 48 MAINTENANCE WORK ON CHASSIS AND ENGINE CLEANING THE AIR FILTER The air filter must be cleaned prior to every race or depending on the accu mulation 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 maintenance Motorex Bio Dirt Remover Motorex Liquid Bio Power 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 ol Check the carburetor connection boot for damage and a good fit Mount the air filter on the filter support Attach the air filter and filter sup port to the frame making sure it is centered and fix with the wing screw cl Hi O lt Tr CHECKING THE ADJUSTMENT OF THE HAND DECOMPRESSION RELEASE CABLE Start the engine and at idling speed slowly pull the hand decompression
69. k or the brake pads are completely worn In this case consult an authorized Husaberg dea ler 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 recommend 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 product is purple red The gaskets and brake hoses of Husaberg motor cycles are not designed for DOT 5 brake fluid CN WARNING Have the brake fluid changed at least once annually Ifyou 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 36 MAINTENANCE WORK ON CHASSIS AND ENGINE CHANGING THE BASIC POSITION THE HAND BRAKE LEVER FE Free travel at the hand brake lever may be readjusted by using adjust ment screw 1 In this way the position of the point of pressure e g the resistance you feel on the hand brake lever when the brake pads are pres sed 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
70. le 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 secu red 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 permissible laden weight is comprised of the following components 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 components 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 capa city 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 ter rain road easy off road trails CAUTION The Husaberg models were uncompromi singly designed for off road competition purposes only On the road approved models FE FS are only allowed on public roads in the
71. led out howe ver 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 The work marked with an in the chapter Servicing the chassis and engine must be perfor med by an authorized Husaberg dealer If such service work becomes necessary during a competition it must be performed by a trained mechanic 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 res pect the rights of others We wish you a lot of fun when driving HU
72. linker hinterer Blinker Lichtschalter Multifunktionsdigitaltacho Bouton de clignotants Systeme de clignotants Contacteur de frein avant Alternateur Contacteur au guidon pour ordinateur de bord Phare Contacteur code phare Avertisseur sonore Bouton d avertisseur sonore Bobine d allumage Contacteur d allumage Clignotant avant gauche Clignotant arriere gauche Contacteur d clairage Ordinateur de bord Pick up Position light Rear brake switch Rear light brakelight Regulator rectifier Right front flasher Right rear flasher Speed sensor Start relay Start stop button Impulsgeber Begrenzungslicht hinterer Bremslichtschalter hinteres Begrenzungslicht Bremslicht Regelgleichrichter rechter vorderer Blinker Rechter hinterer Blinker Geschwindigkeitssensor Startrelais Start Stop schalter Capteur d allumage feu de position Contacteur de frein arri re Feu rouge stop R gulateur redresseur Clignotant avant droit Clignotant arri re droit Capteur de vitesse Relais de d marreur Contacteur start stop Starter motor Temperature switch Throttle position sensor TPS CABLE COLOURS KABELFARBEN Startermotor Temperaturschalter Vergaserpotentiometer Demarreur Contacteur de temp rature Capteur d ouverture de carburateur COULEUR DE CABLE bl black ye yellow bu blue gn green re red wh white br brown or orange pi pink gr grey pu purple bl schw
73. ltage and startability of the bat tery and generator It is impossible to overcharge the battery with this device Charge the battery immediately if it is empty when you start the motor cycle If left to stand in an uncharged condition for a longer period of time the battery will run down and sulfatize destroying the battery Recharge the battery every 3 months if it is being stored for a longer period of time CAUTION Never remove the closure 2 since it will be damaged To avoid damage to the on board electronic system always disconnect the minus pole before you charge the battery To charge connect the battery to the battery charger before you switch on the battery charger When the battery is char ged switch off the battery charger before you disconnect the battery Provide adequate ventilation when charging the battery in a closed room the battery emits explosive gases when charging Electrolytes will escape through the safety valves if the bat tery is charged too long or at an excessive voltage or ampe rage This will reduce battery capacity Try to avoid quick charges 45 MAINTENANCE WORK ON CHASSIS AND ENGINE FUSE The fuse 1 is located in the electric starter relay 2 above the battery 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
74. ly a 100 liter fuel consumption is equivalent to approx 15 operating hours 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 S of the valve springs Check the spring cap for wear 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 E the conrod ng Replace the balancer shaft Replace the balancer shaft bearings 1 Replace the crankshaft main bearings Check the entire transmission including the roller and bearings for wear 25 m Z G m r I PERIODIC MAINTENANCE SCHEDULE INSPECTION OF THE HUSABERG ENGINES USED FOR ENDURO COMPETITIONS BY YOUR HUSABERG WORKSHOP ADDITIONAL ORDER FOR THE HUSABERG WORKSHOP 15 30 135 hours hours hours 100 liter 200 liter 900 liter a 100 liter fuel consumption is equivalent to approx 15 operating hours Check the clutch disks for wear Check the length of the clutch springs Check the cylinder and piston for wear Check the groove on th
75. meter 3 8 mm diameter 3 8mm diameter 3 8 mm diameter 2 5 mm m Z Q P r I TECHNICAL DATA ENGINE DATA ENGINE HH collar screws on housing clutch cover ignition cover Oil drain plug M12x1 5 HH plug oil screen M20x1 5 AH collar screw on oil filter cover M5 6 Nm Plug on pressure relief valve M12x1 5 20 Nm HH screws on oil pump cover Loctite 243 5 Nm HH collar screw on cylinder head top section 10 Nm AH screws on valve cover 6 Nm HH collar screws on water pump cover M6 10 Nm HH screws on cylinder head M10 50 Nm HH screw on cylinder head 10 Nm AH screws on camshaft gear Loctite 243 28 Nm HH nut on automatic decompression stop M5 Loctite 270 8 Nm AH screws on rocker arm shaft silencer cap M5 Loctite 243 6 Nm Counternut on valve adjusting screw M6x0 75 11 Nm HH nut on primary pinion M16x1 Loctite 2701 110 Nm HH nut on idler shaft gear M16x1 Loctite 2701 110 Nm HH nut on clutch drive M18x1 5 Loctite 243 120 Nm HH collar screws on clutch springs Loctite 243 8 Nm AH screw shift on shift roller lock Loctite 243 10 Nm HH collar screw on locking lever HH collar screw on shift roller bearing M6 Loctite 243 10 Nm Loctite 243 10 Nm HH collar screws on chain tensioner HH screw chain tensioning rail M6 10 Nm Loctite 243 6 Nm HH screw on chain guide rail Loctite 243 6 Nm HH collar screws on stator FE F
76. mm 4 6 N mm 14457D03 FS 450 650 44N mm 4 6N mm 4 8 N mm 30 MAINTENANCE WORK ON CHASSIS AND ENGINE CHANGING THE FORK OFFSET CASTER The fork offset A in these models center fork legs center steering head angle can be changed This allows you to optimize the handling to match the race course You can see which offset is preset when you remove the end screw 1 If the flat area B is in the rear the offset is 16 mm FS or 20 mm FE This setting will improve driving stability on fast race courses If the flat area B is in the front the offset is 18 mm FS or 22 mm FE This setting will improve the handling in curves The offset is set to 16 mm FS or 22 mm FE in the condition at delivery ENGLISH To adjust the offset dismount the front wheel and remove the front wheel fender Remove the headlight mask and disconnect the plug connector from the brake light switch and speedometer sensor Remove the clamp screws on the hand brake cylinder and fasten the hand brake cylinder to the left fork leg with a cable tie to keep the brake line from kinking see illustration Loosen the clamp screws and take the fork legs out of the triple clamps Loosen the collar screw 2 on the lower triple clamp 2 turns Remove the end screw 1 from the upper triple clamp and rest the upper triple clamp on the tank Remove the adjusting nut 3 and protection ring 4 Tap gently on the lower
77. 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 stron gly reduced Tighten the collar nut with the required torque A loose wheel spindle may lead to an unstable behavior of your motorcycle 42 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 rubbers 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 spro cket 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 cl Hi O lt Tr CAUTION If the shock absorption rubbers are not replaced in good time the rear sprocket carrier and the rear hub will be damaged Allways replace all 6 absorption rubbers never single rubbers CHECKING SPOKE TENSION The correct
78. n of the clutch lever thus allowing adjustment to an optimal position for every hand size Turning the adjusting screw counterclockwise reduces the distance between the clutch lever and the handlebar Turning the adjusting screw clockwise increases the distance between the clutch lever and the hand lebar 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 rub ber 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 Moto rex Kupplungs Fluid 75 Biodegradable hydraulic oil is available from your Husaberg dealer 50ml D Z G E U I 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 BLEEDING OF THE HYDRAULIC CLUTCH To bleed the cover of the master cylinder of the clutch needs to be removed For this purpose remove screws 2 and take off cover 3 toget her with rubber bellows 4 At the slave cylinder of the clutch remove the bleeder nipple 5 In its plac
79. nd 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 automatic decom pressor 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 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 set clock Fill up tank with fresh fuel Check motorcycle as before each start See driving instructions Take a short careful test ride first 57 ENGLISH TECHNICAL DATA ENGINE ENGNE TCS ABO Design 1 cylinder 4 stroke engi
80. nd is mounted on the left por tion 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 cl Hi O lt Tr a Flasher left gt Flasher right HEADLAMP SWITCH USA In this model the headlamp is switched on with the pull switch 4 INDICATOR LAMPS The green control lamp 5 flashes in the same rhythm as the flashing indicator when the indicator is working The blue control lamp 6 lights up when the high beam is on D Z G E U I OPERATION INSTRUMENTS STARTER BUTTON G Pushing the black starter button 1 will actuate the E starter EMERGENCY OFF SWITCH AUSTRALIA The red emergency OFF switch 2 is arranged adjacent to the throttle grip C In this position the E starter is operational and the engine can be started Gi In this position the E starter and ignition circuits are interrupted The E starter cannot be actuated and the engine will not start not even if you attempt to start it with the kickstarter G Pushing the black starter button 3 will actuate the E starter ELECTRONIC SPEEDOMETER The display in the electronic speedometer is activated as soon as you press a button on the speedometer or an impulse is received from the wheel sensor The display lights up when the engine is running The display is cle
81. ne with balancer shaft liquid cooled Displacement 449 2 cc Bore Stroke 100 57 2 mm Ratio 13 1 Fuel unleaded fuel with at least RON 95 USA Premium PON91 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 Valve clearence cold Exhaust 0 12 mm Crank shaft bearing 2 cylinder roller bearing Connecting rod bearing needle bearing Top end bearing bronze bushing alluminium alloy forged Piston rings 1 compression ring 1 oil Scraper ring Engine lubrication pressure circulation lubrication with two rotor pumps Eingine oil full synthetic oil Motorex Power Synt 4T SAE 10W50 Quantity of engine oil 1 0 liter Primary ratio straight geared spur wheels 29 78 Z Clutch mult disc clutch in oil bath Transmission clawn shifted 6 speed m Z G m r I Gear ratio 1st gear 14 33 2nd gear 17 30 3rd gear 19 26 5th gear 24 22 6th gear 27 20 Ignition system contactless DC CDI ignition with digital advanced system Typ KOKUSAN Generator 12V 150W Spark plug gap 0 6 mm Cooling system liquid cooled permanent rotation through mechanically driven water pump Cooling liquid 1 0 liter 50 antifreeze 50 distilled water at least 25 C Starting equipment kickstarter electric starter BASIC CARBURETOR SETTING
82. o z gt SR O uE U gt SCHALTPLAN WIRING DIAGRAM light switch high low beam switch horn switch brake switch flasher switch start switch kill switch RESCH Poe unpushed SCHALTPLAN WIRING DIAGRAM multi func digital speedometer H zoecch jeuondo YOUMSs Jeg jpuey 80 SO YSN SA SA BseqesnH ISS Ly youms YI LULUSIDESIp DUUIM m Ss ulEU UISU APPENDICE gt u a o a1 Z lt T Z lt 007 SZ0 11 008 rear light brakelight S a S 1 Jn9 J1 io e n6 1 GOU CO 0 EWIIaIEEEKM XIQNAddV ONVHNV SCHALTPLAN WIRING DIAGRAM ENGLISH Battery Cooling fan Driving light lamp Flasher control lamp Flasher relay DEUTSCH Batterie Luftermotor Fernlichtkontrollampe Blinkerkontrollampe Blinkerrelais FRANCAIS Batterie Ventilateur temoin feu route temoin de clignoteur Relais de clignotants Flasher switch Flasher system Front brake switch Generator Handle bar switch for multi func digital soeedometer Headlight High low beam switch Horn Horn switch Ignition coil Ignition switch Left front flasher Left rear flasher Light switch Multi func digital soeedometer Blinkerschalter Blinksystem vorderer Bremslichtschalter Generator Lenkerschalter fur Multifunkt Digitaltacho Scheinwerfer Auf Abblendschalter Hupe Hornschalter Zundspule Zundschloss linker vorderer Blinker
83. oggle lens when scrat ched or damaged if bright light shines through a scrat ched visor or lens the operator will be blinded Neverleave your motorcycle without supervision if the engine is running When riding your motorcycle please bear in mind that other people may feel molested by excessive noise cl Hi O lt Tr 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 performing 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 Too much engine oil will lead to higher oil consumption and will clog the carburetor 2 FUEL Check that there is sufficient fuel in the tank when closing the filler 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 unnecessary 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 pre mature wear if worst comes to worst the chain may rupture or the coun tershaft of the transmission may break om Z Q m r I 4 TI
84. 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 tely necessary to bleed the cooling system during filling 10 mm when engine is cold HHMMHINDUUUMUMBUURMHIHDDUUUMDMRHIURUU UND O 47 MAINTENANCE WORK ON CHASSIS AND ENGINE BLEEDING THE COOLING SYSTEM The cooling liquid is drained by removing the hose 1 from the water 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 screw until coolant escapes at the bore without any bubbles Then fill in the coolant until it reaches a level about 10mm above the radi ator 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 muffling power By expe rience the front glassfiber yarn packing 3 needs
85. ools the coolant The slower the speed ofthe 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 controlled 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 use 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 If coolant gets into your eyes rinse them out with water imme diately and consult doctor ENGLISH A mixture of 50 antifreeze liquid and 50 distilled water is used as coolant However the antifreeze protection must be at least 25 C 13 F This mixture offers antifreeze protection but also good corrosion protection and should therefore not be replaced by pure water CAUTION If the coolant has been drained it will be absolu tely necessary to bleed the cooling system during filling For the cooling system use
86. original homologated throttled version Avoid extended on road rides at full throttle 19 WARNING Wear suitable clothing when driving a motorcycle Clever Husaberg drivers always wear a hel met 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 possible Always turn on the light to make sure that other dri vers 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 driving pro perties 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 dimensioned 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 possible Adjust your driving speed according to the conditions 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 you can help each other should difficulties arise Replace the helmet visor or g
87. orized Husaberg dealer BRAKING Close the throttle and apply the hand and foot brake simultane ously Be especially careful when applying the brakes on sandy wet or slippery surfaces Always brake with feeling locked wheels will cause the motorcycle to skid or crash Always shift down the gears in accordance with the speed Always finish braking before you enter a curve When driving down hill use the braking effect of the engine Change down one or two gears but do not overspeed the engine In this way you will not need to brake so much and the brakes will not overheat WARNING In case of rain after washing the motorcy cle 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 brakes 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 indi cation that something is wrong with the brake system Don t ride your motorcycle anymore without first having the brake syst
88. rease 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 pre cautions 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 anti cor rosion agent WARNING Keep the anti corrosion agent from getting into contact with the brake discs otherwise this will signifi cantly reduce the braking power d 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 cham ber to remove the remaining fuel Remove spark plug a
89. s Rinse off spilled or overflowing brake fluid with water CN 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 297 s Ww sara ta pip a ji appre r E GRAMM F E cl Hi O lt Tr MAINTENANCE WORK ON CHASSIS AND ENGINE 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 d CAUTION Don t let brake fluid get in contact with paint it is an effective paint remover Use only clean brake fluid not older than six months 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 Z G E U I 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 FRONT BRAKE PADS FE Press the brake caliper toward the brake disk to put the brake
90. s not removed the oil sea ling 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 D Z G E U I Pry the dust boots out of the outer pipes with a screwdriver and slide down Clean dust boots outer pipes and fork tubes thoroughly Oil generously with Universal oil spray Motorex Joker 440 or engine oil Press the dust boots into the outer pipes by hand WARNING No oil may reach the front tire or the brake disk since this would considerably reduce the tire s road grip and the braking effect of the front brake 28 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 weig hing 75 85 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 suitable for your weight
91. sc brakes 36 Hand brake ever 6 Hand decompression lever 6 Headlamp switch USA 7 Hot start device EEN 14 How to change the handlebar position 33 INGICALOMIAMDS EE T Instructions for initial operation 19 le ln EE 15 Kilometers or miles 13 Maintenance work on chassis and engine 28 OCCU oo aie shies eee aqa ba S niet eo pele Sa ha 52 Operation instruments 6 Periodic maintenance schedule 24 Pugin STANCES oawe hard Wading Se ee eh eet DQ 16 Rebound damping of fork 0s 16 Rebound damping of shock absorber 18 Refilling the front brake fluid reservoir 37 Refilling the rear brake fluid reservoir 39 Replacing fork springS 30 Replacing headlight lamp parking lightlamp 46 Replacing the front brake pads FE 38 Replacing the front brake pads FS 38 Replacing the glassfiber yarn packing of the silencer 48 Replacing the rear brake pads 40 Running in the Husaberg models 19 Serial number locations 5 Setting the clock serci Fea ae OE ish Ate 13 Shiftlever 15 SHIlfling E elt e NEE 22 Short circuit eu el EE 6 Side Lui WEE 15 Starter button 8 SANNO OI toe ove
92. t carburetor Replace glass fibre yarn filling of the exhaust main silencer Treat electric contacts and switches with contact spray K EE Change hydraulic clutch fluid E rv 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 24 PERIODIC MAINTENANCE SCHEDULE IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each After every For cross start cleaning country use Check oil level Ges e Check brake pads for wear SE Check horn for function O O Oo 0 horn for function Lubricate and adjust cables and nipples Remove and clean fork dust bellows regularly Clean and lubricate chain check tension and adjust if necessary Clean air filter and filter box S a S Check tires for pressure and wear Check cooling fluid level Check fuel lines for leaks Drain and clean float chamber ENGLISH 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 regular
93. th Transmission clawn shifted 6 speed Gear ratio 1st gear 14 33 2nd gear 17 30 3rd gear 19 26 4th gear 23 25 5th gear 24 22 6th gear 27 20 Ignition system breakerless transitorized DC CDI ignition system with digital ignition advance type KOKUSAN Generator 12V 150W Spark plug Spark plug gap NGK DCPR 8 E 0 6 mm Cooling system liquid cooled permanent circulation of cooling liquid through water pump Cooling liquid 1 0 liter mixing ratio 50 antifreeze 50 distilled water at least 25 C Starting equipment kickstarter electric starter BASIC CARBURETOR SETTING Type of carburetor FE 550e 6 EU AUS UK Keihin FCR MX 41 FS 650c 6 FE 550e 6 FE FS 650e 6 FE 650e 6 EU USA USA EU Keihin FCR MX 41 Keihin FCR MX 41 Keihin FCR MX 41 Keihin FCR MX 41 Carburetor ID number 4125D 4125D 4138E 4138E 4138E Main jet 182 160 160 Jet needle OBDVT OBDVR OBDVT OBEKR Idling jet Idle air jet 38 45 45 200 100 38 40 100 100 100 100 Needle position 5th from top 5th from top 2nd from top 2nd from top 4th from top Starting jet 85 85 85 85 85 Mixture control screw open Restriction 1 5 1 5 0 5 0 5 1 5 slide stop slide stop Pump diaphragm stop 858 2 15 mm 858 2 15 mm 858 2 15 mm 858 2 15 mm 858 2 15 mm Hot start knob diameter 2 5mm dia
94. the prescribed tor que the motorcycle will exhibit unsteady driving characteri stics and can get out of control d CAUTION If you drive with play in the steering head bearing for longer periods the bearings and subsequently the bearing seats in the frame will be destroyed If the steering head nut is not tightened to the prescribed tor que the triple clamp and steering stem may be damaged The steering head bearings should be regreased at least once a year e g Motorex Long Term 2000 27 cl N O lt Tr MAINTENANCE WORK ON CHASSIS AND ENGINE BREATHER PLUG FRONT FORK After every 5 hours of use for competitive racing slacken the breather plugs 1 a few turns in order to relieve excess pressure from the inside ofthe fork To do this place the motorcycle on a stand with the front wheel lifted off the ground When riding the motorcycle mainly on the road it will suffice to have this job performed in the course of the periodical mainte nance service 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 TELESCO PIC FORK The dust protection bellows 2 are to remove dust and coarse dirt parti cles from the fork tube However after some time dirt may also get in behind the dust protection bellows If this dirt i
95. 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 53 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 cover lt NOTE only tighten the screw by hand otherwise you will damage the oil filter cover Pull the oil filter cover 3 out of the hole with the screw M6 and remove the screw 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 om Z G r I 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 che
96. to be replaced more often than the rear silencing mat 4 For this purpose remove the silencer from the vehicle and dismount the front cap 5 Pull the front glassfiber yarn packing together 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 glassfiber yarn packing all the way into the silencer and mount the front cap C mn Z r I 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 lt NOTE In every exhaust repair procedure the O rings must be replaced by new ones Glass fiber yarn packings are avai lable from your licensed Husaberg mechanic WARNING The exhaust system becomes very hot while the motorcycle is running to avoid burns do not start work on the exhaust system until it has properly cooled down CLEANING THE SPARK ARRESTER The spark arrester should be cleaned every time the glassfiber yarn fil ling
97. uld be due to old fuel in the float chamber The highly inflammable con stituents in the new fuel volatilize if left standing over longer periods of time If the motorcycle was not used for over 1 week drain the old fuel from the float chamber The engine will start immediately after the float chamber is filled with fresh igni table fuel STARTING WHEN THE ENGINE IS WARM 1 Open the fuel tap 1 2 Swing 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 AT G E w i e 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 decompression 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 des cribed 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 pas sage When starting be sure that you open the throttle com pletely only once 21 m Z G m Q I DRIVING INSTRUCTIONS STARTING OFF Pull the clutch lever engage 1st gear slowly release the clutch lever while you open the throttle WARNING Always mak
98. ure 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 41 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 longer tou ches 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 swingarm 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 damaged 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 om Z Q r I 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 WARNING If you don t happen to have a torque wrench at hand make sure you have the tightening torque corrected by a Husaberg dealer as soon as possible A loose axle may lead to an unstable driving behavior of your motorcycle After
99. ut 1 loosen lock nuts 2 and turn right and left adjus ting 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 relation to the reference marks B Tighten the counter nut of the adjusting screws Before tightening thr collar nut verify that the chain adjusters 4 are sit ting close to the adjusting screws and that the rear wheel has been alig ned with the front wheel Tighten collar nut 1 to 80 Nm CN WARNING If you don t happen to have a torque wrench at hand make sure you have the tightening torque corrected 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 allows you to use different secondary ratios in combination with the same chain length The chain adjusters 4 can be rotated by 180 34 MAINTENANCE 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 wa
100. 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 minimum preload 4mm STANDARD PRELOAD FE 450 501 550 650 D mm STANDARD PRELOAD FS 450 650 11 mm maximum preload 12 mm 33 MAINTENANCE WORK ON CHASSIS AND ENGINE CHECK CHAIN TENSION Jack the motorcycle up on its frame so that the rear wheel no longer tou ches 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 WARNING Excessive tensioning of the chain will put addi tional load on the components of the secondary drivetrain 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 on 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 mn Z G r I CORRECT CHAIN TENSION Loosen collar n
101. work from the beginning 5 Then use the adjusting wheel to set the desired idle speed 6 In cases of greater changes in the outside temperature and extremely different altitudes the idling speed should be readjusted 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 51 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 cham ber 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 a
102. y is to use lots of water but never use brushes or cleaning liquids After let ting the chain dry you can use a special X ring chain spray e g Moto rex Chainlube 622 WARNING No lubrication is allowed to reach the rear tire or the brake disks otherwise the road adherence and the rear wheel braking effects would be strongly reduced and the motorcycle could easily lose control d CAUTION mounting the chain masterlink clip the closed side of the masterlink clip must point in running direction 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 Ib 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 therefore repeat the measurement at diffe rent places on the chain lt NOTE If you mount a new chain the sprockets should also be replaced New chains wear faster if used on old used sprockets d CAUTION Secure the screws of the chain wheel by applying Loctite and fasten them in a crosswise order Tigh tening torque for nuts 35 Nm Tightening torque for screws 50 Nm 35 ny CICIEDCICS cl O lt Tr MAINTENANCE WORK ON CHASSIS AND

BEDIENUNGSANLEITUNG OWNERS MANUAL MANUEL D

Contents

Download Pdf Manuals

Related Search

Related Contents