“04 Edition 2004 BEDIENUNGSANLEITUNG OWNERS MANUAL MANUEL D’UTILISATION
Page INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Important limited warranty and limited guarantee information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .21 Check the following before each start . . . . . . . . . . .21 Starting when the engine is cold . . . . . . . . . . . . . . .22 Starting when the engine is warm . . . . . . . . . . . . . .22 What to do when the engine is “flooded” . .
INTRODUCTION IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS: ENGLISH WARNING: IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE.
INTRODUCTION 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 familiarize yourself with how to operate your new motorcycle and with its characteristics, even if this means that you will have to dedicate some of your valuable time to this task.
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.
SERIAL NUMBER LOCATIONS CHASSIS NUMBER ENGINE-NUMBER The engine number is embossed in the engine case on the left side of the engine under the radiator hose. -5- ENGLISH The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 2.
OPERATION INSTRUMENTS CLUTCH LEVER The clutch lever (1) is located on the left side of the handlebar. The adjusting screw (A) is used to change the original position of the clutch lever (see maintenance work on chassis and engine). 1 A ENGLISH HAND DECOMPRESSION LEVER The hand decompression lever (2) is needed only if the carburetor overflows after a fall. To "pump the engine free", pull the hand decompression lever during the starting procedure.
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. 2 1 A FLASHER SWITCH The flasher switch (3) is a separate unit and is mounted on the left portion of the handlebar.
OPERATION INSTRUMENTS INDICATOR LAMPS The green control lamp (1) flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp (2) lights up when the high beam is on. 2 1 ENGLISH STARTER BUTTON Pushing the black starter button (3) will actuate the E-starter. 3 EMERGENCY OFF SWITCH (AUSTRALIA) The red emergency-OFF switch (4) is arranged adjacent to the throttle grip. In this position, the E-starter is operational and the engine can be started.
OPERATION INSTRUMENTS WS (WHEEL SIZE) ENGLISH The display will change and briefly show the diameter of the front wheel in millimeters. If the front wheel does not turn, the display will automatically change to the SPEED/H mode. If the front wheel turns, the display will automatically change to the SPEED /ODO mode. SPEED/H (HOURS) DISPLAY MODE When you stop driving and no impulses are sent from the wheel sensor, the display mode will automatically change from SPEED/ODO to SPEED/H.
OPERATION INSTRUMENTS SPEED/ODO DISPLAY MODE SPEED displays the speed in KPH or MPH. The displayed figure cannot be cleared. ODO displays the kilometers or miles traveled. The displayed figure cannot be cleared. + button no function – button no function press the MODE button to change to the next mode press and hold the MODE button 3 seconds to change to the next mode ENGLISH SPEED/MAX DISPLAY MODE MAX displays the maximum speed. It is always active.
OPERATION INSTRUMENTS LAP/LAP DISPLAY MODE The lap number is shown at the top and the lap time in hours, minutes and seconds at the bottom of the display. If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped. Hold the MODE button for 3 seconds in the SPEED/LAP mode to clear the stored lap times. SPEED/CLK (CLOCK) DISPLAY MODE CLK will display time in hours, minutes and seconds. + button no function – button no function press the MODE button to change to the next mode.
OPERATION INSTRUMENTS SPEED/AVS1 (AVERAGE SPEED 1) DISPLAY MODE AVS1 is always active and shows the average speed based on the TRP1 and STP1 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 press the MODE button to change to the next mode press and hold the MODE button 3 seconds to reset the TRP1, AVS1 and STP1 figures to 0.
OPERATION INSTRUMENTS SPEED/STP2 (STOP 2) DISPLAY MODE STP2 is a manual stop watch. Start the stop watch by pressing the + button, press again to hold. Press again to continue timing. Press the MODE button to change to the next mode. The STP2 display will blink in the other modes if STP2 continues to run in the background. To stop STP2, return to the SPEED/STP2 mode and press the + button. SETTING THE CLOCK To set the clock, switch the ignition off and select the SPEED/CLK mode.
OPERATION INSTRUMENTS KILOMETERS OR MILES Driving motorcycle Standing motorcycle ENGLISH The unit (kilometers or miles) can also be changed. The ODO figure will be retained and converted accordingly. The TRP1, AVS1, STP1, TRP2 and AVS2 figures will be cleared. To select the unit, select the SPEED/H mode and hold the MODE button for 3 seconds to access the SETUP menu. Press the MODE button 10 times until the KMH/MPH function blinks. Press the + button to move to the options.
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. 1 ENGLISH Install the tank breather hose (1) without kinks. FUEL TAPS OFF In this position the fuel taps are closed. No fuel can flow to the carburetor. ON/RES The knob is in the ON or RES position when the motorcycle is running. Fuel is conveyed to the carburetor in this position and the tank will drain completely.
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. 2,3,4 (5,6) N 1 ENGLISH KICKSTARTER The kickstarter is located on the left side of the engine. The upper part is tiltable. 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).
OPERATION INSTRUMENTS COMPRESSION DAMPING OF FORK Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs.Remove the protecting cap (1). Turn the adjusting screws (2) clockwise to increase damping, turn it counterclockwise to reduce damping during compression. Typ White Power 1445Y728 . . . . . . . . .18 clicks Typ White Power 1445Y729 . . . . . . . . .
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.
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 counterclockwise to reduce damping during rebounding. 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).
TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE INSTRUCTIONS FOR INITIAL OPERATION ENGLISH – 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.
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.
STARTING WHEN THE ENGINE IS COLD 1 2 3 4 5 Open the fuel taps (1). Swing up the side stand or center stand. Put the gear in neutral. Operate the choke (2). Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E-starter. WARNING: If you want to start the engine, make sure that you always put on sturdy motorcycle boots in order to avoid injuries. You might slip off the kickstarter, or the engine may kick back and propel your foot upward with great force.
SHIFTING/RIDING BRAKING You are now in first gear, refered to as the drive or uphill gear. Depending on the conditions (traffic, hill size, etc.), you can shift to a higher gear. Close throttle, at the same time pull clutch lever in and shift to the next higher gear. Let clutch lever go again and accelerate. If you turned on the choke, make sure you turn it off again as soon as engine is warm.
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 or switch off the ignition. Close the fuel taps, park the motorcycle on a firm surface and lock. WARNING: Motorcycle engines produce a great amount of heat while running. The engine, exhaust pipe, muffler, brake rotors, and shock absorbers can become very hot.
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PERIODIC MAINTENANCE SCHEDULE 2004 FC 450/4, FC 550/4 MODEL 2004 ADD-ON-PARTS BRAKES CHASSIS WHEELS ENGLISH CARBURETOR ENGINE A clean motorcycle can be checked more quickly which saves money! 1.
PERIODIC MAINTENANCE SCHEDULE 2004 MODEL WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBURETOR ENGINE A clean motorcycle can be checked more quickly which saves money! 2004 1.
PERIODIC MAINTENANCE SCHEDULE 2004 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Check oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regularly Remove and clean fork dust bellows regularly Clean and lubricate chain, check tension and adjust if necessary Clean air filter and filter box Check tires for pressure and wear Check cooling fluid level Check fuel lines for l
PERIODIC MAINTENANCE SCHEDULE 2004 60 hours 400 liter 90 hours 600 liter 120 hours 800 liter 135 hours 900 liter ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● NOTE: IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED, THE RESPECTIVE COMPONENTS MUST BE REPLACED.
MAINTENANCE WORK ON CHASSIS AND ENGINE WARNING: Maintenance and adjusting work marked with an asterisk (*) requires expert skills and technical know-how. For your own safety, always have such work performed by a specialized Husaberg dealer where your motorcycle will be optimally serviced by appropriately qualified, skilled staff. CAUTION: When cleaning the motorcycle, do not use a high pressure cleaning unit if possible, otherwise water will penetrate the bearings, carburetor, electric connectors, etc.
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 of the 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 maintenance service.
MAINTENANCE WORK ON CHASSIS AND ENGINE BASIC SUSPENSION SETUP FOR THE WEIGHT OF THE DRIVER To achieve maximum handling performance and to prevent the fork, shock absorber, swing arm and frame from being damaged, the basic setup of the suspension components must be suitable for your weight. At delivery, Husaberg's offroad motorcycles are set to accommodate a driver weighing 70 - 80 kg (wearing full protective clothing).
MAINTENANCE WORK ON CHASSIS AND ENGINE MODELL 1245Y721 FC 450,550 1245Y722 FE 450,501,550,650 SOFTER STANDARD HARDER 66-86/260 76-95/260 81-99,5/260 66-86/260 1245Y723 80/250 FS 450,650 71,5-90,5/260 81-99,5/260 84/250 88/250 ENGLISH The riding sag should lie between 90 and 105 mm. If the riding sag is less than 90 mm, the spring is too hard (the spring rate is too high). If the riding sag is more than 105 mm, the spring is too soft (the spring rate is too low).
MAINTENANCE WORK ON CHASSIS AND ENGINE HOW TO CHANGE THE HANDLEBAR POSITION The handlebar position can be readjusted by 22 mm. Thus, you can put the handlebar in the position that is the most convenient for you. The upper triple clamp (1) includes 2 bores arranged at a distance of 15 mm (0.6 in) from one another. The bores at the handlebar support (2) are offset from the center by 3.5 mm (0.13 in). Accordingly, you can mount the handlebar in 4 different positions.
MAINTENANCE WORK ON CHASSIS AND ENGINE CHECK CHAIN TENSION Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Press the chain upward at the end of the chain sliding component. The distance between the chain and the swing arm should be approx. 8 - 10 mm (0.31 - 0.39 in). In the course of this procedure, the upper chain portion (A) must be taut (see drawing). If necessary, correct the chain tension.
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 way is to use lots of water, but never use brushes or cleaning liquids. After letting the chain dry, you can use a special X-ring chain spray (e.g. Motorex Chainlube 622).
MAINTENANCE WORK ON CHASSIS AND ENGINE GENERAL INFORMATION ABOUT HUSABERG DISC BRAKES BRAKE CALIPERS: Secure the screws of the caliper support with Loctite 243 and tighten to 25 Nm. BRAKE DISCS: Wear will reduce the thickness of the brake disk around the mounting face (1) of the brake pads. Brake disks with less than the minimum thickness are a safety risk. Have the brake disk replaced as soon as it reaches the wear limit.
CHANGING THE BASIC POSITION THE HAND BRAKE LEVER (FC, FE) Free travel at the hand brake lever may be readjusted by using adjustment 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 pressed against the brake disc) can be adjusted for any hand size.When you press the hand brake lever forwards, you min. 3 mm 1 should have at least 3 mm free travel. Turn the adjusting screw (1) if necessary.
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 5 mm CAUTION: Don’t let brake fluid get in contact with paint, it is an effective paint remover. ENGLISH Use only clean brake fluid taken from a tightly sealed container. CHECKING THE FRONT BRAKE PADS The brake pads can be seen from the bottom (FS from the rear). The lining thickness should not be less than 1 mm.
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 adjusted by means of the piston rod (2). Measured on the outside, the foot brake pedal must have 3-5 mm (0.12–0.20 in) of free play before the piston rod can move the piston in the brake cylinder (to be recognised from the resistance on the foot brake pedal).
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 don’t put off having your brake pads changed. min.
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 clamping screws (1) on the left side of the fork fists. Loosen and remove the collar nut (2), loosen the clamping screws (3) on the right side of the fork fist. Hold the front wheel, pull out the wheel spindle (4). 1 CAUTION: Do not operate the hand brake when the front wheel has been dismounted.
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 touches the ground. Loosen the collar nut (1), remove chain tensioner (2), hold the rear wheel and pull out the wheel spindle (3) until the rear wheel is free but the brake caliper support is still held. Push the rear wheel as far forward as possible, take the chain from the chain wheel and carefully take the rear wheel out of the swingarm.
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.
MAINTENANCE WORK ON CHASSIS AND ENGINE Tire type, tire condition, and air pressure level affect the way your motor-cycle rides and must therefore be checked whenever you are getting ready to go anywhere on your motorcycle. – Tire size can be found in the technical specifications and in the homologation certificate – Tire condition has to be checked every time you want to ride your motorcycle. Before leaving, check tires for punctures and nails or other sharp objects that might have become embedded in them.
MAINTENANCE WORK ON CHASSIS AND ENGINE BATTERY The battery (1) is located in front of the shock absorber and is maintenance-free. It is not necessary to check the electrolyte level or to add water. Merely keep the battery poles clean and grease slightly with acidfree grease if required. WARNING: If electrolyte (sulphuric acid) leaks from the battery, proceed with great care. The electrolyte can cause severe burns. In the case of skin contact rinse thoroughly with water.
MAINTENANCE WORK ON CHASSIS AND ENGINE FUSE (FE/FS) 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 A 2 ENGLISH The starter relay also contains a (10 amp) spare fuse (3). Replace a blown fuse only with an equivalent one.
MAINTENANCE WORK ON CHASSIS AND ENGINE COOLING SYSTEM Coolant is circulated by a water pump (1) located in the engine. Air blowing in through the radiators cools the coolant. The slower the speed of the motorcycle, the less the coolant is cooled down. Dirty radiators also reduce the cooling efficiency. Pressure induced by heating of the coolant in the system is 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.
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 radiator fins. After a short ride, check the coolant level once more.
MAINTENANCE WORK ON CHASSIS AND ENGINE CLEANING THE AIR FILTER * The air filter must be cleaned prior to every race or depending on the accumulation of dust. To clean, remove the seat, unscrew the wing screw and remove the air filter together with the filter support. CAUTION: Do not clean air filter with fuel or petroleum since these damage the foam. Husaberg recommends the products of the company „Motorex“ for air filter maintenance.
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 original position of the clutch lever, thus allowing adjustment to an optimal position for every hand size. Turning the adjusting screw clockwise reduces the distance between the clutch lever and the handlebar. Turning the adjusting screw counterclockwise increases the distance between the clutch lever and the handlebar.
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. ENGLISH 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE CHECKING THE FLOAT LEVEL (FLOAT HEIGHT) * For this purpose, dismount the carburetor and remove the float chamber. Hold the carburetor in a slanted position such that the float will abut the float needle valve but not compress it. In this position, the edge of the float should be parallel with the float chamber sealing surface (see illustration). If the float height does not correspond to the desired value, check the float needle valve and, if necessary, replace it.
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.
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. NOTE: only tighten the screw by hand, otherwise you will damage the oil filter cover. 1 Pull the oil filter cover (3) out of the hole with the screw M6 and remove the screw. 3 2 ENGLISH 1 Use pliers to pull the oil filter element (4) from the housing.
TROUBLESHOOTING CAUSE TROUBLE Engine doesn’t (E-starter). crank Engine cranks but doesn’t start (E-starter). Engine will not start (Kickstarter). ENGLISH Engine fails to idle REMEDY Operating errror Turn on the emergency-OFF switch (Australia only) Blown fuse Dismount the left paneling and the filter box cover and replace the fuse in the starter relay. Discharged battery. Recharge the battery and investigate the causes for discharging; contact a Husaberg dealer.
ERROR CAUSE REMEDY Engine won't rev up Carburetor overflows because the float needle is soiled or worn Disassemble the carburetor and check for wear Loose carburetor jets Tighten the jets Electronic ignition advance is defective Have the ignition system checked Fuel supply is interrupted or the carburetor soiled Clean and check the fuel system and carburetor Air filter is heavily soiled Clean or replace the air filter Exhaust system is not tight, deformed or there is not enough glass-fiber yar
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: Never clean your motorcycle with a high-pressured cleaner or a high-pressured water jet.
Engine Design Displacement Bore/Stroke Ratio Carburetor Keihin Fuel Valve timing Valve diameter Intake Valve diameter Exhaust Valve clearence cold Intake Valve clearence cold Exhaust Crank shadt bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Eingine oil Quantity of engine oil Primary ratio Clutch Transmission (clawn shifted) Gear ratio 1. Gear 2. Gear 3. Gear 4. Gear 5. Gear 6.
TECHNICAL DATA - ENGINE Engine Design Displacement Bore/Stroke Compression ratio Keihin carburetor FC 550/4 FE 550e/6 FE 650e/6 FS 650e/6 Liquid-cooled, 1-cylinder 4-stroke Otto engine with balancer weight 550 cm3 644 cm3 100 / 70 mm 100 / 82 mm 11,8:1 11,5:1 FCR-MX 41 Fuel unleaded fuel with at least RON 95 (USA = Premium RON 91) ENGLISH 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 clearance
FC 450/4, 550/4 FE 450/501/550/650e/6 FS 450e/6, 650e/6 Frame tubular chrome-molybdenum-steel frame, powder-coated Fork WP Up Side Down 4860 MXMA Spring travel, front/rear 295/320 mm 260/287 mm Rear suspension WP Progressive Damping System shock absorber, aluminum rear swinging fork Disk brake,perforated Ø 260 mm brake disk, floating brake caliper Ø 310 mm Front brake Brake disk front minimum thickness 2,5 mm minimum thickness 5,0 mm Rear brake Disk brake,perforated Ø 220 mm brake disk, floating brake calip
TECHNICAL DATA - ENGINE TIGHTENING TORQUES ENGLISH HH collar screws on housing, clutch cover, ignition cover Oil drain plug HH plug oil screen AH collar screw on oil filter cover Plug on pressure relief valve HH screws on oil pump cover HH collar screw on cylinder head top section AH screws on valve cover HH collar screws on water pump cover HH screws on cylinder head HH screw on cylinder head AH screws on camshaft gear HH nut on automatic decompression stop AH screws on rocker arm shaft silencer cap Coun
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES - CHASSIS M24x1,5 M8 M6 M6 M8 M8 M22x1 M8 M20x1,5 M16x1,5 M8 M10 M12 M10 M8 M6 M8 M8 M8 M6 M4,5 / M5 M6 M8 M10 M6 M8 M10 Other collar nuts on chassis - 63 - 40 Nm Loctite 243 + 25 Nm 10 Nm Loctite 243 + 10 Nm 20 Nm 15 Nm 20 Nm 10 Nm 80 Nm 100 Nm 20 Nm Loctite 243 + 40 Nm 60 Nm 40 Nm Loctite 243 + 35 Nm Loctite 243 + 10 Nm 25 Nm 20 Nm 6 Nm 8 Nm 5 Nm 10 Nm 25 Nm 45 Nm 15 Nm 30 Nm 50 Nm ENGLISH Collar screw, front wheel spindle Brake caliper, front Collar scre
HEAD WORD INDEX ENGLISH Page Activating/deactivating the display modes . . . . . . . . .13 Adjusting the mixture control screw . . . . . . . . . . . . . . .52 Adjusting the throttle cables . . . . . . . . . . . . . . . . . . . .50 Basic information on carburetor wear . . . . . . . . . . . . . .52 Basic suspension setup for the weight of the driver . . .32 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . .
-1- ignition coil brown blue-white yellow-black C ANHANG-APPENDIX APPENDICE Husaberg FC 04 black stop button red-black red-white G generator 3 pick up blue 800.11.075.
flasher control lamp left front flasher right front flasher br bu wh-gn ye br bl bl pu br gn gn ye br ye ye-bl br ye-bl br re ye ye ignition coil Husaberg FE 04 br wh br re-bl re bl or re-wh headlight multi-func.-digital-speedometer black bl br ye-re wh-re re ye-bl bu-wh gn-wh rear brake switch wh ye ye-re br wiring diagramm TPS pick up 800.11.075.150 800.11.078.
SCHALTPLÄNE light switch high/low beam switch cable color horn switch cable color re bu ye gn wh LIGHT OFF br P.LIGHT HORN LO OFF HI P.
multi-func.-digital-speedometer headlight ye br ignition coil bl-wh ye br wh ye-bl ye-bl Husaberg FE USA 04 br wh ye-re ye-re ye-bl br-bl flasher system br re-wh br br bu-wh C gn re-bl D -4bu bl ye bl TPS ye br bu cooling fan M wh-re bl pick up gn 10 A start relay G generator re-bl 3 battery wh main harness ye-re black bl br ye-re wh-re re wiring diagramm I starter motor re-wh start bottom ye light switch wh ye ye-re br wh 800.11.075.
SCHALTPLÄNE start switch cable switch re- yewh re START ANHANG-APPENDIX APPENDICE unpushed -5-
flasher control lamp left front flasher right front flasher br bu wh-gn ye br bl bl pu pu br gn gn ye br ye ye-bl br ye-bl br re ye ye ignition coil Husaberg FS 04 br wh br re-bl re bl ye headlight multi-func.-digital-speedometer black bl br ye-re wh-re re ye-bl bu-wh gn-wh rear brake switch wh ye ye-re br wiring diagramm TPS pick up 800.11.075.150 800.11.077.
SCHALTPLÄNE light switch high/low beam switch cable color horn switch cable color bu ye gn wh LIGHT OFF re br HORN P.LIGHT LO HI OFF P.
SCHALTPLÄNE ANHANG-APPENDIX APPENDICE ENGLISCH Battery Cooling fan Driving light lamp Flasher control lamp Flasher relay Flasher switch Flasher system Front brake switch Generator Handle bar switch for multi-func.-digital-speedometer Headlight High / low beam switch Horn Horn switch Ignition coil Ignition switch Left front flasher Left rear flasher Light switch Multi-func.
Cover: Büro 3 Communication, Photos: Florian Jaenicke. 09/2003 ART. NR. 3802000 HUSABERG - a company of the KTM Group Stallhofner Straße 3, A-5230 Mattighofen E-mail: info@husaberg.cc, Internet: www.husaberg.
