“04 Edition 2004 REPARATURANLEITUNG REPAIR MANUAL MANUEL DE REPARATION
PREFACE This manual contains detailed instructions on repairing the engine. It was prepared according to the state of the art for this model series. We reserve the right to make modifications based on technical progress without making the respective corrections in this repair manual. This manual does not contain a description of general shop or working methods.
INDEX GENERAL INFORMATION A DISMOUNTING AND MOUNTING THE ENGINE B DISASSEMBLING THE ENGINE C SERVICING THE INDIVIDUAL PARTS D ASSEMBLING THE ENGINE E ELECTRIC SYSTEM F FUEL SYSTEM G TROUBLESHOOTING H TECHNICAL SPECIFICATIONS I PERIODIC MAINTENANCE SCHEDULE J WIRING DIAGRAMS K L M N
TABLE OF CONTENTS GENERAL INFORMATION Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . .A1 Changing the engine oil . . . . . . . . . . . . . . . . . . . . .A2 Cleaning the oil screen . . . . . . . . . . . . . . . . . . . . . .A2 Changing the oil filter . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 9 OIL CIRCUIT 6 4 7 5 3 10 1 8 2 DESCRIPTION: The oil pump (1) draws the engine oil from the oil sump through the oil screen (2) and pumps it past the pressure relief valve (3) to the oil filter (4). It continues to the crankshaft (5), partly branching off through a hole to lubricate and cool the piston (6) and the piston pin bearing. Once through the crankshaft, the engine oil is pumped to the conrod bearing (7) and branches off again to the bearings in the balance weight (8).
GENERAL INFORMATION A 2 CHANGING THE ENGINE OIL NOTE: Replace the oil screen and the oil filter when you change the engine oil. Change the engine oil when the engine is at operating temperature. WARNING: the engine oil will be very hot when the engine is at operating temperature – be careful not to burn yourself. – Place the motorcycle on a level surface, remove the plug (1) and allow the oil to drain into a suitable vessel. – Thoroughly clean the plug (with the magnet).
GENERAL INFORMATION A 3 CHANGING THE OIL FILTER – Place a suitable vessel under the engine to allow the oil to drain. – Remove both bolts (1) and screw an M6 bolt in the center hole (2) of the oil filter cover. 1 NOTE: only tighten the bolt by hand, otherwise you will damage the oil filter cover. 3 2 – Pull the oil filter cover (3) out of the hole with the bolt M6 and remove the bolt. 1 – Use pliers to pull the oil filter element (4) from the housing.
GENERAL INFORMATION A 4 CHECKING THE OIL HYDRAULIC CLUTCH LEVEL IN THE Remove the cover to check the oil level in the master cylinder of the clutch. Remove the screws (1) and lift off the cover together with the rubber boot (2). The oil level should be 4 mm below the upper edge when the master cylinder is in a horizontal position. If necessary, add SAE 10 biodegradable hydraulic oil (e.g.: Motorex clutch fluid 75). 1 2 CAUTION: only fill SAE 10 biodegradable hydraulic oil into the master cylinder.
GENERAL INFORMATION CLEANING Clean the motorcycle regularly to retain the beauty of the plastic parts. Use warm water with a commercial detergent and a sponge. Coarse dirt can be removed with a soft water jet. CAUTION: never clean the motorcycle with a power washer or a high pressure jet. This will cause the water to reach the electric components, socket connectors, cables, bearings, carburetor, etc. and will cause these parts to malfunction or break. – Only use commercial detergents to clean the engine.
GENERAL INFORMATION A 6 SPECIAL TOOLS - ENGINE 2 1 3 4 5 7 6 8 12 11 13 10 14 16 15 19 9 18 17 25 20 22 23 21 27 24 26
GENERAL INFORMATION SPECIAL TOOLS - ENGINE FIG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 PART NUMBER 560.12.001.000 800.29.002.000 309098 6 899 785 800.29.059.000 503.29.050.000 590.29.041.000 590.29.072.000 580.30.080.000 590.29.019.000 510.12.011.000 600.29.015.000 590.29.026.006 580.12.009.000 800.29.030.000 590.29.033.000 584.29.037.037 151.12.017.000 151.12.018.000 800.29.004.000 800.29.003.000 800.29.020.000 800.29.031.000 590.29.005.010 800.29.005.000 800.29.105.
DISMOUNTING AND MOUNTING THE ENGINE DISMOUNTING THE ENGINE – Thoroughly clean the motorcycle and jack up on a sturdy work stand. – Remove the seat. – Unscrew the air filter (1). – Close both fuel taps and disconnect the fuel hoses – Unscrew both lateral bolts (2) on the spoiler. 1 B 1 NOTE: Hold the retaining sleeve on the radiator shield with pliers if it turns at the same time. – Remove the tank with the spoilers. – Disconnect the ground and positive cable.
DISMOUNTING AND MOUNTING THE ENGINE – Dismount the right frame protector (1). B 2 – Unscrew the bearing bolt (2) on the foot brake lever and tilt the foot brake lever aside. – Remove the retaining clip from the push rod holder (3), pull out the bolt and the foot brake lever 1 3 2 – Disconnect the generator and pickup connector (4) and remove the cable clips from the clutch line. 4 – Open the chain joint (5), separate the chain and remove.
DISMOUNTING AND MOUNTING THE ENGINE – Remove the retaining bolt from the starter relay (1), disconnect the connectors from the starter relay and lift out the starter relay. – Unscrew the nut on the chain roller bolt (2). – Dismount the starter holding bridge (3) and lift the battery out of the frame together with the battery case. 1 B 3 2 3 – Use a suitable tool (hooked handle) to detach the front (4) and rear (5) exhaust springs.
DISMOUNTING AND MOUNTING THE ENGINE B 4 – Remove the nut from the swing arm pivot (1) and knock out the swing arm pivot with a suitable pipe. – Pull the swing arm towards the back and let it rest against the frame. 1 – Unscrew the engine mounting plantes (2) and remove the bolts. NOTE: hold the engine to prevent it from tilting out of the frame. – Lift the engine and lift out of the frame towards the left.
DISMOUNTING AND MOUNTING THE ENGINE MOUNTING THE ENGINE – Lift the engine into the frame, position the engine mounting plates (1), insert the bolts and screw on the nuts but do not tighten yet. B 5 1 – Position the swing arm and push in the swing arm pivot (2) from the right until it touches the engine. – Lift the engine until the swing arm pivot can be pushed through the engine case, gently tapping with a plastic hammer if necessary. – Screw the nut on the swing arm pivot and tighten to 100 Nm.
DISMOUNTING AND MOUNTING THE ENGINE B 6 – Mount the intermediate exhaust pipe (1) and tighten the bolt (2). – Use a suitable tool (hooked handle) to mount the rear exhaust springs (3). 3 5 1 2 – Apply copper paste to the front exhaust pipe at the connections to the cylinder head and mount. – Screw on the exhaust nuts (4). – Mount the front exhaust springs (5). 4 4 – Place the battery and battery case in the frame. – Screw on the starter holding bridge (6).
DISMOUNTING AND MOUNTING THE ENGINE – Mount the clutch slave cylinder (1) and tighten the bolts to 6 Nm. – Position the chain and mount the chain joint (2). B 7 2 1 – Connect the generator and pickup connector (3) and fasten the wiring harness to the clutch line with cable clips. 3 – Mount the bolt for the push rod holder (4) and secure with the retaining clip. – Position the foot brake lever, secure the bearing bolt (5) with Loctite 243 and tighten the bearing bolt to 10 Nm.
DISMOUNTING AND MOUNTING THE ENGINE B 8 – Mount both radiator hoses and tighten the hose clamps (1). – Connect the overflow hose (2) and attach to the frame with cable clips. 1 – Connect the battery cables. 2 1 1 – Mount the tank and tighten the two bolts (4) on the side of the spoiler. – Connect both fuel hoses and open the fuel taps. – Mount the air filter (5) and screw tight. – Mount the seat. 4 – Lift the motorcycle off the engine work stand. – Bleed the cooling system.
DISMOUNTING AND MOUNTING THE ENGINE BLEEDING THE COOLING SYSTEM – Add cooling liquid until it reaches approx. 10 mm over the radiator fins. – Open the bleeder bolt (1) on the cylinder head until cooling liquid escapes without bubbles, tighten the bleeder bolt again to 6 Nm. Check the cooling liquid level again after another short ride and correct if necessary.
DISASSEMBLING THE ENGINE – Thoroughly clean the outside of the engine and clamp on a universal engine work stand. – Drain the engine oil, remove the oil filter and the oil screen (see Chapter A). – Remove the kickstarter and the shift lever. C 1 – Remove the circlip from the engine sprocket with suitable pliers, pull the engine sprocket off the shaft. – Remove the 4 bolts from the generator cover and remove the generator cover. – Pull both dowels from the housing and discard the gasket.
DISASSEMBLING THE ENGINE REMOVING THE ROTOR – Remove the pickup sensor (1). – Loosen the rotor nut (2) (17 mm – LH thread!) and remove together with the corrugated washer. C 2 2 1 – Screw the extractor 580.12.009.000 (3) to the rotor, hold the extractor while you screw in the extractor bolt until the rotor is released from the crankshaft. Remove the rotor, unscrew the extractor from the rotor.
DISASSEMBLING THE ENGINE – Remove the circlip (1) from the water pump shaft. – Carefully pull out the water pump wheel (2) with pliers and remove the pin (3) from the shaft. 3 1 C 3 2 – Remove all of the bolts in the clutch cover and remove the clutch cover. NOTE: the outer cover does not need to be removed separately. – Discard the gasket and the O-ring in the water duct, pull the dowels out of the housing.
DISASSEMBLING THE ENGINE REMOVING THE INNER CLUTCH HUB – Unscrew the locking bolt. – Insert the clutch holder (1) 800.29.003.000 in the outer clutch hub with at least 6 clutch sleeves, lock the outer clutch hub with the gear wheel segment (2) (800.29.004.000) as shown in the photo and loosen the nut (27 mm). C 4 – Remove the clutch holder, the nut and lock washer and the inner clutch hub (3). 2 1 3 – Remove the stepped disk (4) and both half disks (5).
DISASSEMBLING THE ENGINE – Pull the idler (1) and the freewheel (2) from the engine case (only applies to starter models). 1 2 4 3 – Remove the circlip on the kickstarter idler gear (3) and pull the kickstarter idler gear with the upper and lower disk and the needle bearing off of the bearing bolt. – Forcefully pull the kickstarter shaft (4) out of the housing and dismount together with the gear wheel, the bearing and the spring.
DISASSEMBLING THE ENGINE REMOVING THE CHAIN TENSIONER – Remove the bolt (1) together with the seal ring and chain tensioning spring. – Unscrew the chain tensioner (2). 1 C 6 2 – Remove both valve covers, discarding the gaskets. – Loosen the bolts on the cylinder head top section, carefully tap on the side with a plastic hammer and remove the cylinder head top section. SEPARATING THE TIMING CHAIN – Turn the camshaft until the chain joint (3) is on top and can be easily opened.
DISASSEMBLING THE ENGINE – Pull the rear sprocket (1) off of the idler shaft with the extractor 590.29.033.000. CAUTION: Hold the extractor and do not let it touch the chain guide. 1 – Pry the woodruff key from the shaft. C 7 REMOVING THE CYLINDER HEAD 3 – Remove the bolt on the left side (2). – Loosen the 4 cylinder head bolts (3) crosswise and remove together with the washers. – Lift off the cylinder head with the sleeves and gasket, discarding the gasket.
DISASSEMBLING THE ENGINE REMOVING THE CRANKSHAFT – Lift the crankshaft out of the housing together with the conrod, piston and cylinder liner, tapping gently on the rear crankshaft with a plastic hammer if necessary. C 8 REMOVING THE TRANSMISSION – Pull both shift rails (1) out of the housing. – Tilt the shift forks (2) aside, the shift rolls (3) usually remain in the shift drum (4) and should be removed with a magnet.
DISASSEMBLING THE ENGINE REMOVING THE IDLER SHAFT – Knock the idler shaft out of the bearing seat from behind with a plastic hammer.
SERVICING THE INDIVIDUAL PARTS IMPORTANT INFORMATION ON WORKING WITH THE ENGINE CASE Generally, all gaskets, O-rings, crankshaft bearings and the transmission shaft bearings should be replaced when repairing the engine. In addition, all of the parts need to be cleaned thoroughly, removing any residual sealant from the sealing areas. Any bearings removed with an extractor need to be replaced. Read the following section before you start to work.
SERVICING THE INDIVIDUAL PARTS – Check the oil pump housing for scores and seizing marks. – Blow compressed air through all oil ducts and make sure they are not clogged. D 2 – Check the diaphragm valve for damage, replace the diaphragm if necessary. – Remount the diaphragm valve, apply Loctite 243 to the M4x6 screws and tighten to 1,5 Nm. – Press the shaft seal ring onto the crankshaft with a suitable mandrel until flush. – Mount the chain guide, apply Loctite 243 to the bolt and tighten to 6 Nm.
SERVICING THE INDIVIDUAL PARTS PRESSURE RELIEF VALVE – Check the valve ball (1) and the pressure spring (2) for damage. 2 1 D 3 CLUTCH COVER – Pry the shaft seal ring for the shift shaft (3), the kickstarter shaft (4) and the water pump shaft (5) out of the clutch cover. – Press in new shaft seal rings with a suitable mandrel until flush, making sure the open side of the seal ring for the water pump faces towards the outside.
SERVICING THE INDIVIDUAL PARTS CRANKSHAFT – Pull the cylinder liner off of the piston, lift the piston pin retainer out of the groove and push the piston pin out of the piston. D 4 – Clamp the crankshaft into the vise – use protective jaws. – Heat the special tool 584.29.037.037 to approx. 150° C on a hotplate and immediately push on the inner ring of the crankshaft bearing. Firmly press the tool together to obtain a good heat transfer and pull the inner ring off of the crankshaft with the special tool.
SERVICING THE INDIVIDUAL PARTS – Press the outer ball bearing out of the balance weight (on the side with the toothing). NOTE: the ball bearing cannot be pressed out through the bottom since it will be blocked by the ring (1). 1 D 5 PRESS OUT THE CRANK PIN – Place the crankshaft and a crankshaft web in the press out tool 800.29.035.000 (2) as shown in the photo, being careful not to jam the conrod. – Move the wedges (3) until the crankshaft lies flat. – Tighten the screws on the clamping bracket (4).
SERVICING THE INDIVIDUAL PARTS PRESS IN THE CRANK PIN – Press in the crankpin until flush. The lubrication bore (1) must point to the exact center (2) of the crankshaft web, as shown in the photo. 1 CAUTION: if the lubrication bore is incorrectly aligned the conrod bearing will not be supplied with lubricating oil and which will lead to engine damage. 2 D 6 – Slide the conrod bearing and the conrod on the crankpin. – Insert a suitable centering sleeve (3) in the outer part (4) of the pressing tool 800.
SERVICING THE INDIVIDUAL PARTS CHECKING THE CRANKSHAFT FOR LATERAL RUNOUT – Place the crankshaft on a roller stand or similar support and use a dial gauge to check the crankshaft for lateral runout. Lateral runout: max. 0.12 mm Check the radial clearance and axial clearance at the conrod bearing. Radial clearance: max. 0.05 mm Axial clearance: max. 1.00 mm D 7 OUTER DIMENSION OF THE CRANKSHAFT WEB – Measure the outer dimension of the crankshaft web using a sliding gauge as shown.
SERVICING THE INDIVIDUAL PARTS – Press the inner ball bearing (1) on the balance weight (2) onto the crankshaft with a suitable pipe – Only press on the inner ring. Press on the balance weight with the outer ball bearing (3) – only press on the inner ring. – Slide the spacing washer (4) (0.2 mm) onto the crankshaft. – Heat the special tool 584.29.037.037 with the new bearing inner ring (5) on a hotplate to approx. 150° C and immediately slide onto the crankshaft (see page D4).
SERVICING THE INDIVIDUAL PARTS NIKASIL CYLINDER COATING Nikasil is the brand name for a cylinder coating process developed by the Mahle piston company. The name is derived from the two materials used in the process – one layer of nickel in which the exceptionally hard silicon carbite is embedded. The major advantages of the Nikasil coating include its outstanding heat dissipation and the improved power output, the insignificant wear and low weight of the cylinder/cylinder liner.
SERVICING THE INDIVIDUAL PARTS CHECKING THE PISTON – Replace the piston if oil consumption is high or the piston skirt is excessively grooved. – If the piston is to be remounted: 1. Check the piston bearing surface for damage 2. Piston ring grooves: use a feeler gauge (A) to measure the piston ring clearance in the piston ring groove. Wear limit: 0,15 mm D 10 A The piston rings must move freely in the groove. Use old piston rings or sandpaper (400 grit) to clean the piston ring grooves. 3.
SERVICING THE INDIVIDUAL PARTS 10 4 10 6 4 D 11 5 7 2 7 11 3 1 9 CYLINDER HEAD TOP SECTION – Remove the circlip (1) and the decompression shaft (2) out of the bore together with the spring (3). – Pull the 2 end pieces (4) out of the cylinder head top section together with the rocker arm shafts (5) + (6). Remove the rocker arms (7). – Clean all parts and check for wear. – Check the rocker arm shafts (5) + (6) for score marks and smooth operation in the rocker arms (7).
SERVICING THE INDIVIDUAL PARTS CYLINDER HEAD – Remove the chain tensioning rail. – Remove the 4 valves with 590.29.019.000. the special tool D 12 NOTE: if you are mounting the used valves again, they must be mounted in the same valve guide as before. For this purpose, place the valves in a box, marking the position they were mounted in the cylinder head (see photo). – Remove the valve spring retainer (1) and the valve springs (2) from the cylinder head.
SERVICING THE INDIVIDUAL PARTS Valve guides Use the limit plug gauge 590.29.026.006 (A) (Ø 6.05 mm) to check the valve guides. If the limit plug gauge can easily be pushed into the valve guide, the valve guide needs to be replaced at a special workshop. A D 13 Valve springs Check the valve springs for fractures or other wear (visual check). Measure the spring length with a sliding gauge. The minimum length may not be less than 38.30 mm. Replace the spring if it is shorter.
SERVICING THE INDIVIDUAL PARTS CAMSHAFT – Use the extractor 590.29.033.000 to pull both grooved ball bearings (1) off of the camshaft (see illustration). CAUTION: never clamp the camshaft in a vise on the cams. – Detach the spring (2) on the automatic decompression shaft (3) while pulling the automatic decompression shaft out of the camshaft. – Loosen the 2 bolts M8x10 (4) and remove the camshaft gear (5). – Clean all of the parts, check and replace if necessary.
SERVICING THE INDIVIDUAL PARTS TIMING CHAIN TENSIONER – Pull the pressure bolt all the way out of the timing chain tensioner and check for smooth operation. – Check the toothing on the pressure bolt and the ratchet for wear. D 15 – To mount, press the ratchet in the direction shown by the arrow to keep the pressure bolt from locking and push the pressure bolt all the way into the tensioner housing. TIMING TRAIN Thoroughly clean all parts and check for wear.
SERVICING THE INDIVIDUAL PARTS 5 4 8 6 2 D 16 1 7 A B 9 3 10 CHECKING THE CLUTCH FOR WEAR Pressure piece (1) Check for seizing marks and smooth operation. Axial needle bearing (2) Check for damage. Push rod (3) Place on a flat surface and check for eccentricity. Clutch springs (4) Minimum length 41.5 mm (new 43 mm), replace all 6 springs if necessary. 7 lining disks (5) Minimum thickness 1.9 mm (new 2.0 mm). The lining disks must be flat. 8 clutch disks 1.0 mm (6) The clutch disks must be flat.
SERVICING THE INDIVIDUAL PARTS 1 D 17 6 2 5 7 4 6 3 CHECKING THE KICKSTARTER FOR WEAR Remove all parts from the kickstarter shaft, clean and perform the following visual test: – Check the toothing and the driver running surface on the kickstarter wheel (1) for wear. – Check the kickstarter shaft (2) for wear or damage. – Check the inner clutch hub (3) and the driver spring (4) for wear or damage. – Check the toothing on the kickstarter idler (5) for wear.
SERVICING THE INDIVIDUAL PARTS 10 9 6 D 18 C 7 B D 3 1 2 C A 4 1 5 4 1 4 5 SHIFT MECHANISM – Disassemble the shift shaft and clean the individual parts. – Check the shift forks (1) at the blade (A) for wear. They are 3.9 mm thick when new; the wear limit is 3.6 mm. 8 6 – Check the shift grooves on the shift drum (2) for wear. – Check whether the shift drum is properly seated in the grooved ball bearing (3). – Check the grooved ball bearing (3) for smooth operation.
SERVICING THE INDIVIDUAL PARTS GENERAL INFORMATION ON WORKING WITH THE TRANSMISSION Clamp the main shaft or countershaft in a vise (use protective jaws). Remove the gears. NOTE: if the 2nd fixed gear cannot be removed from the main shaft, use the extractor 590.29.033.000 to pull it off together with the 6th idler gear.
SERVICING THE INDIVIDUAL PARTS D 20 3 1 2 4 6 5 7 8 9 ASSEMBLING THE MAIN SHAFT (6-SPEED) – Clamp the main shaft in a vise with the thread facing down (use protective jaws). – Carefully oil all parts before assembling. – Mount the needle bearing (1), slip on the 5-speed idler (2) with the shift dogs facing up. – Mount the stop disk (3) (25.2x30x1 mm) and circlip (4) with the sharp edge facing up.
SERVICING THE INDIVIDUAL PARTS 17 16 15 12 14 13 8 11 9 7 6 3 4 5 1 2 ASSMBLING THE COUNTERSHAFT (4-SPEED/6-SPEED) – Clamp the countershaft in a vise with the toothing for the Ritzel facing down (use protective jaws). – Carefully oil all parts before assembling. – Mount the needle bearing (1) and the 2nd gear idler (2) on the countershaft with the recess for the shift dogs facing up. – Mount the stop disk (3) (25.2x32x1 mm) and the circlip (4) with the sharp edge facing up.
SERVICING THE INDIVIDUAL PARTS STARTER DRIVE D 22 – Check the toothing and the pivot point on the starter idler (1) for wear. Also check the bearing bolt for running marks. – Check the toothing and pivot point on the freewheel gear (2) for wear. Also check the bearing bolt on the freewheel gear for running marks. – Remove the freewheel gear from the freewheel and check the points of contact for pressure marks.
ASSEMBLING THE ENGINE MOUNTING THE IDLER SHAFT – Clamp the left housing half in the universal engine work stand. – Briefly heat the bearing (1) of the idler shaft (2) with a hot-air blower and mount the idler shaft, carefully tapping with a plastic hammer to the stop if necessary. 2 1 CAUTION: do not heat the bearing too long or you will damage the bearing sealing. – Connect both transmission shafts and insert in the bearings.
ASSEMBLING THE ENGINE MOUNTING THE CRANKSHAFT – Turn the mark on the idler shaft gear (1) towards the bottom as shown in the photo. 1 E 2 – The toothing on the balance weight has a punch mark (2) between 2 teeth directly opposite the compensating mass. Use a felt-tip pen to draw the mark on the outer side of the balance weight (see photo). 2 – Screw the mounting sleeve 800.29.005.000 on the left end of the crankshaft. – Position the crankshaft in the engine case, making sure both marks are aligned.
ASSEMBLING THE ENGINE – Mount new O-rings on the cylinder liner and lubricate with a little oil. – Position the well-lubricated piston on the cylinder liner and clamp the piston rings together with the piston ring clamp 600.29.015.000 (1). 1 – Tap on the top of the piston ring clamp with a hammer to make it fit flush with the cylinder liner. E 3 – Carefully tap the piston into the cylinder liner with the hammer handle, making sure the piston rings do not get caught.
ASSEMBLING THE ENGINE – Degrease the sealing areas on both engine case halves and apply a thin coat of silicone gasket sealant 309098 to the sealing area on the left housing half; mount the dowels – Place protective sleeve 800.29.105.000 on the crankshaft (1) mount the right engine housing half. 1 CAUTION: do not try to draw the two housing halves together with the housing bolts. If necessary, carefully tap on the housing near the bearings with a plastic hammer.
ASSEMBLING THE ENGINE – Screw on the oiled cylinder head bolts (1) with the washers. – Tighten the cylinder head bolts crosswise until you feel a slight resistance. – Tigthen the cylinder head bolts crosswise to 40 Nm. – Tighten the cylinder head bolts crosswise to 50 Nm. 1 – Secure the lateral cylinder head bolt (2) with Loctite 243 and tighten to 10 Nm. CAUTION: do not tighten the lateral cylinder head bolt any tighter since you may damage the feeder on the engine case.
ASSEMBLING THE ENGINE – Turn the camshaft gear until the marks (1) are aligned with the edge of the cylinder head. – Allow the chain to fall into the chain compartment on the guide side; insert the end of the chain at approx. 45º (see photo). – Continue to turn the camshaft gear in a clockwise direction one complete rotation until the marks are aligned again. The end of the chain will be just in front of the rear sprocket on the idler shaft in this position.
ASSEMBLING THE ENGINE – Degrease the sealing area on the cylinder head and the cylinder head top section and apply a thin layer of silicone gasket sealant 309098 to the sealing area of the cylinder head. – Mount the dowels and the cylinder head top section. – Mount the bolts and tighten to 10 Nm (see photo for bolt lengths). M6x55 M6x55 M6x45 NOTE: mount the M6x55 and M6x60 bolts with new copper sealing washers.
ASSEMBLING THE ENGINE MOUNTING THE OIL PUMP – Oil the outer rotor (1) and insert in the engine case with the mark towards the inside (the mark should no longer be visible once mounted). – Insert the pin in the oil pump shaft and slide on the inner rotor (2). – Mount the shaft with the inner rotor, the mark on the inner rotor pointing towards the outside (the mark should still be visible once mounted).
ASSEMBLING THE ENGINE MOUNTING THE KICKSTARTER SHAFT – Attach the kickstarter spring (1) behind the transmission gear (2) in the engine case and push the kickstarter shaft into the bearing seat. 1 2 – Slide the kickstarter (3) on the kickstarter shaft as shown in the photo. E 9 3 – Turn the kickstarter shaft with the kickstarter half a turn in a clockwise direction (to pretension the spring), slide the kickstarter shaft into the housing all the way to the stop and relieve the kickstarter.
ASSEMBLING THE ENGINE – Make sure the marks on the primary pinion and the idler shaft gear are aligned and loosen the crankshaft locking bolt 580.30.080.000. – Lock the primary pinion (1) with the special tool 800.29.004.000 (gear segment) as shown in the photo, apply Loctite 2701 to the thread of the nut M16x1 (30 mm) and tighten to 110 Nm. – Lock the idler shaft (2) with the special tool 800.29.004.
ASSEMBLING THE ENGINE – Mount the pressure cap (1) with the collar bolts, clutch springs and spring retainers. – Secure the collar bolts with Loctite 243 and tighten in several stages crosswise to 8 Nm. 1 MOUNTING THE CLUTCH COVER – Insert a new O-ring in the groove around the water duct (2). – Mount a new O-ring on the water pump shaft (3) and grease thoroughly. – Place protective sleeves (590.29.005.010 (4) and 800.29.205.000) over the water pump shaft and kickstarter shaft.
ASSEMBLING THE ENGINE M6x25 M6x25 M6x25 M6x25 M6x25 M6x30 M6x30 M6x25 E 12 M6x25 M6x25 – Screw in the bolts (see photo for bolt lengths). – Tightening torque: 10 Nm. – Insert the pin (1) in the water pump shaft, slip on the water pump wheel (2) and mount the circlip (3). 1 3 2 – Mount the water pump cover (4) with a new gasket, tighten the M6x15 bolts to 10 Nm.
ASSEMBLING THE ENGINE MOUNTING THE PRESSURE RELIEF VALVE – Slide the ball (1) and spring (2) in the hole, screw in the plug (3) with a new seal ring and tighten to 20 Nm. 3 1 2 MOUNTING THE ROTOR AND THE PICK UP – Mount the ignition rotor and the nut (4) with corrugated washer; make sure that the woodruff key is mounted. E 13 NOTE: LH thread! – Lock the crankshaft (tighten the locking bolt 580.30.080.000) and the nut (17 mm) to 60 Nm). – Remove the locking bolt again and screw in the M8x15 plug.
ELECTRIC SYSTEM CHECKING FOR LOSS OF CURRENT Check for loss of current before you check the voltage regulator-rectifier. – Switch off the ignition and disconnect the ground cable (1) from the battery. – Clamp an ampmeter between the ground cable and the negative pole (2) of the battery. 2 Setpoint value: max. 2 mA – If the value is lower than the setpoint value, look for power consumers.
ELECTRIC SYSTEM FILLING THE BATTERY – Take the battery and electrolyte container out of the packing. Read the instructions for use carefully before you fill the battery. – Remove the cover from the electrolyte container. – Insert the electrolyte container in the openings in the battery and press down firmly. – When all of the chambers in the electrolyte container are drained, pull the container off of the battery. – Tightly close the openings in the battery with the cover.
ELECTRIC SYSTEM CHECKING THE STARTER RELAY – Unscrew the brake fluid reservoir for the foot brake and let it hang down on the side. – Unscrew the negative pole from the battery and the two cables (1) from the starter relay. – Pull the connector (2) from the starter relay and remove the starter relay from the support. 2 1 – Connect the starter relay to a 12-V battery as shown in the drawing. – Use an ohmmeter to check the continuity between the screw connections.
ELECTRIC SYSTEM CHECKING THE VOLTAGE REGULATOR A defective voltage regulator (1) can have the following effect: – No voltage in the circuit In this case, disconnect the voltage regulator with the engine at idle speed. If the consumers run, the voltage regulator is defective. If there is still no voltage, the error must be in the switch, the wiring harness or in the ignition system. – Excessive voltage in the circuit Bulbs burn out. In this case the voltage regulator needs to be replaced.
ELECTRIC SYSTEM TROUBLESHOOTING IN THE IGNITION SYSTEM Before checking the ignition, make sure: – The emergency OFF switch is in the ON position – The battery is charged – The main fuse is OK Check whether there is an ignition spark upon starting: – Pull off the spark plug connector. – Disconnect the spark plug connector from the ignition wire – Hold the loose end of the ignition wire approx. 5 mm from the ground. – A strong spark should be visible when the starter is actuated.
ELECTRIC SYSTEM CDI UNIT Check the cables and socket connections to the CDI unit. The CDI unit can only be tested on an ignition test stand. CAUTION: never test the CDI unit with a conventional measuring device. Highly sensitive electronic components could be destroyed. 1 CHECKING THE IGNITION COIL – Disconnect the ignition coil and remove the spark plug connector.
ELECTRIC SYSTEM IGNITION SYSTEM General information The measurements described below will only detect serious defects. Short circuits in the coil that lead to a weak ignition spark or poor generator capacity can only be established on an ignition test stand. In case of a defect, check the cable and the plug and socket connections in the ignition system first.
ELECTRIC SYSTEM STATIC IGNITION VALUES - KOKUSAN 4K-3A, B Measuring conditions: – Cold engine – Seat and tank removed – All plugs and the ground connections are in a non-corroding condition, plugs are tightly connected – Battery charged (if installed) and the light switch turned off – Gap between the rotor and the pulse generator is set to 0.
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ELECTRIC SYSTEM STATIC GENERATOR VALUES - KOKUSAN 4K-3B Measuring conditions: – Cold engine – Seat and tank removed – All plugs and the ground connections are in a non-corroding condition, plugs are tightly connected – Battery charged (if installed) and the light switch turned off – Decompression lever is pulled – Depress the kickstarter forcefully at least 5 times for each measurement Check the generator outlet (also see circuit diagram on opposite page) for voltage between the following cable colors: – B
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FUEL SYSTEM KEIHIN FCR-MX 39/41 CARBURETOR G 1
FUEL SYSTEM DISASSEMBLING THE KEIHIN FCR-MX 39/41 CARBURETOR NOTE: Before you start to disassemble the carburetor, make sure your workplace is clean and offers enough room to spread out the individual carburetor parts. – Dismount the carburetor and remove any accumulated dirt. – Loosen the 2 screws (1) and disconnect all of the vent hoses from the carburetor. 1 1 – Remove the 2 screws (2) and lift the slide cover and gasket from the carburetor.
FUEL SYSTEM – Turn the carburetor around, remove the 3 screws and remove the cover on the accelerator pump. NOTE: When dismounting the cover, pay special attention to the spring and seal rings since they are easily lost. – Take the 2 seal rings, spring and membrane out of the pump housing. – Remove the screws from the float chamber and lift off the float chamber. G 3 – Pull out the float hinge pin (1) and remove the float together with the float needle valve. – Remove the main jet (2).
FUEL SYSTEM – Remove the screws (1) with special tool 800.29.052.000 and take off the throttle sensor (2). NOTE: Only remove the throttle sensor if it is defective. The throttle sensor must be readjusted if the screws (1) are loosened. 1 2 1 – Remove the screw (3) and pull the connecting piece out of the carburetor. 3 G 4 – Remove the 2 screws and take the intake trumpet and the O-ring (4) off of the carburetor. – Unscrew the idle-air jet (5) and main air jet (6).
FUEL SYSTEM CHECKING THE CHOKE SLIDE AND THE HOT START KNOB Choke slide: The choke slide must be easily actuated. The piston (1) on the choke slide may not have any deep scores or deposits. 1 Hot start knob: The hot start knob must be easily actuated. The piston on the hot start knob may not have any deep scores or deposits. CHECKING THE ACCELERATOR PUMP Check the diaphragm for crack formation or brittleness. Check the gaskets for damage. Check the holes (2) for free passage.
FUEL SYSTEM CHECKING THE THROTTLE SLIDE The rollers (1) on the throttle slide should be easy to turn and not have any flat areas. Check the throttle slide shim (2) for damage. 2 1 ASSEMBLING THE KEIHIN FCR-MX 39/41 CARBURETOR – Mount the idle-air jet (3) and the main air jet (4). – Place the O-ring (5) in the groove and attach the intake trumpet to the carburetor with the 2 screws. 5 3 G 6 4 – Insert the fuel connection in the carburetor and fix with the screw (6).
FUEL SYSTEM – Mount the spring, washer and the O-ring on the mixture control screw (1) and turn the mixture control screw all the way in to the stop. – Now unscrew the mixture control screw the number of turns written down during disassembly. 1 2 NOTE: Basic carburetor setting: see Technical specifications. 4 – Mount the idling jet (2), starting jet (3) and needle jet together with the main jet (4). 3 – Insert the needle valve seat (5) in the hole and fix with the screw (6).
FUEL SYSTEM – Place the spring and the diaphragm (1) in the pump housing with the inscription facing up. – Place the O-ring (2) in the groove. Fix the seal ring (3) in the cover with a little grease and fasten the cover with the 3 screws. 1 2 3 – Mount the throttle sensor so that the flat part of the carburetor engages in the groove in the throttle sensor, tighten the screws with special tool 800.29.052.000.
FUEL SYSTEM – Position the slide cover with the gasket and fasten with the 2 screws (1). 1 1 – Attach the vent hoses to the float chamber with the 2 screws (2).
FUEL SYSTEM ADJUSTING THE POSITION THROTTLE SENSOR OF THE NOTE: The idle speed must be correctly adjusted before you check the position of the throttle sensor. – Disconnect the plug and socket connection on the throttle sensor. – Connect a multimeter (measuring range Ω x 1k) to the blue (+) and the black (–) cable on the throttle sensor and measure the throttle resistance. – Multiply this value by 0.15 to obtain the setting for the throttle sensor.
FUEL SYSTEM CHECKING THE THROTTLE SENSOR NOTE: The following measurement must be performed at a component temperature of approx. 20°C. – Disconnect the plug connection on the throttle sensor. – Connect a multimeter (measuring range . x 1k) to the blue (+) and the black (–) cable on the throttle sensor. Throttle sensor resistance: 4 - 6 kΩ – Now connect the multimeter to the yellow (+) and the black (–) cables on the throttle sensor.
FUEL SYSTEM ADJUSTING THE CARBURETOR IDLE The carburetor idle setting has a strong influence on the engine's starting behavior. In other words, an engine with a correctly adjusted idle will be easier to start than an engine with an incorrectly adjusted idle. The idle is adjusted via the adjusting knurl (1) and the mixture control screw (2). The basic throttle slide position is adjusted with the adjusting knurl.
FUEL SYSTEM GENERAL INFORMATION ON CARBURETOR WEAR Engine vibrations make the throttle slide, jet needle and main jet holder subject to increased wear. Wear leads to malfunctioning of the carburetor (e.g. over enrichment). These parts should be replaced after 200 operating hours. ADJUSTING THE MIXTURE CONTROL SCREW The mixture control screw (1) is used to adjust the idle mixture.
TROUBLESHOOTING ERROR CAUSE REMEDY Engine does not switch on (starter) Operating error Switch on the emergency OFF switch (Australia only) Fuse is blown Replace the fuse in the starter relay Battery is dead Charge the battery and determine the cause of discharging Low outdoor temperature Start the engine with the kickstarter Operating error Open the fuel tap, refuel, do not actuate the choke, follow start-up instructions (see driving instructions) Motorcycle was not operated for a longer perio
TROUBLESHOOTING 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 Check the ignition system 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-
TECHNICAL SPECIFICATIONS - ENGINE Engine Design Displacement Bore/Stroke Compression ratio Keihin carburetor FC 450/4 FE 450e/6 FS 450e/6 FE 501e/6 Liquid-cooled, 1-cylinder 4-stroke Otto engine with balancer weight 449 cm3 501 cm3 100 / 57,2 mm 95 / 70,7 mm 13:1 11,6:1 FCR-MX 41 FCR-MX 39 Fuel unleaded fuel with at least RON 95 (USA = Premium RON 91) 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 Val
TECHNICAL SPECIFICATIONS - ENGINE Engine Design Displacement Bore/Stroke Compression ratio Keihin carburetor Fuel I 2 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 unleaded fuel with at least RON 95 (USA = Premium RON 91) 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 cle
TECHNICAL SPECIFICATIONS - CHASSIS 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
TECHNICAL SPECIFICATIONS - ENGINE TIGHTENING TORQUES I 4 HH collar bolts on housing, clutch cover, ignition cover Oil drain plug HH plug oil screen AH collar bolt on oil filter cover Plug on pressure relief valve HH bolts on oil pump cover HH collar bolt on cylinder head top section AH bolts on valve cover HH collar bolts on water pump cover HH bolts on cylinder head HH bolt on cylinder head AH bolts on camshaft gear HH nut on automatic decompression stop AH bolts on rocker arm shaft silencer cap Countern
TECHNICAL SPECIFICATIONS - CHASSIS TIGHTENING TORQUES Collar bolt on front wheel spindle Bolts on front brake caliper Collar bolts of front brake pads - FS models only Bolts on brake disks Clamp bolts on top triple clamp Clamp bolts on bottom triple clamp Clamp nut on triple clamp Clamp bolt on fork leg Collar nut on rear axle passage Hexagon nut on swing arm pivot Collar bolt on handlebar clamp AH bolt on handlebar mount Shock absorber top Shock absorber bottom Rear sprocket bolts Ball joint on push rod En
TECHNICAL SPECIFICATIONS - ENGINE MOUNTING CLEARANCES, WEAR LIMITS Crankshaft Conrod bearings Cylinder liner 450, 550, 650 Zylinderlaufbüchse 501 Piston 450, 550, 650 uncoated Piston 450, 550, 650 coated Piston 501 Piston ring end gap Valves Valve springs Oil pump I 6 Clutch Transmission shafts Rocker arm Axial clearance 450. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,15 - 0,25 mm Axial clearance 501, 550. . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE SCHEDULE FC 450/4, FC 550/4 MODEL 2004 WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBURETOR ENGINE A clean motorcycle can be checked more quickly which saves money! 1.
PERIODIC MAINTENANCE SCHEDULE FE 450,501,550,650 E/6, FS 450,650 E/6 MODEL WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBURETOR ENGINE A clean motorcycle can be checked more quickly which saves money! J 2 2004 1.
PERIODIC MAINTENANCE SCHEDULE IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED 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 leaks Drain and clean flo
PERIODIC MAINTENANCE SCHEDULE 90 hours 600 liter 120 hours 800 liter 180 hours 1200 liter 240 hours 1600 liter 270 hours 1800 liter Check the clutch disks for wear Check the length of the clutch springs Check the cylinder and piston for wear Check the groove on the piston pin retainer for wear (visual check) Check the camshaft for wear (visual check) Check the camshaft bearings Check the length of the valve springs Check the spring cap for wear Check the eccentricity of the valve disk Check the valve
ignition coil brown blue-white yellow-black C Husaberg FC 04 black red-white G generator red-black D stop button 3 pick up blue 800.11.075.
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WIRING DIAGRAMS 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.
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WIRING DIAGRAMS start switch cable switch re- yewh re START unpushed K 5
headlight position light driving light lamp front brake switch flasher control lamp left front flasher right front flasher br bu wh-gn ye br pu br bl bu bu pu br ye br ye ye-bl br ye-bl br re ye ignition coil ye-bl ye-bl Husaberg FS 04 br wh br br ye ye-re bl-wh multi-func.
WIRING DIAGRAMS 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.
WIRING DIAGRAMS Cable colours bl: black ye: yellow bu: blue gn: green re: red wh: white br: brown or: orange pi: pink gr: grew pu: purple K 8
Cover: Büro 3 Communication, Photos: Florian Jaenicke. 09/2003 ART. NR. 3.803.000 HUSABERG - a company of the KTM Group Stallhofner Straße 3, A-5230 Mattighofen E-mail: info@husaberg.cc, Internet: www.husaberg.
