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Table of Contents
Related Manuals for Husqvarna FE 450
Summary of Contents for Husqvarna FE 450
- Page 1 OWNER'S MANUAL 2017 FE 450 FE 501 Art. no. 3402103en...
- Page 3 Husqvarna Motorcy- cles accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.
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Page 4: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS Setting the service display........23 MEANS OF REPRESENTATION........5 Speed, time, and DST distance 1 ....... 24 Symbols used ............5 Speed, time, and DST2 distance 2 ..... 24 Formats used ............5 7.10 AVG average speed, ART operating hours, SAFETY ADVICE ............... - Page 5 TABLE OF CONTENTS SERVICE WORK ON THE CHASSIS ....... 45 13.8 Checking the free travel of foot brake lever..75 12.1 Raising the motorcycle with a lift stand....45 13.9 Adjusting the basic position of the foot brake lever ..............75 12.2 Removing the motorcycle from the lift stand..
- Page 6 TABLE OF CONTENTS STORAGE..............108 20.1 Storage ............. 108 20.2 Preparing for use after storage ......108 TROUBLESHOOTING ........... 109 TECHNICAL DATA ............111 22.1 Engine ............... 111 22.2 Engine tightening torques......... 111 22.3 Capacities ............113 22.3.1 Engine oil............113 22.3.2 Coolant ............
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Page 7: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interests of your own safety, have these jobs performed by an authorized Husqvarna Motorcycles workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required. -
Page 8: Safety Advice
SAFETY ADVICE Use definition – intended use Husqvarna motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations. Info Only trained personnel are allowed to drive the vehicle. The motorcycle is authorized for public road traffic in the homolo- gated (reduced) version only. -
Page 9: Safe Operation
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized Husqvarna Motorcycles dealer will be glad to advise you. -
Page 10: Owner's Manual
SAFETY ADVICE Owner's Manual It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual con- tains useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury. -
Page 11: Important Notes
Manufacturer and implied warranty The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles workshop only and con- firmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motorcycles Dealer.net; otherwise, all warranty claims will be void. -
Page 12: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) H01739-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Filler cap Air filter box cover Side stand ( p. 19) Engine number ( p. 12) Shift lever ( p. -
Page 13: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) H01738-10 Fork compression adjustment Kill switch ( p. 14) Horn button ( p. 14) Light switch ( p. 15) Turn signal switch ( p. 15) Emergency OFF switch ( p. 15) Electric starter button ( p. -
Page 14: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Key number The key number for the steering lock is stamped onto the key connector. -
Page 15: Shock Absorber Article Number
SERIAL NUMBERS Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 0 0 1 401948-10... -
Page 16: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. F00257-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The hand brake lever is used to activate the front brake. -
Page 17: Light Switch
CONTROLS Light switch Light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on. High beam on –... -
Page 18: Combination Switch
CONTROLS 6.10 Combination switch The combination switch is fitted on the left side of the handlebar. Possible states STANDARD – STANDARD mapping is activated when LED 1 lights up. STANDARD with TC – STANDARD mapping with traction control is activated when LED 1 and TC light up. ADVANCED –... -
Page 19: Closing The Filler Cap
CONTROLS Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Press release button , turn the filler cap counterclockwise, and lift it off. F00265-10 6.13 Closing the filler cap... -
Page 20: Idle Speed Adjusting Screw
CONTROLS 6.15 Idle speed adjusting screw The idle speed is adjusted using the idle speed adjusting screw Increase the idle speed by turning the idle speed adjusting screw clockwise. Decrease the idle speed by turning the idle speed adjusting screw counterclockwise. The idle setting of the throttle valve body has a big influence on the vehicle's starting behavior, on stable idling, and on vehicle response when the throttle is opened. -
Page 21: Side Stand
CONTROLS 6.18 Side stand The side stand is attached to the left side of the vehicle. 401943-10 The side stand is used for parking the motorcycle. Info When you are riding, side stand must be folded up and secured with rub- ... -
Page 22: Unlocking The Steering
CONTROLS 6.21 Unlocking the steering – Insert the key in the steering lock ( p. 19), turn it to the left, pull it out, and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock. -
Page 23: Speedometer
Message on the speedometer Possible states Battery voltage of the speedometer – Battery voltage of the speedometer is too low. Change the battery. Service – A service is due. Contact an authorized Husqvarna Motorcy- cles workshop. 401901-01 Setting the speedometer Condition The motorcycle is stationary. -
Page 24: Setting The Kilometers Or Miles
SPEEDOMETER – Wait for 5 seconds. The speedometer changes to the next menu item. The symbol flashes. Resetting the time – Press the left button. The value decreases. Advancing the time – Press the right button. The value increases. 401912-01 –... -
Page 25: Setting The Clock
SPEEDOMETER Setting the clock Condition The motorcycle is stationary. – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. – Wait for the menu of the clock to flash. – Press one of the buttons to select the 24h or 12h display of the clock. 401911-01 –... -
Page 26: Speed, Time, And Dst Distance 1
SPEEDOMETER Speed, time, and DST distance 1 – Press one of the buttons until DST appears on the speedometer. KM/H or M/H shows the speed. shows the time. DST shows the distance since the last reset, such as between two refueling stops. Info If the value of 39999.9 is exceeded, DST is automatically reset to 0.0. -
Page 27: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized Husqvarna Motorcycles workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover. -
Page 28: Running-In The Engine
PREPARING FOR USE – Try also to ride as slowly as possible and in a standing position to get a better feeling for the motorcycle. – Do not make any off-road trips that exceed your ability and experience. – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. –... -
Page 29: Preparing For Rides On Dry Sand
Preparing for rides on dry sand – Fit a dust cover on the air filter. Dust cover for air filter (79006920000) Info See the Husqvarna Motorcycles accessories fitting instructions. 102136-01 – Fit a sand cover on the air filter. Sand cover for air filter (79006922000) Info See the Husqvarna Motorcycles accessories fitting instructions. -
Page 30: Preparing For Rides On Wet And Muddy Surfaces
Preparing for rides on wet and muddy surfaces – Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info See the Husqvarna Motorcycles accessories fitting instructions. 102137-01 – Fit the steel sprocket. – Clean the motorcycle. ( p. -
Page 31: Preparing For Rides At High Temperature And Slow Speed
Check the coolant level. ( p. 95) Preparing for rides at low temperature or in snow – Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info See the Husqvarna Motorcycles accessories fitting instructions. 102137-01... -
Page 32: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –... -
Page 33: Activating Launch Control
RIDING INSTRUCTIONS – Press the electric starter button. Info Press the electric starter button for a maximum of 5 seconds. Wait for 30 seconds before a further attempt at starting. At temperatures below 15 °C (60 °F), several attempts at starting may be necessary to warm-up the lithium-ion battery and thereby increase the starting power. -
Page 34: Starting Off
Do not change into a low gear at high engine speed. Info If unusual noises occur while riding, stop immediately, switch off the engine, and contact an authorized Husqvarna Motorcy- cles workshop. First gear is used for starting off and for steep inclines. -
Page 35: Stopping, Parking
RIDING INSTRUCTIONS – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. – Make use of the braking effect of the engine when driving down long downhill stretches. To do so, shift back one or two gears, but do not overrev the engine. -
Page 36: Refueling
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Environmental hazard Improper handling of fuel is a danger to the environment. -
Page 37: Service Schedule
Every 30 operating hours/after every race Every 15 operating hours Once after 1 operating hour ○ ● ● Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. ○ ● ● Check that the electrical system is functioning properly. ●... -
Page 38: Recommended Work
Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics tool. ○ ● ● Make the service entry in the Husqvarna Motorcycles Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval 10.3... -
Page 39: Tuning The Chassis
The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber. -
Page 40: Adjusting The High-Speed Compression Damping Of The Shock Absorber
The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber. -
Page 41: Measuring The Rear Wheel Dimension Unloaded
TUNING THE CHASSIS 11.6 Measuring the rear wheel dimension unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) Main work – Position the sag gauge in the rear axle and measure the distance to marking SAG on the rear fender. -
Page 42: Checking The Riding Sag Of The Shock Absorber
The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 43: Adjusting The Riding Sag
TUNING THE CHASSIS – Remove the motorcycle from the lift stand. ( p. 45) 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) – Remove the shock absorber. p. 52) – After removing the shock absorber, clean it thoroughly. -
Page 44: Adjusting The Rebound Damping Of The Fork
TUNING THE CHASSIS – Turn white adjusting screw clockwise as far as it will go. Info Adjusting screw is located at the upper end of the left fork leg. The compression damping is located in left fork leg COM (white adjusting screw). -
Page 45: Handlebar Position
TUNING THE CHASSIS Guideline Spring preload - Preload Adjuster Comfort Standard Sport The adjusting wings engage noticeably at the numerical values. Info Adjust the spring preload to the numerical values only as the preload will not engage between the numerical values. Turn clockwise to increase the spring preload;... - Page 46 TUNING THE CHASSIS – Position the handlebar clamps. Mount and tighten screws evenly. Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Info Make sure the gap width is even.
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Page 47: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (81329955100) Neither wheel is in contact with the ground. -
Page 48: Removing The Fork Protector
SERVICE WORK ON THE CHASSIS Warning Danger of accidents Oil or grease on the brake discs reduces the brak- ing effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –... -
Page 49: Installing The Fork Legs
SERVICE WORK ON THE CHASSIS – Loosen screws . Take out the left fork leg. – Loosen screws . Take out the right fork leg. F00275-10 12.8 Installing the fork legs Main work – Position the fork legs. ... -
Page 50: Installing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS Main work – Open the cable holder in front of the right radiator and detach the wiring harness. – Remove screws and hang the voltage regulator to the side. – Open the cable holder in front of the left radiator and detach the wiring harness. F00277-10 –... - Page 51 SERVICE WORK ON THE CHASSIS – Secure wiring harness and clutch line with cable holder. – Position the voltage regulator, and mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Secure the wiring harness with the cable holder in front of the right radiator. F00373-10 –...
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Page 52: Checking The Play Of The Steering Head Bearing
Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time. -
Page 53: Adjusting The Steering Head Bearing Play
SERVICE WORK ON THE CHASSIS 12.12 Adjusting the steering head bearing play Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) Main work – Loosen screws – Remove screw – Loosen and retighten screw Guideline Screw, top steering head M20x1.5... -
Page 54: Installing The Front Fender
SERVICE WORK ON THE CHASSIS 12.15 Installing the front fender Main work – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) F00283-10 Finishing work... -
Page 55: Installing The Shock Absorber
SERVICE WORK ON THE CHASSIS – Disconnect plug-in connector F00458-10 – Remove screws – Pull off foot brake cylinder from the push rod. F00459-10 – Remove the connecting link of the chain. – Take off the chain. F00294-01 –... -
Page 56: Mount And Tighten Screw
SERVICE WORK ON THE CHASSIS – Position the swingarm and mount the swingarm pivot. Info Pay attention to flat area – Mount and tighten nut Guideline Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) F00463-10 – Mount the chain. –... -
Page 57: Removing The Seat
SERVICE WORK ON THE CHASSIS – Position the frame protectors on the left and right. – Mount and tighten screws Guideline Screw, frame protector 3 Nm (2.2 lbf ft) – Mount and tighten screws with the washers. Guideline Screw, frame protector 3 Nm (2.2 lbf ft) K00589-11... -
Page 58: Removing The Air Filter Box Cover
SERVICE WORK ON THE CHASSIS 12.20 Removing the air filter box cover – Pull off the air filter box cover sideways in areas , and remove toward the front. F00457-10 12.21 Installing the air filter box cover –... -
Page 59: Installing The Air Filter
SERVICE WORK ON THE CHASSIS 12.23 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 118) 102178-10 – Insert air filter and position retaining pin in bushing The air filter is correctly positioned. -
Page 60: Sealing The Air Filter Box
SERVICE WORK ON THE CHASSIS 12.25 Sealing the air filter box Preparatory work – Remove the air filter box cover. ( p. 56) Main work – Seal the air filter box in the marked area F00248-01 Finishing work – Install the air filter box cover. -
Page 61: Removing The Main Silencer
SERVICE WORK ON THE CHASSIS 12.28 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. Preparatory work –... -
Page 62: Removing The Fuel Tank
SERVICE WORK ON THE CHASSIS Main work – Remove all screws on the main silencer. – Take off silencer cap and O-ring – Take off outer tube and O-ring – Remove glass fiber yarn filling from inner tube –... -
Page 63: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Disconnect the plug-in connection of the fuel line. Info Remaining fuel may flow out of the fuel hose. – Mount wash cap set Wash cap set (81212016100) – Remove the tube from the fuel tank breather. K00597-10 –... -
Page 64: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS Main work – Check throttle cable routing. ( p. 67) – Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracket. – Make sure that no cables or throttle cables are trapped or damaged. F00309-11 –... -
Page 65: Cleaning The Chain
SERVICE WORK ON THE CHASSIS 12.34 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. – Remove the lubricant from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –... -
Page 66: Adjusting The Chain Tension
SERVICE WORK ON THE CHASSIS Main work – Pull the chain at the end of the chain sliding piece upward to measure chain ten- sion Info The lower chain section must be taut. When the chain guard is mounted, it must be possible to pull up the chain ... -
Page 67: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide
SERVICE WORK ON THE CHASSIS 12.37 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) Main work – Shift the transmission to idle. – Check the rear sprocket and engine sprocket for wear. »... -
Page 68: Checking The Frame
If the frame exhibits cracks or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechan- ical impact. Repair of the frame is not authorized by Husqvarna Motorcycles. F00255-01... -
Page 69: Checking The Swingarm
» If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info Always change a damaged swingarm. Repair of the swingarm is not authorized by Husqvarna Motorcycles. 401520-01 12.40 Checking throttle cable routing Preparatory work –... -
Page 70: Adjusting The Basic Position Of The Clutch Lever
SERVICE WORK ON THE CHASSIS – Check that screw is firmly seated. Guideline Screw, fixed grip 5 Nm Loctite ® 243™ (3.7 lbf ft) Diamond must be located at the top. F00323-10 12.42 Adjusting the basic position of the clutch lever –... -
Page 71: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS 12.44 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. –... -
Page 72: Removing The Engine Guard
SERVICE WORK ON THE CHASSIS 12.45 Removing the engine guard – Remove screws and engine guard. H01655-01 12.46 Installing the engine guard – Attach the engine guard on the frame at the rear and swing up at the front. –... -
Page 73: Brake System
Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Check the thickness of the front and rear brake discs at multiple points on each ... -
Page 74: Checking The Front Brake Fluid Level
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. -
Page 75: Checking The Front Brake Linings
Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥... - Page 76 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
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Page 77: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Insert the new brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. -
Page 78: Checking The Rear Brake Fluid Level
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. -
Page 79: Checking The Rear Brake Linings
Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥... -
Page 80: Changing The Rear Brake Linings
Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings. - Page 81 BRAKE SYSTEM – Press the brake caliper onto the brake disc by hand in order to push back the brake piston and ensure that brake fluid does not flow out of the brake fluid reser- voir, extracting it by suction if it does. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.
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Page 82: Wheels, Tires
WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons. -
Page 83: Removing The Rear Wheel
WHEELS, TIRES – Insert the spacers. – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) – Operate the hand brake lever several times until the brake linings are seated cor- rectly against the brake disc. -
Page 84: Installing The Rear Wheel
WHEELS, TIRES 14.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Main work –... -
Page 85: Checking The Tire Condition
DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. Husqvarna Motorcycles recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear. H01144-01 »... -
Page 86: Checking Spoke Tension
Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) –... -
Page 87: Electrical System
ELECTRICAL SYSTEM 15.1 Removing the battery Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. – Only charge batteries in well-ventilated rooms. – Maintain a minimum clearance from inflammable materials when charging batteries. -
Page 88: Recharging The Battery
ELECTRICAL SYSTEM – Slide positive terminal cover over the positive terminal. – Connect negative cable to the battery. Guideline Screw, battery terminal 2.5 Nm (1.84 lbf ft) – Slide negative terminal cover over the negative terminal. Finishing work –... -
Page 89: Changing The Main Fuse
ELECTRICAL SYSTEM – Recharge the battery. Guideline Maximum charging voltage 14.4 V Maximum charging current 3.0 A Maximum charging time 12 h Charge the battery regularly when 6 months the motorcycle is not in use Ideal charging and storage tem- 10…... -
Page 90: Changing The Fuses Of Individual Power Consumers
ELECTRICAL SYSTEM – Take off protection caps – Remove faulty main fuse Info You can recognize a defective fuse by a burned-out fuse wire A spare fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109120) ( p. -
Page 91: Removing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Use spare fuses with the correct rating only. Fuse (75011088010) ( p. 114) Replace the spare fuse in the fuse box so that it is available if needed. -
Page 92: Installing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM 15.7 Installing the headlight mask with the headlight Main work – Connect plug-in connectors F00340-11 – Position the headlight mask and secure it with rubber bands The holding lugs engage in the fender. F00341-10 – ... -
Page 93: Changing The Turn Signal Bulb
ELECTRICAL SYSTEM – Pull out headlight bulb – Insert the new headlight bulb. Headlight (HS1 / Sockel PX43t) ( p. 114) – Insert the protection cap with the bulb socket into the reflector and turn it clock- wise all the way. –... -
Page 94: Adjusting The Headlight Range
ELECTRICAL SYSTEM » If the light-dark border does not meet specifications: – Adjust the headlight range. ( p. 92) 15.11 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 91) Main work – Loosen screw –... -
Page 95: Diagnostics Connector
ELECTRICAL SYSTEM 15.13 Diagnostics connector Diagnostics connector is located under the seat. H00933-12... -
Page 96: Cooling System
COOLING SYSTEM 16.1 Cooling system The water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. -
Page 97: Checking The Coolant Level
COOLING SYSTEM – Mount the radiator cap. 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature. -
Page 98: Refilling Coolant
COOLING SYSTEM – Position the motorcycle upright. – Place a suitable container under the water pump cover. – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) -
Page 99: Tuning The Engine
TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3…... -
Page 100: Setting The Characteristic Map Of The Throttle Response
TUNING THE ENGINE – Check the throttle grip for smooth operation. Finishing work – Check the play in the throttle cable. ( p. 97) 17.3 Setting the characteristic map of the throttle response Info On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate. A guide plate with a different characteristic map is supplied. -
Page 101: Changing The Mapping
Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Run the engine until warm. -
Page 102: Teaching The Throttle Valve Position
TUNING THE ENGINE Info Turning counterclockwise lowers the idle speed. Turning clockwise raises the idle speed. 17.6 Teaching the throttle valve position Info If the control unit detects that the throttle valve idle position needs to be retaught, then the malfunction indicator lamp flashes 2x per second. - Page 103 TUNING THE ENGINE – Mount and tighten screw with the washers. Guideline Screw, shift lever 14 Nm Loctite ® 243™ (10.3 lbf ft)
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Page 104: Service Work On The Engine
SERVICE WORK ON THE ENGINE 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –... -
Page 105: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens
SERVICE WORK ON THE ENGINE Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil is at a level between the lower edge and the middle the level viewer. - Page 106 SERVICE WORK ON THE ENGINE – Mount and tighten screw plug with the short oil screen and the O-rings. Guideline Screw plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) F00442-11 – Position long oil screen with the O-rings on a pin wrench. –...
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Page 107: Adding Engine Oil
SERVICE WORK ON THE ENGINE – Remove filler plug with the O-ring from the clutch cover and fill up with engine oil. Engine oil 1.2 l (1.3 qt.) Engine oil (SAE 10W/50) ( p. 117) Info Too little engine oil or poor-quality engine oil results in premature wear of the engine. -
Page 108: Cleaning, Care
CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –... -
Page 109: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If you use the vehicle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt. -
Page 110: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info Husqvarna Motorcycles recommends raising the motorcycle. – Raise the motorcycle with a lift stand. ( p. 45) –... -
Page 111: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Carry out the start procedure. ( p. 30) tric starter) – Battery is discharged Recharge the battery. p. 86) – Check the charging voltage. – Check the closed current. –... - Page 112 TROUBLESHOOTING Faults Possible cause Action – Engine overheats Foam formation in cooling system Drain the coolant. p. 95) – Refill the coolant. p. 96) – Bent radiator hose Change the radiator hose. – Thermostat defective Check the thermostat. Guideline Opening temperature: 70 °C (158 °F) –...
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Page 113: Technical Data
TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement (All 450 models) 449.9 cm³ (27.455 cu in) Displacement (All 501 models) 510.9 cm³ (31.177 cu in) Stroke (All 450 models) 63.4 mm (2.496 in) Stroke (All 501 models) 72 mm (2.83 in) Bore 95 mm (3.74 in) Compression ratio... - Page 114 TECHNICAL DATA ® Loctite 243™ Nut, water pump impeller 6 Nm (4.4 lbf ft) – Screw, alternator cover 10 Nm (7.4 lbf ft) ® Loctite 243™ Screw, bearing bolt, torque limiter 10 Nm (7.4 lbf ft) ® Screw, camshaft support plate 10 Nm (7.4 lbf ft) Loctite 243™...
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Page 115: Capacities
TECHNICAL DATA 22.3 Capacities 22.3.1 Engine oil Engine oil 1.2 l (1.3 qt.) Engine oil (SAE 10W/50) ( p. 117) 22.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p. 117) 22.3.3 Fuel Total fuel tank capacity, 8.5 l (2.25 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. -
Page 116: Electrical System
140/80 - 18 M/C 70M M+S TT Metzeler MCE 6 DAYS EXTREME Metzeler MCE 6 DAYS EXTREME The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com 22.7 Fork Fork article number 14.15.8Q.69... -
Page 117: Shock Absorber
TECHNICAL DATA +0.39 Air chamber length mm (4.33 −20 −0.79 Fork oil per fork leg 610 ml (20.62 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 117) 22.8 Shock absorber Shock absorber article number 18.15.7Q.69 Shock absorber WP Performance Systems 5018 DCC Link Compression damping, low-speed Comfort 17 clicks... - Page 118 TECHNICAL DATA – Fuel connection on fuel pump 10 Nm (7.4 lbf ft) – Nut, foot brake lever stop 20 Nm (14.8 lbf ft) ® Loctite 2701™ Nut, rear sprocket screw 35 Nm (25.8 lbf ft) – Nut, rim lock 12 Nm (8.9 lbf ft) –...
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Page 119: Substances
SUBSTANCES Brake fluid DOT 4 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the cor- responding properties. Recommended supplier ® Bel‑Ray – Super DOT 4 Brake Fluid Coolant Guideline –... -
Page 120: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel‑Ray – Foam Filter Cleaner & Degreaser High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier ® Bel‑Ray – Waterproof Grease Offroad chain spray Guideline Recommended supplier ®... -
Page 121: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines. -
Page 122: Index Of Special Terms
INDEX OF SPECIAL TERMS On-board diagnosis Vehicle system that monitors emission- and safety-related val-... -
Page 123: List Of Abbreviations
LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly... -
Page 124: List Of Symbols
LIST OF SYMBOLS 28.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an emission- or safety-critical fault. -
Page 125: Index
INDEX INDEX Clutch fluid level, checking/correcting ....68 Accessories ....... . . 9 fluid, changing . - Page 126 INDEX Foot brake lever ......18 Kill switch ........14 basic position, adjusting .
- Page 127 INDEX checking ....... . . 97 Safe operation ....... 7 Throttle cable routing checking .
- Page 128 *3402103en* 3402103en 07/2016 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer, www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...