Husqvarna FE 450 2016 Repair Manual
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Husqvarna FE 450 2016 Repair Manual

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PIONEERING SINCE 1903
REPAIR MANUAL2016
leJ
FE 450
FE 501
FE 501 S
®
Husqvarna
Art. no. 3403030en
MOTORCYCLES

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Summary of Contents for Husqvarna FE 450 2016

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2016 FE 450 FE 501 FE 501 S ® Husqvarna Art. no. 3403030en MOTORCYCLES...
  • Page 3 Husqvarna accepts no liability for delivery options, deviations from figures 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.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.14 Disassembling the hydrostop unit ..26 MEANS OF REPRESENTATION ......8 6.15 Disassembling the seal ring Symbols used ........8 retainer ..........27 Formats used ........8 6.16 Checking the fork legs ......27 SAFETY ADVICE ..........9 6.17 Assembling the seal ring retainer ..
  • Page 5 TABLE OF CONTENTS Adjusting the spring preload of the 12.3 Removing the right side cover .... 97 shock absorber ........54 12.4 Installing the right side cover ....97 Adjusting the riding sag ...... 55 12.5 Removing the seat ......98 Removing the shock absorber ....
  • Page 6 TABLE OF CONTENTS WIRING HARNESS, BATTERY ...... 141 18.3.5 Removing the starter motor ..183 18.3.6 Removing the spark plug ..... 183 15.1 Changing the fuses of individual 18.3.7 Removing the valve cover .... 183 power consumers ......141 18.3.8 Removing the alternator cover ..
  • Page 7 TABLE OF CONTENTS 18.4.39 Disassembling the 18.4.3 Removing the oil pressure regulator valve ......201 countershaft ......... 224 18.4.4 Checking spring length of oil 18.4.40 Assembling the countershaft ..224 pressure regulator valve ....201 18.4.41 Checking the transmission ... 225 18.4.5 Installing the oil pressure 18.4.42...
  • Page 8 TABLE OF CONTENTS TECHNICAL DATA ........273 18.5.35 Installing the valve cover ....246 18.5.36 Installing the spark plug ....247 Engine ..........273 26.1 18.5.37 Installing the starter motor ... 247 26.2 Tolerance, engine wear limits ... 274 18.5.38 Installing the oil filter .....
  • Page 9 TABLE OF CONTENTS 30.24 Page 2 of 8 (FE 501 S US) ....334 30.25 Page 3 of 8 (FE 501 S US) ....336 30.26 Page 4 of 8 (FE 501 S US) ....338 30.27 Page 5 of 8 (FE 501 S US) ....340 30.28 Page 6 of 8 (FE 501 S US) ....

  • Page 10: Means Of Representation

    MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips .

  • Page 11: Safety Advice

    Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special Husqvarna tools and Husqvarna workplace and workshop equipment are available.

  • Page 12: Important Notes

    IMPORTANT NOTES Manufacturer and im�lied warran� The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles workshop only and confirmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motor­ cycles Dealer.net;...

  • Page 13: Serial Numbers

    4 SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 401945-10 T¥ e label {FE EU/ AU FE 501 S US) (FE EU/AU) The type label is fixed to the front of the steering head. 401946-10 (FE 501 SUS) The type label...

  • Page 14: Key Number (Fe Eu/Au, Fe 501 S Us)

    4 SERIAL NUMBERS Ke� number (FE EU/ AU, FE 501 S US) (FE EU/AU) The key number for the steering lock is stamped onto the key connector. 402247-10 (FE 501 SUS) Key number for the ignition and steering lock is indicated on the KEYCODECARD.

  • Page 15: Shock Absorber Article Number

    4 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.

  • Page 16: Motorcycle

    5 MOTORCYCLE Raising the motorcycle with a lift stand Note The parked vehicle can roll away or fall Danger of damage over. Park the vehicle on a firm and level surface. Raise the motorcycle at the frame underneath the engine. I Lift stand (81329955100) (!;,!I p.

  • Page 17: Starting The Motorcycle To Check The Function

    5 MOTORCYCLE Raise the motorcycle off of the stand and secure the stand with the rubber band Shift transmission to neutral. (FE 501 SUS) Turn the key in the ignition lock to the position 0. Turn the emergency OFF switch to the position 0. (FE AU) Turn the emergency OFF switch to the position 0.

  • Page 18: Fork, Triple Clamp

    6 FORK, TRIPLE CLAMP Adjusting the com�ression dam�ing of the fork Info The hydraulic compression damping determines the fork suspension behavior. Turn white adjusting screw all the way clockwise. Info Adjusting screw is located at the upper end of the left fork leg.

  • Page 19: Bleeding The Fork Legs

    6 FORK, TRIPLE CLAMP Info Turn clockwise to increase damping; turn counter­ clockwise to reduce damping. Bleeding the fork legs Preparatory work Raise the motorcycle with a lift stand.(� p. 14) Main work Release bleeder screws ✓ Any excess pressure escapes from the interior of the fork.

  • Page 20: Removing The Fork Legs

    6 FORK, TRIPLE CLAMP Finishing work Install the fork protector. (l!!ll p. 20) Remove the motorcycle from the lift stand. (l!!ll p. 14) Removing the fork legs Preparatory work Remove the headlight mask with the headlight. (l!!ll p. 114) Raise the motorcycle with a lift stand. (l!!ll p.
  • Page 21 6 FORK, TRIPLE CLAMP Info The compression damping is located in left fork COMP (white adjusting screw). The rebound damping is located in right fork leg REB (red adjusting screw). Grooves are milled into the side of the upper end of the fork legs.

  • Page 22: Removing The Fork Protector

    6 FORK, TRIPLE CLAMP Removing the fork �rotector Remove screws and take the clamp. Remove screws on the left fork leg and take the left fork protector. Remove screws (D on the right fork leg and take the right fork protector. Installing the fork �rotector Position the fork protector on the left fork leg.

  • Page 23: Disassembling The Fork Legs

    6 FORK, TRIPLE CLAMP Disassembling the fork legs Info The operations are the same on both fork legs. Condition The fork legs have been removed. Note down the current state of rebound damping (red adjuster on the right fork leg). Note down the current state of compression damping (white adjuster on the left fork leg).
  • Page 24 6 FORK, TRIPLE CLAMP Clamp the fork leg with the axle clamp. Release hydrostop unit and remove it. Info Do not use an impact wrench. Place a pan underneath since oil will run out. Remove the cartridge from the fork leg. Pressing tool (T14051) (�...

  • Page 25: Removing The Spring

    6 FORK, TRIPLE CLAMP Remove upper sliding bushing Info Without using a tool, pull the stack slightly apart by hand. Take off lower sliding bushing@. Take off support ring Take off seal ring Take off lock ring CS,. Take off dust boot Unclamp the fork leg.

  • Page 26: Disassembling The Cartridge

    6 FORK, TRIPLE CLAMP Disassembling the cartridge Info The procedures are the same on both fork legs. Preparatory work Disassemble the fork legs.(� p. 21) Remove the spring. (� p. 23) Main work Degrease piston rod and clamp using the special tool. I Clamping stand (T14049S) (�...

  • Page 27: Disassembling The Piston Rod

    6 FORK, TRIPLE CLAMP Pull sleeve out of the reservoir. Remove spring with preload spacers R00028-10 Remove seal rings (& and O-ring Remove pilot bushings • R00029-10 Disassembling the �iston rod Info The steps are identical for both fork legs, except for the hydrostop needle and valve. Preparatory work Disassemble the fork legs.(�...

  • Page 28: Disassembling The Hydrostop Unit

    6 FORK, TRIPLE CLAMP Remove compression shim stack Remove the spring. R00031-10 Remove adapter with spring @. Remove spring Remove valve needle@) from the piston rod. Info The adjusting tube can be used for this. Disassembling the hydrostop unit Info The procedures are the same on both fork legs.

  • Page 29: Disassembling The Seal Ring Retainer

    6 FORK, TRIPLE CLAMP Remove adapter Remove hub Remove O-ring from the hub. Remove shim stack (D. Remove washer Remove O-ring G). Disassembling the seal ring retainer Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs.(� p. 21) Remove the spring.
  • Page 30 6 FORK, TRIPLE CLAMP Check the inner tube and axle clamp for damage. If there is damage: Change the inner tube. B03581-10 Measure the outside diameter at multiple locations of the inner tube. Outside diameter of inner 47.975 ... 48.005 mm tube (1.88878 ...

  • Page 31: Assembling The Seal Ring Retainer

    6 FORK, TRIPLE CLAMP Check the spring length. Guideline Spring length with preload 475 mm (18.7 in) spacer(s) » If the measured value is larger than the specified value: Reduce the thickness of the preload spacers. » If the measured value is smaller than the specified value: Increase the thickness of the preload spacers.

  • Page 32: Assembling The Piston Rod

    6 FORK, TRIPLE CLAMP Mount washer and shim stack@. Info Note the setting list. Mount sleeve fD. Turn hydrostop unit and clamp sleeve fDwith special tool. I Clamping stand (T1202S) p. 365) Tighten sleeve fD. Guideline Hydrostop unit M6x0.5 6 Nm (4.4 lbf ft) sleeve Assemblin the piston rod...

  • Page 33: Assembling The Cartridge

    6 FORK, TRIPLE CLAMP Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper. Clean the piston. Lubricate the piston ring. Fork oil (SAE 4) (48601166S1) (� p. 348) Mount the piston with chamfer facing down. Mount rebound shim stack with the smaller shims facing upward.
  • Page 34 6 FORK, TRIPLE CLAMP Main work Mount and grease seal rings and O-ring I Lubricant (T158) (� p. 350) Mount and lubricate pilot bushings I Fork oil (SAE 4) (48601166S1) (� p. 348) R00029-11 Check the length of the reservoir spring. Guideline Reservoir spring length with 46 mm (1.81 in)

  • Page 35: Assembling The Fork Legs

    6 FORK, TRIPLE CLAMP Clamp piston rod with the special tool. Clamping stand (T14049S) (I!!.:! p. 368) Mount spring guide Gi) all the way on. Info The nut must be firmly tightened against the stop by hand. Do not use a tool. Mount adjusting tube 202480-11 Unclamp the piston rod.
  • Page 36 6 FORK, TRIPLE CLAMP Sand the edges of the sliding bushings with 600 grit sandpa­ per; then clean and grease the bushings. I Fork oil (SAE 4) (48601166S1) (l!!ll p. 348) 201715-10 Push on lower sliding bushing (3. Mount upper sliding bushing (3. Info Without using a tool, pull the stack slightly apart by hand.
  • Page 37 6 FORK, TRIPLE CLAMP Mount dust boot Mount fork protector ring B03520-13 Grease the O-ring. Fork oil (SAE 4) (48601166S1) (I!!:! p. 348) Slide the cartridge all the way into the fork leg. Turn the fork. Have the entire filling quantity of fork oil available. Oil capacity per fork 630 ml Fork oil (SAE 4)
  • Page 38 6 FORK, TRIPLE CLAMP Pull out the piston rod and push it back in numerous times while pressing it to one side slightly. ✓ Air bubbles emerge and the cartridge is bled. Keep bleeding until no more air bubbles emerge. ✓...

  • Page 39: Lubricating The Steering Head Bearing

    6 FORK, TRIPLE CLAMP Alternative 1 Turn the adjuster for rebound damping Gi) (mark REB) and the adjuster for compression damping (mark COMP) clockwise all the way. Turn counterclockwise by the number of clicks corre­ sponding to the fork type. Guideline Rebound damping Comfort...

  • Page 40: Removing The Lower Triple Clamp

    6 FORK, TRIPLE CLAMP 6.23 Removing the lower tri�le clam� Preparatory work Remove the headlight mask with the headlight. p. 114) Raise the motorcycle with a lift stand. p. 14) Remove the front wheel. p. 122) Remove the fork legs. (ilill p.

  • Page 41: Installing The Lower Triple Clamp

    6 FORK, TRIPLE CLAMP Remove O-ring Remove protective ring @t. Take off the lower triple clamp with the steering stem. Remove the upper steering head bearing. 6.24 lnstallin the lower triple clamp Main work Clean the bearing and sealing elements, check for damage, and grease.
  • Page 42 6 FORK, TRIPLE CLAMP Info The compression damping is located in left fork (white adjusting screw). The rebound COMP damping is located in right fork leg REB (red adjusting screw). Grooves are milled into the side of the upper end of the fork legs.

  • Page 43: Checking The Play Of The Steering Head Bearing

    6 FORK, TRIPLE CLAMP (FE EU/AU, FE 450/501 US) Tighten screws Guideline Screw, top triple 17 Nm (12.5 lbf ft) clamp Secure the wiring harness with cable holder @). (FE 501 SUS) Tighten screws Guideline Screw, top triple 17 Nm (12.5 lbf ft) clamp Secure the wiring harness with cable holder@).

  • Page 44: Changing The Steering Head Bearing

    6 FORK, TRIPLE CLAMP Preparatory work Raise the motorcycle with a lift stand. (llill p. 14) Main work Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bear­ ing.

  • Page 45: Adjusting The Steering Head Bearing Play

    6 FORK, TRIPLE CLAMP Remove upper bearing ring with special tool fl}. Tool bracket (58429089000) p. 355) Pressing tool (58429092000) (� p. 356) Press the new bearing ring up to the stop with special tool Cs). Tool bracket (58429089000) (� p.
  • Page 46 6 FORK, TRIPLE CLAMP Main work (FE EU/AU, FE 450/501 US) Loosen screws Remove screw @} . Loosen and retighten screw Guideline Screw, top steering M20x1 .5 12 Nm (8.9 lbf ft) head Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.

  • Page 47: 7 Handlebar,Controls

    7 HANDLEBAR,CONTROLS Handlebar �osition On the upper triple clamp, there are two holes at a distance to each other. 1 15 mm (0.59 in) Hole distance The holes on the handlebar supports are placed at a distance from the center. I 3.5 mm (0.138 in) Hole distance The handlebar supports can be mounted in four different posi­...

  • Page 48: Adjusting The Basic Position Of The Clutch Lever

    7 HANDLEBAR,CONTROLS Info Make sure the gap width is even. 7 .3 Adjustin the basic position of the clutch lever Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.

  • Page 49: Checking The Play In The Throttle Cable

    7 HANDLEBAR,CONTROLS (FE 501 SUS) Check the throttle cable routing. Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bearing. If the throttle cable is not routed as specified: Correct the throttle cable routing.

  • Page 50: Adjusting The Play In The Throttle Cable

    7 HANDLEBAR,CONTROLS Adjusting the �la in the throttle cable Preparatory work Remove the seat. p. 98) Remove the fuel tank. p. 99) Check the routing of the throttle cable. p. 46) Main work (FE EU/AU, FE 450/501 US) Move the handlebar to the straight-ahead position. Push back sleeves Loosen nut@.
  • Page 51 7 HANDLEBAR,CONTROLS Move the handlebar to the straight-ahead position. Push back sleeves (D. Loosen nut Turn adjusting screw@) in as far as pos- sible. Loosen nut (D. Turn adjusting screw @ so that there is play in the throttle cable at the throttle grip. Guideline I Play in throttle cable I 3 ...

  • Page 52: 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 mechanical impact. Repair of the frame is not authorized by Husqvarna 401799-01 Motorcycles.

  • Page 53: Shock Absorber, Swingarm

    9 SHOCK ABSORBER, SWINGARM Adjusting the high-s eed com�ression dam�ing of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor­ rectly. The shock absorber is filled with highly compressed nitrogen. Please follow the description provided.

  • Page 54: Adjusting The Rebound Damping Of The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Turn adjusting screw clockwise with a screwdriver up to the last perceptible click. Info Do not loosen fitting@! Turn counterclockwise by the number of clicks correspond­ ing to the shock absorber type. Guideline Compression damping, low-speed Comfort 20 clicks Standard...

  • Page 55: Measuring Rear Wheel Sag Unloaded

    9 SHOCK ABSORBER, SWINGARM Measuring rear wheel sag unloaded Preparatory work Raise the motorcycle with a lift stand. p. 14) Main work Measure the distance - as vertically as possible - between the rear axle and a fixed point such as a mark on the side cover.

  • Page 56: Checking The Riding Sag Of The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber Measure distance of rear wheel unloaded. (� p. 53) With another person holding the motorcycle, the rider, wear­ ing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.

  • Page 57: Adjusting The Riding Sag

    9 SHOCK ABSORBER, SWINGARM Main work Loosen screw Turn adjusting ring until the spring is no longer under ten- sion. Hook wrench (T1 06S) p. 364) Measure the overall spring length while the spring is not under tension. Tighten the spring by turning adjusting ring to measure­...

  • Page 58: Removing The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Main work Choose and mount a suitable spring. Guideline Spring rate Weight of rider: 65 ... 54 N/mm (308 lb/in) 75 kg (143 ... 165 lb.) Weight of rider: 75 ... 57 N/mm (325 lb/in) 85 kg (165 ... 187 lb.) Weight of rider: 85 ...

  • Page 59: Installing The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Installing the shock absorber Main work Carefully position the shock absorber into the vehicle from above. Finishing work Install the manifold.(� p. 86) Install the fuel tank. (� p. 101) Mount the seat. (� p. 98) Install the main silencer.
  • Page 60 9 SHOCK ABSORBER, SWINGARM 303096-10 @» Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check spacers and @ for damage and wear. If there is damage or wear: Change the spacers. Check the shaft seal rings for damage and wear.

  • Page 61: Servicing The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Mount screw but do not tighten yet. Guideline M 1 0 60 Nm (44.3 lbf ft) Screw, bottom ® Loctite 2701 shock absorber • Info Raise the wheel slightly to be able to mount the screw more easily.

  • Page 62: Removing The Spring

    9 SHOCK ABSORBER, SWINGARM Remove the spring. (!!',! p. 60) Disassemble the damper.(!!',! p. 61) Disassemble the piston rod. (!!',! p. 62) Disassemble the seal ring retainer. (!!',! p. 63) Check the damper. p. 65) Remove the heim joint. p. 66) Install the heim joint.

  • Page 63: Disassembling The Damper

    9 SHOCK ABSORBER, SWINGARM 9.14 Disassembling the dam er Preparatory work Remove the spring. (� p. 60) Main work Note down the current state of rebound damping compression damping Completely open the adjusters of the rebound and compres­ sion damping. Remove rubber cap of the reservoir.

  • Page 64: Disassembling The Piston Rod

    9 SHOCK ABSORBER, SWINGARM Remove the piston rod. Remove adjusting ring with the intermediate washer. Drain the oil. Remove compression adjuster@). Remove the spring and piston. 9.15 Disassembling the piston rod Preparatory work Remove the spring. (� p. 60) Disassemble the damper.(� p. 61) Main work Clamp the piston rod with the fork in a vise.

  • Page 65: Disassembling The Seal Ring Retainer

    9 SHOCK ABSORBER, SWINGARM Remove rebound shim stack Info Place the rebound shim stack onto a screwdriver and set it down as a unit. Remove piston Remove compression shim stack • Info Place the compression shim stack onto a screwdriver and set it down as a unit.

  • Page 66: Changing The Pilot Bushing

    9 SHOCK ABSORBER, SWINGARM Remove centering disk Remove seal ring 201406-10 Remove washer for seal ring Remove washer @. Remove dust boot. 201407-10 9.17 Changing the ilot bushing Preparatory work Remove the spring. (!!.!I p. 60) Disassemble the damper. (!!.!I p.

  • Page 67: Checking The Damper

    9 SHOCK ABSORBER, SWINGARM Lubricate the special tool. Shock absorber fluid (SAE 2.5) (50180751 S1) (!!l p. 349) Calibrating unit (T1205) (l!,JI p. 365) Support seal ring retainer @} with sleeve of the special tool. Mounting tool (T150S) (l!,JI p. 368) Press the special tool through the new pilot bushing.

  • Page 68: Removing The Heim Joint

    9 SHOCK ABSORBER, SWINGARM Check the piston rings for damage and wear. If damage or a bronze-colored surface is visible: Change the piston. 201404-10 9.19 Removin the heim joint Condition The shock absorber has been removed. Clamp the shock absorber in the vise using soft jaws for pro­ tection.

  • Page 69: Installing The Heim Joint

    9 SHOCK ABSORBER, SWINGARM Installing the heim joint Position the new heim joint and the special tool into a vise as shown. Guideline Use soft jaws. Pressing tool (T1206) (� p. 365) Press the heim joint all the way in. Press the heim joint against the lock ring using the special tool.

  • Page 70: Assembling The Piston Rod

    9 SHOCK ABSORBER, SWINGARM Mount washer Position washer on seal ring 201409-10 Grease seal ring and mount with the washer facing down­ ward. I Lubricant (T14034) p. 350) Mount centering disk 201410-10 Mount rebound rubber (D. Grease the 0-ring groove. I Lubricant (T158) p.
  • Page 71 9 SHOCK ABSORBER, SWINGARM Mount rebound washer with the cut-out facing down­ ward. Mount the compression shim stack with the smaller shims facing downward. 201418-10 Sand both sides of piston on a surface plate using 1200- grit sandpaper. Clean the piston. Assemble the piston.

  • Page 72: Assembling The Damper

    9 SHOCK ABSORBER, SWINGARM Grease the thread of the piston rod. I Lubricant (T152) (� p. 350) Mount and tighten nut Q). Guideline I Nut, piston rod M16x1 45 Nm (33.2 lbf ft) 201422-10 9.23 Assemblin the damper Preparatory work Assemble the seal ring retainer.
  • Page 73 9 SHOCK ABSORBER, SWINGARM Install the seal ring bearer and push it under the ring groove. Mount lock ring • Info Do not scratch the inner surface. Pull out the piston rod so that the seal ring retainer rests against the lock ring. Mount locking cap (3 of the damper cartridge.

  • Page 74: Bleeding And Filling The Damper

    9 SHOCK ABSORBER, SWINGARM Turn counterclockwise by the number of clicks corre­ sponding to the shock absorber type. Guideline Rebound damping Comfort 20 clicks Standard 18 clicks Sport 16 clicks Alternative 2 Warning Modifications to the sus­ Danger of accident pension setting may seriously alter the handling characteristic.
  • Page 75 9 SHOCK ABSORBER, SWINGARM Clamp the control lever as shown in the figure. ✓ The External tank control lever is Closed, Damper on Vacuum, Oil reservoir on Vacuum. Operate the On/Off switch (D. ✓ The vacuum pump process starts. ✓ Pressure gauge @ drops to the specified value. <...
  • Page 76 9 SHOCK ABSORBER, SWINGARM When the pressure gauge reaches the specified value, turn Oil reservoir control lever to Vacuum. Guideline 0 bar ✓ The vacuum gauge falls to the specified value. mbar When the vacuum pressure gauge reaches the specified value, turn the control lever Oil reservoir...

  • Page 77: Filling Damper With Nitrogen

    9 SHOCK ABSORBER, SWINGARM Info The floating piston must be positioned at exactly this point when the rod is fully extended; otherwise, damage will occur during compression of the shock absorber. Remove the special tool. Remove adapter from connection of the vacuum pump.

  • Page 78: Installing The Spring

    9 SHOCK ABSORBER, SWINGARM Info Watch the pressure regulator dial. Ensure that the damper is filled to the specified pres­ sure. Screw the filling port shut with tap handle f). Close spigot and take the damper out of the special tool. Tighten the filling port screw.

  • Page 79: Checking The Swingarm

    9 SHOCK ABSORBER, SWINGARM Alternative 2 Warning Modifications to the sus­ Danger of accident pension setting may seriously alter the handling characteristic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components. Only make adjustments within the recom­...

  • Page 80: Removing The Swingarm

    9 SHOCK ABSORBER, SWINGARM Main work Move the swingarm up and down. If there is detectable play: Change the swingarm bearing. (I!!:! p. 81) Move the swingarm from one side to the other. If there is detectable play: Change the swingarm bearing. (I!!:! p.

  • Page 81: Installing The Swingarm

    9 SHOCK ABSORBER, SWINGARM Remove connecting link of the chain. Info Cover the components to protect them against dam­ age. Take off the chain. Remove fitting Lower the swingarm. Remove nut Remove the swingarm pivot. Take off the swingarm. Main work Position the swingarm.
  • Page 82 9 SHOCK ABSORBER, SWINGARM Mount the chain. Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel. Position the engine sprocket cover and mount in the holder. Mount and tighten screws Guideline Screw, clutch slave 10 Nm (7.4 lbf ft)

  • Page 83: Changing The Swingarm Bearing

    9 SHOCK ABSORBER, SWINGARM 9.31 Changing the swingarm bearing Preparatory work Raise the motorcycle with a lift stand. p. 14) Remove the rear wheel. p. 125) Remove the swingarm. p. 78) Left swingarm bearing Remove collar bushings R02757-10 Remove bushing R02758-10 Remove shaft seal rings @) using a suitable tool.
  • Page 84 9 SHOCK ABSORBER, SWINGARM Mount bushing R02758-10 Grease the shaft seal rings. Long-life grease (� p. 350) Position collar bushings with the shoulder facing inward. R02763-10 Right swingarm bearing Remove collar bushings Q). R02760-10 Remove bushing@. R02761-10...
  • Page 85 9 SHOCK ABSORBER, SWINGARM Remove shaft seal rings using a suitable tool. Press out bearing @) using a suitable tool. Using a suitable tool, press in new bearing@). Press in shaft seal rings R02762-10 Mount bushing@ . R02761-10 Grease the shaft seal rings. I Long-life grease (ll!ll p.

  • Page 86: 10 Exhaust

    10 EXHAUST Removing the manifold 10.1 Preparatory work Raise the motorcycle with a lift stand. (� p. 14) Remove the seat. (� p. 98) Remove the right side cover. (� p. 97) Remove the main silencer. (� p. 88) Remove the fuel tank. (�...
  • Page 87 EXHAUST Remove screws on both sides. Loosen screws on both sides. Remove screw @. Raise the rear frame slightly and lower the shock absorber. Remove springs Spring hook (50305017000) (� p. 354)

  • Page 88: Installing The Manifold

    10 EXHAUST (FE EU) Remove screw Disconnect plug-in connector Ci) on lambda sensor and remove cable binder. Take off the manifold. (FE AU, FE 450/501 US, FE 501 S US) Remove screw Take off the manifold. Main work Position the manifold and mount springs Spring hook (50305017000) (�...
  • Page 89 EXHAUST Lift the rear frame slightly and position the shock absorber. Mount and tighten screw Guideline Screw, top 60 Nm (44.3 lbf ft) ® Loctite 2701 shock absorber Position the rear frame. Mount and tighten screws on both sides. Guideline Screw, sub­...

  • Page 90: Removing The Main Silencer

    10 EXHAUST Info Raise the wheel slightly to be able to mount the screw more easily. (FE EU) Route cable avoiding stress; connect plug-in connec­ on lambda sensor and secure with a new cable binder. Finishing work Install the fuel tank. (�...

  • Page 91: Changing The Glass Fiber Yarn Filling In The Main Silencer

    EXHAUST Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis Finishing work Install the right side cover. (� p. 97) Changing the glass fiber am filling in 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.

  • Page 92: (Fe 450/501 Us, Fe 501 S Us)

    10 EXHAUST (FE 450/501 US, FE 501 S US) Remove screws of connecting cap Remove connecting cap with the perforated pipe, O- ring and glass fiber yarn filling Remove screws and silencer cap with O-ring Remove screws and insert Q) together with insulat- ing pad�- Remove the insulating pad from the insert.
  • Page 93 EXHAUST Cleaning the s ark arrestor (FE 450/501 US, FE 501 S US) Warning The exhaust system gets very hot when the vehicle is driven. Danger of burns Allow the exhaust system to cool down before performing any work on the vehicle. Info Soot particles accumulate on the screen of the spark arrestor over time.
  • Page 94 10 EXHAUST Finishing work Install the main silencer.(� p. 88) Install the right side cover. (� p. 97)

  • Page 95: 11 Air Filter

    11 AIR FILTER Release catch pull off the air filter box lid sideways in areas f) and and remove toward the rear. Position the air filter box cover and catch Engage the air filter box cover in areas f) and Engage catch 11.3 Removin the air filter...

  • Page 96: Installing The Air Filter

    11 AIR FILTER 11.4 Installing the air filter Main work Mount the clean air filter on the air filter support. Grease the air filter in area t). I Long-life grease (� p. 350) Insert both parts together, position them, and secure them using air filter holder in area G).

  • Page 97: Sealing The Air Filter Box

    11 AIR FILTER Finishing work Install the air filter. (� p. 94) Install the air filter box cover. (!1ll p. 93) 11.6 Sealing the air filter box Preparatory work Remove the air filter box cover. (!1ll p. 93) Main work Seal the air filter box in the marked area f).

  • Page 98: 12 Fuel Tank, Seat, Trim

    12 FUEL TANK, SEAT, TRIM 12.1 O�ening the filler ca� 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. Switch off the engine for refueling.

  • Page 99: Closing The Filler Cap

    FUEL TANK, SEAT, TRIM (FE EU) Replace the filler cap and turn clockwise until the release button locks in place. Info Run the fuel tank breather hose @ without kinks. (FE AU, FE 450/501 US, FE 501 S US) Replace the filler cap and turn clockwise until the release button locks in place.

  • Page 100: Removing The Seat

    12 FUEL TANK, SEAT, TRIM 12.5 Removing the seat Remove screws Raise the rear of the seat, push the seat back, and lift it off. 12.6 Mounting the seat Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear while pushing it forward.

  • Page 101: Removing The Fuel Tank

    FUEL TANK, SEAT, TRIM 12.7 Removing the fuel tank 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. Switch off the engine for refueling.
  • Page 102 12 FUEL TANK, SEAT, TRIM (FE EU/AU) Disconnect the connector of the horn. Remove screws (D with the collar bushings and horn. -· - .'.a. (FE 450/501 US) Remove screws (D with the collar bushings. (FE 501 SUS) Remove screws (D with the collar bushings and horn. Remove screw with the rubber bushing.

  • Page 103: Installing The Fuel Tank

    FUEL TANK, SEAT, TRIM (FE 501 SUS) Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. 12.8 lnstallin the fuel tank 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 104 12 FUEL TANK, SEAT, TRIM (FE EU/AU) Position the collar bushings and horn, and mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis -· - Connect the connector of the horn. .'.a. (FE 450/501 US) Position the collar bushings, and mount and tighten screws @ .

  • Page 105: Changing The Fuel Screen

    FUEL TANK, SEAT, TRIM 12.9 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. Switch off the engine for refueling.

  • Page 106: Changing The Fuel Filter

    12 FUEL TANK, SEAT, TRIM Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
  • Page 107 FUEL TANK, SEAT, TRIM Main work Remove nut with the gasket. Remove fuel connection @ with the gasket. 305313-10 Remove screws Pull out the fuel pump. 305314-10 Remove hose clamps Remove fuel filter 305315-10 Press lock Pull back fuel pump housing@. 305317-10 Change fuel screen Mount the fuel pump housing.

  • Page 108: Changing The Fuel Pump

    12 FUEL TANK, SEAT, TRIM Mount fuel filter ✓ Arrow points away from the fuel pump. Mount hose clamps I Hose clamp plier (60029057000) (ll!:!l p. 3 58) 305316-10 Position the fuel pump. Mount fuel connection with the gasket but do not tighten yet.
  • Page 109 FUEL TANK, SEAT, TRIM Warning Fuel is poisonous and a health hazard. Danger of poisoning Avoid skin, eye and clothing contact with fuel. Immediately consult a doctor if you swallow fuel. Do not inhale fuel vapors. In case of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

  • Page 110: Checking The Fuel Pressure

    12 FUEL TANK, SEAT, TRIM Guideline Fuel connection on 10 Nm (7.4 lbf ft) fuel pump Mount and tighten screws Guideline I Screw, fuel pump Nm (1.7 lbf ft) EJOT PT ® 305314-10 12.12 Checking the fuel �ressure Danger Fuel is highly flammable. Fire hazard The fuel in the fuel tank expands when warm and can escape if overfilled.
  • Page 111 FUEL TANK, SEAT, TRIM Info Remaining fuel may flow out of the fuel hose. Mount special tool@. Pressure testing tool (61029094000) (� p. 358) Mount special tool with nozzle label 0,60. Testing hose (61029093000) (� p. 358) Position the hose end in a fuel cannister. Guideline Minimum size of fuel cannis- 10 I (2.6 US gal)

  • Page 112: Removing The Activated Charcoal Filter (Fe 501 Sus)

    12 FUEL TANK, SEAT, TRIM 12.13 Removing the activated charcoal filter (FE 501 S US) Preparatory work Remove the seat. p. 98) Remove the fuel tank. p. 99) Main work Remove the cable binder(s). Push back hose clamp Remove the hose. Detach rubber strap@}.
  • Page 113 FUEL TANK, SEAT, TRIM Position the activated charcoal filter. Reconnect rubber band Mount the hose and secure with a cable binder. Position hose clamp Finishing work Install the fuel tank. (� p. 101) Mount the seat. (� p. 98)

  • Page 114: 13 Mask, Fender

    13 MASK, FENDER 13.1 Removing front fender Preparatory work Remove t h e headlight m ask wit h t h e headlight . p. 114) Main work (FE EU/AU, FE 450/501 US) and @ .Takeoff t h e fr o nt fender . Remove scr ews (FE 501 SUS) and @ .Takeoff t h e fr o nt fender .

  • Page 115: Installing Front Fender

    13 MASK, FENDER Main work (FE EU/ AU, FE 450/501 US) Position front fender. Mount and tighten screws and @ . Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis (FE 501 SUS) Position front fender. Mount and tighten screws and @ .

  • Page 116: Removing The Headlight Mask With The Headlight

    13 MASK, FENDER 13.3 Removing the headlight mask with the headlight (FE EU/AU) Press and hold the kill switch � while the engine is idling until the engine stops. (FE 450/501 US) Press and hold the kill switch � while the engine is idling until the engine stops.

  • Page 117: Installing The Headlight Mask With The Headlight

    13 MASK, FENDER (FE 501 SUS) and wiring harness @ . Detach brake line Release rubber bands (D . Slide the headlight mask up and swing it forward. Detach plug-in connectors and take off the headlight mask with the headlight. 13.4 Installing the headlight mask with the headlight Main work...
  • Page 118 13 MASK, FENDER (FE 450/501 US) Connect plug-in connector Position the headlight mask and secure it with rubber bands @ . ✓ The holding lugs engage in the fender. Position brake line and wiring harness in the brake line guide. (FE 501 SUS) Connect plug-in connectors Position the headlight mask and secure it with rubber...
  • Page 119 13 MASK, FENDER Position brake line and wiring harness in the brake line guide. K00261-10 Finishing work Check the headlight setting. (� p. 169)

  • Page 120: 14 Wheels

    Checking the tire condition Info Only mount tires approved and/or recommended by Husqvarna Motorcycles. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcy­...

  • Page 121: Checking The Wheel Bearing For Play

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. Husqvarna Motorcycles recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear.

  • Page 122: Checking The Brake Discs

    14 WHEELS Checking the brake discs Warning Worn-out brake discs reduce the braking effect. Danger of accidents Make sure that worn-out brake discs are replaced immediately. Check the front and rear brake disc thickness at multiple points for the dimension r �...

  • Page 123: Checking The Rim Run-Out

    14 WHEELS Check the spoke torque. Guideline Spoke nipple, front M4.5 6 Nm (4.4 lbf ft} wheel Spoke nipple, rear M4.5 6 Nm (4.4 lbf ft} wheel Torque wrench set (58429094000) (!!:! p. 356) Checking the rim run-out Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage.

  • Page 124: Front Wheel

    14 WHEELS Front wheel 14.7 14.7.1 Removing the front wheel Preparatory work Raise the motorcycle with a lift stand. (!:Jl p. 14) Main work Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. •...

  • Page 125: Installing The Front Wheel

    14 WHEELS 14.7.2 Installing the front 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. Check the wheel bearing for damage and wear.

  • Page 126: Changing Front Wheel Bearing

    14 WHEELS Main work Remove screws Remove the brake disc. Clean the contact surface of the brake disc. Position the new brake disc with the label facing outward. Mount and tighten screws Guideline Screw, front 14 Nm (10.3 lbf ft) Loctite ®...

  • Page 127: Rear Wheel

    14 WHEELS Position spacing tube Press in new bearing all the way using a suitable tool. Info Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in. Grease new shaft seal rings and press in until they are flush.
  • Page 128 14 WHEELS Warning Danger of accidents Damaged brake discs reduce the braking effect. Always lay the wheel down in such a way that the brake disc is not damaged. Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the swingarm. Info Do not operate the foot brake lever when the rear wheel is removed.

  • Page 129: Installing The Rear Wheel

    14 WHEELS 14.8.2 Installing the rear wheel Warning Oil or grease on the brake discs reduces the braking effect. Danger of accidents Always keep the brake discs free of oil and grease. Clean the brake discs with brake cleaner when necessary. Main work Check the wheel bearing for damage and wear.

  • Page 130: Changing The Rear Brake Disc

    14 WHEELS (FE 501 SUS) Clean and grease the wheel spindle. Long-life grease p. 350) Position the rear wheel and insert wheel spindle Mount the chain. ✓ The brake linings are correctly positioned. Position chain adjuster @) . Mount nut but do not tighten it yet.

  • Page 131: Checking The Chain Tension

    14 WHEELS (FE 501 SUS) Remove screws Remove the brake disc. Clean the contact surface of the brake disc. Position the new brake disc with the label facing outward. Mount and tighten screws Guideline 14 Nm (10.3 lbf ft) Screw, rear brake disc ®...

  • Page 132: Adjusting The Chain Tension

    14 WHEELS 14.8.5 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 133: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    14 WHEELS (FE 501 SUS) Loosen nut Loosen nuts @. Adjust the chain tension by turning adjusting screws (D left and right. Guideline Chain tension 55 ... 58 mm (2.17 ... 2.28 in) Turn adjusting screws (D on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks f).
  • Page 134 14 WHEELS Pull at the top part of the chain with the specified weight fj. Guideline 10 ... 15 kg (22 ... 33 lb.) Weight of chain wear mea­ surement Measure distance of 18 chain rollers in the lower chain section.
  • Page 135 14 WHEELS Check the chain sliding piece for wear. If the lower edge of the chain pins is in line with or below the chain sliding piece: Change the chain sliding piece. Check that the chain sliding piece is firmly seated. If the chain sliding piece is loose: Tighten the screw of the chain sliding piece.

  • Page 136: Checking For Chain Dirt Accumulation

    14 WHEELS 14.8.7 Checking for chain dirt accumulation Check the chain for coarse dirt accumulation. If the chain is very dirty: Clean the chain. p. 134) 400678-01 14.8.8 Cleaning the chain Warning Oil or grease on the tires reduces the road grip. Danger of accidents Remove the lubricant from the tires using a suitable cleaning agent.
  • Page 137 14 WHEELS Main work Remove screws Take off the engine sprocket cover. Have an assistant operate the rear brake. Remove screw with the washer. Remove the rear wheel. p. 125) Remove connecting link of the chain. Info Cover the components to protect them against dam­ age.
  • Page 138 14 WHEELS (FE 501 SUS) Remove fittings (3. Take off the rear sprocket. Position the new rear sprocket. Mount and tighten the fittings. Guideline Nut, rear 35 Nm (25.8 lbf ft) 2701 TM Loctite ® sprocket screw Slide new engine sprocket onto the countershaft.

  • Page 139: Changing The Rear Wheel Bearing

    14 WHEELS 14.8.10 Changing the rear wheel bearing Preparatory work Raise the motorcycle with a lift stand.(� p. 14) Remove the rear wheel. (� p. 125) Main work (FE EU/ AU, FE 450/501 US) Remove shaft seal ring Remove lock ring @. Remove shaft seal ring@).
  • Page 140 14 WHEELS Position spacer washer @. Press new bearing all the way in from the outside to the inside. Info Only press the bearing in via the outer ring oth­ erwise the bearing will be damaged when it is pressed in. Clean, grease, and mount spacing tube (3.
  • Page 141 14 WHEELS Remove shaft seal ring 6). Using a suitable tool, press bearing out from the inside to the outside. Remove spacing tube Using a suitable tool, press bearing (D out from the inside to the outside. Check spacer washer @ for damage and wear. If the spacer washer is damaged or worn: Replace the spacer washer.
  • Page 142 14 WHEELS Grease new shaft seal ring and press it in until it is flush. Mount lock ring ✓ The lock ring engages audibly. Grease new shaft seal ring and press it in until it is flush. Finishing work Install the rear wheel. (�...

  • Page 143: 15 Wiring Harness, Battery

    15 WIRING HARNESS, BATTERY Changing the fuses of individual �ower consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work (FE EU/AU) Press and hold the kill switch C>9 while the engine is idling until the engine stops.
  • Page 144 15 WIRING HARNESS, BATTERY Replace the spare fuse in the fuse box so that it is available if needed. Check that the power consumer is functioning properly. Close the fuse box cover. (FE 501 SUS) Open fuse box cover Remove the defective fuse. Guideline Fuse 1 - 10 A - EFI control unit Fuse...

  • Page 145: Changing The Main Fuse

    15 WIRING HARNESS, BATTERY Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. Only use fuses with the required ampere value. Do not bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box lid.

  • Page 146: Checking The Starter Relay

    15 WIRING HARNESS, BATTERY 15.3 Checking the starter rela� Preparatory work (FE EU/AU) Press and hold the kill switch � while the engine is idling until the engine stops. (FE 450/501 US) Press and hold the kill switch � while the engine is idling until the engine stops.

  • Page 147: Installing The Battery

    15 WIRING HARNESS, BATTERY Main work Pull back the negative terminal cover and disconnect the negative cable from the battery. Pull back positive terminal cover @ and disconnect the pos­ itive cable from the battery. Detach rubber band at the bottom. Lift the battery up and out.
  • Page 148 Warning Environmental hazard Batteries contain environmentally-hazardous materials. Do not dispose of batteries as household waste. Return batteries to your authorized Husqvarna Motorcycles dealer or dispose of them at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 149: Checking The Charging Voltage

    15 WIRING HARNESS, BATTERY 15.7 Checking the charging voltage Condition The battery must be fully functional and completely charged. Preparatory work Remove the seat. (lit!I p. 98) Main work Carry out the start procedure. (lit!I p. 14) Measure the voltage between the specified points. - Measuring point Measuring point Plus(+)

  • Page 150: 16 Brake System

    16 BRAKE SYSTEM Checking the front brake linings Warning Worn-out brake linings reduce the braking effect. Danger of accidents Ensure that worn-out brake linings are replaced immediately. Check the brake linings for minimum thickness I Minimum thickness I � 1 mm (� 0.04 in) If the minimum thickness is less than specified: Change the front brake linings.
  • Page 151 Brake linings which have not been approved alter the braking efficiency. Danger of accidents 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 152 16 BRAKE SYSTEM Check that leaf spring (3 in the brake caliper and sliding plate @ in the brake caliper support are seated correctly. 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 lin­...

  • Page 153: Checking The Free Travel Of The Hand Brake Lever

    BRAKE SYSTEM Info Clean up overflowed or spilled brake fluid immedi­ ately with water. Checking the free travel of the hand brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. Set the free travel on the hand brake lever in accordance with the specification.

  • Page 154: Adjusting The Basic Position Of The Hand Brake Lever (Fe 450/501 Us)

    16 BRAKE SYSTEM Adjusting the basic �osition of the hand brake lever (FE 450/501 US) Check the free travel of the hand brake lever. (!lll p. 151) Adjust the basic setting of the hand brake lever to your hand size by turning adjusting screw Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the han­...

  • Page 155: Adding Front Brake Fluid

    BRAKE SYSTEM Adding front brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. 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.

  • Page 156: Changing The Front Brake Fluid

    16 BRAKE SYSTEM Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilled brake fluid immedi­ ately with water. (FE 501 SUS) Move the brake fluid reservoir mounted on the handlebar to a horizontal position. Remove screws Remove cover with membrane...
  • Page 157 BRAKE SYSTEM (FE EU/AU, FE 450/501 US) Move the brake fluid reservoir mounted on the handlebar to a horizontal position. Cover painted parts. Remove screws Take off cover with the membrane. Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid.
  • Page 158 16 BRAKE SYSTEM Disconnect the bleeding device. Remove the bleeder cover. Add brake fluid to level (!). Guideline 5 mm (0.2 in) Level (!) Brake fluid DOT 4 (ilel p. 348) Position the cover with the membrane. Mount and tighten the screws.

  • Page 159: Checking The Rear Brake Linings

    BRAKE SYSTEM Pull off protection cap of the brake caliper bleeder screw. Connect the bleeder bottle hose. I Bleeding device (00029013100) (I!!:! p. 352) Open bleeder screw by approx. one half turn. • Info Drain until fresh brake fluid emerges in the bleeder bottle hose without bubbles.

  • Page 160: Changing The Rear Brake Linings

    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 161 BRAKE SYSTEM Stand the vehicle upright. Remove screw cap with membrane and the 0-ring. 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 reservoir, extracting it by suction if it does.

  • Page 162: Checking The Free Travel Of Foot

    16 BRAKE SYSTEM Add brake fluid to level f). I Brake fluid DOT 4 (I!\',! p. 348) Mount screw cap with membrane and O-ring. Info Clean up overflowed or spilled brake fluid immediately with water. Checking the free travel of foot brake lever Warning The brake system fails in the event of overheating.

  • Page 163: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKE SYSTEM Adjusting the basic �osition of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

  • Page 164: Adding Rear Brake Fluid

    16 BRAKE SYSTEM Stand the vehicle upright. Check the brake fluid level in level viewer lf the brake fluid level has dropped below marking Add rear brake fluid. (� p. 162) Addin rear brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. 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.

  • Page 165: Changing The Rear Brake Fluid

    BRAKE SYSTEM Main work Stand the vehicle upright. Remove screw cap with membrane f!} and the 0-ring. Add brake fluid to level fj. Brake fluid DOT 4 (!ill p. 348) Mount the screw cap with the membrane and the 0-ring. Info Clean up overflowed or spilled brake fluid immediately with water.
  • Page 166 16 BRAKE SYSTEM Cover the painted parts. Remove screw cap with membrane and the O-ring. Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid. Syringe (50329050000) (� p. 354) Brake fluid DOT 4 (�...
  • Page 167 BRAKE SYSTEM Stand the vehicle upright. Correct the brake fluid up to marking (!). Brake fluid DOT 4 (Ii!:! p. 348) Fit and tighten plug with oil screen and 0-ring. Info Clean up overflowed or spilt brake fluid immediately with water. Check the foot brake lever for a firm pressure point.

  • Page 168: Lighting System, Instruments

    LIGHTING SYSTEM, INSTRUMENTS 17.1 Adjusting the combination instrument Condition The motorcycle is stationary. Press and hold both buttons for 3 - 5 seconds. ✓ The Setup menu is displayed. The display flashes. UNIT ____ ,�_ I _L Press one of the buttons to select for the speed in kilo­...

  • Page 169: Adjusting The Kilometers Or Miles

    17 LIGHTING SYSTEM, INSTRUMENTS Switching off the service interval display Press and hold the left button. ✓ appears on the display. 401914-01 Adjustin the kilometers or miles Info If the unit is changed, the value ODO is retained and converted accordingly. Condition The motorcycle is stationary.

  • Page 170: Setting The Wheel Circumference

    LIGHTING SYSTEM, INSTRUMENTS 17.4 Setting the wheel circumference Condition The motorcycle is stationary. Preparatory work Disconnect speedometer connector CZ. Main work Press both buttons for 3 - 5 seconds. ✓ The Setup menu is displayed. The UNIT display flashes. ____ ,�_1_1, . ✓...

  • Page 171: Checking The Headlight Setting

    17 LIGHTING SYSTEM, INSTRUMENTS Switching off the service interval display Press and hold the left button. ✓ appears on the display. 401914-01 Checkin the headli Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight.
  • Page 172 LIGHTING SYSTEM, INSTRUMENTS (FE 501 SUS) Loosen screw Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver (instruc­ tions on how to apply the mark: Checking the headlight setting).

  • Page 173: 18 Engine

    18 ENGINE 18.1 Removing the engine Preparatory work Remove the engine guard. p. 50) Drain the coolant. p. 255) Raise the motorcycle with a lift stand. p. 14) Remove the right side cover. (Ii.,! p. 97) Remove the main silencer. (Ii.,! p.
  • Page 174 18 ENGINE Push back hose clamp off the air release hose. Pull Remove screws (D. Loosen screw @. Repeat these steps on the opposite side. Pivot up the subframe and secure it. Remove screw @. Swing the shock absorber to the rear. Remove springs C!).
  • Page 175 18 ENGINE Remove screw Ci). Take off the manifold. Push back the cover. «D­ Remove nut Take off the cable. Loosen hose clips �. Pull off the radiator hoses. Detach spring Pull back the protection cap. Unplug connector Disconnect the spark plug connector.
  • Page 176 18 ENGINE Remove screw �. Remove screw Ci). Take off the engine sprocket cover. Remove the connecting link of the chain. Take off the chain. Remove the cable ties. Remove screws Take off the slave cylinder of the clutch and hang it to one side.
  • Page 177 ENGINE Remove fittings fl!). Take off the engine braces. Disconnect plug-in connector @D. Disconnect plug-in connector Remove nut Remove the swingarm pivot. Pull the swingarm slightly toward the rear. Remove screws �. Lift out the engine sideways. Info The help of an assistant is useful in this step. Make sure that the engine is sufficiently secured against falling over.

  • Page 178: Installing The Engine

    18 ENGINE Main work Position the engine in the frame. Info The help of an assistant is useful in this step. Make sure that the engine is sufficiently secured against falling over. Protect the frame and attachments against damage. Mount screws but do not tighten yet.
  • Page 179 18 ENGINE Mount the radiator hose. Position and tighten hose clip 0). Mount the throttle valve body. Position and tighten hose clip @. Position the clutch slave cylinder with the gasket. Mount and tighten screws Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder Mount the chain.
  • Page 180 18 ENGINE 48 . Plug in connector Position the protection cap. Plug in the spark plug connectors. Mount spring G). Mount the radiator hoses. 4D . Position and tighten hose clips Position the cable. Mount and tighten nut Position the cover. Position the manifold and mount springs�­...
  • Page 181 18 ENGINE Mount and tighten screw Guideline 25 Nm (18.4 lbf ft) Remaining screws, chassis Position the shock absorber. Gs,. Mount and tighten screw Guideline Screw, top 60 Nm (44.3 lbf ft) ® Loctite 2701 shock absorber Remove the locking piece and position the subframe. Info Watch out for the intake flange.
  • Page 182 18 ENGINE Position the intake air temperature sensor. Mount and tighten screws�- Guideline Screw, intake air 2 Nm (1.5 lbf ft) temperature sensor Plug in connector fJ). Position the protection cap. Position and tighten hose clip ... Connect negative cable � of the battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft)

  • Page 183: Engine Disassembly

    254) Execute the initialization run. (l!!,!I p. 271) Finishing work Take a test ride. Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. Check the engine for leak tightness. Check the engine oil level. (l!!,!I p. 257) Check the coolant level.

  • Page 184: Removing The Clutch Push Rod

    18 ENGINE Remove engine oil screen plug@. Completely drain the engine oil. Remove engine oil screen Remove engine oil screen plug Removing the clutch push rod 18.3.3 Remove clutch push rod 18.3.4 Removing the oil filter Remove screws Remove oil filter cover with the O­...

  • Page 185: Removing The Starter Motor

    18 ENGINE Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) (i!!,!l p. 355) 18.3.5 Removing the starter motor Remove screws and take off the starter motor. 18.3.6 Removing the spark plug Remove the spark plug using the special tool. Spark plug wrench with link (77229172000) (�...

  • Page 186: Removing The Alternator Cover

    18 ENGINE 18.3.8 Removing the alternator cover Remove screws Remove the alternator cover. Remove centering pins Take off the alternator cover gas­ ket@). 18.3.9 Positioning the engine at ignition top dead center Turn the crankshaft counterclockwise until the markings are flush with the marking on the cylinder head.

  • Page 187: Removing The Timing Chain Tensioner

    18 ENGINE 18.3.10 Removing the timing chain tensioner Remove screw Remove screw Take off the chain adjuster with the gasket. 18.3.11 Removing the camshaft Remove screw Remove the camshaft support plate Pull the camshaft out of the bearing seats. Take the timing chain off the camshaft gear.

  • Page 188: Removing The Cylinder Head

    18 ENGINE 18.3.12 Removing the cylinder head Remove screw Unscrew screws @ in a crisscross pattern and remove. Remove the cylinder head. Take off the dowels. Remove the cylinder head gasket. 18.3.13 Removing the piston Push the cylinder upward. Info Only push the cylinder as far up as necessary to take the piston pin out.

  • Page 189: Removing The Timing Chain Guide Rail

    18 ENGINE Attach special tool to the rotor. Hold it tight using the special tool and pull off the rotor by turning the screw in. Puller (58012009000) (ll!:!l p. 355) Remove the woodruff key. 18.3.15 Removing the timing chain guide rail Remove screw Take off timing chain guide rail toward the top.

  • Page 190: Removing The Timing Chain

    18 ENGINE 18.3.18 Removing the timing chain Take off the timing chain. Info Identify the direction of travel. 18.3.19 Removing the ignition pulse generator Remove screws Pull the cable support sleeve from the engine case. Take off the crankshaft position sensor. Removing the suction pump 18.3.20 Remove screws...

  • Page 191: Removing The Water Pump Cover

    18 ENGINE @) . Take off pin Remove pin upward. Remove O-ring 18.3.21 Removing the water pump cover Remove screws Take off the water pump cover. Take off the water pump cover seal. 18.3.22 Removing the clutch cover Remove screws Take off the clutch cover.

  • Page 192: Removing The Clutch Discs

    18 ENGINE 18.3.23 Removing the clutch discs Remove screws Take off spring retainer@. Take off spring washer@). Take off pretension ring Take off pressure cap Completely remove clutch disc pack (D. Remove clutch pressure piece@.

  • Page 193: Removing The Primary Gear Nut

    18 ENGINE 18.3.24 Removing the primary gear nut Remove the special tool. Locking screw (113080802) (� p. 353) Lock the clutch basket and primary gear using special tool Gear segment (80029004000) (� p. 363) • Info LH thread Remove nut 18.3.25 Removing the outer clutch hub Bend up the lock washer.

  • Page 194: Removing The Torque Limiter

    18 ENGINE 18.3.26 Removing the torque limiter Remove the screw with the washer. Remove torque limiter Remove the washer. 18.3.27 Removing the starter idler gear Remove the lock ring. Take off the washer. Take off starter idler gear Removing the shift shaft 18.3.28 Push sliding plate away from the shift drum locating unit.

  • Page 195: Removing The Locking Lever

    18 ENGINE 18.3.30 Removing the locking lever Unscrew and remove together with locking lever@, washer, sleeve and spring. 18.3.31 Removing the oil pump gear wheels Remove lock ring Take off washer@. Remove oil pump idler gear (s). Remove lock washer Take off washer@).

  • Page 196: Removing The Force Pump

    18 ENGINE 18.3.32 Removing the force pump Remove screws Take off oil pump cover@. Remove internal rotor and external rotor Remove the pin. Push oil pump shaft inward and take it out of the engine • from the ignition side. 18.3.33 Removing the primary gear Insert special tool...

  • Page 197: Removing The Left Engine Case Section

    18 ENGINE 18.3.35 Removing the left engine case section Remove screws Mount special tool with suitable screws. Puller (90129048100) (� p. 364) Info • Use the drill hole with marking 781. Tilt the left section of the engine case upward and remove the fitting of the engine fixing arm.

  • Page 198: Removing The Shift Rails

    18 ENGINE 18.3.36 Removing the shift rails Remove shift rails together with upper springs the lower springs. 18.3.37 Removing the shift drum Tilt shift forks to the side. Info Do not misplace the shift rollers. Remove shift drum@. Removing the shift forks 18.3.38 Take shift forks out of the shift grooves.

  • Page 199: Removing The Crankshaft

    18 ENGINE Secure the engine in an upright position. Remove lock ring Pull out both transmission shafts together from the bearing seats. Info Do not lose the washers. 18.3.40 Removing the crankshaft Attach the special tool to the crankshaft. Protection cap (75029090000) (�...
  • Page 200 18 ENGINE Main work Remove all remaining dowels. Remove oil jets Remove the bearing retainer of main shaft bearing (D, of countershaft bearing and of shift drum bearing Remove any sealing mass remnants and clean the engine case section thoroughly. Warm the engine case section in an oven.

  • Page 201: Working On The Left Section Of The Engine Case

    18 ENGINE Guideline Screw, bearing 6 Nm (4.4 lbf ft) ® Loctite 2701 retainer Mount and tighten oil jet Guideline Oil jet, piston 2 Nm (1.5 lbf ft) ® Loctite cooling ™ Mount and tighten oil jet Guideline Oil nozzle for con rod M6x0.
  • Page 202 18 ENGINE Info Any bearings that remain in the section of the engine case must be removed using a suitable tool. Press out the crankshaft shaft seal ring @ from the inside toward the outside. Press in the shaft seal ring from the outside toward the inside, with the open side facing outward.

  • Page 203: Removing The Oil Pressure Regulator Valve

    18 ENGINE Guideline Screw, oil spray 5 Nm (3. 7 lbf ft) tube ® Loctite ™ Mount the dowels. Blow compressed air through all oil channels and check that they are clear. 18.4.3 Removing the oil pressure regulator valve Remove screw plug with sealing washer Remove pressure spring and ball...

  • Page 204: Installing The Oil Pressure Regulator Valve

    18 ENGINE 18.4.5 Installing the oil pressure regulator valve Install ball and pressure spring Mount and tighten plug@} with sealing washer �-­ Guideline Oil pressure control M12x1.5 20 Nm (14.8 lbf ft) e " - • valve plug •-· "-:) "- 304671-11 Removing the crankshaft seal ring in the clutch cover...

  • Page 205: Installing The Water Pump

    18 ENGINE Remove balancer shaft Remove shaft seal ring Press out water pump shaft bearing toward the inside with an appropriate tool. Info Suitably support the clutch cover while pressing it out. 18.4.9 Installing the water pump Press water pump shaft bearing in until it is flush using the appropriate tool.

  • Page 206: Removing The Timing Chain Sprocket

    18 ENGINE Mount special tool on the water pump shaft. I Protection cap (90129005000) (I!!,! p. 363) 304714-10 Mount balancer shaft • Info Be careful not to damage the shaft seal rings. Remove the special tool. I Protection cap (90129005000) (I!!,! p.

  • Page 207: Changing The Connecting Rod, Conrod Bearing, And Crank Pin

    18 ENGINE Warm up the new timing chain sprocket and immediately push it onto the crankshaft. Guideline c (356 °F) 304701-10 18.4.12 Changing the connecting rod, conrod bearing, and crank pin Main work Position the crankshaft with special tool in the press. Separator plate (78029009100) (ll!:!l p.
  • Page 208 18 ENGINE Place the crankweb onto special tool I Crankshaft pressing tool insert (78029008000) (l!!,!I p. 362) • Info The special tool must be positioned with the flat sur­ face facing downward. Press in new crank pin all the way. ✓...

  • Page 209: Checking Crankshaft Run-Out At Bearing Pin

    18 ENGINE Measure axial play between the connecting rod and the crankwebs using the special tool. Feeler gauge (59029041100) (I!!:! p. 357) Connecting rod - end play 0.20 ... 0.45 mm (0.0079 ... of lower conrod bearing 0.0177 in) If the measured value is less than the specification: Correct it so the dimension is equal to the specified value.

  • Page 210: Checking/Measuring The Piston

    18 ENGINE The cylinder size is labeled on the side of the cylinder. 304689-10 Using a straightedge and the special tool, check the sealing area of the cylinder head for distortion. I Feeler gauge (59029041100) (I!!;! p. 357) :5 0.10 mm (:5 0.0039 in) Cylinder/cylinder head sealing area distortion If the measured value does not meet specifications:...

  • Page 211: Checking The Piston Ring End Gap

    18 ENGINE Measure the piston at the piston skirt, parallel to the gudgeon pin.at a distance of 6). Guideline 7 mm (0.28 in) Distance Piston - diameter Size I 94.93 ... 94.96 mm (3.7374 ... 3.7386 in) Size II 94.94 ... 94.97 mm (3.7378 ...

  • Page 212: Checking The Oil Pumps

    18 ENGINE Guideline Piston/cylinder - mounting clearance Size I 0.040 ... 0.082 mm (0.00157 ... 0.00323 in) Size II 0.043 ... 0.085 mm (0.00169 ... 0.00335 in) Wear limit 0.120 mm (0.00472 in) 18.4.19 Checking the oil pumps Info The following steps apply to both oil pumps. Use special tool to measure the play between the exter­...

  • Page 213: Assembling The Autodecompressor

    18 ENGINE Pull autodecompression shaft out of the camshaft. 304674-10 ·� Release and remove autodecompression spring Info Autodecompression weight cannot be taken off. 304675-10 18.4.21 Assembling the autodecompressor Insert long flange of the autodecompression spring in the hole, push the autodecompression spring over bearing bolt and hook it into autodecompression weight 304675-11...

  • Page 214: Checking Camshaft

    18 ENGINE 18.4.22 Checking camshaft Check the camshaft for damage and wear. If there is damage or wear: Change the camshaft. If the camshaft surface is damaged, check the oil supply of the camshaft and the rocker arm. Measure the cams of the camshaft. Camshaft - cam height Exhaust 33.10 ...

  • Page 215: Removing The Rocker Arm

    18 ENGINE If there is damage or wear: Replace the timing chain guide rail. Check the timing chain securing guide for damage and wear. If there is damage or wear: Replace the timing chain securing guide. Check timing chain for damage and wear. If there is damage or wear: Replace the timing chain.

  • Page 216: Changing The Camshaft Bearing

    18 ENGINE Remove valve spring retainer @ and the valve spring. Pull the valve out of the valve guide from below and remove valve stem seal@) and valve spring seat •• 304686-10 Mark the valves corresponding to their installation position. Info !:'II EV�...

  • Page 217: Checking The Valves

    18 ENGINE Press the large camshaft bearing in all the way using special tool@). Pressing tool (7502904401 0) p. 359) 18.4.27 Checking the valves Info The valve shaft is hard-chrome plated; wear generally appears at the valve guide. Check the run-out at the valve plate. Valve Run-out at valve plate ::;...

  • Page 218: Checking Valve Spring Seat

    18 ENGINE Exhaust minimum length 40. 7 mm (1 .602 in) (without valve spring seat) If the measured value does not meet specifications: Change the valve spring. 18.4.29 Checking valve spring seat Check the valve spring seat for breakage and wear (visual check).

  • Page 219: Checking The Rocker Arm Shafts

    18 ENGINE Check sealing seat of the valves. Valve Intake sealing seat width 2.00 mm (0.0787 in) Valve Exhaust sealing seat 2.00 mm (0.0787 in) width If the measured value does not meet specifications: Rework the valve seat. 302808-10 Blow compressed air through all oil channels and check that they are clear.

  • Page 220: Installing The Rocker Arm

    18 ENGINE Mount the valve keys. Info When mounting the valve keys, check that they are seated correctly; preferably, fix the valve keys to the valve with a little grease. Place shims into the valve spring retainers according to the installation position.

  • Page 221: Checking The Clutch

    18 ENGINE 18.4.34 Checking the clutch 311354-10 Check clutch push rod for damage and wear. If there is damage or wear: Change the clutch push rod. Place clutch push rod @} on a flat surface and check for run-out. If there is run-out: Change the clutch push rod.

  • Page 222: Checking The Shift Mechanism

    18 ENGINE If there is damage or wear: Change the clutch facing discs and the clutch basket. Check needle bearings and collar bushing for damage and wear. If there is damage or wear: Change the needle bearings and collar bushing. Check intermediate clutch discs G) for damage and wear.

  • Page 223: Preassembling The Shift Shaft

    18 ENGINE Check grooved ball bearing for smooth operation and wear. If the grooved ball bearing does not move easily or is worn: Change the grooved ball bearing. Check shift rollers for surface damage and cracking. If the shift roller exhibits surface damage or cracking: Change the shift drum.

  • Page 224: Disassembling The Main Shaft

    18 ENGINE 18.4.37 Disassembling the main shaft 304684-10 Secure the main shaft with the toothed end facing downward in the vise. Guideline Use soft jaws. Remove stop disk and 2nd-gear fixed gear Remove 6th-gear idler gear (D. Remove the split needle bearing and stop disk @t.
  • Page 225 18 ENGINE 304684-11 Main work Secure the main shaft in the vise with the gear teeth facing downward. Guideline I Use soft jaws. Mount the divided needle bearing and attach the fifth-gear idler gear with the shift dogs facing up. Mount stop disk@) and lock ring Push on the third/fourth-gear sliding gear with the small gear wheel facing downward and mount lock...

  • Page 226: Disassembling The Countershaft

    18 ENGINE 18.4.39 Disassembling the countershaft @ c, � i 304685-10 Secure the countershaft in the bench vise with the toothed end facing downward. Guideline Use soft jaws. Remove stop disk and first-gear idler gear Remove needle bearing and stop disk Remove the fifth-gear sliding gear and lock ring (D.

  • Page 227: Checking The Transmission

    18 ENGINE • 0 (;) 0 6D • • e • • J � 304685-11 Main work Secure the countershaft in the bench vise with the toothed end facing downward. Guideline I Use soft jaws. Mount needle bearing and second-gear idler gear onto the countershaft with the protruding collar facing downward.
  • Page 228 18 ENGINE 304691-10 Check needle bearings for damage and wear. there is damage or wear: Change the needle bearings. Check the pivot points of main shaft and countershaft for damage and wear. there is damage or wear: Change the main shaft and/or countershaft. Check the tooth profiles of main shaft and countershaft for damage and wear.

  • Page 229: Checking The Starter Drive

    18 ENGINE Use new lock rings with every repair. 18.4.42 Checking the starter drive 304688-10 Check the gear mesh and bearing of starter idler gear for damage and wear. If there is damage or wear: Change the starter idler gear. Check the gear mesh and bearing of torque limiter for damage and wear.

  • Page 230: Removing The Freewheel

    18 ENGINE 18.4.43 Removing the freewheel Press expansion ring together with suitable pliers and take off. 304703-10 Take the freewheel out of the primary gear. 304704-10 18.4.44 Checking the freewheel Insert freewheel gear into primary gear@, turning the primary gear clockwise; do not wedge! Check the locking action of freewheel gear If the primary gear does not turn clockwise or if it does not lock counterclockwise:...

  • Page 231: Engine Assembly

    18 ENGINE Mount spreader ring @. 304705-10 Ensure that all lugs of the spreader ring pass through slots of the freewheel and engage in groove of the primary gear. 18.5 Engine assembl}' 18.5.1 Installing the crankshaft Tighten the right section of the engine case in the engine assembly stand.

  • Page 232: Installing The Shift Forks

    18 ENGINE Mount lock ring Installing the shift forks 18.5.3 Thoroughly oil all parts. Shift fork has a smaller inside diameter; mount this in the shift groove of the main shaft. Mount shift fork in the lower shift groove of the counter­ shaft.

  • Page 233: Installing The Shift Rails

    18 ENGINE 18.5.5 Installing the shift rails Install shift rails together with upper springs @ and lower springs. Info Fix the springs in the shift rails with grease. 18.5.6 Installing the left engine case Mount dowels onto the left section of the engine case. Grease the sealing surfaces.

  • Page 234: Installing The Freewheel Gear

    18 ENGINE Mount the 0-ring on the countershaft. Lightly grease and mount spacer @. 18.5.7 Installing the freewheel gear Mount freewheel gear 18.5.8 Installing the primary gear Mount woodruff key Degrease the cone and thinly apply thread locker to it. I Loctite ®...

  • Page 235: Installing The Oil Pump Gear Wheels

    18 ENGINE Position oil pump cover Mount and tighten screws Guideline 10 Nm (7.4 lbf ft) Screw, oil pump ® Loctite ™ cover 18.5.10 Installing the oil pump gear wheels Insert pin Position oil pump gear wheel @. Position washers (D. Mount lock washer Mount oil pump idler gear Mount washer...

  • Page 236: Installing The Shift Drum Locating Unit

    18 ENGINE 18.5.12 Installing the shift drum locating unit Push away locking lever from the shift drum locating unit and position the shift drum locating unit @. Info The flat areas of the shift drum locating unit are not symmetric. Relieve tension from the locking lever.

  • Page 237: Installing The Outer Clutch Hub

    18 ENGINE 18.5.16 Installing the outer clutch hub Mount collar bushing and both needle bearings@. Slide clutch basket onto the gearbox main shaft. Turn oil pump gear wheel until the gear teeth of the clutch basket engage. Slide on washer and inner clutch hub (3.

  • Page 238: Installing The Clutch Discs

    18 ENGINE Position the crankshaft at top dead center (TDC) and block using the special tool. I Locking screw (113080802) (llill p. 353) 18.5.18 Installing the clutch discs Thoroughly oil the clutch facing discs. Beginning with an intermediate clutch disc, alternately insert all other clutch facing discs and intermediate clutch discs into the clutch basket.
  • Page 239 18 ENGINE Position spring retainer with marking I. Mount screws and tighten in a crisscross pattern. Guideline Screw, clutch spring 6 Nm (4.4 lbf ft) retainer Using a straightedge and the special tool, check the spring washer for distortion. Feeler gauge (59029041100) (�...

  • Page 240: Installing The Clutch Cover

    18 ENGINE 18.5.19 Installing the clutch cover Position the balancer shaft with special tool I Marking mandrel (78129032000) p. 362) ✓ Marking and the special tool are aligned. Mount dowels Put the new clutch cover gasket place. Mount the clutch cover. Mount screws and tighten once all of the clutch cover screws have been mounted.

  • Page 241: Installing The Suction Pump

    18 ENGINE Guideline Screw, water pump M6x25 10 Nm (7.4 lbf ft) cover Mount screw and tighten all screws in a crisscross pat­ tern. Guideline 10 Nm (7.4 lbf ft) Screw, water pump M6x55 cover 18.5.21 Installing the suction pump Oil the internal rotor and external rotor before mounting.

  • Page 242: Installing The Timing Chain

    18 ENGINE Position the cable and insert the cable sleeve into the engine • case. 18.5.23 Installing the timing chain Thread in the timing chain and place it over the timing chain sprocket. Info • If the timing chain was used before, ensure it is run­ ning in the correct direction.

  • Page 243: Installing The Rotor

    18 ENGINE 18.5.27 Installing the rotor Mount the woodruff key. Mount the rotor. Mount the spring washer and nut. Tighten the nut. Guideline Nut, rotor I M12x1 I 60 Nm (44.3 lbf ft) 18.5.28 Installing the piston Move the joints of the compression ring and oil scraper ring so they are offset by 1 80 °...
  • Page 244 18 ENGINE Ensure that piston mark faces toward the exhaust side. 304606-10 Cover the engine case opening with a cloth. Thread the tim­ ing chain through the chain shaft. Mount the piston pin. • Info In order to present them more clearly, the following steps are shown with a removed piston.

  • Page 245: Installing The Cylinder Head

    18 ENGINE Insert the special tool and press it forcefully to the piston. Turn the special tool counterclockwise, thereby pushing the piston pin retainer into the groove. Insertion for piston ring lock (77329030100) (!1ll p. 361) Ensure that the piston pin retainer is seated properly on both sides.

  • Page 246: Installing The Camshaft

    18 ENGINE Guideline Screw, cylinder head 110 Nm (7.4 lbf ft) 18.5.30 Installing the camshaft Place the timing chain over the camshaft gear. Push the camshaft into the bearing seats. ✓ The markings on the camshaft and of the cylinder head are lined up with each other.

  • Page 247: Checking The Valve Clearance

    18 ENGINE Mount and tighten screw plug @ with washer spring Guideline Plug, timing chain M8x1 8 Nm (5.9 lbf ft} tensioner 18.5.32 Checking the valve clearance Remove special tool Locking screw (113080802) p. 353) Crank the engine several times. Position the engine at ignition top dead center.

  • Page 248: Installing The Alternator Cover

    18 ENGINE Raise rocker arm on the outside. Remove shims and set down in the position in which they were installed. Correct the shims according to the findings from checking the valve clearance. Insert suitable shims. Install the camshaft. p. 244) Install the timing chain tensioner.

  • Page 249: Installing The Spark Plug

    18 ENGINE 18.5.36 Installing the spark plug Mount and tighten the spark plug using the special tool. Guideline Spark plug M12x1 .25 15 ... 20 Nm (11.1 ... 14.8 lbf ft) Spark plug wrench with link (77229172000) (� p. 361) 309224-10 Installing the starter motor 18.5.37...

  • Page 250: Installing The Clutch Push Rod

    18 ENGINE 18.5.39 Installing the clutch push rod Mount clutch push rod 18.5.40 Installing the oil screen Mount and tighten engine oil screen plug with the O-ring. Guideline Screw plug, engine M20x1.5 15 Nm (11 .1 lbf ft) oil screen Push the oil screen with O-rings onto a pin wrench.

  • Page 251: Removing The Engine From The Engine Assembly Stand

    18 ENGINE 18.5.41 Removing the engine from the engine assembly stand Remove the fitting from the special tool. Holder and fitting for work stand (78029002000) (� p. 361) Remove the engine from the engine assembly stand. • Info Work with an assistant or a motorized hoist.

  • Page 252: 19 Clutch

    19 CLUTCH Checking/correcting the fluid level of the h draulic clutch Info The fluid level rises with increasing wear of the clutch facing discs. Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid.

  • Page 253: Changing The Hydraulic Clutch Fluid

    19 CLUTCH Changing the h�draulic 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. Consult a doctor immediately if brake fluid has been swallowed.
  • Page 254 19 CLUTCH Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) (lal p. 354) Brake fluid DOT 4 (il,) p. 348) On the clutch slave cylinder, remove bleeder screw mount bleeding syringe (FE EU/AU, FE 450/501 US) Now inject the fluid into the system until it emerges from drill hole of the master cylinder without bubbles.

  • Page 255: 20 Water Pump, Cooling System

    20 WATER PUMP, COOLING SYSTEM 20.1 Cooling s�stem Water pump in the engine circulates the coolant. The water flow through the radiator is controlled as a function of the coolant temperature. The cooling system is divided into two circuits. In the warming-up phase of the engine, the coolant flows through the small cooling circuit.

  • Page 256: Checking The Coolant Level

    20 WATER PUMP, COOLING SYSTEM Stand the motorcycle upright on a horizontal surface. Remove the radiator cap. Check the antifreeze in the coolant. I -25 ... -45 °C (-13 ... -49 °F) If the antifreeze in the coolant does not match the speci­ fied value: Correct the antifreeze in the coolant.

  • Page 257: Draining The Coolant

    20 WATER PUMP, COOLING SYSTEM Draining the coolant 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 258: Refilling Coolant

    20 WATER PUMP, COOLING SYSTEM Refilling coolant Warning Coolant is toxic and a health hazard. Danger of poisoning Keep coolant out of the reach of children. Do not allow coolant to come into contact with the skin, the eyes and clothing. Consult a doctor immediately if coolant is swallowed.

  • Page 259: Lubrication System

    LUBRICATION SYSTEM 21.1 Oil circuit 305159-10 Engine oil screen Force pump Oil pressure regulator valve Oil filter Oil nozzles for piston cooling Suction pump 21.2 Checking the engine oil level Condition The engine is at operating temperature. Preparatory work Stand the motorcycle upright on a horizontal surface. Main work Check the engine oil level.

  • Page 260: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    LUBRICATION SYSTEM Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. Wear suitable protective clothing and safety gloves. In the event of scalding, rinse the area affected immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 261 LUBRICATION SYSTEM Mount and tighten screw plug with the gear oil screen and the O-rings. Guideline Screw plug, gear oil M20x1 .5 15 Nm (11.1 lbf ft) screen Position oil screen with the O-rings on a pin wrench. Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case.

  • Page 262: Adding Engine Oil

    LUBRICATION SYSTEM Lay the motorcycle on its side and fill the oil filter housing to about ½ full with engine oil. Insert the new oil filter into the oil filter housing. Oil the O-ring of the oil filter cover and mount it with oil filter cover@.

  • Page 263: Checking The Engine Oil Pressure

    LUBRICATION SYSTEM Main work Remove oil filler plug with the O-ring from the clutch cover. Fill engine oil to the middle of the level viewer. Engine oil (SAE 1 0W/50) p. 348) • Info For optimal performance of the engine oil, do not mix different types of engine oil.
  • Page 264 LUBRICATION SYSTEM Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 265: 22 Ignition System

    22 IGNITION SYSTEM 22.1 Ignition coil - checking the seconda� winding Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. Ignition coil cylinder 1 - check the secondary winding resistance Measure the resistance between the specified points. Ignition coil cylinder 1 pin (-) - Ignition coil cylin­...

  • Page 266: Removing The Stator

    22 IGNITION SYSTEM Stator winding, measurement II - check the resistance Measure the resistance between the specified points. Stator, connector pin 1 - Stator, connector Alternator Resistance of stator 0.368 ... 0.552 Q winding at: 20 °c (68 °F) If the value displayed does not meet specifications: Change the stator.

  • Page 267: Installing The Stator

    22 IGNITION SYSTEM Installing the stator Position the stator in the alternator cover. Mount and tighten screws Guideline Screw, stator 6 Nm (4.4 lbf ft) ® Loctite ™ Position cable support sleeve in the alternator case. Position the cable holder. Mount and tighten screw Guideline 700079-11 Screw, cable...

  • Page 268: 23 Cylinder Head

    23 CYLINDER HEAD 23.1 Checking the valve clearance Preparatory work (FE EU/AU, FE 450/501 US) Raise the motorcycle with a lift stand. p. 14) Remove the seat. p. 98) Remove the fuel tank. p. 99) (FE 501 SUS) Raise the motorcycle with a lift stand. p.
  • Page 269 23 CYLINDER HEAD (FE 501 SUS) Engage the highest gear. Turn the rear wheel until the engine is at ignition top dead center. ✓ The markings on the camshaft and of the cylinder head are lined up with each other. Info Make sure that the crankshaft is at top dead cen­...

  • Page 270: Adjusting Valve Clearance

    23 CYLINDER HEAD Position the valve cover with the gasket. Mount and tighten screws Guideline Screw, valve cover 110 Nm (7.4 lbf ft) Mount the vent hose and hose clamp Mount and tighten the spark plug using the special tool. Guideline Spark plug M12x1 .25...
  • Page 271 23 CYLINDER HEAD Main work Swing up cam lever Correct the shims based on the results of the valve clearance check. Finishing work Install the camshaft. (� p. 244) Install the timing chain tensioner. (I!!:! p. 244) Check the valve clearance. (I!!:! p.

  • Page 272: 24 Electric Starter

    24 ELECTRIC STARTER 24.1 Checking the starter motor Condition The starter motor has been removed. Connect the negative cable of a 12 volt power supply to the housing of the starter motor. Connect the positive cable of the power supply briefly to connector of the starter motor.

  • Page 273: 25 Throttle Valve Body

    25 THROTTLE VALVE BODY Adjusting the idle s�eed Warning 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. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
  • Page 274 25 THROTTLE VALVE BODY Start the engine without operating the throttle grip. Guideline I Coolant temperature I < 25 °C (< 77 °F) Let the engine idle until it reaches the specified temperature. Guideline I Coolant temperature I so ... 90 °c (176 ... 194 °F) •...

  • Page 275: 26 Technical Data

    26 TECHNICAL DATA 26.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement (FE 450 EU/AU, FE 450 US) 449.3 cm (27.418 cu in) Displacement (FE 501 EU, FE 501 AU, FE 501 US, 510.4 cm (31.147 cu in) FE 501 SUS) Stroke (FE 450 EU/AU, FE 450 US) 63.4 mm (2.496 in) Stroke (FE 501 EU, FE 501 AU, FE 501 US,...

  • Page 276: Tolerance, Engine Wear Limits

    26 TECHNICAL DATA 26.2 Tolerance, engine wear limits Camshaft - cam height Exhaust 33.10 ... 33.30 mm (1.3031 ... 1.311 in) Camshaft - cam height (FE 450 EU/AU, FE 450 US) Intake 34 ... 34.20 mm (1.34 ... 1 .3465 in) Camshaft - cam height (FE 501 EU, FE 501 AU, FE 501 US, FE 501 S US) Intake 34.40 ...

  • Page 277: Engine Tightening Torques

    26 TECHNICAL DATA 26.3 engine tightening tor ues Screw, membrane 1.5 Nm (1.11 lbf ft) Loctite ® ™ Oil jet, piston cooling 2 Nm (1.5 lbf ft) Loctite ® ™ 4 Nm (3 lbf ft) Screw, cable holder in alternator ®...
  • Page 278 26 TECHNICAL DATA Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite ® ™ Screw, shift lever 14 Nm (10.3 lbf ft) Loctite ® ™ Screw, starter motor 10 Nm (7.4 lbf ft) Screw, timing chain guide rail 10 Nm (7.4 lbf ft) ®...

  • Page 279: Capacities

    26 TECHNICAL DATA M14x1.25 20 Nm (14.8 lbf ft) Plug, rocker arm Nut, inner clutch hub M18x1.5 80 Nm (59 lbf ft) Nut, primary gear M20LHx1 .5 100 Nm (73.8 lbf ft) ® Loctite ™ Screw plug, engine oil screen M20x1 .5 15 Nm (11.1 lbf ft) Screw plug, gear oil screen...

  • Page 280: Electrical System

    26 TECHNICAL DATA front 1 .5 bar (22 psi) rear 1 .5 bar (22 psi) Final drive (FE 450 EU/AU) 14:52 (13:52) 13:50 Final drive (FE 450 US) Final drive (FE 501 EU, FE 501 AU) 14:50 (13:50} Final drive (FE 501 US) 13:50 Final drive (FE 501 S US) 15:45 (13:50)

  • Page 281: Tires

    110/100 - 18 64M TT Dunlop GEOMAX AT81 F Dunlop GEOMAX AT81 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com Fork 26.8 Fork part number 24.18.7P.69 Fork...

  • Page 282: Chassis Tightening Torques

    26 TECHNICAL DATA Rebound damping Comfort 20 clicks Standard 18 clicks Sport 16 clicks Spring preload 15 mm (0.59 in) Spring rate Weight of rider: 65 ... 75 kg (143 ... 165 lb.} 54 N/mm (308 lb/in) Weight of rider: 75 ... 85 kg (165 ... 187 lb.) 57 N/mm (325 lb/in) Weight of rider: 85 ...
  • Page 283 26 TECHNICAL DATA Remaining nuts, chassis 25 Nm (18.4 lbf ft) Remaining screws, chassis 25 Nm (18.4 lbf ft) Screw, bottom triple clamp 15 Nm (11.1 lbf ft) 15 Nm (11.1 lbf ft) Screw, chain sliding piece Screw, engine brace 33 Nm (24.3 lbf ft) ®...

  • Page 284: 27 Cleaning, Care

    27 CLEANING, CARE 27.1 Cleaning the motorc�cle 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. Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.

  • Page 285: Checks And Maintenance Steps For Winter Operation

    27 CLEANING, CARE Treat bare metal (except for brake discs and the exhaust sys­ tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 35 1) (� Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 286: Storage

    Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info Husqvarna Motorcycles recommends raising the motorcycle. Raise the motorcycle with a lift stand. p. 14) Preferably cover the vehicle with a tarp or similar cover that is permeable to air.

  • Page 287: Preparing For Use After Storage

    28 STORAGE 28.2 Pre�aring for use after storage Remove the motorcycle from the lift stand. (illll p. 14) Install the battery. (lillll p. 145) Perform checks and maintenance measures when preparing for use. Take a test ride. 401059-01...

  • Page 288: 29 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 equipment is functioning properly. • •...

  • Page 289: Service Work As Additional Order)

    Final check: Check the vehicle for roadworthiness and take a test ride. • • • • 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 War- ranty Booklet.

  • Page 290: Fe Eu)

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  • Page 291: 30 Wiring Diagram

    30 WIRING DIAGRAM Components: Battery Starter relay with main fuse Electric starter system E-tip switch...

  • Page 292: Fe Eu)

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  • Page 293 30 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...
  • Page 295 30 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Speedometer Horn Parking light Light switch, horn button, kill switch...

  • Page 296: Fe Eu)

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  • Page 297 30 WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Brake/tail light...

  • Page 298: Fe Eu)

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  • Page 299 30 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator lamp Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right S2 5 Turn signal switch...

  • Page 300: Fe Eu)

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  • Page 301 30 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level sensor Lambda sensor (cylinder 1) Fuse Speedometer...

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  • Page 303 30 WIRING DIAGRAM Components: A 11 EFI control unit Front wheel speed sensor Fuel pump Injection valve (cylinder 1) Speedometer CAN-bus terminating resistor 1 X295 Diagnostics connector...

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  • Page 305 30 WIRING DIAGRAM Components: A 11 EFI control unit Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Induction manifold pressure sensor (cylinder 1) Throttle position sensor Ignition coil (cylinder 1) Map-Select switch for ride mode (optional) Map-Select switch for basic position (optional) Cable colors:...

  • Page 306: Fe Au)

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  • Page 307 30 WIRING DIAGRAM Components: Battery Starter relay with main fuse Electric starter system Emergency OFF switch, tip switch...

  • Page 308: Fe Au)

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  • Page 309 30 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...

  • Page 310: Fe Au)

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  • Page 311 30 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Speedometer Horn Parking light Light switch, horn button, kill switch S2 3 Emergency OFF switch, tip switch...

  • Page 312: Fe Au)

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  • Page 313 30 WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Brake/tail light...

  • Page 314: Fe Au)

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  • Page 315 30 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator lamp Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right S2 5 Turn signal switch...

  • Page 316: Fe Au)

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  • Page 317 30 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level sensor Fuse Speedometer...

  • Page 318: Fe Au)

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  • Page 319 30 WIRING DIAGRAM Components: A 11 EFI control unit Front wheel speed sensor Fuel pump Injection valve (cylinder 1) Speedometer CAN-bus terminating resistor 1 X295 Diagnostics connector...

  • Page 320: Fe Au)

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  • Page 321 30 WIRING DIAGRAM Components: A 11 EFI control unit Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Induction manifold pressure sensor (cylinder 1) Throttle position sensor Ignition coil (cylinder 1) Map-Select switch for ride mode (optional) Map-Select switch for basic position (optional) Cable colors:...

  • Page 322: Fe 450/501 Us)

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  • Page 323 30 WIRING DIAGRAM Components: Battery Starter relay with main fuse Electric starter system E-tip switch...

  • Page 324: Fe 450/501 Us)

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  • Page 325 30 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch (optional) Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan (optional) Voltage regulator X295 Diagnostics connector...

  • Page 326: Fe 450/501 Us)

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  • Page 327 30 WIRING DIAGRAM Components: A 11 EFI control unit Low beam Parking light Tail light Kill switch Light switch...

  • Page 328: Fe 450/501 Us)

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  • Page 329 30 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level sensor Fuse Speedometer...

  • Page 330: Fe 450/501 Us)

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  • Page 331 30 WIRING DIAGRAM Components: A 11 EFI control unit Front wheel speed sensor Fuel pump Injection valve (cylinder 1) Speedometer CAN-bus terminating resistor 1 X295 Diagnostics connector...

  • Page 332: Fe 450/501 Us)

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  • Page 333 30 WIRING DIAGRAM Components: A 11 EFI control unit Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Induction manifold pressure sensor (cylinder 1) Throttle position sensor Ignition coil (cylinder 1) Map-Select switch for ride mode (optional) Map-Select switch for basic position (optional) Cable colors:...

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  • Page 335 30 WIRING DIAGRAM Components: Fuse Battery Starter relay with main fuse Electric starter system Ignition lock S2 3 Emergency OFF switch, tip switch...

  • Page 336: Fe 501 S Us)

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  • Page 337 30 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...

  • Page 338: Fe 501 S Us)

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  • Page 339 30 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Horn High beam indicator lamp Parking light S2 9 Light switch, horn button, turn signal switch...

  • Page 340: Fe 501 S Us)

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  • Page 341 30 WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Brake/tail light...

  • Page 342: Fe 501 S Us)

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  • Page 343 30 WIRING DIAGRAM Components: Turn signal relay Turn signal switch Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right S2 9 Light switch, horn button, turn signal switch...

  • Page 344: Fe 501 S Us)

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  • Page 345 30 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level sensor Fuse Speedometer...

  • Page 346: Fe 501 S Us)

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  • Page 347 30 WIRING DIAGRAM Components: A 11 EFI control unit Front wheel speed sensor Fuel pump Evaporate emission control valve Injection valve cylinder 1 Speedometer CAN-bus terminating resistor 1 X295 Diagnostics connector...

  • Page 348: Fe 501 S Us)

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  • Page 349 30 WIRING DIAGRAM Components: A 11 EFI control unit Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Induction manifold pressure sensor (cylinder 1) Throttle position sensor Ignition coil (cylinder 1) Map-Select switch for ride mode (optional) Map-Select switch for basic position (optional) Cable colors:...

  • Page 350: 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 corresponding properties. Recommended supplier ® Bel-Ray Super DOT 4 Brake Fluid Coolant Guideline Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade and unsuitable antifreeze causes corrosion, deposits and frothing.
  • Page 351 31 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification p. 370) (SAE 2.5) Guideline Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline...

  • Page 352: 32 Auxiliary Substances

    32 AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel-Ray Foam Filter Cleaner & Degreaser High viscosi't}f grease Recommended supplier ® LGHB 2 Long-life grease Recommended supplier ® Bel-Ray Waterproof Grease Lubricant (I158) Recommended supplier Lubcon ® ® Turmogrease PP 300 Lubricant 14034...
  • Page 353 32 AUXILIARY SUBSTANCES Oil for foam air filter Recommended supplier ® Bel-Ray Foam Filter Oil Preserving materials for �aints metal and rubber Recommended supplier ® Bel-Ray Silicone Detailer & Protectant Spray Universal oil s�ra}! Recommended supplier ® Bel-Ray 6 in 1...

  • Page 354: 33 Special Tools

    33 SPECIAL TOOLS Bleeder cover Art. no.: 00029013005 00029013005 H00504-01 Bleeder cover Art. no.: 00029013006 00029013006 H00505-01 Bleeding device Art. no.: 00029013100 00029013100 H00518-01 EU batte charger XCharge- rofessional Art. no.: 00029095050 Feature EU safety plug Nominal voltage 230 V Mains fuse Power cable length 5 m (16 ft)
  • Page 355 33 SPECIAL TOOLS US batterY charger XCharge-�rofessional Art. no.: 00029095051 Feature US plug Nominal voltage 120 V Mains fuse 32 A Power cable length 5 m (16 ft) approx. Charger cable 5 m (16 ft) H01065-01 length approx. e-professional Art. no.: 00029095052 Feature UK safety plug Nominal voltage...
  • Page 356 33 SPECIAL TOOLS Bearing �uller Art. no.: 15112017000 15112017000 H00520-01 Internal bearing �uller Art. no.: 15112018100 Feature 1 18 ... 23 mm (0.71 ... 0.91 in) 15112018100 H00522-01 S ring hook Art. no.: 50305017000 50305017000 H00973-01 ringe Art. no.: 50329050000 £&...
  • Page 357 33 SPECIAL TOOLS Lock ring �lier Art. no.: 51012011000 51012011000 H00572-01 Holding wrench Art. no.: 51129003000 51129003000 H00575-01 Puller Art. no.: 58012009000 58012009000 H00592-01 Tool bracket Art. no.: 58429089000 58429089000 H00603-01...
  • Page 358 33 SPECIAL TOOLS Pressing tool Art. no.: 58429091000 58429091000 H00604-01 Pressing tool Art. no.: 58429092000 58429092000 H00605-01 Torgue wrench set Art. no.: 58429094000 Feature Torque 3 ... 15 Nm (2.2 ... 11 .1 lbf ft) Open ended bit 3.9 mm (0.154 in) Open ended bit 4.9 mm (0.193 in) 5.5 mm (0.217 in)
  • Page 359 33 SPECIAL TOOLS Limit �lug gauge Art. no.: 59029026006 Feature Diameter I 6.05 mm (0.2382 in) 59029026006 H00612-01 Feeler gauge Art. no.: 59029041100 & Feature 15 piece I 0.10 ... 0.25 mm (0.0039 ... 0.0098 in) 59029041100 H00616-01 Piston ring mounting tool Art.
  • Page 360 33 SPECIAL TOOLS Hose clam� �lier Art. no.: 60029057000 60029057000 H00650-01 Testing hose Art. no.: 61029093000 61029093000 H00659-01 Pressure testing tool Art. no.: 61029094000 .£. 61029094000 H00660-01 Puller Art. no.: 75029021000 75029021000 H00707-01...
  • Page 361 33 SPECIAL TOOLS Pressing tool Art. no.: 75029044010 75029044010 H00712-01 Pressing tool Art. no.: 75029044020 75029044020 H00713-01 Crankshaft ressing tool Art. no.: 75029047000 75029047000 H00714-01 Clam Art. no.: 75029050000 75029050000 H00719-01...
  • Page 362 33 SPECIAL TOOLS Pressing tool Art. no.: 75029051000 �� 75029051000 H00721-01 Protection caR Art. no.: 75029090000 75029090000 H00726-01 Oil Rressure ada�ter Art. no.: 75029094000 � 75029094000 H00728-01 Limit Art. no.: 77029026000 .& Feature Diameter 5.05 mm (0.1988 in) 77029026000 H00741-01...
  • Page 363 33 SPECIAL TOOLS Insert for valve s�ring lever Art. no.: 77029041200 77029041200 H00746-01 S�ark �lug wrench with link Art. no.: 77229172000 Feature Drive 3/8 in Hexagonal part 14 mm (0.55 in) Length 130 mm (5.12 in) 77229172000 H00761-01 Insertion for �iston ring lock Art.
  • Page 364 33 SPECIAL TOOLS Protection ca� Art. no.: 78029005000 78029005000 H00784-01 Crankshaft ressing tool insert Art. no.: 78029008000 78029008000 H00786-01 Se�arator �late Art. no.: 78029009100 78029009100 H01174-01 Marking mandrel Art. no.: 78129032000 78129032000 H00796-01...
  • Page 365 33 SPECIAL TOOLS Gear segment Art. no.: 80029004000 80029004000 H00813-01 Engine work stand Art. no.: 80329001000 80329001000 H01047-01 Lift stand Art. no.: 81329955100 Feature Height 315 ... 425 mm (12.4 ... 16.73 in) Load s; 150 kg (:5 331 lb.) 81329955100 H00985-01 Protection ca...
  • Page 366 33 SPECIAL TOOLS Puller Art. no.: 90129048100 90129048100 H00828-01 Hook wrench Art. no.: T106S Feature I Diameter 68 ... 75 mm (2.68 ... 2.95 in) T106S H00841-01 De�th micrometer Art. no.: T107S T107S H00842-01 Drift Art. no.: T120 Feature 8 mm (0.31 in) I Diameter T120 H00844-01...
  • Page 367 33 SPECIAL TOOLS Clam�ing stand Art. no.: T1202S Feature Diameter 10 mm (0.39 in) Diameter 18 mm (0.71 in) T1202S H01149-01 Mounting sleeve Art. no.: T1204 Feature Diameter I 25.5 ... 30.5 mm (1.004 ... 1.201 in) T1204 H00878-01 Calibrating unit Art.
  • Page 368 33 SPECIAL TOOLS Pressing tool Art. no.: T1207S T1207S H00881-01 Mounting sleeve Art. no.: T1215 Feature I Diameter 118 mm (0.71 in) T1215 H00886-01 Pressing tool Art. no.: T1216 Feature I Diameter 38 ... 49 mm (1 .5 ... 1.93 in) T1216 H00887-01 Vacuum...
  • Page 369 33 SPECIAL TOOLS Protecting sleeve Art. no.: T1401 & Feature Diameter I 48 mm (1 .89 in) cs)) T1401 H00894-01 Clam�ing stand Art. no.: T1403S 2x£. Feature Diameter 48 mm (1 .89 in) Diameter 60 mm (2.36 in) �� T1403S H00896-01 Mounting tool Art.
  • Page 370 33 SPECIAL TOOLS Clam�ing stand Art. no.: T14049S .&. Feature Diameter 8 mm (0.31 in) Diameter 24.8 mm (0.976 in) T14049S H00924-01 Pressing tool Art. no.: T14051 Feature I Diameter 50 mm (1.97 in) T14051 H00926-01 Pressing tool Art. no.: T1504 Feature I Diameter 118 mm (0.71 in)
  • Page 371 33 SPECIAL TOOLS Filling tool Art. no.: T170S1 2x£3x.£. T170S1 H00855-01...

  • Page 372: Standards

    STANDARDS JASOT903MA Different technical development directions required a separate specification for motorcycles - the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 373: 35 List Of Abbreviations

    35 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 374: Index

    INDEX Capacity Accessories ......1 0 coolant ....... 256, 277 Activated charcoal filter engine oil ....180, 260, 277 installing fuel ......
  • Page 375 INDEX transmission shafts, removing Engine - working on the individual parts camshaft bearing, changing Drivetrain kit clutch, checking changing countershaft, assembling ... . . 224 countershaft, disassembling ... 224 Engine engine case section, left .
  • Page 376 INDEX Engine disassembly alternator cover, removing Figures ......10 camshaft, removing ....185 Filler cap clutch discs, removing ....190 closing ......
  • Page 377 INDEX removing ......99 Motorcycle cleaning ......282 Fuse lift stand, raising with .
  • Page 378 INDEX Seat Steering head bearing play mounting ......98 adjusting ......43 removing .
  • Page 379 INDEX Page 2 of 8 ....290, 306, 334 Page 3 of 6 ..... . . 324 Page 3 of 8 ....
  • Page 380 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 11 1 1 1 1 111 1 1 1 I I I I I I II I I II 3403030en 07/2017 ® Husqvarna llmi Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria fiiiHiAv � LZZa" ·...

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