Husqvarna FE 450 2018 Owner's Manual
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Husqvarna FE 450 2018 Owner's Manual

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OWNER'S MANUAL 2018
FE 450
FE 501
Art. no. 3402177en

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Summary of Contents for Husqvarna FE 450 2018

  • Page 1 OWNER'S MANUAL 2018 FE 450 FE 501 Art. no. 3402177en...
  • Page 3 DEAR HUSQVARNA MOTORCYCLES CUSTOMER Congratulations on your decision to purchase a Husqvarna motorcycle. You are now the owner of a state-of- DEAR HUSQVARNA MOTORCYCLES CUSTOMER the-art sports motorcycle that will give you enormous pleasure if you service and maintain it properly.
  • Page 4 TABLE OF CONTENTS TABLE OF CONTENTS Indicator lamps overview ....21 MEANS OF REPRESENTATION......6 6.10 Ignition lock......... 21 Symbols used ........6 6.11 Opening the filler cap......21 Formats used ........6 6.12 Closing the filler cap ......22 SAFETY ADVICE ..........
  • Page 5 TABLE OF CONTENTS Stopping, parking ....... 39 12.7 Removing the fork legs ....57 Transporting........40 12.8 Installing the fork legs ..... 58 Refueling ..........41 12.9 Removing the lower triple clamp ..58 12.10 Installing the lower triple clamp ..
  • Page 6 TABLE OF CONTENTS BRAKE SYSTEM ..........89 16.5 Refilling coolant ......120 13.1 Adjusting the basic position of the TUNING THE ENGINE ........122 hand brake lever ......... 89 17.1 Checking the play in the throttle 13.2 Checking the brake discs ....89 cable ..........
  • Page 7 TABLE OF CONTENTS STANDARDS ..........154 INDEX OF SPECIAL TERMS ......155 LIST OF ABBREVIATIONS ......156 LIST OF SYMBOLS ........157 29.1 Yellow and orange symbols....157 29.2 Green and blue symbols....157 INDEX ..............158...

  • Page 8: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interests of your own safety, have these jobs performed by an authorized Husqvarna Motorcycles workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.
  • Page 9 2 SAFETY ADVICE Use definition – intended use This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the currently valid regulations and categories of the top international motorsport organizations. Info This vehicle is only authorized for operation on public roads in the homologated (restricted) version.
  • Page 10 2 SAFETY ADVICE Overview of labels E00946-10 Canada type label Information on noise emission Information on chain tension Information on starting up Brake fluid information Information on emissions control USA type label E00947-10 Canada type label...
  • Page 11 2 SAFETY ADVICE E00948-10 Information on noise emission Information on chain tension F00490-10 Information on starting up F00491-10 Brake fluid information F00489-10 E00949-10 Information on emissions control...

  • Page 12: Noise Emission Warranty

    Otherwise, the owner may become subject to penalties under the applicable ordinances. Consumer rights Warranty claims should be submitted to a Husqvarna Motorcycles workshop. If you are not satisfied, please contact: Husqvarna Motorcycles North America, Inc., c/o KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA Phone: (440) 985–3553...

  • Page 13: Safe Operation

    An appropriate driver's license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized Husqvarna Motorcycles workshop. Adhere to the information and warning labels on the vehicle.
  • Page 14 – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, Husqvarna Motorcycles recommends that you only operate the vehicle while wearing protective clothing. 2.13 Work rules Special tools are necessary for certain tasks.

  • Page 15: Spare Parts, Accessories

    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; otherwise, all warranty claims will be void. Damage or secondary damage caused by tam- pering with and/or conversions on the vehicle are not covered by the warranty.

  • Page 16: Important Notes

    3 IMPORTANT NOTES Customer service Your authorized Husqvarna Motorcycles dealer will be happy to answer any questions you may have regarding your vehicle and Husqvarna Motorcycles. A list of authorized Husqvarna Motorcycles dealers can be found on the Husqvarna Motorcycles website.

  • Page 17: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) M01466-10 Filler cap Air filter box cover Side stand ( p. 24) Engine number ( p. 18) Shift lever ( p. 23)
  • Page 18 4 VIEW OF VEHICLE View of vehicle, rear right (example) E00952-10 Fork compression adjustment Horn button ( p. 19) Light switch ( p. 20) Turn signal switch ( p. 20) Clutch lever ( p. 19) Emergency OFF switch ( p. 20) Electric starter button ( p.

  • Page 19: Type Label

    5 SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 401945-10 Type label The type label is fixed to the front of the steering head. The additional type label for Canada is fixed to the front of the front pipe.

  • Page 20: Serial Numbers

    5 SERIAL NUMBERS Engine number Engine number is embossed on the left side of the engine behind the shift lever. 0 0 1 H00940-01 Fork part number The fork part number is stamped on the inner side of the fork stub.

  • Page 21: Clutch Lever

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. F00482-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar.
  • Page 22 6 CONTROLS Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – The light switch is turned down- ward. In this position, the low beam and tail light are switched on. High beam on –...
  • Page 23 – The OBD has detected an error in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized Husqvarna Motorcycles workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.
  • Page 24 6 CONTROLS Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Press release button , turn the filler cap counterclockwise, and lift it off. F00265-10 6.12 Closing the filler cap...
  • Page 25 6 CONTROLS 6.14 Idle speed adjusting screw The idle speed is adjusted using the idle speed adjusting screw Increase the idle speed by turning the idle speed adjusting screw clockwise. Decrease the idle speed by turning the idle speed adjusting screw counterclockwise.
  • Page 26 6 CONTROLS 6.16 Foot brake lever The foot brake lever is attached in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.17 Side stand The side stand is attached to the left side of the vehicle. 401943-10 The side stand is used for parking the motorcycle.
  • Page 27 6 CONTROLS 6.19 Locking the steering Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Park the vehicle. – Turn the handlebar as far as possible to the right. –...

  • Page 28: Combination Instrument

    Battery voltage of the combination instrument – Bat- tery voltage of the combination instrument is too low. Change the battery. Service – A service is due. Contact an authorized Husqvarna Motorcycles workshop. 401901-01 Adjusting the combination instrument Condition The motorcycle is stationary.
  • Page 29 7 COMBINATION INSTRUMENT – Wait for 5 seconds. Combination instrument changes to the next menu item. symbol flashes. – Press one of the buttons to select the 24h or 12h display of the clock. 401911-01 – Wait for 5 seconds. Combination instrument changes to the next menu item.
  • Page 30 7 COMBINATION INSTRUMENT Setting the kilometers or miles Info If the unit is changed, the value ODO is retained and converted accordingly. Condition The motorcycle is stationary. – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. –...
  • Page 31 7 COMBINATION INSTRUMENT Setting the service display Condition The motorcycle is stationary. – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. – Wait for the menu of the service display to flash. – Set the service.
  • Page 32 7 COMBINATION INSTRUMENT Press the DST is reset to 0.0. right button for 3 – 5 sec- onds. Speed, time, and DST2 distance 2 – Press one of the buttons until DST2 appears on the combina- tion instrument. KM/H or M/H shows the speed. shows the time.

  • Page 33: Preparing For Use

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized Husqvarna Motorcy- cles workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.
  • Page 34 8 PREPARING FOR USE – Adjust the basic position of the hand brake lever. ( p. 89) – Adjust the basic position of the foot brake lever. p. 95) – Adjust the basic position of the shift lever. p. 126) –...
  • Page 35 Preparing for rides on dry sand – Mount a dust cover on the air filter. Dust cover for air filter (79006920000) Info See the Husqvarna Motorcycles accessories fitting instructions. 102136-01 – Mount a sand cover on the air filter. Sand cover for air filter (79006922000)
  • Page 36 M01459-01 Preparing for rides on wet sand – Fit a rain cover on the air filter. Waterproofing device for air filter (79006921000) Info See the Husqvarna Motorcycles accessories fitting instructions. 102137-01 – Clean the chain. – Mount the steel sprocket.
  • Page 37 8 PREPARING FOR USE Preparing for rides on wet and muddy surfaces – Fit a rain cover on the air filter. Waterproofing device for air filter (79006921000) Info See the Husqvarna Motorcycles accessories fitting instructions. 102137-01 – Mount the steel sprocket. –...
  • Page 38 8 PREPARING FOR USE Preparing for rides at low temperature or in snow – Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info See the Husqvarna Motorcycles accessories fitting instructions. 102137-01...

  • Page 39: Riding Instructions

    9 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...
  • Page 40 Do not change into a low gear at high engine speed. Info If unusual noises occur while riding, stop immediately, switch off the engine, and contact an authorized Husqvarna Motorcycles workshop. First gear is used for starting off and for steep inclines. –...

  • Page 41: Stopping, Parking

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 42: Transporting

    9 RIDING INSTRUCTIONS Note Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle. –...

  • Page 43: Refueling

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Environmental hazard Improper handling of fuel is a danger to the environment.

  • Page 44: Service Schedule

    Every 30 operating hours/after every race Every 15 operating hours Once after 1 operating hour ○ ● ● ● Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. ○ ● ● ● Check that the electrical system is functioning properly. ●...
  • Page 45 ● Final check: Check the vehicle is roadworthy 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 Warranty Booklet.

  • Page 46: Recommended Work

    10 SERVICE SCHEDULE 10.3 Recommended work Annually Every 135 operating hours Every 70 operating hours when used for motorsports Once after 20 operating hours Once after 10 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. ●...

  • Page 47: Tuning The Chassis

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 48: Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber.

  • Page 49: Adjusting The Rebound Damping Of The Shock Absorber

    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. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 50: Checking The Static Sag Of The Shock Absorber

    11 TUNING THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 55) 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 47) – Hold the motorcycle upright with the aid of an assistant. –...

  • Page 51: Adjusting The Spring Preload Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring length.

  • Page 52: Adjusting The Riding Sag

    11 TUNING THE CHASSIS 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 55) – Remove the shock absorber. p. 64) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 53: Adjusting The Compression Damping Of The Fork

    11 TUNING THE CHASSIS 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn white adjusting screw clockwise as far as it will go. Info Adjusting screw is located at the upper end of the left fork leg.

  • Page 54: Adjusting The Spring Preload Of The Fork

    11 TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counter- clockwise to reduce damping. 11.14 Adjusting the spring preload of the fork Preparatory work – Raise the motorcycle with a lift stand. ( p. 55) Main work – Turn the adjusting wings counterclockwise all the way.

  • Page 55: Handlebar Position

    11 TUNING THE CHASSIS 11.15 Handlebar position On the upper triple clamp, there are two holes at a distance to each other. 15 mm (0.59 in) Hole distance The holes on the handlebar supports are placed at a distance from the center. 3.5 mm (0.138 in) Hole distance The handlebar supports can be mounted in four different posi-...
  • Page 56 11 TUNING THE CHASSIS Info Make sure the gap width is even.

  • Page 57: Service Work On The Chassis

    12 SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (81329955100) Neither wheel is in contact with the ground.

  • Page 58: Cleaning The Dust Boots Of The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 55) – Remove the fork protector. ( p. 56) Main work – Push dust boots of both fork legs downward.

  • Page 59: Installing The Fork Protector

    12 SERVICE WORK ON THE CHASSIS 12.6 Installing the fork protector – Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake line, wiring harness, and clamp. Mount and tighten screws –...

  • Page 60: Installing The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.8 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front. Info The compression damping is located in left fork leg COM (white adjusting screw). The rebound damping is located in right fork leg REB (red adjusting screw).

  • Page 61: Installing The Lower Triple Clamp

    12 SERVICE WORK ON THE CHASSIS Main work – Open the cable holder in front of the right radiator and detach the wiring harness. – Remove screws and hang the voltage regulator to the side. – Open the cable holder in front of the left radiator and detach the wiring harness.
  • Page 62 12 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the handlebar. – Mount screw but do not tighten yet. S02075-10 – Secure wiring harness and clutch line with cable holder. – Position the voltage regulator, and mount and tighten screws Guideline Remaining screws,...

  • Page 63: Checking The Play Of The Steering Head Bearing

    Checking the play of the steering head bearing Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)

  • Page 64: Adjusting The Steering Head Bearing Play

    12 SERVICE WORK ON THE CHASSIS Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time. Preparatory work – Raise the motorcycle with a lift stand.

  • Page 65: Lubricating The Steering Head Bearing

    12 SERVICE WORK ON THE CHASSIS Finishing work – Check the play of the steering head bearing. ( p. 61) – Remove the motorcycle from the lift stand. ( p. 55) 12.13 Lubricating the steering head bearing – Remove the lower triple clamp. p.

  • Page 66: Installing Front Fender

    12 SERVICE WORK ON THE CHASSIS 12.15 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F00283-10 Finishing work...
  • Page 67 12 SERVICE WORK ON THE CHASSIS – Press angle lever toward the rear. – Press linkage lever downward. F00285-10 – Disconnect plug-in connector E00933-10 – Remove screws – Pull off foot brake cylinder from the push rod. S02080-10 – Remove the connecting link of the chain. –...

  • Page 68: Installing The Shock Absorber

    12 SERVICE WORK ON THE CHASSIS – Hold the shock absorber and remove screw – Remove the shock absorber carefully at the bottom. E00936-10 12.17 Installing the shock absorber Main work – Carefully position the shock absorber into the vehicle from the bottom.
  • Page 69 12 SERVICE WORK ON THE CHASSIS – Position the foot brake cylinder. Push rod engages in the foot brake cylinder. The dust boot is correctly positioned. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S02084-10 –...

  • Page 70: Removing The Seat

    12 SERVICE WORK ON THE CHASSIS 12.18 Removing the seat Preparatory work – Remove the air filter box cover. ( p. 69) Main work – Remove screw – Pull seat back and lift it off. F00296-10 12.19 Mounting the seat Main work –...

  • Page 71: Removing The Air Filter Box Cover

    12 SERVICE WORK ON THE CHASSIS 12.20 Removing the air filter box cover – Pull off the air filter box cover sideways in areas , and remove toward the front. E00940-10 12.21 Installing the air filter box cover – Position air filter box cover on collar bushings and push toward the rear.

  • Page 72: Installing The Air Filter

    12 SERVICE WORK ON THE CHASSIS Main work – Detach retaining tab . Remove air filter with air filter sup- port. – Remove air filter from air filter support. F00300-10 12.23 Installing the air filter Main work – Mount the clean air filter on the air filter support. –...

  • Page 73: Sealing The Air Filter Box

    12 SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaning agent ( p. 153) Info Only press the air filter to dry it, never wring it out. –...

  • Page 74: Installing The Right Side Cover

    12 SERVICE WORK ON THE CHASSIS 12.27 Installing the right side cover – Position the side cover on collar bushings , and push toward the rear. – Engage the side cover in areas – Mount and tighten screw Guideline Remaining screws, 5 Nm (3.7 lbf ft) chassis E00943-10...

  • Page 75: Installing The Main Silencer

    12 SERVICE WORK ON THE CHASSIS 12.29 Installing the main silencer Main work – Position the main silencer. – Mount screws but do not tighten yet. – Attach spring Spring hook (50305017000) – Tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) K00595-10 chassis Finishing work...
  • Page 76 12 SERVICE WORK ON THE CHASSIS H01751-10 Main work – Remove screws , take off silencer cap Info Do not remove the glass fiber yarn filling. Warning Danger to health Soot particles irritate the eyes and mucuous membranes. – Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen. –...

  • Page 77: Changing The Glass Fiber Yarn Filling In The Main Silencer

    12 SERVICE WORK ON THE CHASSIS 12.31 Changing the glass fiber yarn 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. Info Over time, the fibers of the glass fiber yarn escape and the damper "burns"...
  • Page 78 12 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. –...

  • Page 79: Installing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS – Remove screw with the rubber bushing. F00308-10 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. F00309-10 12.33 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled.
  • Page 80 12 SERVICE WORK ON THE CHASSIS – Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracket. – Make sure that no cables are trapped or damaged. F00309-11 – Mount the fuel tank breather. –...

  • Page 81: Checking For Chain Dirt Accumulation

    12 SERVICE WORK ON THE CHASSIS 12.34 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 79) 400678-01 12.35 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip.

  • Page 82: Checking The Chain Tension

    12 SERVICE WORK ON THE CHASSIS 12.36 Checking 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 83: Checking The Chain, Rear Sprocket Engine Sprocket And Chain Guide

    12 SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with a lift stand. ( p. 55) – Check the chain tension. ( p. 80) Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right.
  • Page 84 12 SERVICE WORK ON THE CHASSIS – Pull at the top part of the chain with the specified weight Guideline Weight of chain wear mea- 10 … 15 kg (22 … 33 lb.) surement – Measure distance of 18 chain rollers in the lower chain section.
  • Page 85 12 SERVICE WORK ON THE CHASSIS – 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.

  • Page 86: Checking The Frame

    – 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 F00255-01 Motorcycles. 12.40 Checking the swingarm – Check the swingarm for damage, cracking, and deformation.

  • Page 87: Checking The Rubber Grip

    12 SERVICE WORK ON THE CHASSIS Main work – Check throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the fuel tank contact area rub- ber band.

  • Page 88: Adjusting The Basic Position Of The Clutch Lever

    12 SERVICE WORK ON THE CHASSIS 12.43 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info When the adjusting screw is turned clockwise, the clutch lever moves closer to the handlebar.

  • Page 89: Changing The Hydraulic Clutch Fluid

    12 SERVICE WORK ON THE CHASSIS – Correct the fluid level of the hydraulic clutch. Brake fluid DOT 4 ( p. 151) – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilled brake fluid immediately with water.

  • Page 90: Removing The Engine Guard

    12 SERVICE WORK ON THE CHASSIS – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 ( p. 151) – On the clutch slave cylinder, release bleeder screw mount bleeding syringe F00454-10 – Now press the fluid into the system until it emerges from the hole of the master cylinder without bubbles.

  • Page 91: Brake System

    Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple...

  • Page 92: Checking The Front Brake Fluid Level

    – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 93: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...

  • Page 94: Changing The Front Brake Linings

    Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 95 13 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane S02090-10 – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suc- tion if it does.

  • Page 96: Checking The Free Travel Of Foot Brake Lever

    13 BRAKE SYSTEM – Correct the brake fluid quantity to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 ( p. 151) – Position cover with membrane – Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water.

  • Page 97: Adjusting The Basic Position Of The Foot Brake Lever

    Warning Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)

  • Page 98: Adding Rear Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 99: Checking The Rear Brake Linings

    Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 100 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 101 13 BRAKE SYSTEM – Stand the vehicle upright. – Remove the cable ties on the frame protector. – Remove screw cap with membrane and the shim. S02094-10 – 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 102 13 BRAKE SYSTEM – Add brake fluid to level Brake fluid DOT 4 ( p. 151) – Mount and tighten screw cap with membrane and the shim. Info Clean up overflowed or spilled brake fluid immediately with water. S02093-10 – Mount new cable ties on the frame protector.

  • Page 103: Wheels, Tires

    14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 55) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pis-...

  • Page 104: Installing The Front Wheel

    14 WHEELS, TIRES 14.2 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. –...

  • Page 105: Installing The Rear Wheel

    14 WHEELS, TIRES Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. –...
  • Page 106 14 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p.

  • Page 107: Checking The Tire Air Pressure

    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- cle.

  • Page 108: Checking Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) –...

  • Page 109: Electrical System

    15 ELECTRICAL SYSTEM 15.1 Removing the battery Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. – Only charge batteries in well-ventilated rooms. –...
  • Page 110 15 ELECTRICAL SYSTEM 15.2 Installing the battery Main work – Insert the battery into the battery compartment with the ter- minals facing forward and secure with holding bracket Battery (HJTZ5S-FP) ( p. 147) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis –...

  • Page 111: Recharging The Battery

    15 ELECTRICAL SYSTEM 15.3 Recharging the battery Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. – Only charge batteries in well-ventilated rooms. –...

  • Page 112: Changing The Main Fuse

    15 ELECTRICAL SYSTEM Guideline The battery charger must be suitable for lithium-ion batteries. The charging current and charging voltage must not be exceeded. Maximum charging volt- 14.4 V Maximum charging cur- 3.0 A rent Charge the battery regu- 6 months larly when the motorcy- cle is not in use Ideal charging and stor-...

  • Page 113: Changing The Fuses Of Individual

    15 ELECTRICAL SYSTEM Main work – Pull starter relay from the holder. F00357-10 – Take off protection caps – Remove faulty main fuse Info You can recognize a faulty fuse by a burned-out fuse wire A spare fuse is located in the starter relay. –...
  • Page 114 15 ELECTRICAL SYSTEM Main work – Pull EFI control unit off the holder and hang to the side. F00359-10 – Open fuse box cover – Remove the defective fuse. Guideline Fuse 1 ‑ 10 A - EFI control unit, combination instrument, fuel injection, diagnostics connector, evaporate emission control valve, fuse 4 Fuse 2 –...

  • Page 115: Removing The Headlight Mask With

    15 ELECTRICAL SYSTEM – Mount EFI control unit on the holder. F00359-10 Finishing work – Mount the seat. ( p. 68) – Install the air filter box cover. ( p. 69) 15.6 Removing the headlight mask with the headlight – Turn the key in the ignition lock to the position while the engine is idling.

  • Page 116: Changing The Headlight Bulb

    15 ELECTRICAL SYSTEM – Position the headlight mask and secure it with rubber bands The holding lugs engage in the fender. K00611-10 – Position brake line and wiring harness in the brake line guide. F00480-10 Finishing work – Check the headlight setting. ( p.

  • Page 117: Changing The Turn Signal Bulb

    15 ELECTRICAL SYSTEM – Pull out headlight bulb – Insert the new headlight bulb. Headlight (HS1 / Sockel PX43t) ( p. 147) – Insert the protection cap with the bulb socket into the reflec- tor and turn it clockwise all the way. –...

  • Page 118: Checking The Headlight Setting

    15 ELECTRICAL SYSTEM 15.10 Checking the headlight setting – 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. – Make another mark at a distance under the first mark.

  • Page 119: Changing The Combination Instrument

    15 ELECTRICAL SYSTEM 15.12 Changing the combination instrument Preparatory work – Remove the headlight mask with the headlight. ( p. 113) Main work – Remove screws with the washers. – Pull the combination instrument upward out of the holder. F00370-10 –...

  • Page 120: Cooling System

    16 COOLING SYSTEM 16.1 Cooling system The water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
  • Page 121 16 COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...

  • Page 122: Refilling Coolant

    16 COOLING SYSTEM 16.4 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 123 16 COOLING SYSTEM Main work – Make sure that the screw is tightened. – Stand the vehicle upright. – Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Coolant 1.2 l (1.3 qt.) Coolant ( p.

  • Page 124: Tuning The Engine

    17 TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 …...

  • Page 125: Setting The Characteristic Map Of The Throttle Response

    17 TUNING THE ENGINE Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop. –...
  • Page 126 17 TUNING THE ENGINE – Remove guide plate from handle tube – Position the required guide plate on the grip tube. Guideline The label OUTSIDE must be visible. Marking must be positioned at marking Grey guide plate (79002014000) Alternative 1 Black guide plate (79002014100) Info The gray guide plate opens the throttle valve more...

  • Page 127: Adjusting The Idle Speed

    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. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Run the engine until warm.

  • Page 128: Checking The Basic Position Of The Shift Lever

    17 TUNING THE ENGINE 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 129 17 TUNING THE ENGINE – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.

  • Page 130: Service Work On The Engine

    18 SERVICE WORK ON THE ENGINE 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 131: Checking The Engine Oil Level

    18 SERVICE WORK ON THE ENGINE 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 132 18 SERVICE WORK ON THE ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Drain engine oil with engine at operating temperature. Preparatory work –...
  • Page 133 18 SERVICE WORK ON THE ENGINE – Position long oil screen with the O-rings on a pin wrench. – Position the pin wrench through the drill hole of the screw plug in the opposite section of the engine case. – Push the oil screen all the way into the engine case.

  • Page 134: Adding Engine Oil

    18 SERVICE WORK ON THE ENGINE – Remove filler plug from the clutch cover together with the O-ring, and fill up with engine oil. Engine oil 1.2 l (1.3 qt.) Engine oil (SAE 10W/50) p. 151) Info Too little engine oil or poor-quality engine oil will result in premature wear of the engine.
  • Page 135 18 SERVICE WORK ON THE ENGINE 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 10W/50) ( p. 151) Info For optimal performance of the engine oil, do not mix different types of engine oil.

  • Page 136: Cleaning, Care

    19 CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...

  • Page 137: Checks And Maintenance Steps For Winter Operation

    19 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. 153) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 138: 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. 55) –...

  • Page 139: Preparing For Use After Storage

    20 STORAGE Info Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and the exhaust system to rust. 20.2 Preparing for use after storage –...

  • Page 140: Troubleshooting

    Check the electrical system. tive – Defect in fuel injection system Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the Husqvarna Motorcycles diagnostics tool.
  • Page 141 Possible cause Action – Engine has too little power Defect in fuel injection system Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. – Exhaust system leaky, Check exhaust system for damage. deformed or too little glass –...
  • Page 142 21 TROUBLESHOOTING Faults Possible cause Action – Battery discharged Battery is not being charged Check the charging voltage. by alternator – Check the stator winding of the alter- nator. – Undesired power consumer Check the closed current. – Combination instrument values The battery in the combination Change the combination instrument.

  • Page 143: Blink Code

    22 BLINK CODE Info The blink codes are only displayed by the derestricted version of the vehicle. Blink code for malfunc- tion indicator lamp 02a Malfunction indicator lamp flashes 2x per second Error level condition Teaching of throttle valve position required Blink code for malfunc- tion indicator lamp 02 Malfunction indicator lamp flashes 2x short...
  • Page 144 22 BLINK CODE Blink code for malfunc- tion indicator lamp 22 Malfunction indicator lamp flashes 2x long, 2x short Gear position sensor – input voltage too high Error level condition Gear position sensor – input voltage too low Blink code for malfunc- tion indicator lamp 33 Malfunction indicator lamp flashes 3x long, 3x short Error level condition...

  • Page 145: Technical Data

    23 TECHNICAL DATA 23.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement (FE 450 US) 449.9 cm³ (27.455 cu in) Displacement (FE 501 US) 510.9 cm³ (31.177 cu in) Stroke (FE 450 US) 63.4 mm (2.496 in) Stroke (FE 501 US) 72 mm (2.83 in) Bore 95 mm (3.74 in)

  • Page 146: Engine Tightening Torques

    23 TECHNICAL DATA 23.2 Engine tightening torques Oil jet, piston cooling 2 Nm (1.5 lbf ft) ® Loctite 243™ Oil nozzle for clutch lubrication 2 Nm (1.5 lbf ft) ® Loctite 243™ Oil nozzle, piston cooling 2 Nm (1.5 lbf ft) ®...

  • Page 147: Capacities

    23 TECHNICAL DATA Screw, timing chain tensioner 10 Nm (7.4 lbf ft) Screw, timing chain tensioning rail 10 Nm (7.4 lbf ft) ® Loctite 243™ Screw, valve cover 10 Nm (7.4 lbf ft) Screw, water pump cover 10 Nm (7.4 lbf ft) Oil nozzle for conrod bearing M6x0.75 4 Nm (3 lbf ft)

  • Page 148: Chassis

    23 TECHNICAL DATA Fuel reserve, approx. 1.5 l (1.6 qt.) 23.4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Performance SystemsXplor 48 PA Suspension travel front 300 mm (11.81 in) rear 330 mm (12.99 in) Fork offset 22 mm (0.87 in) WP Performance Systems 5018 DCC Link...

  • Page 149: Electrical System

    120/90 - 18 M/C 65R M+S TT Continental TKC 80 Continental TKC 80 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com 23.7 Fork Fork article number 14.15.8R.69...

  • Page 150: Shock Absorber

    23 TECHNICAL DATA Weight of rider: 65 … 75 kg (143 … 165 lb.) 4.4 N/mm (25.1 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 4.6 N/mm (26.3 lb/in) Weight of rider: 85 … 95 kg (187 … 209 lb.) 4.8 N/mm (27.4 lb/in) Fork length 928 mm (36.54 in)
  • Page 151 23 TECHNICAL DATA Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) Remaining nuts, chassis 5 Nm (3.7 lbf ft) Remaining screws, chassis 5 Nm (3.7 lbf ft) Screw, battery terminal 2.5 Nm (1.84 lbf ft) Screw, shock absorber adjusting 5 Nm (3.7 lbf ft)
  • Page 152 23 TECHNICAL DATA Screw, bottom shock absorber 60 Nm (44.3 lbf ft) ® Loctite 2701™ Screw, handlebar holder 40 Nm (29.5 lbf ft) ® Loctite 243™ Screw, top shock absorber 60 Nm (44.3 lbf ft) ® Loctite 2701™ Nut, fuel pump fixation 15 Nm (11.1 lbf ft) Nut, angle lever on swingarm M14x1.5...

  • Page 153: Substances

    24 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 –...
  • Page 154 24 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 154) (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 –...

  • Page 155: Auxiliary Substances

    25 AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel‑Ray – Foam Filter Cleaner & Degreaser High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier ® Bel‑Ray – Waterproof Grease Offroad chain spray Guideline Recommended supplier Bel‑Ray ®...

  • Page 156: Standards

    26 STANDARDS JASO T903 MA 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 157: Index Of Special Terms

    27 INDEX OF SPECIAL TERMS On-board diagnosis Vehicle system, which monitors the specified param- eters of the vehicle electronics...

  • Page 158: List Of Abbreviations

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

  • Page 159: List Of Symbols

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized Husqvarna Motorcy- cles workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 160: Index

    INDEX INDEX Chain guide checking ......81 Accessories ......13 Chain tension Air filter adjusting .
  • Page 161 INDEX Engine guard Fuse installing ......88 individual power consumers, changing ..111 removing .
  • Page 162 INDEX Misuse ......7 Shift lever ......23 basic position, adjusting .
  • Page 163 INDEX Transporting ......40 Troubleshooting ....138-140 Turn signal bulb changing .
  • Page 164 *3402177en* 3402177en 06/2017 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer, www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...

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