2009-2012 Husaberg FE 450 FE 570 Bike Service & Repair Manual

REPAIR MANUAL FE 450 EU FE 450 AUS FE 450 USA FE 570 EU FE 570 AUS FE 570 USA 2009 Article no. 3803004en

INTRODUCTION 1 INTRODUCTION It is important that you read this owner's manual carefully and completely before the start of work. Only use ORIGINAL HUSABERG SPARE PARTS. This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified experts. The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in the interest of technical advancement without, at the same time, updating this repair manual. We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It is assumed that repair work will be performed by a fully trained mechanic. All specifications are non-binding. HUSABERG, a division of KTM SMC AG (referred to herein as HUSABERG), specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. HUSABERG accepts no liability for delivery options, deviations from illustrations and descriptions or misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery. © 2008 by HUSABERG eine Division der KTM SMC AG, Mattighofen Austria All rights reserved Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) Within the meaning of the international quality management standard ISO 9001, HUSABERG uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service HUSABERG eine Division der KTM SMC AG 5230 Mattighofen, Austria

CONTENTS 2 CONTENTS MEANS OF REPRESENTATION ............................................ 5 IMPORTANT NOTES ............................................................ 6 LOCATION OF SERIAL NUMBERS ........................................ 7 Chassis number ............................................................... 7 Type label (FE EU, FE AUS) ............................................. 7 Type label (FE USA) ........................................................ 7 Key number (FE EU, FE AUS)........................................... 7 Engine number................................................................ 7 Fork part number............................................................. 8 Shock absorber part number ............................................. 8 MOTORCYCLE..................................................................... 9 Jacking up the motorcycle ................................................ 9 Removing the motorcycle from the work stand .................... 9 Starting .......................................................................... 9 01/FORK, TRIPLE CLAMP.................................................. 10 Adjusting the compression damping of the fork ................ 10 Adjusting the rebound damping of the fork....................... 10 Adjusting the spring preload of the fork ........................... 10 Bleeding the fork legs .................................................... 11 Cleaning the dust boots of the fork legs ........................... 11 Loosening the fork protection.......................................... 11 Positioning the fork protection ........................................ 12 Removing the fork legs................................................... 12 Installing the fork legs ................................................... 12 Removing the fork protector............................................ 13 Installing the fork protector ............................................ 13 Performing a fork service ................................................ 14 Disassembling the fork legs ............................................ 14 Cartridge disassembly .................................................... 17 Disassembling the compression damping fitting ............... 19 Checking the fork legs.................................................... 19 Assembling the compression damping fitting.................... 20 Assembling the cartridge ................................................ 21 Assembling the fork legs ................................................ 23 Greasing the steering head bearing.................................. 27 Removing the lower triple clamp ..................................... 27 Installing the lower triple clamp ...................................... 28 Checking the play of the steering head bearing ................. 29 Adjusting the play of the steering head bearing ................ 29 03/FRAME ........................................................................ 30 Removing the engine guard ............................................ 30 Installing the engine guard ............................................. 30 04/SHOCK ABSORBER, SWINGARM................................... 31 Adjusting the high-speed compression damping of the shock absorber .............................................................. 31 Adjusting the low-speed compression damping of the shock absorber .............................................................. 31 Adjusting the rebound damping of the shock absorber....... 32 Measuring rear wheel sag unloaded ................................. 32 Checking the static sag of the shock absorber .................. 32 Checking the riding sag of the shock absorber .................. 33 Adjusting the spring preload of the shock absorber ........... 33 Adjusting the riding sag ................................................. 34 Removing the shock absorber ......................................... 34 Installing the shock absorber .......................................... 34 Performing a shock absorber service ................................ 35 Removing the spring ...................................................... 35 Disassembling the shock absorber ................................... 36 Disassembling the piston rod .......................................... 37 Disassembling the seal ring retainer ................................ 38 Replacing the pilot bushing ............................................ 39 Checking the shock absorber .......................................... 39 Disassembling the rebound adjuster ................................ 40 Removing the heim joint ................................................ 41 Installing the heim joint ................................................. 41 Assembling the rebound adjuster .................................... 42 Assembling the seal ring retainer .................................... 43 Assembling the piston rod .............................................. 43 Assembling the shock absorber ....................................... 45 Bleeding and filling the shock absorber ........................... 47 Filling the shock absorber with nitrogen ........................... 49 Installing the spring ....................................................... 50 Removing the swingarm, with shock absorber and rear wheel ........................................................................... 51 Installing the swingarm, with shock absorber and rear wheel ........................................................................... 52 05/EXHAUST .................................................................... 54 Removing the main silencer............................................ 54 Installing the main silencer ............................................ 54 Removing the exhaust system ......................................... 54 Installing the exhaust system.......................................... 55 06/AIR FILTER.................................................................. 57 Removing the air filter ................................................... 57 Installing the air filter .................................................... 57 Cleaning air filter........................................................... 57 07/FUEL TANK, SEAT, TRIM.............................................. 59 Removing the seat ......................................................... 59 Mounting the seat ......................................................... 59 Removing the fuel tank .................................................. 59 Installing the fuel tank ................................................... 60 Removing the spoiler ..................................................... 61 Installing the spoiler ...................................................... 61 Checking the fuel pressure ............................................. 62 08/MASK, FENDER, DECAL ............................................... 63 Removing the front fender .............................................. 63 Installing the front fender ............................................... 63 Removing the start number plate (FE USA) ...................... 63 Installing the start number plate (FE USA) ....................... 64 09/FRONT WHEEL ............................................................ 65 Removing the front wheel ............................................... 65 Installing the front wheel................................................ 65 Checking the tire air pressure ......................................... 66 Checking the tire condition............................................. 66 Checking the brake disks................................................ 67 10/REAR WHEEL .............................................................. 68 Removing the rear wheel ................................................ 68 Installing the rear wheel ................................................. 68 Checking the chain tension ............................................ 69 Adjusting the chain tension ............................................ 69 Checking the chain wear ................................................ 70 Checking the rear sprocket/engine sprocket for wear ......... 71 Checking for chain dirt accumulation .............................. 71 Cleaning the chain......................................................... 71 Adjusting the chain guide............................................... 72 Checking the spoke tension ............................................ 72 11/WIRING HARNESS, BATTERY ....................................... 73 Disconnecting the negative cable of the battery ................ 73 Connecting the negative cable of the battery .................... 73 Changing the main fuse ................................................. 73 Changing the fuses of individual power consumers............ 74 Removing the battery ..................................................... 75 Installing the battery ...................................................... 75 Charging the battery ...................................................... 76

CONTENTS 3 13/BRAKE SYSTEM........................................................... 78 Checking the free travel of the hand brake lever ............... 78 Adjusting the free travel of the handbrake lever (FE EU, FE AUS) ....................................................................... 78 Adjusting the basic position of the handbrake lever (FE USA) ...................................................................... 78 Checking the front brake fluid level ................................. 79 Adding front brake fluid ................................................. 79 Checking the front brake linings...................................... 80 Changing the front brake linings ..................................... 80 Checking the free travel of the foot brake lever ................. 82 Adjusting the basic position of the footbrake lever ............ 82 Checking the rear brake fluid level .................................. 83 Adding rear brake fluid .................................................. 83 Checking the rear brake linings ....................................... 84 Changing the rear brake linings ....................................... 84 14/LIGHTING SYSTEM, INSTRUMENTS ............................. 86 Adjusting the speedometer functions ............................... 86 Setting kilometers or miles ............................................. 86 Activating the additional functions .................................. 87 Setting the wheel circumference ..................................... 87 Setting the clock ........................................................... 88 Removing the headlight mask with the headlight (FE EU, FE AUS) ....................................................................... 88 Installing the headlight mask with the headlight (FE EU, FE AUS) ....................................................................... 88 Checking the headlight adjustment (FE EU, FE AUS) ........ 89 Adjusting the beam width of the headlight (FE EU, FE AUS) ....................................................................... 89 Changing the headlight bulb (FE EU, FE AUS) ................. 89 30/ENGINE....................................................................... 91 Removing the engine ..................................................... 91 Installing the engine ...................................................... 94 30/ENGINE DISASSEMBLY................................................ 99 Clamping the engine in the engine work stand.................. 99 Draining the engine oil ................................................... 99 Removing the oil line ..................................................... 99 Removing the starter motor ............................................ 99 Removing the oil filter.................................................... 99 Removing the valve cover ............................................. 100 Removing the spark plug .............................................. 100 Removing the generator cover ....................................... 100 Positioning the engine at ignition top dead center (TDC) ......................................................................... 100 Removing the timing chain tensioner ............................. 101 Removing the camshaft ................................................ 101 Removing the cylinder head.......................................... 102 Removing the piston .................................................... 102 Removing the distance bushing .................................... 102 Removing the rotor ...................................................... 103 Removing the balance weight ....................................... 103 Removing the timing chain guide rail ............................ 103 Removing the timing chain tensioning rail...................... 103 Removing the timing chain securing guide ..................... 104 Removing the timing chain ........................................... 104 Removing the ignition pulse generator ........................... 104 Removing the water pump cover ................................... 104 Removing the clutch cover ........................................... 104 Disassembling the clutch disks ..................................... 105 Removing the primary gear nut ..................................... 105 Removing the outer clutch hub ..................................... 106 Removing the balancer shaft ........................................ 106 Removing the primary gear ........................................... 106 Removing the free wheel gear ....................................... 107 Removing the torque limiter ......................................... 107 Removing the starter idler gear ..................................... 107 Removing the oil pump gears........................................ 107 Removing the oil pumps............................................... 108 Removing the shift shaft .............................................. 108 Removing the shift drum locating unit ........................... 108 Removing the locking lever ........................................... 108 Removing the left section of the engine case .................. 109 Removing the shift rails ............................................... 109 Removing the shift drum .............................................. 109 Removing the shift forks .............................................. 109 Removing the diaphragm.............................................. 110 Removing the transmission shafts ................................. 110 Removing the crankshaft .............................................. 110 30/ENGINE - WORK ON THE INDIVIDUAL PARTS ............. 111 Working on the right section of the engine case .............. 111 Working on the left section of the engine case ................ 112 Removing the oil pressure regulator valve....................... 113 Checking the spring length of the oil pressure regulator valve .......................................................................... 113 Installing the oil pressure regulator valve ....................... 113 Removing the crankshaft seal ring in the clutch cover ..... 113 Installing the crankshaft seal ring in the clutch cover ...... 114 Removing the water pump ............................................ 114 Installing the water pump............................................. 115 Checking the balancer shaft ......................................... 115 Removing the timing chain sprocket .............................. 116 Installing the timing chain sprocket............................... 116 Removing the crankshaft bearing inner ring.................... 116 Installing the crankshaft bearing inner ring .................... 117 Changing the conrod bearing ........................................ 117 Checking the crankshaft run-out at the bearing pin ......... 119 Measuring the crankshaft end play ................................ 119 Checking/measuring the cylinder ................................... 120 Checking/measuring the piston ..................................... 120 Checking the piston ring end gap .................................. 121 Piston/cylinder - determining the mounting clearance ..... 121 Checking the oil pumps for wear ................................... 122 Disassembling the autodecompressor ............................ 122 Assembling the autodecompressor................................. 123 Checking the camshaft................................................. 123 Checking the timing assembly ...................................... 124 Preparing the timing chain tensioner for installation ....... 124 Removing the coolant temperature sensor ...................... 125 Removing the rocker arm.............................................. 125 Removing the valves .................................................... 125 Changing the camshaft bearing ..................................... 126 Checking the valves ..................................................... 127 Checking the valve springs ........................................... 127 Checking the valve spring seat ...................................... 127 Checking the cylinder head .......................................... 128 Installing the valves ..................................................... 128 Installing the rocker arm .............................................. 129 Installing the coolant temperature sensor ....................... 129 Checking the clutch ..................................................... 130 Checking the shift mechanism ...................................... 131 Preassembling the shift shaft........................................ 132 Disassembling the main shaft ....................................... 132 Assembling the main shaft ........................................... 132 Disassembling the countershaft .................................... 133

CONTENTS 4 Assembling the countershaft......................................... 133 Checking the transmission............................................ 134 Checking the electric starter mode ................................ 135 Removing the free wheel .............................................. 135 Installing the free wheel ............................................... 136 30/ENGINE ASSEMBLY ................................................... 137 Installing the crankshaft............................................... 137 Installing the transmission shafts .................................. 137 Installing the diaphragm .............................................. 137 Installing the shift fork................................................. 138 Installing the shift drum............................................... 138 Installing the shift rails ................................................ 138 Installing the left engine case ....................................... 138 Installing the locking lever............................................ 139 Installing the shift drum locating unit ............................ 139 Installing the shift shaft ............................................... 139 Installing the oil pumps ............................................... 140 Installing the oil pump gears ........................................ 140 Installing the starter idler gear ...................................... 140 Installing the torque limiter .......................................... 141 Installing the free wheel gear ........................................ 141 Installing the primary gear ............................................ 141 Installing the balancer shaft ......................................... 141 Installing the outer clutch hub ...................................... 141 Installing the primary gear nut ...................................... 142 Installing the clutch discs ............................................ 142 Installing the clutch cover ............................................ 143 Installing the water pump cover .................................... 143 Installing the ignition pulse generator ............................ 143 Installing the timing chain............................................ 144 Installing the timing chain securing guide ...................... 144 Installing the timing chain tensioning rail ...................... 144 Installing the timing chain guide rail ............................. 144 Installing the balance weight ........................................ 144 Installing the rotor ....................................................... 145 Installing the distance bushing ..................................... 145 Installing the piston ..................................................... 145 Installing the cylinder head .......................................... 147 Installing the camshaft ................................................ 148 Installing the timing chain tensioner ............................. 148 Checking the valve clearance ........................................ 148 Adjusting the valve clearance........................................ 149 Installing the generator cover ........................................ 149 Installing the spark plug............................................... 150 Installing the valve cover .............................................. 150 Installing the oil filter .................................................. 150 Installing the oil screen ................................................ 150 Assembling the starter motor ........................................ 151 Installing the oil line .................................................... 151 Removing the engine from the work stand ...................... 151 32/CLUTCH .................................................................... 152 Checking the fluid level of the hydraulic clutch .............. 152 Changing the hydraulic clutch fluid ............................... 152 35/WATER PUMP, COOLING SYSTEM .............................. 154 Checking the coolant level ............................................ 154 Checking the antifreeze and coolant level ...................... 154 Draining the coolant .................................................... 155 Refilling coolant .......................................................... 155 38/LUBRICATION SYSTEM .............................................. 156 Oil circuit ................................................................... 156 Checking the engine oil pressure ................................... 156 Checking the engine oil level ........................................ 158 Adding engine oil ........................................................ 158 Changing the engine oil and oil filter, cleaning the engine oil screen ......................................................... 158 Draining engine oil, cleaning engine oil screen ............... 158 Removing the oil filter.................................................. 159 Installing the oil filter .................................................. 160 Filling up with engine oil .............................................. 160 41/THROTTLE VALVE BODY............................................. 161 Idle speed adjusting screw ........................................... 161 Taking off the throttle valve body and allowing it to hang to the side .......................................................... 161 Installing the throttle valve body ................................... 162 Adjusting the idle speed............................................... 163 FAULT CODE .................................................................. 164 TECHNICAL DATA - ENGINE ............................................ 219 Capacity - engine oil .................................................... 219 Capacity - coolant ........................................................ 219 TECHNICAL DATA - ENGINE TOLERANCES, WEAR LIMITS ........................................................................... 220 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ........ 222 TECHNICAL DATA - CHASSIS .......................................... 224 Lighting equipment ..................................................... 224 Tires .......................................................................... 225 Capacity - fuel............................................................. 225 TECHNICAL DATA - FORK................................................ 226 TECHNICAL DATA - SHOCK ABSORBER ........................... 227 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 228 CLEANING/PROTECTION ................................................. 229 Cleaning the motorcycle ............................................... 229 Protection for winter operation ...................................... 230 STORAGE ....................................................................... 231 Storage....................................................................... 231 Putting into operation after storage ............................... 231 SERVICE SCHEDULE....................................................... 232 Important maintenance work to be carried out by an authorized HUSABERG workshop .................................. 232 Important maintenance work to be carried out by an authorized HUSABERG workshop. (as additional order) ... 233 Important checks and maintenance work to be carried out by the rider ........................................................... 234 WIRING DIAGRAM .......................................................... 236 1 of 3 (FE EU) ............................................................ 236 2 of 3 (FE EU) ............................................................ 238 3 of 3 (FE EU) ............................................................ 242 1 of 3 (FE USA) .......................................................... 246 2 of 3 (FE USA) .......................................................... 248 3 of 3 (FE USA) .......................................................... 252 1 of 3 (FE AUS) .......................................................... 254 2 of 3 (FE AUS) .......................................................... 256 3 of 3 (FE AUS) .......................................................... 260 SUBSTANCES ................................................................. 263 AUXILIARY SUBSTANCES................................................ 265 SPECIAL TOOLS.............................................................. 267 STANDARDS ................................................................... 278 INDEX ............................................................................ 279

MEANS OF REPRESENTATION 5 Symbols used The symbols used are explained in the following. 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). Identifies a page reference (more information is provided on the specified page). Formats used The typographical and other formats used are explained in the following. Name Indicates a proprietary name. Name ® Identifies a protected name. Brand™ Identifies a brand in merchandise traffic.

IMPORTANT NOTES 6 Warranty The work prescribed in the service schedule must be carried out in an authorized HUSABERG workshop and confirmed in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle. Fuel, oils, etc. You should use the fuels, oils and greases according to specifications as listed in the repair manual. Spare parts, accessories Only use spare parts and accessory products that have been approved and/or recommended by HUSABERG. HUSABERG accepts no liability for other products and any resulting damage or loss. The current HUSABERG Force Depot parts for your vehicle can be found on the HUSABERG website. International HUSABERG website: www.husaberg.com Work rules Special tools are required for some work. These are not part of the vehicle standard equipment, but they can be ordered with the item number stated in parentheses. Ex.: Valve spring mounter (59029019000) When the vehicle is assembled, non-reusable parts (e.g., self-locking screws and nuts, gaskets, seal rings, O-rings, splints, lock wash- ers) must be replaced with new parts. Where thread lockers are used on screw connections (e.g., Loctite ® ), follow the instructions for use from the manufacturer. After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts. After you complete the repair or maintenance work, check the roadworthiness of the vehicle. Notes/warnings Pay close attention to the notes/warnings. Info Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss- ing, you or others may not recognize sources of danger and may therefore be injured. Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken. Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken. Repair manual – It is imperative that you read this owner's manual carefully and completely before the start of work. It contains useful information and many tips on how to repair and maintain your vehicle. – The presence of the appropriate HUSABERG special tools, workbench and workshop equipment are a prerequisite.

LOCATION OF SERIAL NUMBERS 7 3.1 Chassis number 100345-10 The chassis number  is stamped on the right side of the steering head. 3.2 Type label (FE EU, FE AUS) 100458-10 The type label  is fixed to the frame at the front right. 3.3 Type label (FE USA) 100464-10 The type label  is fixed to the front of the steering head. 3.4 Key number (FE EU, FE AUS) 500125-10 The key number  is stamped on the key strap. 3.5 Engine number 100347-10 The engine number  is stamped on the left side of the engine under the engine sprocket.

LOCATION OF SERIAL NUMBERS 8 3.6 Fork part number 100348-10 The fork part number  is stamped on the inner side of the fork stub. 3.7 Shock absorber part number 100419-10 The shock absorber part number  is stamped on the upper part of the shock absorber above the adjusting ring. The shock absorber part number is not visible when the shock absorber is installed.

2009-2012 Husaberg FE 450 FE 570 Bike Service & Repair Manual

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