Husaberg 450 500 550 650 Service Repair Manual 2004-2007

REPARATURANLEITUNG REPAIR MANUAL MANUEL DE REPARATION “ 04 Edition 2004 Downloaded from www.Manualslib.com manuals search engine

PREFACE This manual contains detailed instructions on repairing the engine. It was prepared according to the state of the art for this model series. We reserve the right to make modifications based on technical progress without making the respective corrections in this repair manual. This manual does not contain a description of general shop or working methods. It does not include safety rules generally observed in workshops and is based on the assumption that the work is performed by a mechanic who has completed his vocational training. Please read the entire manual before starting to work. WARNING: failing to observe these instructions can be dangerous to life and limb. CAUTION: failing to observe these instructions may damage the motorcycle/engine components or impair the motorcycle's traffic safety. NOTE: provides useful information. Only use ORIGINAL HUSABERG SPARE PARTS if parts need to be replaced. The engine will only continue to operate safely if the prescribed service work is performed regularly and professionally. Subject to changes in construction and design. C by HUSABERG All rights reserved Downloaded from www.Manualslib.com manuals search engine

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INDEX A B C D E F G H I J K L M N GENERAL INFORMATION DISMOUNTING AND MOUNTING THE ENGINE DISASSEMBLING THE ENGINE SERVICING THE INDIVIDUAL PARTS ASSEMBLING THE ENGINE ELECTRIC SYSTEM FUEL SYSTEM TROUBLESHOOTING TECHNICAL SPECIFICATIONS PERIODIC MAINTENANCE SCHEDULE WIRING DIAGRAMS Downloaded from www.Manualslib.com manuals search engine

TABLE OF CONTENTS GENERAL INFORMATION Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . .A1 Changing the engine oil . . . . . . . . . . . . . . . . . . . . .A2 Cleaning the oil screen . . . . . . . . . . . . . . . . . . . . . .A2 Changing the oil filter . . . . . . . . . . . . . . . . . . . . . . .A3 Checking the oil level in the hydraulic clutch . . . . .A4 Bleeding the clutch . . . . . . . . . . . . . . . . . . . . . . . . .A4 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5 Preservation for winter operation . . . . . . . . . . . . . .A5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6 DISMOUNTING AND MOUNTING THE ENGINE Dismounting the engine . . . . . . . . . . . . . . . . . . . . .B1 Mounting the engine . . . . . . . . . . . . . . . . . . . . . . .B5 Bleeding the cooling system . . . . . . . . . . . . . . . . . .B9 Adjusting the decompression cable . . . . . . . . . . . .B9 Adjusting the throttle cable . . . . . . . . . . . . . . . . . .B9 DISASSEMBLING THE ENGINE Blocking the engine . . . . . . . . . . . . . . . . . . . . . . . .C1 Removing the rotor . . . . . . . . . . . . . . . . . . . . . . . . .C2 Removing the pressure relief valve . . . . . . . . . . . . .C2 Removing the clutch . . . . . . . . . . . . . . . . . . . . . . . .C3 Removing inner clutch hub . . . . . . . . . . . . . . . . . . .C4 Removing primary pinion and the idler shaft gear . .C4 Removing the oil pump . . . . . . . . . . . . . . . . . . . . .C5 Removing the chain tensioner . . . . . . . . . . . . . . . .C6 Separating the timing chain . . . . . . . . . . . . . . . . . .C6 Removing the cylinder head . . . . . . . . . . . . . . . . . .C7 Separating the housing . . . . . . . . . . . . . . . . . . . . .C7 Removing the crankshaft . . . . . . . . . . . . . . . . . . . .C8 Removing the transmission . . . . . . . . . . . . . . . . . . .C8 Removing the idler shaft . . . . . . . . . . . . . . . . . . . . .C9 SERVICING THE INDIVIDUAL PARTS Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1 Left housing half . . . . . . . . . . . . . . . . . . . . . . . . . .D1 Right housing half . . . . . . . . . . . . . . . . . . . . . . . . . .D2 Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . .D3 Clutch cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4 Press out the crank pin . . . . . . . . . . . . . . . . . . . . . .D5 Press in the crank pin . . . . . . . . . . . . . . . . . . . . . . .D6 Checking the crankshaft journal . . . . . . . . . . . . . . .D7 Outer dimension of the crankshaft webs . . . . . . . .D7 Balancing the axial clearance of the crankshaft . . .D8 Nikasil cylinder coating . . . . . . . . . . . . . . . . . . . . . .D9 Measuring the piston and cylinder liner, determining the piston mounting clearance . . . . .D9 Checking the piston . . . . . . . . . . . . . . . . . . . . . . .D10 Checking the piston ring end gap . . . . . . . . . . . .D10 Checking the oil pump for wear . . . . . . . . . . . . . .D10 Cylinder head top section . . . . . . . . . . . . . . . . . .D11 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . .D12 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D14 Timing chain tensioner . . . . . . . . . . . . . . . . . . . . .D15 Timing train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D15 Checking the clutch for wear . . . . . . . . . . . . . . . .D16 Checking the kickstarter for wear . . . . . . . . . . . . .D17 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . .D18 Assembling the main shaft (four-speed) . . . . . . . .D19 Assembling the main shaft (six-speed) . . . . . . . . .D20 Assembling the countershaft (four/six-speed) . . .D21 Starter drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D22 Checking the freewheel. . . . . . . . . . . . . . . . . . . . .D22 Checking the freewheel hub . . . . . . . . . . . . . . . . .D22 ASSEMBLING THE ENGINE Mounting the idler shaft . . . . . . . . . . . . . . . . . . . . .E1 Mounting the crankshaft . . . . . . . . . . . . . . . . . . . .E2 Mounting the cylinder head . . . . . . . . . . . . . . . . . .E4 Mounting the timing chain . . . . . . . . . . . . . . . . . . .E5 Mounting the timing chain tensioner . . . . . . . . . . .E7 Adjusting the valve clearance . . . . . . . . . . . . . . . . .E7 Mounting the oil pump . . . . . . . . . . . . . . . . . . . . . .E8 Mounting the shift mechanism . . . . . . . . . . . . . . . .E8 Mounting the kickstarter shaft . . . . . . . . . . . . . . . . .E9 Mounting the clutch . . . . . . . . . . . . . . . . . . . . . . . .E9 Mounting the clutch cover . . . . . . . . . . . . . . . . . .E11 Mounting the pressure relief valve . . . . . . . . . . . .E13 Mounting rotor and pick up . . . . . . . . . . . . . . . . .E13 ELECTRIC SYSTEM Checking for loss of current . . . . . . . . . . . . . . . . . .F1 Dismounting/mounting the battery . . . . . . . . . . . . .F1 Charging the battery . . . . . . . . . . . . . . . . . . . . . . . .F1 Filling the battery . . . . . . . . . . . . . . . . . . . . . . . . . .F2 Checking the starter . . . . . . . . . . . . . . . . . . . . . . . .F2 Checking the starter relay . . . . . . . . . . . . . . . . . . . .F3 Checking the main fuse . . . . . . . . . . . . . . . . . . . . . .F3 Checking the voltage regulator . . . . . . . . . . . . . . . .F4 Kokusan 4K3B dynamic generator values . . . . . . . .F4 Troubleshooting in the ignition system . . . . . . . . . .F5 CDI unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F6 Checking the ignition coil . . . . . . . . . . . . . . . . . . . .F6 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . .F7 Checking the stator and pulse generator . . . . . . . .F7 Replacing the stator in FC models (Kokusan 4K-3A) . .F7 Replacing the stator in FE and FS models (Kokusan 4K-3B) . .F7 Static ignition values Kokusan 4K-3A/B . . . . . . . . .F8 Static generator values Kokusan 4K3B . . . . . . . . .F10 FUEL SYSTEM KEIHIN FCR-MX 39/41 . . . . . . . . . . . . . . . . . . . . . .G1 Disassembling the carburetor . . . . . . . . . . . . . . . . .G2 Choke slide and hot start knob . . . . . . . . . . . . . . .G5 Accelerator pump . . . . . . . . . . . . . . . . . . . . . . . . . .G5 Jet needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G5 Float needle valve . . . . . . . . . . . . . . . . . . . . . . . . .G5 Throttle slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G6 Assembling the carburetor . . . . . . . . . . . . . . . . . . .G6 Adjusting the throttle sensor position . . . . . . . . .G10 Checking the throttle sensor . . . . . . . . . . . . . . . .G11 Dismounting and mounting the throttle sensor . .G11 Adjusting the idle . . . . . . . . . . . . . . . . . . . . . . . . .G12 Checking/adjusting the float height . . . . . . . . . . .G13 TROUBLESHOOTING Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .H1 TECHNICAL SPECIFICATIONS Engine 450, 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . .I1 Carburetor 450, 501 . . . . . . . . . . . . . . . . . . . . . . . . .I1 Engine 550, 650 . . . . . . . . . . . . . . . . . . . . . . . . . . . .I2 Carburetor 550, 650 . . . . . . . . . . . . . . . . . . . . . . . . .I2 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I3 Engine torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4 Chassis torques . . . . . . . . . . . . . . . . . . . . . . . . . . . .I5 Mounting clearances, engine wear limits . . . . . . . ..I6 PERIODIC MAINTENANCE SCHEDULE FC 450, 550/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J1 FE 450 - 650e/6, FS 450, 650e/6 . . . . . . . . . . . . . . .J2 Additional work - driver . . . . . . . . . . . . . . . . . . . . . .J3 Additional work - workshop . . . . . . . . . . . . . . . . . ..J4 WIRING DIAGRAMS FC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K1 FE models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K2 FE USA models . . . . . . . . . . . . . . . . . . . . . . . . . . . .K4 FS models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K6 Cable colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K8 Downloaded from www.Manualslib.com manuals search engine

ENGINE OIL Only use fully synthetic brand-name engine oils (e.g.: Motorex Power Synt. 4T) that meet or exceed the Jaso T903 MA quality requirements (information on the can). CAUTION: not enough engine oil or low-quality oil will lead to premature engine wear. CHECKING THE ENGINE OIL LEVEL NOTE: the engine oil level can be checked when the engine is cold or warm. – Place the motorcycle on a level surface (not on the side stand). If the engine is cold, the engine oil should be visible at the lower edge (A) of the inspection glass. If the engine is warm, the engine oil should reach the upper edge (B) of the inspection glass. Add engine oil if necessary. CAUTION: not enough engine oil or low-quality oil will lead to premature engine wear. – Check the engine for leakage. GENERAL INFORMATION A 1 A B 0°C 10W/50 5W/40 JASO T903 MA TEMPERATURE OIL CIRCUIT DESCRIPTION: The oil pump (1) draws the engine oil from the oil sump through the oil screen (2) and pumps it past the pressure relief valve (3) to the oil filter (4). It continues to the crankshaft (5), partly branching off through a hole to lubricate and cool the piston (6) and the piston pin bearing. Once through the crankshaft, the engine oil is pumped to the conrod bearing (7) and branches off again to the bearings in the balance weight (8). The camshaft (9) is lubricated by the engine oil which is transported to the cylinder head by the timing chain (10). On the downward movement of the piston, engine oil is pressed from the crankcase through the diaphragm valve (not depicted) to the transmission and shift mechanism. 1 2 3 4 6 5 8 7 9 10 Downloaded from www.Manualslib.com manuals search engine

CHANGING THE ENGINE OIL NOTE: Replace the oil screen and the oil filter when you change the engine oil. Change the engine oil when the engine is at operating temperature. WARNING: the engine oil will be very hot when the engine is at operating temperature – be careful not to burn yourself. – Place the motorcycle on a level surface, remove the plug (1) and allow the oil to drain into a suitable vessel. – Thoroughly clean the plug (with the magnet). – After the oil is completely drained, clean the sealing area, mount the plug with a new seal ring and tighten to 20 Nm. CLEANING THE OIL SCREEN NOTE: the oil screen (3) is located in the plug with the hexagon drive (2) next to the oil drain plug on the right side of the engine. – Dismount the plug with the oil screen, thoroughly clean the parts and blow clean with compressed air. – Check the O-rings (4) for damage and replace if necessary. – Insert the oil screen in the plug, mount and tighten the plug to 15 Nm. GENERAL INFORMATION A 2 1 2 3 4 4 Downloaded from www.Manualslib.com manuals search engine

GENERAL INFORMATION A 3 CHANGING THE OIL FILTER – Place a suitable vessel under the engine to allow the oil to drain. – Remove both bolts (1) and screw an M6 bolt in the center hole (2) of the oil filter cover. NOTE: only tighten the bolt by hand, otherwise you will damage the oil filter cover. – Pull the oil filter cover (3) out of the hole with the bolt M6 and remove the bolt. – Use pliers to pull the oil filter element (4) from the housing. – Clean the oil filter cover, the sealing areas on the O-rings and the engine case. check the O-rings (5) in the oil filter cover for damage and replace if necessary. – Lay the motorcycle down and fill the oil filter housing approx. half-full with engine oil. Insert the oil filter in the housing. – Grease the O-rings in the oil filter cover and mount the cover. Mount the bolts and tighten to 6 Nm. – Place the motorcycle in an upright position again. – Unscrew the oil filler plug (6) and add 1 liter of fully synthetic engine oil (e.g.: Motorex Power Synt. 4T). – Start the engine and check all of the plugs and the oil filter cover for leakage. – Finally, check the engine oil level and correct if necessary. 1 1 2 3 4 6 5 5 Downloaded from www.Manualslib.com manuals search engine

GENERAL INFORMATION A 4 CHECKING THE OIL LEVEL IN THE HYDRAULIC CLUTCH Remove the cover to check the oil level in the master cylinder of the clutch. Remove the screws (1) and lift off the cover together with the rubber boot (2). The oil level should be 4 mm below the upper edge when the master cylinder is in a horizontal position. If necessary, add SAE 10 biodegradable hydraulic oil (e.g.: Motorex clutch fluid 75). CAUTION: only fill SAE 10 biodegradable hydraulic oil into the master cylinder. Do not add brake fluid. BLEEDING THE CLUTCH To bleed, remove the cover on the master cylinder of the clutch. Remove the screws (1) and lift off the cover together with the rubber boot (2). Remove the vent nipple from the slave cylinder of the clutch. Mount the bleeder syringe (3) filled with SAE 10 biodegradable hydraulic oil (e.g.: Motorex clutch fluid 75). Continue to add oil until the oil runs out of the hole (A) in the master cylinder without bubbles. Make sure the oil does not overflow. CAUTION: after bleeding the clutch, check the oil level in the master cylinder. Only fill SAE 10 biodegradable hydraulic oil (e.g.: Motorex clutch fluid 75) into the master cylinder. Do not use brake fluid or mix with mineral hydraulic oil. 1 2 3 A Downloaded from www.Manualslib.com manuals search engine

GENERAL INFORMATION A 5 Clean the motorcycle regularly to retain the beauty of the plastic parts. Use warm water with a commercial detergent and a sponge. Coarse dirt can be removed with a soft water jet. CAUTION: never clean the motorcycle with a power washer or a high pressure jet. This will cause the water to reach the electric components, socket connectors, cables, bearings, carburetor, etc. and will cause these parts to malfunction or break. – Only use commercial detergents to clean the engine. Use a brush to clean any heavily soiled areas. – Before you start cleaning, close the exhaust pipe to prevent water from penetrating. – After cleaning the motorcycle thoroughly with a soft water jet, dry with compressed air and a soft cloth. Drain the float chamber in the carburetor. Take a short ride until the engine reaches the operating temperature, applying the brakes while driving. The heat will cause the water to evaporate from the inaccessible engine and brake areas. – Slide back the protection covers on the handlebar instruments to allow water that has penetrated to evaporate. – After the motorcycle has cooled down, oil or grease all of the sliding and bearing points. Treat the chain with chain spray. Oil the fuel tap. – To prevent defects in the electric system, apply contact spray to the emergency stop switch, the short-circuit button, the light switch and the socket connector. If the motorcycle is used during the winter where roads will be spread with salt, precautions must be taken to protect the motorcycle against the aggressive road salt. – Clean the motorcycle thoroughly and allow to dry after each ride. – Treat the engine, carburetor, swing arm and all other bare or galvanized parts (except the brake disks) with a wax-based anti-corrosion agent. WARNING: do not allow any anti-corrosion agent to get on the brake disks since this will significantly reduce the braking effect. CAUTION: clean the motorcycle with cold water and dry thoroughly after driving on salted roads. If your motorcycle is to be immobilized for a longer period of time, proceed as follows: – Clean the motorcycle thoroughly. – Change the engine oil, the short and the long oil filter (old engine oil contains aggressive impurities). – Check the quantity of antifreeze and coolant. – Allow the engine to warm up, close the fuel tap and wait until the engine stalls. Open the drain plug on the float chamber to allow any remaining fuel to drain. – Remove the spark plug and fill approx. 5 cm 3 of engine oil into the cylinder through the spark plug hole. Actuate the kickstarter 10 times to distribute the engine oil over the cylinder wall and mount the spark plug again. – Set the piston in the compression position to close the valves. – Drain the fuel from the tank into a suitable vessel. – Check the tire air pressure. – Oil the bearing points on the control levers, footrests, chain, etc. – Dismount and charge the battery. – The storage site should be dry and not have any extreme fluctuations in the temperature. – Cover the motorcycle with a permeable cover or blanket. Do not use impermeable material since it will not allow any moisture to escape and cause corrosion. CAUTION: Do not briefly run the engine of an immobilized motorcycle since the engine will not become warm enough and any vapor produced during the combustion process will condense and cause corrosion. STARTING UP AFTER IMMOBILIZATION – Connect the charged battery (check for correct polarity). – Fill fresh fuel into the tank. – Inspect the motorcycle as you would before each start-up (see Driving Instructions) – Go on a short, cautious test ride CLEANING PRESERVATION FOR WINTER OPERATION STORAGE Downloaded from www.Manualslib.com manuals search engine

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Husaberg 450 500 550 650 Service Repair Manual 2004-2007

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