HUSABERG FE 400 e, FE 501 e, FE 650 e, FS 400 e, FS 650 e User Manual

...

Download

Page 1

INDEX

INTRODUCTION Page 2-

SAFETY AND PRECAUTIONS Page 4-

GENERAL INFORMATION Page 6-

MAINTENANCE SCHEDULE Page 9-

CONTROLS Page 12-

STARTING PROCEDURE Page 15

ENGINE Page 16-

FUEL & COOLING Page 20-

CLUTCH & DECOMPRESSION Page 22

WHEELS & BRAKES Page 23-

A LUBRICATION SYSTEM B IGNITION C AIR FILTER D VALVE ADJUSTMENT

A CARBURETTOR B FUEL C COOLING SYSTEM

A WHEELS B CHAIN C BRAKES

SUSPENSION Page 29-

WIRING DIAGRAMS Page 33-

A SUSPENSION B STEERING HEAD C SWINGARM

Page 2

INTRODUCTION

Please read and observe the following:

Warning

If the engine has to be running during any maintenance, make sure that the area is properly ventilated. Never run the engine in a closed area though the exhaust fumes are posionous and thus hazardous to your health and life.

Warning

Although the battery is of a sealed construction, please take care. The electrolyte contains sulfuric acid and you must protect your eyes, skin and clothing if such fluid is assumed to be leaking or likewise exposed. In case of contact, wash and flush thoroughly with water and contact medical help if needed, especially if your eyes have been exposed to the fluid.

Warning

Fuel is extremely flammable and explosive under certain conditions. Do not smoke or expose the fuel to open fire or sparks.

SERVICE CONDITIONS:

1. Always use original Husaberg parts.

2. Use the special Husaberg tools when required.

3. Install new gaskets, o-rings, circlips etc whenever possible.

4. Always clean all parts thoroughly before assembly.

5. All screws, nuts and bolts etc. are in the metric system. Do not use incorrect tools.

PRINT & COPY RIGHTS

The material and information included in this Owner’s Manual are all of the latest editions available at the time of the printing.

Husaberg Motor AB reserves the right to make changes regarding the products at any time without prior notice.

This Owner’s Manual is subject to corrections without prior notice.

No part of this Owner’s Manual may be reproduced without written permission

Endurovägen, S-695 72 SWEDEN

www.husaberg.se

[email protected]

Page 3

INTRODUCTION

Dear client,

We feel ourselves privileged and honoured to be the supplier of your choice of motorcycle. We know for sure that our product will give you years of fun and performance though the Husabergs are based upon decades of experience in racing and a dedication hard to find elsewere. You’re bound to feel this through the inborn lively spirit of your bike.

Although mainly designed and constructed for competition purposes it is still very rider-friendly but due to the design the product needs careful and proper maintenannce. In order to get the most out of your "beast" and before any use of the motorbike; we highly recommend you to carefully read this Owner's Manual through. We also recommend you to pay your outmost attention to the following page regarding safety and precautions and always remember the fundamental base of all activities on two wheels:

- "Do not overestimate your capabilities, follow the domestic regulations and do think about your surroundings"

Although the Owner's Manual is put together and written in a way that will make it possible for an average mechanical experienced person to take care of the maintenance, we recommend you to let an authorized Husaberg dealer take care of at least the parts we’ve mentioned under:

Also, part of the maintenance has to be performed by an authorized dealer in order to fulfill the terms of warranty.

If you follow the advice regarding the set-up and of course also regarding the vital maintenance of the motorcycle; the Husaberg of yours will provide a maintained level of performance (read: joy and satisfaction - the reason to your choice of brand).

The personnel of Husaberg Motor AB Sweden

ATTENTION:

Never ride in a too low or too high gear Never let the engine run for more than one minute while stationary It may cause severe mechanical damages

Always put the motorcycle on a stable centerstand whenever removing either front or rear wheel.

Never ride your motorcycle under the influence of alcohol, drugs, barbiturates or any other kind of medical treatments hazardous to your riding performance.

WARNING:

Do not check the coolant

level while the engine is hot.

ATTENTION:

Service more frequently when riding under hard conditions

ATTENTION:

Less clearances than the required cause severe engine damages

ATTENTION:

Do not use a highpressure jet-cleaning equipment on surfaces around bearings and other fragile components.

Page 4

SAFETY AND PRECAUTIONS

SAFETY

PROTECTION:

Always protect yourself with adequat clothing and protective apparel. Always wear a helmet, goggles and boots.

MOTORCYCLE:

The motorcycle may become dangerous to ride if it is modified or if any other parts than original Husaberg parts are used. The use of other parts than original makes the warranty no longer valid. Always keep your motorcycle in a safe state and in the best of conditions. Regular cleaning and maintenance are extremely vital in order to avoid any mechanical damages hazardous to you and/or your surroundings.

TRANSPORTATION:

Always transport your bike upright in order to avoid any leakages of oil and/or fuel. Such fluids may increase the risk of fire. Always make sure that the bike is properly fastened in a safe and firm position during transportation.

RIDING:

Always check the motorcycle for any deterioration/damages and any necessary adjustments before you start the motorcycle (see "Pre-ride inspection").

Though the Husaberg motorcycle has a very high level of performance; always ride with care and do not overestimate your capabilities. Get to know your Husaberg motorcycle really well before you try to get the most out of it.

Never lend your motorcycle to any other rider unless you are sure that he/she is fully capable of handling it.

Always obey all local and federal regulations and laws valid within the territory.

Never ride in terrain unfamiliar to you unless inspected and guaranteed by the local authorities.

PRE-RIDE INSPECTION:

Make it a habit to give your motorcycle an inspection before and after every ride.

Always check all bolts and nuts and tighten if necessary - All for your own safety.

A clean and well lubricated bike makes for a safer ride as well as a higher value of the machine. The Pre-ride Inspection Checklist on the next page is to be regarded as a brief summary of the main important items to be controlled and, if necessary; to be adjusted or replaced.

Never ride your motorcycle under the influence of

ATTENTION:

alcohol, drugs, barbiturates or any other kind of medical treatments hazardous to your riding performance.

Page 5

SAFETY AND PRECAUTIONS

PRE-RIDE INSPECTION CHECK LIST

Engine oil Check the level and fill up if necessary.

Check for any leakages in the casing.

Ignition Check the sparkplug cap/HV lead for damages.

Radiator Check the coolant level and fill up if necessary.

Check for leakages and/or damages of the cells and hoses and attachments.

Airfilter Clean, or if necessary, replace the filter

Carburettor Check the function of the throttle/cable and adjust/replace

any damaged parts if necessary. Adjust the idling- and/or mixture screw if necessary. After every time the motorbike has been washed drain the float chamber of the carburettor.

Clutch Check the function and for any leakages.

Decompression Check the function of the manual and the semi-automatic

decompression lever and adjust if necessary (non-electrical starter models only).

Chain Check and adjust/replace the chain if necessary.

Check the sprockets and replace if necessary.

Suspension Check the operation of the front fork and the shock absorber

and adjust if necessary. Check and tighten the swingarm if necessary.

Wheels Check the air pressure of the tyres and fill up if necessary.

Check the spokes and tighten if necessary.

Brakes Check the level of brakefluid and fill up if necessary.

Check for any leakages and the function of the brakes. Adjust levers and/or replace hoses/pads if necessary.

Fuel Check the level and fill up if necessary.

Check for any leakages in the fuel lines.

Steering Check the clearance of the steering head bearings and

adjust if necessary.

Controls Check the function of the speedometer or odometer (if

incl.in equipment).

Lighting Check the functions of the front-, tail-, and brake lights

(and any occuring turn signals).

Page 6

GENERAL INFORMATION

SPECIFICATIONS

242 lb. 243 lb. 244 lb. 247 lb. 249 lb. 233 lb. 235 lb. 228 lb. 228 lb. 229 lb. 242 lb. 242 lb. 243 lb.

Ratios 1st: 14/33 - 2,357 2nd: 17/30 - 1,765 3rd: 19/26 - 1,368 4th: 23/25 - 1,087 5th: 24/22 - 0,917 6th: 27/20 - 0,741 (6th CR: 25/21-0,840)

SUBJECT/MODEL FE 400 e FE 501 e FE 650 e FS 400 e FS 650 e FS 400 c FS 650 c FC 470/6 FC 550/4 FC 550/6 FC 470 e FX 470 e FX 650 e

Displacement 399cc 501cc 644cc 399cc 644cc 399cc 644cc 472cc 550cc 550cc 472cc 472cc 644cc

Bore x Stroke (mm) 92 x 60,1 95 x 70,7 100 x 82,0 92 x 60,1 100 x 82,0 92 x 60,1 100 x 82,0 100 x 60,1 100 x 70,0 100 x 70,7 100 x 60,1 100 x 60,1 100 x 82,0

Compression ratio 12,5:1 11,8:1 11,0:1 12,5:1 11,0:1 12,5:1 11,0:1 12,4:1 12,7:1 12,7:1 12,4.1 12,4:1 11,0:1

Start system Electrical and kick-starter Kick-starter Electrical and kick-starter

Decompression system Three separate ones; one activated by the kickstart lever, one activated by the camshaft and one activated by a lever on the handlebar

Decomp. cable clearance 2mm ± 1mm / 0,08 in ± 0,04 in.

Engine Liquid cooled single cylinder 4-stroke, SOHC-4 valves, counter balancer

Valve clearance Intake and Exhaust: 0,10mm / 0,004 in.

Lubrication system Orbit oil pump and reed valve controlled. High pressure jet spray of piston and connecting rod, pressure lubrication of connecting rod bearing and rocker arms. Oil screen and micro filter

Engine oil 1,0 Litre Synthetic SAE 5W-50 API SG/CF (minimum SAE 10W-50)

Ignition system SEM Dynamic Force Control, DFC™, Dual Ignition Curves; High & Low. A load sensitive digital system with six sensors

Spark plug - Spark plug gap NGK DCPR8E - 0,6 mm / 0,025 in.

Alternator 12 V 70 + 70 W Not available 12 V 70 + 70 W

Air intake system Single foam filter

Carburettor (DELLORTO) PHM 38 PHM 40 PHM 40 PHM 38 PHM 40 PHM 40 PHM 40 PHM 40 PHM 40 PHM 40 PHM 40 PHM 40 PHM 40

Fuel RON 98 (octane), unleaded

Exhaust system Chrome plated steel pipes, 2 into 1 collector, Aluminium/steel silencer. USA versions, except FC and FSc models, equipped with spark arresters

Coolant 1,3 Litre of 50% Anti-freeze, with corrosion inhibitor, and 50% water

Clutch Hydraulic, 7 friction- and 8 mating plates in oil bath

Clutch hydraulic oil Mineral oil SAE 2-7W

Wear limit clutch discs 19,6 mm / 0,772 in.

Primary transmission Spur gears, ratio 29/78 - 2,690

Gearbox 6-speed 6-speed 6-speed 6-speed 6-speed 6-speed 6-speed 6-speed CR 4-speed 6-speed CR 6-speed CR 6-speed 6-speed

Secondary transmission D.I.D. 520 O-ring chain

Sprockets front/rear 13/48 15/48 15/42 15/42 15/42 15/42 15/42 13/42 15/42 15/48 13/48 13/48 15/42

Wear limit drive chain 272 mm - 18 chain reels (tensioned, center distance between reels)

Frame Heat treated BTR / 25CrMo4 steel

Caster 28,5°

Weight (dry) 109,8 kg 110,1 kg 110,9 kg 111,9 kg 113,1 kg 105,7 kg 106,8 kg 103,5 kg 103,5 kg 103,9 kg 109,6 kg 109,6 kg 110,4 kg

Page 7

GENERAL INFORMATION

SPECIFICATIONS

Rear EXCEL 2.15 x 18” BEHR 4.25 x 17” EXCEL 2.15 x 19” EXCEL 2.15 x 18”

SUBJECT/MODEL FE 400 e FE 501 e FE 650 e FS 400 e FS 650 e FS 400 c FS 650 c FC 470/6 FC 550/4 FC 550/6 FC 470 e FX 470 e FX 650 e

Rims Front EXCEL 1.60 x 21” BEHR 3.50 x 17” EXCEL 1.60 x 21” EXCEL 1.60 x 21”

Rear 140/80-18” 150/60-17” 110/100-19” 130/80-18”

Tyres (MICHELIN)Front 90/90-21” 120/60-17” 80/100-21” 90/90-21”

Tyre pressure (cold)

Rear 0,8 bar / 12,0 psi 0,8 bar / 12,0 psi

Rear 1,0 bar / 14,5 psi 2,0 bar / 29,0 psi

Offroad Front 0,8 bar / 12,0 psi 0,8 bar / 12,0 psi

Tarmac Front 1,0 bar / 14,5 psi 2,2 bar / 31,9 psi

ø 260 mm Inox steel disc ø 310 mm Plated cast iron disc ø 260 mm Inox steel disc

Hydraulic twin piston floating caliper Hydraulic four piston floating caliper Hydraulic twin piston floating caliper

Rear PDS 5018-HBG E PDS 5018-HBG S PDS 5018-HBG MX

Rear 320 mm / 12,6 in. 287 mm / 11,3 in. 320 mm / 12,6 in.

Suspension (WP) Front MXMA 4860-HBG E ø 48 mm MXMA 4860-HBG S ø 48 mm MXMA 4860-HBG MX ø 48 mm

Wheel travel Front 295 mm / 11,6 in. 260 mm / 10,2 in. 295 mm / 11,6 in.

Front fork oil WP SAE 5

Brakes Front BREMBO BERINGER BREMBO

Rear BREMBO hydraulic single piston floating caliper, ø 220 mm Inox steel disc

Brake fluid DOT 4

Alt. B 12 V 45/40 W - BA20d Not applicable

Wear limit brake pads 1,5 mm / 0,06 in.

Head light Alt. A 12 V 65/50 W - P43t Not applicable

Tail / Stop light 12 V 21/5 W - BAY 15d Not applicable

Parking light 12 V 4 W - BA9s Not applicable

Turn signal lights 12 V 10 W - BA15s Not applicable

Speedometer light 12 V 2 W - BA7s Not applicable

Battery / Main fuse 12 V 8 Ah / 15 A Not applicable

Wheel base - Width 1490 mm / 58,66 in. - 810 mm / 31,89 in.

Seat height 930 mm / 36,61 in. 870 mm / 34,25 in. 930 mm / 36,61 in.

Ground clearance 380 mm / 14,96 in. 320 mm / 12,60 in. 380 mm / 14,96 in.

Overall length 2200 mm / 86,61 in. 2150 mm / 84,65 in. 2200 mm / 86,61 in.

Page 8

GENERAL INFORMATION

CARBURETTOR STD. JETTINGS

MODEL/SUBJECT

Exploded view number Enduro

Enduro ECE

Enduro USA

Super Motard Street Super Motard Street ECE Super Motard Street USA Super Motard

Competition Cross Country

Motocross

FE 400 e FE 501 e FE 650 e FE 400 e FE 501 e FE 650 e FE 400 e FE 501 e FE 650 e FS 400 e FS 650 e FS 400 e FS 650 e FS 400 e FS 650 e FS 400 c FS 650 c FX 470 e FX 650 e FC 470 FC 550 FC 470 e

Main

Needle

jet

# 6

185 DR 270 K 51 #3 33 40 300 185 DR 272 K 51 #3 35 40 300 190 DR 272 K 51 #3 40 40 300 110 DR 266 K 51 #2 48 40 300 110 DR 264 K 35 #4 33 40 300 100 DR 266 K 51 #3 33 40 300 190 DR 270 K 51 #3 38 40 300 195 DR 268 K 35 #3 33 40 300 195 DR 270 K 35 #3 33 40 300 185 DR 270 K 51 #3 33 40 300 190 DR 272 K 51 #3 40 40 300 110 DR 266 K 51 #2 48 40 300 100 DR 266 K 51 #3 33 40 300 190 DR 270 K 51 #3 38 40 300 195 DR 270 K 35 #3 33 40 300 180 DR 272 K 35 #3 33 40 300 190 DR 272 K 51 #3 40 40 300 185 DR 266 K 35 #3 33 30 300 190 DR 270 K 51 #3 33 40 300 185 DR 266 K 35 #3 33 30 300 190 DR 272 K 51 #3 33 40 300 185 DR 266 K 35 #3 33 30 300

jet

# 4

Needle

# 3

Needle clip pos.

# 26

Pilot

jet

# 7

Throttle

# 2

Float valve

# 9

Start

jet

# 8

45 45 45 45 45 45 45 45 45 45 45 45 45 45 45 45 45 45 45 45 45 45

Mixture

screw

# 33

2 turns 1½ turns 1½ turns

½ turn ½ turn ½ turn

2 turns 1½ turns 1½ turns

2 turns 1½ turns

½ turn

2 turns 1½ turns 1½ turns 1½ turns 1½ turns 1½ turns 1½ turns 1½ turns 1½ turns

1. Flywheel puller Article No. 270028-01

2. Flywheel holder Article No. 270030-01

3. Air bleeding syringe Article No. 270032-01

4. Tool kit Article No. 390029-01

Page 9

GENERAL INFORMATION

TORQUE VALUES

SUBJECT

Waterpump cover screws

Exhaust pipe screws

Spark plug

Standard torque values M8 M10

TORQUE

5 NmIntake manifold screws 5 NmOil filter cover screws 5 Nm 5 NmValve inspection cover screws 5 Nm 8 NmStator screws

10 NmCrankcase screws 10 Nm

10 NmGearshift lever screw 10 Nm Apply a threadlock liquidKick start lever screw

10 NmValve cover screws 12 NmOil drain plug 12 Nm 12 NmValve adjustment lock nuts 15 NmFront fork triple clamp screws lower (M8) 20 NmFront fork triple clamp screws upper (M8) 25 Nm Apply a threadlock liquidUpper timing sprocket screws 44 NmCylinderstud nuts 50 Nm Left-hand threadFlywheel nut

80 Nm Apply a threadlock liquidIntermediate gear wheel nut 110 Nm 125 NmSwingarm shaft nuts

6 Nm

8 Nm

10 Nm

Apply a threadlock liquidReed valve screws

Apply a threadlock liquidPrimary gear wheel nut

25 Nm 40 Nm

NOTE

M12

40 Nm

M16

125 Nm

MAINTENANCE SCHEDULE

Chassis - FC, FSc and FX models

SRUOH/TCEJBUSSRUOH/TCEJBUS

SRUOH/TCEJBUS

*liokroftnorF

*diulfekarB

sgnihsub/sgniraebmragniwS

sgnihsubrebrosbakcohS

sgniraebdaehgnireetS

sgniraebleehW

Chassis - FE and FSe models

SRUOH/TCEJBUSSRUOH/TCEJBUS

SRUOH/TCEJBUS

*liokroftnorF

*diulfekarB

sgnihsub/sgniraebmragniwS

sgnihsubrebrosbakcohS

sgniraebdaehgnireetS

sgniraebleehW

55555010101010151515151510202020202525252525203030303035353535353040404040454545454540505050505555555555506060606065656565656070707070757575757570808080808585858585809090909095959595959001001

RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR

IIIII IIIII IIIII IIIII

IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII

IIIII IIIII IIIII IIIII

IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII

010101010102020202020303030303040404040405050505050606060606070707070708080808080909090909001001

RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR

IIIII IIIII IIIII IIIII

IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII

IIIII IIIII IIIII IIIII

IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII

001001011011

001

011011021021

011

021021031031

021

031031041041

031

041041051051

041

051051061061

051

061061071071

061

071071081081

071

081081091091

081

091091002002

091

001001

001

002002

002

C: Clean - I: Inspect - R: Replace - *Maximum 12 months interval

Page 10

MAINTENANCE SCHEDULE

Engine - FC, FSc and FX models

Please observe: Riding under hard conditions demands more frequent maintenance

SRUOH/TCEJBUSSRUOH/TCEJBUS

SRUOH/TCEJBUS

lioenignE

neercsliO

retliforcimliO

evlavdeer.lcnipmupliO

*diuqiltnalooC

)pac.lcni(gulpkrapS

**noitingI/rotanretlA

ecnaraelcevlaV

nip&sgnir.lcninotsiP

gninilrednilyC

dorgnitcennoC

niptfahsknarC

***/**rotterubraC

msinahcemtratskciK

msinahcemtfihsraeG

msinahcemleehweerF:LE

55555010101010151515151510202020202525252525203030303035353535353040404040454545454540505050505555555555506060606065656565656070707070757575757570808080808585858585809090909095959595959001001

RALUGERRALUGER

RALUGER

RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR

CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC

RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR

C/IC/I

C/IC/I C/IC/I

C/I

IIIII RRRRR IIIII RRRRR

IIIII IIIII

IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII

sgnilaes&sediug.lcnisevlaV

renoisnet.lcniniahcgnimiT

IIIII RRRRR IIIII RRRRR

scsid.lcnimsinahcemhctulC

IIIII IIIII IIIII IIIII

C/IC/I

C/IC/I C/IC/I

C/I

RRRRR RRRRR

IIIII IIIII

RRRRR

C/IC/I C/IC/I

C/I

IIIII IIIII

C/IC/I C/IC/I

C/I

001001

001

C/IC/I

C/I

RRRRR

IIIII

C/IC/I

C/I

SGNIRAEBSGNIRAEB

SGNIRAEB

dorgnitcennoC

tfahsknarC

tfahsniamxobraeG

tfahsyradnocesxobraeG

murdtfihS

tfahsmaC

etalperusserphctulC

leehwraegtratskciK

leehwraegetaidemretnI

smrarekcoR

.labretnuoctfahsetaidemretnI

recnalabretnuoC

dorgnitcennoC

smrarekcoR

tfahstratskciK

tfahshctulC

RRRRR RRRRR RRRRR RRRRR

SGNIHSUBSGNIHSUB

SGNIHSUB

IIIII RRRRR IIIII RRRRR

RRRRR RRRRR

IIIII RRRRR

IIIII IIIII

RRRRR

C: Clean - I: Inspect - R: Replace

* Maximum 12 months interval - ** Clean whenever the engine has been washed - *** I(R): Especially needle and needle jet

Page 11

MAINTENANCE SCHEDULE

Engine - FE and FSe models

Please observe: Riding under hard conditions demands more frequent maintenance

SRUOH/TCEJBUSSRUOH/TCEJBUS

SRUOH/TCEJBUS

lioenignE

neercsliO

retliforcimliO

evlavdeer.lcnipmupliO

*diuqiltnalooC

)pac.lcni(gulpkrapS

**noitingI/rotanretlA

ecnaraelcevlaV

nip&sgnir.lcninotsiP

gninilrednilyC

dorgnitcennoC

niptfahsknarC

***/**rotterubraC

msinahcemtratskciK

msinahcemtfihsraeG

msinahcemleehweerF:LE

010101010102020202020303030303040404040405050505050606060606070707070708080808080909090909001001

RALUGERRALUGER

RALUGER

RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR

CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC CCCCC

RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR RRRRR

IIIII RRRRR IIIII RRRRR

IIIII IIIII IIIII IIIII

IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII IIIII

sgnilaes&sediug.lcnisevlaV

renoisnet.lcniniahcgnimiT

scsid.lcnimsinahcemhctulC

IIIII IIIII IIIII IIIII

C/IC/I

C/IC/I C/IC/I

C/I

001001011011

011011021021

021021031031

031031041041

041041051051

051051061061

061061071071

071071081081

081081091091

001

011

021

031

041

051

061

071

C/IC/I

C/IC/I C/IC/I

C/I

RRRRR RRRRR

IIIII RRRRR

IIIII IIIII

RRRRR RRRRR

C/IC/I C/IC/I

C/I

IIIII IIIII

C/IC/I C/IC/I

C/I

091091002002

081

091

002002

002

C/IC/I

C/I

RRRRR

IIIII

C/IC/I

C/I

SGNIRAEBSGNIRAEB

SGNIRAEB

dorgnitcennoC

tfahsknarC

tfahsniamxobraeG

tfahsyradnocesxobraeG

murdtfihS

tfahsmaC

etalperusserphctulC

leehwraegtratskciK

leehwraegetaidemretnI

smrarekcoR

.labretnuoctfahsetaidemretnI

recnalabretnuoC

dorgnitcennoC

smrarekcoR

tfahstratskciK

tfahshctulC

RRRRR RRRRR RRRRR RRRRR

SGNIHSUBSGNIHSUB

SGNIHSUB

RRRRR RRRRR RRRRR RRRRR

RRRRR RRRRR

IIIII RRRRR

RRRRR RRRRR

IIIII IIIII

C: Clean - I: Inspect - R: Replace

* Maximum 12 months interval - ** Clean whenever the engine has been washed - *** I(R): Especially needle and needle jet

Page 12

CONTROLS

IDENTIFACTION NUMBERS

The Vehicle Identification Number is placed on the right side of the steering head (Fig. 5A-1). The Engine Number is placed on the right side of the engine, just below the cylinder (Fig. 5B-1).

STEERING LOCK

The lock (if incl. in equipment) is placed on the right side of the steering head (Fig. 5A-2). We recommend you to follow the conditions of your insurance regarding the use of anti-theft devices.

Fig.

IGNITION LOCK

The ignition lock is either placed to the right of any speedometer (Fig. 5C-1) or in a separat bracket. The first position, maximum counter-clockwise, means that the engine can not be started. No lights in function. The second position, clockwise, means that the engine can be started with the kick starter but not with the electrical starter. Available lights in function. The third position, clockwise, means that the engine can be started with both the kick starter and the electrical starter. Available lights in function.

Fig.

Page 13

CONTROLS

Fig. 5E Combination switch Type I:

1- Headlight switch (Off - Low - High beam)

2- Turn signal switch

3- Horn button

4- Engine shortcircuit button

5- Clutch lever

Fig. 5F Combination switch Type II:

1- Headlight switch (Off - Low - High beam)

2- Horn button

3- Engine shortcircuit button

Fig.

Fig. 5G 1- Engine shortcircuit button

(Motocross models)

Fig. 5H 1- Clutch lever adjustment knob

2- Oil reservoir hydraulic clutch

3- Decompression lever

4- Decompression lever adjustment

Fig.

Page 14

CONTROLS

Fig 5I 1- Twistgrip

2- Front brake lever

3- Electrical starter button (if it is an electrical starter model, otherwise the button having no function)

4- Dual ignition curve switch

Fig 5J Low- Normal conditions

High- Starts and heavy conditions

Fig. 7A

Fig.

Fig. 5K 1- Reservoir front brake fluid

2- Brake fluid inspection window

3- Throttle wire adjustment

Fig. 5L 1- Speedometer

(If included in equipment)

2- Highbeam indicator lamp

LOW HIGH

Fig.

3- Turn signal indicator lamp

4- Trip meter knob

Page 15

STARTING PROCEDURE

Kick starter models:

Follow the checklist on page 5. Turn the fuel taps (Fig. 6A-1 & 6B-1) to position ON (Fig. 6D). Cold engine: Turn the choke lever (Fig 6A-2) to position ON (Fig. 6C-1) by pulling it downwards and twisting it 90° (Fig. 6C-2). Warm engine: Choke lever should be in OFF position. Put the gearshift lever into neutral. With the throttle fully closed, make a distinct and long kick all the way through the operational orbit of the kick start lever. If the engine does not start, let the kick start lever return all the way back in order to provide the maximum distance for the kick start lever and also activating the additional semi-automatic decompression system. Cold engine: Warm the engine up (the throttle a little bit opened) with the choke on until it runs smoothly. Engine idling, pull the clutch lever fully towards the handlebar and engage the 1st gear by pushing the gearshift lever downwards. Open the throttle slightly at the same time as you slowly and gently release the clutch lever. Shift the gears as soon as adequate rpms have been achieved.

Fig.

Electrical starter models:

Follow the checklist on page 5. Turn the fuel taps (Fig. 6A-1) to position ON (Fig. 6B-1). Cold engine: Turn the choke lever (Fig 6A-2) to position ON (Fig. 6B-2) by pulling it downwards and twisting it 90°. Warm engine: Choke lever should be in OFF position. Put the gearshift lever into neutral. With the throttle fully closed, push the electrical start button. Cold engine: Warm the engine up (the throttle a little bit opened) with the choke on until it runs smoothly. Engine idling, pull the clutch lever fully towards the handlebar and engage the 1st gear by pushing the gearshift lever downwards. Open the throttle slightly at the same time as you slowly and gently release the clutch lever. Shift the gears as soon as adequate rpms have been achieved. The electrical start models are all equipped with kick starters. Follow the instructions above: ”Kick starter models”, if used.

Fig.

ON OFF

ATTENTION:

In order to ensure an easy start the following must be correctly adjusted: The valve clearances, the idling speed, the spark plug gap and the mixture screw of the carburettor.

RESERVE

ATTENTION:

Do not drain all of the battery capacity

Page 16

7 A

ENGINE

LUBRICATION SYSTEM:

Always use a synthetic oil of a well-known brand, viscosity SAE 5W-50. Depending on the basic design of the engine; competition purposes = equal to a small sized engine thus giving a small capacity of oil, it is vital that the oil is frequently changed. Packed into the crate of a totally new motorcycle is an additional microfilter. The filter installed in the engine and the engine oil have to be changed after the first two hours of operation. The oil screen has to be fully cleaned at the same time. After the first change of oil and filter, including cleaning of the oil screen, the intervals are maximum 5 hours (Motocross, Super Motard Competition and Cross Country models) or 10 hours (all other models) regarding change of oil and cleaning of the screen and every 25/50 hours regarding exchange of the microfilter.

Fig.

After every 100 hours the reed valve of the lubication system has to be inspected and cleaned.

Oil and filter change and cleaning of oil screen:

The oil is preferably changed while the engine is warm.

ATTENTION:

Take care - the oil could be very hot

Drain the oil by removing the oil drain plug (Fig. 7A-1, wrench No. 13) and the attached oil screen. Remove the cover of the microfilter by removing the ignition cable clamp (Fig. 7A-2, wrench No. 8) and the two allen screws (Fig. 7A-3, allen key No.

4) and pull out the cover and filter by using one M 6 screw as a puller into the center of the cover. Lubricate the surface of the cover's O-rings and the O-ring of the new microfilter (Fig. 7B-2, 7B-3). Insert the microfilter in reverse order of disassembly. Refit the oil drain plug and the attached, well cleaned, oil screen. Refill the engine with the adequate amount of oil; 1,0 litre, through the filler hole (Fig. 7C-1). Correct level of oil as shown (Fig. 7C-2 & 7D) Whenever checking the oil level the motorcycle/ engine has to be in an upright position.

Fig.

ATTENTION:

Service more frequently when riding under hard conditions

OIL LEVEL

Page 17

7 B

ENGINE

IGNITION:

The ignition system is a CDI-system without any contact-breaker to change or any other moving parts apart from the flywheel. However, the system has to be frequently checked and cleaned for a maximum of durability and performance.

The inside of the ignition cover, the stator, the flywheel and the surroundings are preferably cleaned after every time the motorcycle has been used and/or washed (cover removal; three allen screws, allen key No.5). Due to the heat of the engine a condensation is built up around the stator and flywheel which could cause the system to work improperly. Check the surface of the cover for any damages in order to avoid any leakages. Frequently check the spark plug (Fig. 7E-1) for wear and the colour of the electrode coating (spark plug wrench, article No. 270007-01). The colour ought to be pale brown. A dark or black colour means that the carburettor's setting is on the rich side and a light or white colour means that it is too lean (see "FUEL & COOLING CARBURETTOR”).

Fig.

Check also the spark plug electrode gap. The correct electrode gap is 0,6 mm. Recommended spark plug is NGK DCPR8E. Tightening torque 12 Nm.

Ignition timing:

Remove the inspection cover (Fig. 7F-1). Put the engine in TDC position (see ”ENGINE VALVE ADJUSTMENT”).

The ignition is propely set if the right mark on the flywheel (Fig. 7G/H-2) is aligned with the mark on the stator (Fig. 7G-1).

If the ignition needs to be adjusted, remove the cover, slightly undo the three screws of the stator (Fig. 7H-1) and adjust the stator. Tighten the screws.

Fig.

Page 18

7 C

ENGINE

AIRFILTER:

To avoid any engine damages or lack of power the air filter has to be frequently cleaned or replaced. Always use a well-known brand of filter oil after cleaning. Use an airfilter cleaning solvent of a well-known brand. Always check the surface of the filter attachment and the filter basket for any damages. Always check the surfaces behind the filter for any loose particles and carefully clean the surfaces.

Airfilter removal:

Remove the seat (Fig. 7I-1, one quick release screw on top of the seat). Remove the wing nut (Fig. 7J-1) holding the airfilter and airfilter basket (Fig. 7J-2). Pull the airfilter basket out of the airfilter. Wash the filter carefully. Soak the filter in filter oil and squeeze it slightly for any superfluous oil. Put the airfilter basket into the filter. Assembly in reverse order of disassembly.

Fig.

ATTENTION:

Service more frequently when riding under hard conditions

Page 19

7 D

ENGINE

VALVES:

The clearances between the valve adjustment screws and the valve stems have to be checked after 2 hours of operation if the engine is brand new or any parts of the valves, valve seats or rockerarms have been changed. The interval between the checks of the clearences is after that every 10 hours (Motocross, Super Motard Competition and Cross Country models) or 20 hours (all other models).

Valve adjustment:

Remove the fuel tank (see "FUEL & COOLING

- FUEL"). Put the engine in TDC position on compression stroke: Remove the ignition cover, install a dial indicator into the spark plug hole (Fig. 7K-1) and turn the flywheel (wrench No. 17), clockwise, in order to find the upper position of the piston.

Fig.

Remove the two valve inspection covers (Fig. 7L-1, 2, allen key No. 4) including the gaskets. Check the clearances of the valves; 0.10 mm on both the intake valves as well as the exhaust valves. Adjust if necessary by releasing the lock nut (Fig. 7M-1, wrench No. 10) and then by adjusting the screw (Fig. 7M-2) into the adequate clearance. Refit in the reverse order of disassembly. Replace the gaskets of the inspection covers if necessary.

ATTENTION:

Service more frequently when riding under hard conditions

Fig.

Page 20

8 A

FUEL & COOLING

CARBURETTOR:

Always make sure that the throttle (Fig. 8A-1) returns to a fully closed position. Always make sure that the twistgrip and cable move easily. Always keep the twistgrip and cable well cleaned and lubricated. The tube on top of the carburettor (Fig. 8A-2) is a point of deterioration to the cable and thus a vital part of the cable to be inspected. Always make sure of a 1-2 mm clearance in the twistgrip. Adjustment is done by removing the dust protection (Fig. 8B-1), releasing the lock nut (Fig. 8B-2) and adjusting the adjustment screw (Fig. 8B-3).

Always check the intake manifold (Fig. 8C-6) and the airfilter tube (Fig. 8C-5) for any cracks and/ or leakages and replace if necessary. Always keep the shaft of the choke lever (Fig. 8C-3) well lubricated. Always check that the overflow tubes (Fig. 8C-4) on each side of the carburettor are positioned in a vertical position straight from the outlets and not crossed nor hanging over the carburettor. Always ensure that an appropriate fuel is used (minimum 98 octane) in order to get the most out of the motorcycle and to ensure a proper function of the engine.

Fig.

Carburettor setting:

To ensure an easy start of the engine, a high level of performance and a reduction of any risk of engine damages, the carburettor has to be correctly set and adjusted. The carburettor has an idling screw (Fig. 8C-1) and a mixture screw (Fig. 8C-2) that have to be properly adjusted. In order to carry out a proper adjustment of these, the engine has to be warm. With the twistgrip fully closed, turn the idling screw to a position that makes the engine run smoothly at idling speed (approximately 16001800 rpm). Adjust the mixture screw to a position of a maximum idling speed. If the engine now runs in a too high idling speed unscrew the idling screw until a satisfying idling speed is established. A guideline regarding the mixture screw is 1½2½ turns from the bottom position of the screw. Depending on the altitude and the humidity, the adjustment may have to be changed whenever riding under various conditions.

Fig.

ATTENTION:

Service more frequently when riding under hard conditions

Page 21

8 B/C

FUEL & COOLING

FUEL:

The Husaberg motorcycle is developed and designed for competition use and this makes a high compression ratio a necessity. In order to avoid any damages caused by too low grade of octane we highly recommend you to use a fuel of minimum 98 octane.

Fuel tank:

Remove the seat (Fig. 8D-1, see ”ENGINE AIRFILTER”). Remove the the two clamps holding the upper fuel lines attached to each fuel tap (Fig. 8D-2). Remove the two hexagon bolts holding the left and right radiator spoiler attached to the radiator (Fig. 8D-3, wrench No.8). Remove the fuel tank by lifting it up in the rear end and moving it up and backwards.

Fig.

RADIATOR:

Always make sure that the coolant level is correct by checking that the coolant is visible after removal of the radiator filler cap (Fig. 8E-1).

WARNING:

Do not check the coolant

level while the engine is hot.

A mixture of 50% water and 50 % anti-freeze with a corrosion inhibitor is recommended. Check all connections and hoses for any leakages. Check the radiator cells for any leakages.

Fig.

Page 22

CLUTCH & DECOMPRESSION

CLUTCH:

Check the hydraulic line for any leakages or deterioration. Always check the level of fluid in the reservoir. The cover of the reservoir has to be removed in order to check the level (Fig. 9A-1). Adjust the pressure point of the lever according to your own preferences with the adjustment knob (Fig. 9A-2). Always keep a clearance in between the lever and the point of pressure.

If the package of discs measures less than 19,6mm the discs are to be replaced.

Air bleeding of clutch:

Undo the screws of the cover (Fig. 9A-1) just slightly in order for the oil to flow over. Set the adjustment knob (Fig. 9A-2) in its outer position and keep the lever fully open during the whole operation. Put a rag or likewise around the oil reservoir. Open the air nipple (Fig. 9B-2) 1-1½ turn. Slip or screw a suitable syringe (article no. 270032-01), fully filled with mineral oil, onto the nipple and inject the oil into the system. Make sure that no air gets through the syringe into the system. Inject the whole contents of the syringe in one operation. Remove the syringe and close the air nipple immediately.Tighten the screws of the cover and adjust the point of pressure to your liking.

Fig.

DECOMPRESSION SYSTEM:

Although all models are equipped with a fully automatic decompression system, activated by the camshaft, they are also equipped with a system activated by the kick start plus a manually operated one with a lever on the handlebar. Always make sure that the clearance of the lever is as shown. Always keep the cable well lubricated and make sure that it moves easily.

Adjustment of decompression cables:

Put the engine in TDC (see ”ENGINE - VALVE ADJUSTMENT”). Make sure that the manual decompression cable has an adequat clearance before performing the adjustment of the semi-automatic adjustment. Adjustment is done by releasing the two lock nuts (Fig. 9C-2, wrench No. 10) before turning the adjustment screw (Fig. 9C-3, wrench No. 10). The adjustment of the manual lever is done by releasing the lock nut (Fig. 9A-3) before turning the adjustment screw (Fig. 9A-4).

Fig.

2 mm

±1 mm

ATTENTION:

Less clearances than the required cause severe engine damages

Page 23

10 A

WHEELS & BRAKES

FRONT WHEEL:

Always check the front wheel for any damages regarding the rim, the spokes and the nipples. Check the bearings for any wear and/or damages. Tighten any loose spokes (spoke wrench No.5.5).

All spokes have to be equally tensioned.

Removal of front wheel:

Remove the hexagon nut (Fig. 10A-1, wrench No

27). Remove the four hexagon bolts (Fig. 10A-2, wrench No.10), two on each side of the front fork legs. Remove the front wheel axle, incl. the left hand spacer (Fig. 10A-3) and the right hand spacer or speedometer gear lever (Fig. 10A-4) and remove the front wheel. Check the wear of the brake pads at the same time.

Assembly of front wheel:

Put the front wheel in by first sliding the brake disc into the brake caliper (in between the two pads). Put the cleaned and lubricated wheel axle in, from right to left, with the spacer (Fig. 10A-3) on the left side of the hub and the thicker part of the spacer towards the front fork. The rest in reverse order of disassembly. Tighten the bolts. Max. torque of the four M8 bolts

(Fig. 10A-2) 15 Nm.

Fig.

10A

ATTENTION:

Always put the motorcycle on a stable centerstand whenever removing either front or rear wheel.

REAR WHEEL:

Always check the rear wheel for any damages regarding the rim, the spokes and the nipples. Check the bearings for any wear and/or damages. Retighten any loose spokes (spoke wrench No.6).

All spokes have to be equally tensioned.

Removal of rear wheel:

Remove the nut (Fig. 10B-1, wrench No.27) and the chain tensioner sledge (Fig. 10B-2) on the right side of the swingarm. Remove the wheel axle and push the wheel forward. Slip the chain off the wheel sprocket and remove the rear wheel. Check the wear of the brake pads at the same time.

Assembly of rear wheel:

Put the rear wheel in by first sliding the brake disc into the caliper (in between the two pads). Slip the chain onto the sprocket and put the cleaned and lubricated wheel axle in, from left to right, including the left and right chain tensioner sledges. Adjust the chain tensioner (see ”WHEELS & BRAKES - CHAIN DRIVING") if necessary. Tighten the rear wheel shaft nut.

Fig.

10B

Page 24

10 A

WHEELS & BRAKES

WHEEL BEARING RENEWAL:

Remove the wheel (see previous page). Position the wheel so that the bearings (Fig. 10D-2) are easily removed from the inside of the hub. Remove the radial sealing (Fig. 10C-1) in order to be able to remove the circlip (Fig. 10D-1), one circlip only but two sealings per each hub. Push the spacing sleeve to one side (Fig. 10C-

2) in order to position a suitable triblet onto the backside of the inner ring of the opposite bearing. By crosswise (Fig. 10E-2) tapping onto the bearing (Fig. 10E-1), knock the bearing out of the hub. Follow the same procedure regarding the opposite bearing. Be careful not to damage the bearing bases in the hub. Measure the length of the spacer sleeve which should be minimum:

front wheel with speedometer

63,3 ± 0,15 mm

front wheel without speedometer

80,3 ± 0,15 mm

Fig.

10C

Fig.

10D

rear wheel

121,6 ± 0,15 mm

Replace if necessary.

Install the new bearing on the circlip side into the hub and put on the circlip. Turn the wheel and install the spacer sleeve towards the bearing on the circlip side and then install the next bearing towards the spacer sleeve. The spacer sleeve should just slightly be touching the two bearings. Make sure to position the bearings in alignment with the bearing bases in the hub and the spacer sleeve in alignment with the two bearings. Install the sealings and assembly the wheel in the reverse order of disassembly.

Fig.

10E

Page 25

10 B

WHEELS & BRAKES

CHAIN:

The Husaberg motorcycle is delivered with a chain of X-ring type. If properly serviced it will last for a long period. Always keep the chain well cleaned and lubricated and make sure that the chain is properly tensioned. Always make sure that the chain is not showing any signs of wear that may cause it to break or causing damages to the front- and/or rear sprocket. With the chain tensioned, the maximum wear as shown (Fig. 10F).

Chain lubrication:

Remove the rear wheel (see "WHEELS & BRAKES - WHEELS"). Remove the swingarm (see "SUSPENSION SWINGARM”). After cleaning of the removed chain; use a suitable solvent, wipe it off with a clean and dry cloth. Lubricate the chain by using a well-known brand of O-ring lubrication. Assembly in reverse order of disassembly.

Fig.

10F

Maximum 272 mm

123 161718

Fig.

10G

Sprockets:

Always check the front- and rear sprocket for any wear that may cause damages to the chain (Fig. 10G). Whereafter changing to a new O-ring chain, always follow the recommendations of the supplier regarding maintenance and wear limits.

Chain tension control:

Control of the tension is done when the bike is in an upright, unloaded, position (wheels on the ground and no centerstand used). Press the chain upwards, using just a minor force. When properly tensioned you should be able to just barely touch the swingarm protection at the position as shown (Fig. 10H-1) with the chain.

Chain tension adjustment:

Undo the rear wheel axle by slacking off the nut (Fig. 10I-1, wrench No.27 ). Release the two lock nuts of the chain tensioners on each side of the swingarm (Fig. 10I-2, wrench No.13). Adjust the chain with the chain tensioner bolts (Fig. 10I-3, wrench No.13) to a correct tension on both sides. Measure the distances in between the swingarm shaft and the rear wheel shaft on each side of the motorcycle and make sure that the distances are exactly the same. Tighten the lock nuts of the chain tensioners. Tighten the rear wheel axle.

CORRECT INCORRECT

Fig.

10H

Fig.

10I

Page 26

10 C

WHEELS & BRAKES

FRONT BRAKE:

The Husaberg motorcycle is equipped with a Brembo hydraulic disc brake. For your own safety it needs to be frequently serviced and checked. Always check the level of brake fluid in the reservoir. The reservoir has a transparent "window" with a mark for the lowest level (Fig. 10J-1). Always check the brake hose for any leakage and/ or deterioration. Always check the wear of the brake pads. Change the pads if the thickness of each brake pad, excluding the metal part, is less than 1,5 mm.

Brake fluid:

Add fluid; DOT 4, by removing the two screws (Fig. 10J-2, Philips screwdriver) and removing the cover and the membrane. Take care - the fluid is toxic and could also harm the surfaces of the motorcycle.

Brake pads:

Remove the two clips (Fig. 10K-1) holding the brake pad pin (Fig. 10K-2). Remove the two brake pads by removing the pin and pulling the two pads out (Fig. 10L-1). Fit new pads in reverse order.

Fig.

10J

Fig.

10K

Air bleeding:

Ensure that the air nipple (Fig. 10M-1, wrench No.11) is easily opened. With the nipple in closed position; pull the lever towards the handlebar a couple of times and keep it under pressure towards the handlebar the last time. Open the air nipple slightly and the brake lever, still under pressure, will move towards the handlebar allowing any occuring air, and fluid, to run through the brakeline and nipple. With the brake lever fully towards the handlebar close the air nipple and then release the lever. Repeat the above mentioned steps until no more air is visible from the air nipple. Make sure that the reservoir has enough fluid all the time (not below the MIN level).

Adjustment of brake lever:

The front brake lever has an adjustment knob (Fig. 10J-3) that allows a personal adjustment of the pressure point. Always keep a clearance in between the lever and the point of pressure.

Fig.

10L

Fig.

10M

Tightening torque brake caliper/bracket (M8): 25 Nm / Use a threadlock liquid on the bolts.

Page 27

WHEELS & BRAKES

FRONT BRAKE: Supermotard.

The supermotard models are equipped with Beringer hydraulic front brakes. Fluid level and safety check are carried out in the same manor as on the enduro brake. The brake disc however, is of a coated cast iron type, which demands a run in period. To obtain the best result of braking power and durability, the following recommendations should be followed.

1. Disc and pads must be run in for 100300 km, depending on your riding, using progressively applied power. Do not overheat the disc. Avoid violent, repeated or continuous braking. A smooth surface on the disc will indicate that the running in period is complete.

2. Be careful. The first braking must be very light. They are reserved to remove the coating from the braking track. In case of not respecting this, a risk exists of damaging pads and disc (vibration) not covered by the

guarantee. During the running in period, braking power will be reduced temporarily.

3. Inspect the brake disc regularly. It must be brilliant or blue or dark brown. If the brake area turns dull, as if sandpapered, rapid wear of disc and pads may occur. This can happen after many low power brakings, or if you ride in rain for a long time. In this case it is advisable to do some powerful brakings in order to laminate the pads friction surface and put down a new protective deposit on the disc.

4. For cleaning the caliper and hub of disc, you must never use aggressive chemicals, solvent or “brake cleaner” Avoid high-pressure cleaner.

5. Wear:

· Min thickness of disc. 4.5 mm. (Replace disc)

· Max rotation play between hub

and disc. 2 mm. ( Replace hub)

Brake pads:

Remove the clip (Fig. 10N-1) holding the brake pad pin (Fig. 10N-2). Remove the two brake pads by removing the pin (Fig. 10O-1) and pulling the two pads out (Fig. 10O-2). Fit new pads in reverse order. Do not forget that a new pair of brake pads will require a slight run in period.

ATTENTION:

Always put the motorcycle on a stable centerstand whenever removing either front or rear wheel.

Fig.

10N

Fig.

10O

Page 28

10 C

WHEELS & BRAKES

REAR BRAKE:

The Husaberg motorcycle is equipped with a Brembo hydraulic disc brake. For your own safety it needs to be frequently serviced and checked. Always check the level of brake fluid in the reservoir (Fig. 10P-1). The level has to be within the MIN and MAX marks when the motorcycle is upright. Always check the brake hoses for any leakage and/or deterioration. Always check the wear of the brake pads. Change the pads if the total thickness of each pad is less than 1,5 mm, excluding the metal part.

Brake fluid:

Add fluid; DOT 4, by removing the cap on the reservoir and the gasket. Take care - the fluid is toxic and could also harm the surfaces of the motorcycle.

Brake pads:

Remove the clip (Fig. 10Q-1) holding the brake pad pin (Fig. 10Q-2). Remove the two brake pads by removing the pin and pulling the two pads out (Fig. 10Q-3). Fit new pads in reverse order.

Fig.

10P

Fig.

10Q

Air bleeding:

Remove the dust cap (Fig. 10Q-4) and ensure that the air nipple (Fig. 10Q-5, wrench No.11) is easily opened. With the nipple in closed position; push the lever downwards a couple of times and keep it under pressure the last time. Open the nipple slightly and the brake lever, still under pressure, will move downwards allowing any air, and fluid, to run through the brakeline and nipple. Before releasing the pressure onto the lever; close the air nipple. Repeat the steps until no more air is visible. Make sure that the reservoir has enough fluid all the time.

Adjustment of brake lever:

The rear brake lever is easily adjusted into a personal point of pressure and height of the lever.

Fig.

10R

Pressure point: release the lock nut (Fig. 10R-1, wrench No.10) of the pushrod and turn the pushrod into selected position (Fig. 10R-2). Always keep a clearance in between the lever and the point of pressure. Tighten the locknut.

Height of the lever: release the allen screw (Fig. 10R-3, allen key No. 4) and turn the eccentric adjustment (Fig. 10R-4) into selected position. Tighten the allen screw.

Page 29

11 A

SUSPENSION

FRONT SUSPENSION:

The Husaberg motorcycle is delivered with an adjustable front fork from WP. For a maximum performance it needs to be adjusted according to the riding conditions and the rider's weight and preferences. The front fork is pre-adjusted from the factory as follows:

Rebound damping:

Adjustment knob (Fig. 11A-1) in 12th position (FE models) or 16th position (FC, FX and FS models) from the bottom position on both front fork legs.

Compression damping:

Adjustment screw (Fig. 11B-1) in 20th position (on all models) from the bottom position on both front fork legs.

+ = more damping / - = less damping

Air bleeding of front fork:

The front fork ought to be bleeded after every time the motorcycle has been used. The front fork unloaded; undo the air bleed screws (Fig. 11A-2) on both front fork legs until you hear the air pass. Tighten the screws.

Fig.

11A

Fig.

11B

Static spring deflection/oil change:

Put the motorcycle on a centerstand in order to get the front wheel off the ground. Measure the distance (Fig. 11C-1). Put the motorcycle on the ground (both wheels on the ground and unloaded). Grab the handlebar and push the front fork firmly down a couple of times. Measure the distance once again which now ought to be 20-35 mm less than the first time.

If the distance is outside these 20-35 mm the pre-load of the front fork has to be adjusted. The pre-load ought to be in between 5-20 mm.

Oil change:

The oil needs to be changed after every 20 hours, FE and FSe models, and 10 hours, FC, FSc and FX models, for a maximum performance and durability. Follow the instructions of the WP Service Manual.

ATTENTION:

Service more frequently when riding under hard conditions

Fig.

11C

ATTENTION:

Always put the motorcycle on a stable centerstand whenever removing either front or rear wheel.

Page 30

11 A

SUSPENSION

REAR SUSPENSION: Off road.

The Husaberg motorcycle is delivered with an adjustable shock absorber from WP. For a maximum performance it needs to be adjusted according to the riding conditions and the rider's weight and preferences. The shock absorber is pre-adjusted from the factory as follows:

Compression damping:

Adjustment knob low speed (Fig. 11D-2) in the 15th position from the inner, most clockwise, position. Adjustment knob high speed (Fig. 11D-1) two full revolutions (+- 0.5) from the inner, most clockwise, position.

Rebound damping:

Adjustment screw (Fig. 11E-1) in 25th position from the bottom, most clockwise position.

+ = more damping / - = less damping

Static spring deflection:

Put the motorcycle on a stand in order to get the rear wheel off the ground and the shock absorber fully unloaded. Measure the distance A1 (Fig. 11F). Put the motorcycle on the ground; both wheels on the ground and the rider, incl. apparel, helmets etc., sitting on the seat and the feet on the footrests. Measure the distance A2 (Fig. 11F) which now ought to be 85-100 mm less than distance A1. If the distance is outside these limits, adjust the pre-load ring (Fig. 11G-2) by slacking off the lock screw (Fig. 11G-1, allen key No. 6) and then turning the ring. Tighten the lock screw after an appropriate preload has been achieved. With the motorcycle still on the ground, but now totally unloaded, measure the distance A3 (Fig. 11F) which now ought to be 30-35 mm less than A1. If the distance A3 is less than 30 mm - the spring is too soft. Try to adjust the rings until mean distances have been achieved according to A2 and A3*. If the distance is more than 35 mm - the spring is too stiff. Try to adjust the rings as above*.

Fig.

11D

Fig.

11E

Fig.

11F

A2 A3

Fig.

11G

*If not possible - Let change to an appropriate spring.

Authorized Personnel

Page 31

SUSPENSION

REAR SUSPENSION: Supermotard.

Compression damping:

Adjustment knob (Fig. 11H-1) in the 6th position from the outer, most counterclockwise, position.

Rebound damping:

Adjustment screw (Fig. 11I-1) in 16th position from the bottom, most clockwise position.

+ = more damping / - = less damping

Static spring deflection:

Put the motorcycle on a stand in order to get the rear wheel off the ground and the shock absorber fully unloaded. Measure the distance A1 (Fig. 11J). Put the motorcycle on the ground; both wheels on the ground and the rider, incl. apparel, helmets etc., sitting on the seat and the feet on the footrests. Measure the distance A2 (Fig. 11J) which now ought to be 85-100 mm less than distance A1. If the distance is outside these limits, adjust the pre-load ring (Fig. 11K-2) by slacking off the lock screw (Fig. 11K-1, allen key No. 6) and then turning the ring. Tighten the lock screw after an appropriate preload has been achieved. With the motorcycle still on the ground, but now totally unloaded, measure the distance A3 (Fig. 11J) which now ought to be 10-25 mm less than A1. If the distance A3 is less than 10 mm - the spring is too soft. Try to adjust the rings until mean distances have been achieved according to A2 and A3*. If the distance is more than 25 mm - the spring is too stiff. Try to adjust the rings as above*.

Fig.

11H

Fig.

11I

Fig.

11J

A2 A3

*If not possible - Let

Authorized Personnel

change to an appropriate spring.

Fig.

11K

Page 32

11 B/C

SUSPENSION

STEERING HEAD:

The clearance has to be checked frequently. Put the motorcycle on a centerstand with the front wheel fully off the ground. Turn the handlebar in both directions. It should not be either too easy nor too hard to move. Also move it front and backwards in order to check the clearance (no "clicking" sound). To adjust, undo the four hexagon screws of the upper tripleclamp (Fig. 11L-1, wrench No.10), undo the lock nut on top of the upper tripleclamp (Fig. 11L-2, wrench No. 32) and lift off the complete tripleclamp including handlebar etc. Remove the dust protection (Fig. 11L-4) turn the adjustment nut underneath (Fig. 11L-5) until appropriate clearance is obtained. The easiest way to feel this is by turning the adjustment nut until you feel a slight resistance while moving the steering from left to right and then turning the adjustment nut ¼ of a turn back (counterclockwise). Assembly in reverse order.

Fig.

11L

ATTENTION:

Do not use a highpressure jet-cleaning equipment on surfaces around bearings and other fragile components.

SWINGARM:

The bearings and the bushings of the swingarm have to be frequently checked and serviced. It should be dissasembled after every 50 hours in order to be checked, cleaned and lubricated.

Removal and lubrication:

Put the motorcycle on a center stand. Remove the seat (see "ENGINE - AIR FILTER”). Remove the rear wheel (see "WHEELS & BRAKES - WHEELS"). Remove the upper bolt of the shock absorber (wrench No.17 and allen key No. 8) and lean the shock absorber backwards. Remove the lower bolt of the shock absorber (wrench No. 17 and allen key No. 8) and remove the shock absorber. Remove the swingarm shaft nut and shaft (Fig. 11M-1, wrench No. 21) and release the swingarm from the frame. Check the bearings (4 pcs) and the bushings (2 pcs) in the swingarm for any damages or wear. Replace if necessary. Clean every part thoroughly and apply a grease of a well-known brand onto the bearings, bushings and other surfaces that need to be lubricated. Refit everything in reverse order. Tighten all screws, bolts and nuts.

Fig.

11M

Fig.

11N

Page 33

WIRING DIAGRAMS

FE and FS electrical starter models without turn signals

FE and FS electrical starter models with turn signals

Page 34

WIRING DIAGRAMS

FC and FX electrical starter models

FC and FS kick-starter models