FE570EU FE570AUS 2009 - jbsracingpage.co.uk Owners... · owner'smanual fe450eu fe450aus fe450usa fe570eu fe570aus fe570usa 2009 art.no.3802014en

OWNER'S MANUALFE 450 EUFE 450 AUSFE 450 USAFE 570 EUFE 570 AUSFE 570 USA

2009ART. NO. 3802014en

DEAR HUSABERG CUSTOMER 1

DEAR HUSABERG CUSTOMER

Congratulations on your decision to purchase a HUSABERG motorcycle. You are now the owner of a state-of-the-art sports motorcyclethat will give you enormous pleasure if you service and maintain it accordingly.

We wish you great pleasure riding the vehicle!

Enter the serial numbers of your vehicle below.

Chassis number ( p. 9) Dealer's stamp

Engine number ( p. 9)

Key number (FE EU, FE AUS) ( p. 9)

The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuingdevelopment and design of our motorcycles can however not be completely excluded.

All specifications are non-binding. HUSABERG, a division of KTM SMC AG (referred to herein as HUSABERG), specifically reservesthe right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without priornotice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model withoutprior notice. HUSABERG accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing andother 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 AustriaAll rights reservedReproduction, 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 assuranceprocesses that lead to the maximum possible quality of the products.Issued by: TÜV Management Service

HUSABERG eine Division der KTM SMC AG5230 Mattighofen, Austria

CONTENTS 2

CONTENTS

MEANS OF REPRESENTATION ............................................ 4IMPORTANT NOTES............................................................ 5VIEW OF VEHICLE............................................................... 7

View of the vehicle from the left front (example) ................. 7View of the vehicle from the right rear (example) ................ 8

LOCATION OF SERIAL NUMBERS ........................................ 9Chassis number............................................................... 9Type label (FE EU, FE AUS) ............................................. 9Type label (FE USA) ........................................................ 9Key number (FE EU, FE AUS)........................................... 9Engine number................................................................ 9Fork part number........................................................... 10Shock absorber part number........................................... 10

CONTROLS....................................................................... 11Clutch lever .................................................................. 11Hand brake lever ........................................................... 11Short circuit button (FE EU, FE AUS).............................. 11Short circuit button (FE USA) ......................................... 11Emergency OFF switch (FE AUS) .................................... 11Electric starter button (FE EU, FE USA) .......................... 12Electric starter button (FE AUS)...................................... 12Light switch (FE EU, FE AUS) ........................................ 12Horn button (FE EU, FE AUS)......................................... 12Flasher switch (FE EU, FE AUS) ..................................... 12Overview of indicator lamps (FE EU, FE AUS) .................. 13Overview of indicator lamps (FE USA).............................. 13Speedometer................................................................. 13Speedometer activation and test ..................................... 13Tripmaster switch .......................................................... 14Setting kilometers or miles ............................................. 14Setting the clock ........................................................... 14Adjusting the speedometer functions............................... 15Querying the lap time .................................................... 15SPEED display mode (speed).......................................... 16SPEED/H display mode (service hours) ............................ 16SPEED/CLK display mode (time)..................................... 16SPEED/LAP display mode (lap time)................................ 16SPEED/ODO display mode (odometer) ............................. 17SPEED/TR1 display mode (trip master 1)......................... 17SPEED/TR2 display mode (trip master 2)......................... 17SPEED/A1 display mode (average speed 1) ...................... 18SPEED/A2 display mode (average speed 2) ...................... 18SPEED/S1 display mode (stop watch 1)........................... 18SPEED/S2 display mode (stop watch 2)........................... 18Opening the filler cap .................................................... 19Closing the filler cap...................................................... 20Idle speed adjusting screw ............................................. 20Seat release .................................................................. 20Shift lever..................................................................... 20Foot brake pedal ........................................................... 21Side stand .................................................................... 21Steering lock (FE EU, FE AUS) ....................................... 21Locking the steering (FE EU, FE AUS)............................. 21Unlocking the steering (FE EU, FE AUS).......................... 22

GENERAL TIPS AND HINTS ON PUTTING INTOOPERATION...................................................................... 23

Advice on first use......................................................... 23Running in the engine.................................................... 24

RIDING INSTRUCTIONS .................................................... 25Checks before putting into operation ............................... 25Starting ........................................................................ 25

Starting up ................................................................... 26Shifting, riding.............................................................. 26Stopping, parking .......................................................... 27Refueling...................................................................... 27

SERVICE SCHEDULE......................................................... 29Important maintenance work to be carried out by anauthorized HUSABERG workshop.................................... 29Important maintenance work to be carried out by anauthorized HUSABERG workshop. (as additional order) ..... 30Important checks and maintenance work to be carriedout by the rider ............................................................. 31

MAINTENANCE WORK ON CHASSIS AND ENGINE.............. 32Jacking up the motorcycle .............................................. 32Removing the motorcycle from the work stand.................. 32Checking the basic chassis setting with the rider'sweight .......................................................................... 32Compression damping of shock absorber.......................... 32Adjusting the high-speed compression damping of theshock absorber .............................................................. 32Adjusting the low-speed compression damping of theshock absorber .............................................................. 33Adjusting the rebound damping of the shock absorber....... 33Measuring rear wheel sag unloaded ................................. 34Checking the static sag of the shock absorber .................. 34Checking the riding sag of the shock absorber .................. 35Adjusting the spring preload of the shock absorberx ...... 35Adjusting the riding sagx............................................. 36Removing the shock absorberx..................................... 36Installing the shock absorberx ..................................... 36Checking the basic setting of the fork.............................. 37Adjusting the compression damping of the fork ................ 37Adjusting the rebound damping of the fork....................... 37Adjusting the spring preload of the fork ........................... 38Bleeding the fork legs .................................................... 38Cleaning the dust boots of the fork legs ........................... 38Loosening the fork protection.......................................... 39Positioning the fork protection ........................................ 39Checking the play of the steering head bearing................. 39Adjusting the play of the steering head bearingx............ 40Handlebar position ........................................................ 40Adjusting the handlebar positionx ................................ 40Checking the gas Bowden cable route.............................. 41Checking the play in the gas Bowden cable...................... 41Adjusting the play in the gas Bowden cablex................. 41Checking for chain dirt accumulation .............................. 42Cleaning the chain......................................................... 42Checking the chain tension ............................................ 42Adjusting the chain tension ............................................ 43Checking the rear sprocket/engine sprocket for wear ......... 43Checking the chain wear ................................................ 44Adjusting the chain guidex .......................................... 44Checking the brake discs................................................ 44Checking the free travel of the hand brake lever ............... 45Adjusting the basic position of the handbrake lever(FE USA) ...................................................................... 45Adjusting the free travel of the handbrake lever (FE EU,FE AUS) ....................................................................... 46Checking the front brake fluid level ................................. 46Adding front brake fluidx ............................................ 46Checking the front brake linings...................................... 47Changing the front brake liningsx................................. 47Checking the free travel of the foot brake lever ................. 49

CONTENTS 3

Adjusting the basic position of the footbrake leverx ....... 49Checking the rear brake fluid level .................................. 50Adding rear brake fluidx.............................................. 50Checking the rear brake linings ....................................... 51Changing the rear brake liningsx .................................. 51Removing the front wheelx .......................................... 52Installing the front wheelx........................................... 53Removing the rear wheelx ........................................... 54Installing the rear wheelx ............................................ 54Checking the tire condition............................................. 55Checking the tire air pressure ......................................... 55Checking the spoke tension ............................................ 56Removing the seat ......................................................... 56Mounting the seat ......................................................... 56Removing the batteryx ................................................ 56Installing the batteryx ................................................. 57Recharging the batteryx .............................................. 58Changing the main fuse ................................................. 59Changing the fuses of individual power consumers............ 59Checking the headlight adjustment ................................. 60Adjusting the beam width of the headlight ....................... 61Removing the headlight mask with the headlight .............. 61Installing the headlight mask with the headlight ............... 61Changing the headlight bulb........................................... 61Removing the spoiler ..................................................... 62Installing the spoiler ...................................................... 62Removing the air filterx............................................... 62Installing the air filterx ............................................... 63Cleaning air filterx...................................................... 63Removing the fuel tankx ............................................. 63Installing the fuel tankx .............................................. 65Cooling system.............................................................. 66Checking the antifreeze and coolant level ........................ 66Checking the coolant level.............................................. 67Draining the coolantx.................................................. 67Refilling coolantx ....................................................... 68Removing the main silencer............................................ 68Installing the main silencer ............................................ 68Changing the glass fiber yarn filling of the mainsilencerx ................................................................... 69Adjusting the basic position of the clutch lever................. 69Checking the fluid level of the hydraulic clutch ................ 69Changing the hydraulic clutch fluidx ............................ 70Adjusting the idle speedx ............................................ 71Removing the engine guard ............................................ 71Installing the engine guard ............................................. 71Checking the engine oil level .......................................... 71Adding engine oil .......................................................... 72Changing the engine oil and oil filter, cleaning theengine oil screenx ...................................................... 72Draining engine oil, cleaning engine oil screenx ............ 72Removing the oil filterx............................................... 73Installing the oil filterx ............................................... 73Filling up with engine oilx ........................................... 74

TROUBLESHOOTING......................................................... 75FLASH CODE .................................................................... 77CLEANING........................................................................ 79

Cleaning the motorcycle ................................................. 79PROTECTION FOR WINTER OPERATION............................. 81

Protection for winter operation ........................................ 81

STORAGE ......................................................................... 82Storage......................................................................... 82Putting into operation after storage ................................. 82

TECHNICAL DATA - ENGINE.............................................. 83Capacity - engine oil ...................................................... 83Capacity - coolant.......................................................... 83

TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 84TECHNICAL DATA - CHASSIS ............................................ 86

Lighting equipment ....................................................... 86Tires ............................................................................ 87Capacity - fuel............................................................... 87

TECHNICAL DATA - FORK.................................................. 88TECHNICAL DATA - SHOCK ABSORBER ............................. 89TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 90SUBSTANCES................................................................... 91AUXILIARY SUBSTANCES.................................................. 93STANDARDS..................................................................... 95INDEX .............................................................................. 96

MEANS OF REPRESENTATION 4

Symbols usedThe 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).

All work marked with this symbol requires specialist knowledge and technical understanding. In the interest ofyour own safety, have these jobs done in an authorized HUSABERG workshop! There, your motorcycle will be ser-viced optimally by specially trained experts using the specialist tools required.

Identifies a page reference (more information is provided on the specified page).

Formats usedThe typographical and other formats used are explained in the following.

Name Identifies a proprietary name.

Name® Identifies a protected name.

Brand™ Identifies a trademark.

IMPORTANT NOTES 5

Use definition (FE EU, FE AUS)HUSABERG sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcyclescomply with currently valid regulations and categories of the top international motorsport organizations.

InfoThe motorcycle is authorized for public road traffic in the homologous (reduced) version only.In the derestricted version, the motorcycle may only be used in closed off areas remote from public road traffic.The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.

Use definition (FE USA)HUSABERG sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcyclescomply with currently valid regulations and categories of the top international motorsport organizations.

InfoThe motorcycle may only be used in closed off areas remote from public road traffic.The motorcycle is designed for off-road sport endurance competition (Enduro) and not for predominant motocross use.

MaintenanceA prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work describedin the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and break-age of components.Using the motorcycle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such asthe transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified inthe service schedule is reached.Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you willensure a much longer service life for your motorcycle.

WarrantyThe work prescribed in the service schedule must be carried out in an authorized HUSABERG workshop and confirmed in thecustomer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damageresulting 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 owner's manual.

Spare parts, accessoriesFor your own safety, only use spare parts and accessory products that are approved and/or recommended by HUSABERG and havethem installed by an authorized HUSABERG workshop. HUSABERG accepts no liability for other products and any resulting damageor loss.

The current HUSABERG Parts for your vehicle can be found on the HUSABERG website.International HUSABERG website: www.husaberg.com

Work rulesWhen 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.

Transport

NoteDanger of damage The parked vehicle can roll away or fall over.

– Always place the vehicle on a firm and even surface.

NoteFire hazard Some vehicle components get very hot when the machine is driven.

– Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is stillwarm from being run. Always let the vehicle cool first.

IMPORTANT NOTES 6

– Switch off the engine.

– Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

EnvironmentMotorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for theenvironment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such prob-lems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, dis-play environmental consciousness, and respect the rights of others.

Notes/warningsPay close attention to the notes/warning.

InfoVarious 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 dangers and may therefore be injured.

Grades of risks

DangerIdentifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measuresare not taken.

WarningIdentifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

NoteIdentifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

WarningIdentifies a danger that will lead to environmental damage if the appropriate measures are not taken.

Owner's manual– It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful infor-

mation and many tips on how to operate and handle your motorcycle. Only then will you find out how to best customize the motor-cycle for your own use and how you can protect yourself from injury. The owner's manual also contains important information onservicing the motorcycle.

– The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle issold.

Tampering warningThe exhaust system on this vehicle has no owner serviceable parts. Should there be an increase in noise or damage to any componentrelating to the noise reduction system, replacement parts should be fitted by an authorized dealer.Tampering with the noise control system is prohibited. Owners are warned that the law may prohibit:

1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any deviceor element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimatepurchaser or while it is in use;

2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

VIEW OF VEHICLE 7

3.1View of the vehicle from the left front (example)

100364-10

1 Hand brake lever

2 Light switch, short circuit button, horn button

3 Clutch lever

4 Seat release

5 Front brake caliper

6 Engine number

7 Shift lever

8 Side stand

9 Chain guide

VIEW OF VEHICLE 8

3.2View of the vehicle from the right rear (example)

100365-10

1 Seat

2 Filler cap

3 Light switch

4 Rear mirror

5 Throttle grip

6 Fork rebound adjustment

7 Rear brake caliper

8 Shock absorber, rebound damping

9 Foot brake cylinder

10 Foot brake pedal

11 Fork compression adjustment

LOCATION OF SERIAL NUMBERS 9

4.1Chassis number

100345-10

The chassis number is stamped on the right side of the steering head.

4.2Type label (FE EU, FE AUS)

100458-10

The type label is fixed to the frame at the front right.

4.3Type label (FE USA)

100464-10

The type label is fixed to the front of the steering head.

4.4Key number (FE EU, FE AUS)

500125-10

The key number is stamped on the key strap.

4.5Engine number

100347-10

The engine number is stamped on the left side of the engine under the enginesprocket.

LOCATION OF SERIAL NUMBERS 10

4.6Fork part number

100348-10

The fork part number is stamped on the inner side of the fork stub.

4.7Shock absorber part number

100419-10

The shock absorber part number is stamped on the upper part of the shock absorberabove the adjusting ring. The shock absorber part number is not visible when the shockabsorber is installed.

CONTROLS 11

5.1Clutch lever

100349-10

The clutch lever is fitted on the left side of the handlebar.The clutch is hydraulically operated and self-adjusting.

5.2Hand brake lever

100350-10

Hand brake lever is located on the right side of the handlebar.The hand brake lever is used to activate the front brake.

5.3Short circuit button (FE EU, FE AUS)

100353-10

Short circuit button is fitted on the left side of the handlebar.

Possible states• Short circuit button in basic position – In this position, the ignition circuit is

closed, and the engine can be started.• Short circuit button pressed – In this position, the ignition circuit is interrupted,

a running engine stops, and a non-running engine will not start.

5.4Short circuit button (FE USA)

100366-10

Short circuit button is fitted on the left side of the handlebar.

Possible states• Short circuit button in basic position – In this position, the ignition circuit is

closed, and the engine can be started.• Short circuit button pressed – In this position, the ignition circuit is interrupted,

a running engine stops, and a non-running engine will not start.

5.5Emergency OFF switch (FE AUS)

100355-10

The emergency OFF switch is fitted on the left side of the handlebar.

Possible states

Ignition off – In this position, the ignition circuit is interrupted, a run-ning engine stops, and a non-running engine will not start.

Ignition on – In this position, the ignition circuit is closed, and theengine can be started.

CONTROLS 12

5.6Electric starter button (FE EU, FE USA)

100356-10

Electric starter button is fitted on the right side of the handlebar.

Possible states• Electric starter button in basic position• Electric starter button pressed – In this position, the electric starter is actuated.

5.7Electric starter button (FE AUS)

100355-11

Electric starter button is fitted on the right side of the handlebar.

Possible states• Electric starter button in basic position• Electric starter button pressed – In this position, the electric starter is actuated.

5.8Light switch (FE EU, FE AUS)

100351-10

The light switch is fitted on the left side of the handlebar.

Possible states

Light off – Light switch is turned to the right. In this position, the lightis switched off.

Low beam on – Light switch is in the central position. In this position,the low beam and tail light are switched on.

High beam on – Light switch is turned to the left. In this position, thehigh beam and the tail light are switched on.

5.9Horn button (FE EU, FE AUS)

100354-10

The horn button is fitted on the left side of the handlebar.

Possible states• Horn button in neutral position• Horn button pressed – The horn is operated in this position.

5.10Flasher switch (FE EU, FE AUS)

100357-10

Flasher switch is fitted on the left side of the handlebar.

Possible states

Flasher light off – Flasher switch is in the central position.

Flasher light, left, on – Flasher switch turned to the left.

Flasher light, right, on – Flasher switch turned to the right.

CONTROLS 13

5.11Overview of indicator lamps (FE EU, FE AUS)

100358-01

Possible states

High beam indicator lamp lights up blue – High beam is switched on.

Flasher indicator lamp flashes green – Flasher light is switched on.

FI warning lamp (MIL) lights up/flashes orange – The OBD has detectedan emission- or safety-critical error.

5.12Overview of indicator lamps (FE USA)

100367-01

Possible states

FI warning lamp (MIL) lights up/flashes orange – The OBD has detectedan emission- or safety-critical error.

5.13Speedometer

400312-01

– Press the key to change the display mode or change to one of the setup menus.

– Press the button to control different functions.

– Press the button to control different functions.

InfoIn its condition at delivery, the display mode SPEED/H and SPEED/ODO is acti-vated.

5.14Speedometer activation and test

400313-01

Activating the speedometer:The speedometer is activated when one of the keys is pressed or an impulse comesfrom the wheel speed sensor.Display testFor the function test of the display, all display segments light up briefly.

400314-01

WS (wheel size)After the display function test, the wheel size WS is displayed briefly.

Info2205 mm corresponds to the size of the 21" front wheel with a series produc-tion tire.

The display then changes to the last selected mode.

CONTROLS 14

5.15Tripmaster switch(Option: Tripmaster switch)

You can use the trip master switch to control the functions of the speedometer from the handlebar.

InfoThe trip master is an optional accessory.

5.16Setting kilometers or miles

InfoIf you change the unit, the value ODO is retained and converted accordingly.The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.

ConditionThe motorcycle is standing.

400329-01

– Press the button briefly and repeatedly until H appears at the bottom right of thedisplay.

– Press the button for 3 - 5 seconds.

The Setup menu opens and the active functions are displayed.

– Press the button repeatedly until the Km/h/Mph display flashes.

Km/hadjusting– Press the button .

Mphadjusting– Press the button .


The settings are saved and the Setup menu closed.

InfoIf no button is pressed for 20 seconds, or if no impulse comes from thewheel speed sensor, the settings are automatically saved and the Setupmenu closed.

5.17Setting the clockConditionThe motorcycle is standing.

400330-01

– Press the button briefly and repeatedly until CLK appears at the bottom right ofthe display.


The hour display flashes.

– Set the hour display with the button and/or button .

– Press the button briefly.

The next segment of the display flashes and can be set.

– You can set the following segments in the same way as the hours by pressingthe button and the button .

InfoThe seconds can only be set to zero.



InfoIf no button is pressed for 20 seconds, or if no impulse comes from thewheel speed sensor, the settings are automatically saved and the Setupmenu closed.

CONTROLS 15

5.18Adjusting the speedometer functions

InfoUpon delivery, only the SPEED/H and SPEED/ODO display modes are activated.


400318-01



The Setup menu opens and the active functions are displayed.

– Switch to the function you require by briefly pressing the button .

The selected function flashes.

Activating a function– Press the button .

The icon remains in the display and the display changes to the next func-tion.

Deactivating a function– Press the button .

The icon disappears from the display and the display changes to the nextfunction.

– Activate or deactivate all functions accordingly.



InfoIf no button is pressed for 20 seconds, or if no impulse comes from thewheel speed sensor, the settings are automatically saved and the Setupmenu is closed.

5.19Querying the lap time

InfoThis function can be called only if lap times are measured.


400321-01

– Press the button briefly and repeatedly until LAP appears at the bottom right ofthe display.


LAP 1 appears on the left side of the display.

– Laps 1-10 can be displayed by pressing the button .

– The button has no function


Next display mode

InfoIf an impulse is received from the wheel speed sensor, the left side of thedisplay changes back to the SPEED mode.

CONTROLS 16

5.20SPEED display mode (speed)

400317-02

– Press the button briefly and repeatedly until SPEED appears on the left side ofthe display.

The current speed is displayed in the SPEED display mode.The current speed can be displayed in Km/h or Mph.

InfoMaking the setting according to the country.When an impulse comes from the front wheel, the left side of the speedometerdisplay changes to the SPEED mode and the current speed is shown.

5.21SPEED/H display mode (service hours)

400316-01

Condition• Vehicle at a standstill


The number of service hours of the engine is shown in the H display mode.The service hour counter stores the total traveling time.

InfoThe service hour counter is necessary for ensuring that maintenance work is car-ried out at the right intervals.If the speedometer is in the H display mode at the start of the trip, it automati-cally changes to the ODO display mode.The H display mode is suppressed during travel.

Press the button . No function


Press the buttonfor 3 - 5 seconds.

The display changes to the Setup menu of the speedometerfunctions.

Press the buttonbriefly.

next display mode

5.22SPEED/CLK display mode (time)

400319-01

– Press the button briefly and repeatedly until CLK appears at the bottom right ofthe display.

The time is displayed in the CLK display mode.




The display changes to the Setup menu of the clock.


next display mode

5.23SPEED/LAP display mode (lap time)

400320-01

– Press the button briefly and repeatedly until LAP appears at the bottom right ofthe display.

In the LAP display mode, up to ten laps can be timed with the stop watch.

InfoIf the lap time continues after you press the button , 9 memory locations arealready occupied.Lap 10 must be timed with the button .

Press the button . Starts or stops the clock.

Press the button . Stops the current lap time and saves it, and the stop watchstarts the next lap.

CONTROLS 17


The stop watch and the lap time are reset.


next display mode

5.24SPEED/ODO display mode (odometer)

400317-01

– Press the button briefly and repeatedly until ODO appears at the bottom right ofthe display.

The total number of kilometers ridden is shown in the ODO display mode.




–


next display mode

5.25SPEED/TR1 display mode (trip master 1)

400323-01

– Press the button briefly and repeatedly until TR1 appears at the top right of thedisplay.

TR1 (trip master 1) runs constantly and counts to 999.9.You can use it to measure trips or the distance between refueling stops.TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).

InfoIf 999.9 is exceeded, the values of TR1, A1 and S1 are automatically reset to0.0.




The TR1, A1 and S1 displays are reset to 0.0.


next display mode

5.26SPEED/TR2 display mode (trip master 2)

400324-01

– Press the button briefly and repeatedly until TR2 appears at the top right of thedisplay.

TR2 (trip master 2) runs constantly and counts to 999.9.The displayed value can be set manually with the button and the button . A verypractical function for rides by the road book.

InfoThe TR2 value can also be corrected manually during the trip using the but-ton and the button .If 999.9 is exceeded, TR2 is automatically reset to 0.0.

Press the button . Increases value TR2.

Press the button . Decreases value TR2.


Clears value TR2.


next display mode

CONTROLS 18

5.27SPEED/A1 display mode (average speed 1)

400325-01

– Press the button briefly and repeatedly until A1 appears at the top right of thedisplay.

A1 (average speed 1) shows the average speed calculated on the basis of TR1 (trip mas-ter 1) and S1 (stop watch 1).The calculation of this value is activated by the first impulse of the wheel speed sensorand ends 3 seconds after the last impulse.






next display mode

5.28SPEED/A2 display mode (average speed 2)

400326-01

– Press the button briefly and repeatedly until A2 appears at the top right of thedisplay.

A2 (average speed 2) shows the average speed on the basis of the current speed if thestop watch S2 (stop watch 2) is running.

InfoThe displayed value can differ from the actual average speed if S2 is notstopped after the ride.




–


next display mode

5.29SPEED/S1 display mode (stop watch 1)

400327-01

– Press the button briefly and repeatedly until S1 appears at the top right of thedisplay.

S1 (stop watch 1) shows the trip time on the basis of TR1 and continues running whenan impulse is received from the wheel speed sensor.The calculation of this value starts with the first impulse of the wheel speed sensor andends three seconds after the last impulse.






next display mode

5.30SPEED/S2 display mode (stop watch 2)

400328-01

– Press the button briefly and repeatedly until S2 appears at the top right of thedisplay.

S2 (stop watch 2) is a manual stop watch.If S2 is running in the background, the S2 display flashes in the speedometer display.

Press the button . Starts or stops S2.



The S2 and A2 displays are reset to 0.0.


next display mode

CONTROLS 19

Table of functions

Display Press the button . Press the button . Press the button for 3 -5 seconds.


SPEED/H display mode(service hours)

No function No function The display changes tothe Setup menu of thespeedometer functions.

next display mode

SPEED/CLK display mode(time)

No function No function The display changes tothe Setup menu of theclock.

next display mode

SPEED/LAP display mode(lap time)

Starts or stops theclock.

Stops the current laptime and saves it, andthe stop watch startsthe next lap.

The stop watch and thelap time are reset.

next display mode

SPEED/ODO display mode(odometer)

No function No function – next display mode

SPEED/TR1 display mode(trip master 1)

No function No function The TR1, A1 and S1 dis-plays are reset to 0.0.

next display mode

SPEED/TR2 display mode(trip master 2)

Increases value TR2. Decreases value TR2. Clears value TR2. next display mode

SPEED/A1 display mode(average speed 1)


next display mode

SPEED/A2 display mode(average speed 2)

No function No function – next display mode

SPEED/S1 display mode(stop watch 1)


next display mode

SPEED/S2 display mode(stop watch 2)

Starts or stops S2. No function The S2 and A2 displaysare reset to 0.0.

next display mode

Table of conditions and activability

Display Vehicle at a stand-still

Menu can be acti-vated

SPEED/H display mode (service hours) •

SPEED/CLK display mode (time) •

SPEED/LAP display mode (lap time) •

SPEED/TR1 display mode (trip master 1) •

SPEED/TR2 display mode (trip master 2) •

SPEED/A1 display mode (average speed 1) •

SPEED/A2 display mode (average speed 2) •

SPEED/S1 display mode (stop watch 1) •

SPEED/S2 display mode (stop watch 2) •

5.31Opening the filler cap

100359-10

– Press release button , turn filler cap counterclockwise and lift it free.

CONTROLS 20

5.32Closing the filler cap

100360-10

– Replace the filler cap and turn clockwise until the release button locks in place.

InfoRun the fuel tank breather hose without kinks.

5.33Idle speed adjusting screw

400529-10

Idle speed adjusting screw is attached to the throttle valve body on the left side.The idle speed adjusting screw has two functions.Turning it controls the idle speed.Pulling it out all the way raises the idle speed during a cold start.

Possible states• RPM increase activated – Idle speed adjusting screw is pulled out all the way.• RPM increase deactivated – Idle speed adjusting screw is pushed in all the way.

5.34Seat release

100362-10

The seat can be released by pulling on loop .

5.35Shift lever

100363-10

Shift lever is mounted on the left side of the engine.

100363-11

The gear positions can be seen in the photograph.The neutral or idle position is between the first and second gears.

CONTROLS 21

5.36Foot brake pedal

100368-10

Foot brake pedal is located in front of the right footrest.The foot brake pedal is used to activate the rear brake.

5.37Side stand

100369-10



NoteMaterial damage Damage and destruction of components by excessive load.

– The side stand is designed for the weight of the motorcycle only. Do not sit on themotorcycle when it is supported by the side stand only. The side stand and/or theframe could be damaged and the motorcycle could fall over.

To park the motorcycle, press side stand to the ground with your foot and lean themotorcycle on it.

100370-10

When you are riding, side stand must be folded up and secured with rubberband .

5.38Steering lock (FE EU, FE AUS)

100371-10

Steering lock is fitted on the left side of the steering head.The steering lock is used to lock the steering. Steering, and therefore riding, is nolonger possible.

5.39Locking the steering (FE EU, FE AUS)



– Park the motorcycle.

– Turn the handlebar as far as possible to the right.

CONTROLS 22

– Insert the key in the steering lock, turn it to the left, press it in and turn it to the right. Remove the key.

Steering is no longer possible.

InfoNever leave the key in the steering lock.

5.40Unlocking the steering (FE EU, FE AUS)– Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key.

You can now steer the bike again.

InfoNever leave the key in the steering lock.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 23

6.1Advice on first use

DangerDanger of accidents Danger from insufficient traffic competence.

– Do not use the vehicle if you are not fit to deal with traffic or if you have consumed alcohol and/or medicaments or drugs.

WarningRisk of injury Missing or insufficient protective clothing increases the risk of injury.

– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Alwayswear protective clothing, which must be in perfect condition and meet legal requirements.

WarningDanger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels.

– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.

WarningDanger of accidents Critical riding behavior due to inappropriate riding.

– Adapt your riding speed to the road conditions and your riding ability.

WarningDanger of accidents Accident risk caused by presence of a passenger.

– Your vehicle is not designed to carry passengers. Do not ride with a passenger.

WarningDanger of accidents Brake system failure.

– If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Takeyour foot off the foot brake pedal if you do not want to brake.

WarningDanger of accidents Unstable riding behavior.

– Do not exceed the maximum permitted weight and axle loads.

WarningRisk of misappropriation Usage by unauthorized persons.

– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.

InfoWhen using your motorcycle, remember that others may feel disturbed by excessive noise.

– Make sure that the pre-delivery inspection work has been carried out by an authorized HUSABERG workshop.

You receive a delivery certificate and the service record at vehicle handover.

– Before your first trip, read the entire operating instructions carefully.

– Get to know the controls.

– Adjust the basic position of the clutch lever. ( p. 69)

(FE EU, FE AUS)– Adjust the free travel of the handbrake lever. ( p. 46)

(FE USA)– Adjust the basic position of the handbrake lever. ( p. 45)

– Adjust the basic position of the footbrake lever.x ( p. 49)

– Get used to handling the motorcycle on a suitable piece of land before making a longer trip.

InfoOffroad, you should be accompanied by another person on another machine so that you can help each other.

– Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.

– Do not make any offroad trips that over-stress your ability and experience.

– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 24

– If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis-tribution between the front and rear wheels.

InfoMotorcycles react sensitively to any changes of weight distribution.

– Do not exceed the overall maximum permitted weight and the axle loads.

Guideline

Maximum permissible overall weight 335 kg (739 lb.)

Maximum permissible front axle load 145 kg (320 lb.)

Maximum permissible rear axle load 190 kg (419 lb.)

– Run the engine in.

6.2Running in the engine– During the running-in phase, do not exceed the specified engine speed and engine performance.

Guideline

Maximum engine speed

During the first 3 service hours 7,000 rpm

Maximum engine performance

During the first 3 service hours ≤ 50 %

During the next 12 service hours ≤ 75 %

– Avoid fully opening the throttle!

RIDING INSTRUCTIONS 25

7.1Checks before putting into operation

InfoMake sure that the motorcycle is in a perfect technical condition before use.In the interests of riding safety, make a habit of making a general check before you ride.Note that the fuel tank does not indicate fuel reserves.

– Check the engine oil level. ( p. 71)

– Check the fuel reserves.

InfoThere is no fuel reserve.

– Check the chain tension. ( p. 42)

– Check for chain dirt accumulation. ( p. 42)

– Check the tire condition. ( p. 55)

– Check the tire air pressure. ( p. 55)

– Check the front brake fluid level. ( p. 46)

– Check the rear brake fluid level. ( p. 50)

– Check the front brake linings. ( p. 47)

– Check the rear brake linings. ( p. 51)

– Check the brake system function.

– Check the coolant level. ( p. 67)

– Check the settings of all controls and ensure that they can be operated smoothly.

– Check the functioning of the electrical equipment.

7.2Starting

DangerDanger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closedspace without an effective exhaust extraction system.

NoteEngine failure High engine speeds in cold engines have a negative effect on the service life of the engine.

– Always warm up the engine at low engine speeds.

100370-11

– Raise the motorcycle off of the stand and secure the stand with rubber band .

– Shift gear to neutral.

(FE AUS)– Turn the emergency OFF switch to the position .

ConditionAmbient temperature: < 20 °C (< 68 °F)

– Pull the idle speed adjusting screw all the way out.

– Press the electric starter button.

InfoDo not open the throttle to start.Press the starter for a maximum of 5 seconds. Wait for a least 5 secondsuntil trying again.Warning lamp FI lights up briefly as a functional control when starting.


7.3Starting up

InfoIf your bike has lights, switch them on before riding. You will then be seen earlier by other motorists.When you are riding, the side stand must be folded up and secured with the rubber band.

– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

7.4Shifting, riding

WarningDanger of accidents An abrupt load alterations can cause the vehicle to get out of control.

– Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions.

WarningDanger of accidents If you change down at high engine speed, the rear wheel can lock up.

– Do not change into a low gear at high engine speed. The engine races and the rear wheel can block.

WarningDanger of accidents Distraction from traffic activity by adjustments to the vehicle.

– Make all adjustments when the vehicle is at a standstill.

WarningDanger of accidents After a fall, check the vehicle.

– After a fall, check the vehicle as usual before putting it into operation.

NoteEngine failure Unfiltered intake air has a negative effect on the service life of the engine.

– Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

InfoIf you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized HUSABERG work-shop.First gear is used for starting off or for steep inclines.

TipOn difficult terrain, an increased idle speed prevents the engine from stalling unintentionally.

– When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simulta-neously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.

– If you raised the idle speed to start the vehicle, push the idle speed adjusting screw in all the way after the engine warms up.

– When you reach maximum speed after fully opening the throttle, turn back the throttle to about 3/4 of its range. This barelyreduces vehicle speed but lowers fuel consumption considerably.

– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.

– To shift down, brake and close the throttle at the same time.

– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.

– Switch off the engine if you expect to be standing for a long time.

Guideline

≥ 2 min

– Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system.

– Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.

– If the FI warning lamp (MIL) starts to light up during the trip, stop immediately. When the engine reaches idle speed, the FI warn-ing lamp (MIL) starts flashing.

InfoFrom the flash rhythm you can deduce a two-digit number, the so-called flash code. The flash code tells you which compo-nent is affected by a fault.


7.5Stopping, parking

WarningRisk of misappropriation Usage by unauthorized persons.

– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.

WarningDanger of burns Some vehicle components get very hot when the machine is driven.

– Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo-nents to cool down before starting work on them.



NoteFire hazard Some vehicle components get very hot when the machine is driven.

– Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is stillwarm from being run. Always let the vehicle cool first.

NoteMaterial damage Damage and destruction of components by excessive load.

– The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the sidestand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.

– Brake the motorcycle.


(FE USA)– Press and hold the short circuit button while the engine is idling until the engine stops.

(FE EU, FE AUS)– Press and hold the short circuit button while the engine is idling until the engine stops.

– Park the motorcycle on firm ground.

7.6Refueling

DangerFire hazard Fuel can easily catch fire.

– Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that nofuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

WarningDanger of poisoning Fuel is poisonous and a health hazard.

– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,contact a doctor immediately. Change clothing that has come into contact with fuel.

WarningEnvironmental hazard Improper handling of fuel is a danger to the environment.

– Do not allow fuel to get into the ground water, the ground, or the sewage system.

– Switch off the engine.

– Open the filler cap. ( p. 19)


400515-10

– Fill the fuel tank with fuel up to measurement .

Guideline

Measurement of 35 mm (1.38 in)

Total fuel tankcapacity, approx.

8.2 l(2.17 US gal)

Super unleaded (ROZ 95 / RON 95 /PON 91) ( p. 92)

– Close the filler cap. ( p. 20)

SERVICE SCHEDULE 29

8.1Important maintenance work to be carried out by an authorized HUSABERG workshop

S1N S3N S15A S30A

Engine Change the engine oil and oil filter, clean the engine oil screen.x( p. 72)

• • • •

Replace the spark plug. •

Check the valve clearance.x • • •

Check the engine mounting screws for tightness. • • •

Clean the spark plug connectors and check for tightness. • • •

Check the shift lever screw for tightness. • • •

Fuel injection Check the bellows for cracks and leakage.x • • •

Read out the fault memory using the HUSABERG diagnostic tool.x • • •

Check the fuel hoses, SLS hoses and vent hoses for damage, correct routingand leaks.x • • •

Clean, check and lubricate the O-ring of the fuel hose connection.x • •

Check the cable harness of the throttle valve body for damage and correctrouting.x • • •

Check the fuel pressure.x • •

Attachments Check the cooling system for leakage. • • •

Check the antifreeze and coolant level. ( p. 66) • • •

Check the exhaust system for leakage and looseness. • •

Check the Bowden cables for damage, smooth operation and routing with-out sharp bends.

• • •

Check the fluid level of the hydraulic clutch. ( p. 69) • • •

Clean the air filter.x ( p. 63) • • •

Check the cables for damage and routing without sharp bends. • •

Check the functioning of the electrical equipment. • • •

Check the headlight adjustment. • •

Brakes Check the front brake linings. ( p. 47) • • •

Check the rear brake linings. ( p. 51) • • •

Check the brake discs. ( p. 44) • • •

Check the front brake fluid level. ( p. 46) • • •

Check the rear brake fluid level. ( p. 50) • • •

Check the brake lines for damage and leakage. • • •

Check the free travel of the hand brake lever. ( p. 45) • • •

Check the free travel of the foot brake lever. ( p. 49) • • •

Check the brake system function. • • •

Check the screws and guide bolts of the brake system for tightness. • • •

Chassis Check the shock absorber and fork for leakage and functioning.x • • •

Clean the dust boots of the fork legs. ( p. 38) • •

Bleed the fork legs. ( p. 38) • •

Check the swingarm bearing.x • •

Check the play of the steering head bearing. ( p. 39) • • •

Check all screws to see if they are tight. • • •

Wheels Check the spoke tension. ( p. 56) • • •

Check the rim run-out. • • •

Check the tire condition. ( p. 55) • • •

Check the tire air pressure. ( p. 55) • • •

Check the chain wear. ( p. 44) • • •

Check the chain tension. ( p. 42) • • •

Clean the chain. ( p. 42) • • •

Check the wheel bearing for play.x • • •

Clean and grease the adjusting screws of the chain adjuster. • • •

SERVICE SCHEDULE 30

S1N: After 1 service hourS3N: After 3 service hoursS15A: Every 15 service hours / after every raceS30A: Every 30 service hours

8.2Important maintenance work to be carried out by an authorized HUSABERG workshop. (as additional order)

Competition use Hobby use J1A J2A

S15A S30A S45A S30A S60A S90A

Carry out a complete fork service.x • •

Carry out a complete shock absorber service.x •

Grease the steering head bearing.x • •

Treat the electric contacts with contact spray. • •

Change the hydraulic clutch fluid.x ( p. 70) • •

Change the front brake fluid.x • •

Change the rear brake fluid.x • •

Check wear of the clutch discs.x • • • • • •

Check the clutch.x • •

Check/measure the cylinder.x • •

Change the piston.x • •

Check the camshaft.x • •

Change the camshaft bearing.x • •

Check the valve spring seat.x • •

Check the cylinder head.x • •

Check the valves.x • •

Check the valve springs.x • •

Check the radial clearance of the rocker arm rollers.x • •

Check the timing-chain tensioner function.x • •

Check the balancer shaft.x • •

Check the crankshaft run-out at the bearing pin.x • •

Change the conrod bearing.x • •

Change the crankshaft main bearing.x • •

Check the transmission.x • •

Check the shift mechanism.x • •

Check the spring length of the oil pressure regulatorvalve.x • •

Change the glass fiber yarn filling of the mainsilencer.x ( p. 69)

• •

Change the foot brake cylinder seals.x • •

S15A: Every 15 service hours / after every raceS30A: Every 30 service hoursS45A: Every 45 service hoursS60A: Every 60 service hoursS90A: Every 90 service hoursJ1A: annuallyJ2A: every 2 years

SERVICE SCHEDULE 31

8.3Important checks and maintenance work to be carried out by the rider

NB1A

Check the engine oil level. ( p. 71) •

Check the front brake fluid level. ( p. 46) •

Check the rear brake fluid level. ( p. 50) •

Check the front brake linings. ( p. 47) •

Check the rear brake linings. ( p. 51) •

Check and adjust the Bowden cables. •

Bleed the fork legs. ( p. 38) •

Clean the dust boots of the fork legs. ( p. 38) •

Clean the chain. ( p. 42) •

Check the chain tension. ( p. 42) •

Check the chain wear. ( p. 44) •

Check the rear sprocket/engine sprocket for wear. ( p. 43) •

Clean the air filter.x ( p. 63) •

Check the tire air pressure. ( p. 55) •

Check the tire condition. ( p. 55) •

Check the coolant level. ( p. 67) •

Check that all operating elements for smooth operation. •

Check braking. •

Check all screws, nuts and hose clamps regularly for tightness. •

NB1A: Depending on conditions of use according to requirements.

MAINTENANCE WORK ON CHASSIS AND ENGINE 32

9.1Jacking up the motorcycle

100420-10



– Jack up the motorcycle underneath the engine. The wheels must no longer touchthe ground.

Work stand (81229055000)

– Secure the motorcycle against falling over.

9.2Removing the motorcycle from the work stand



– Remove the motorcycle from the work stand.

– Remove the work stand.

9.3Checking the basic chassis setting with the rider's weight

InfoWhen adjusting the basic chassis setting, first adjust the shock absorber and then the fork.

– For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic set-tings of the suspension components must match your body weight.

– As delivered, HUSABERG offroad motorcycles are adjusted for a standard rider weight (with full protective clothing).

Guideline

Standard rider weight 75… 85 kg (165… 187 lb.)

– If your weight is above or below the standard range, you need to adjust the basic setting of the suspension components accord-ingly.

– Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, thesprings must be replaced.

9.4Compression damping of shock absorberThe shock absorber can regulate compression damping separately in the low-speed and high-speed ranges (Dual Compression Control).The terms "low speed" and "high speed" refer to the movement of the shock absorber during compression and not the riding speed ofthe motorcycle.Adjustments in the low-speed range have an impact on the high-speed range and vice versa.

9.5Adjusting the high-speed compression damping of the shock absorber

DangerDanger of accidents The shock absorber is under high pressure.

– The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-tenance on it yourself.

InfoThe high-speed setting can be seen during the fast compression of the shock absorber.


100372-10

– Turn adjusting screw clockwise with a socket wrench until it stops.

InfoDo not loosen nut !

– Turn back counterclockwise by the number of turns corresponding to the shockabsorber type.

Guideline

Compression damping, high-speed

Comfort 2 turns

Standard 1.5 turns

Sport 1 turn

InfoTurn clockwise to increase damping, turn counterclockwise to reduce sus-pension damping.

9.6Adjusting the low-speed compression damping of the shock absorber



InfoThe low-speed setting can be seen during the slow to normal compression of the shock absorber.

100421-10

– Turn adjusting screw clockwise with a screwdriver up to the last perceptibleclick.


– Turn back counterclockwise by the number of clicks corresponding to the shockabsorber type.

Guideline

Compression damping, low-speed

Comfort 18 clicks

Standard 15 clicks

Sport 12 clicks


9.7Adjusting the rebound damping of the shock absorber




100373-10

– Turn adjusting screw clockwise up to the last perceptible click.


– Turn back counterclockwise by the number of clicks corresponding to the shockabsorber type.

Guideline

Rebound damping

Comfort 26 clicks

Standard 24 clicks

Sport 22 clicks


9.8Measuring rear wheel sag unloaded– Jack up the motorcycle. ( p. 32)

400520-10

– Measure the distance – as vertical as possible – between the rear axle and a fixedpoint, such as the top edge of the side cover.

– Make a note of the value as measurement .

– Remove the motorcycle from the work stand. ( p. 32)

9.9Checking the static sag of the shock absorber

400521-10

– Measure distance of rear wheel unloaded. ( p. 34)

– Ask someone to help you by holding the motorcycle upright.

– Measure the distance between the rear axle and the fixed point again.


InfoThe static sag is the difference between measurements and .

– Check the static sag.

Static sag 35 mm (1.38 in)

» If the static sag is less or more than the specified value:

– Adjust the spring preload of the shock absorber.x ( p. 35)


9.10Checking the riding sag of the shock absorber

400522-10

– Measure distance of rear wheel unloaded. ( p. 34)

– With another person holding the motorcycle, sit on the saddle with full protectiveclothing in a normal sitting position (feet on footrests) and bounce up and down afew times until the rear suspension levels out.

– The other person now has to measure the distance between the rear axle and afixed point.


InfoThe riding sag is the difference between measurements and .

– Check the riding sag.

Riding sag 105 mm (4.13 in)

» If the riding sag differs from the specified measurement:

– Adjust the riding sag.x ( p. 36)

9.11Adjusting the spring preload of the shock absorberx



InfoBefore changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

– Remove the shock absorber.x ( p. 36)

– After removing the shock absorber, clean it thoroughly.

400516-10

– Loosen screw .

– Turn adjusting ring until the spring is no longer under tension.

Combination wrench (50329080000)

Hook wrench (T106S)

– Measure the overall spring length when not under tension.

– Tighten the spring by turning adjusting ring to measurement .

Guideline

Spring preload 10 mm (0.39 in)

InfoDepending on the static sag and/or the riding sag, it may be necessary toincrease or decrease the spring preload.

– Tighten screw .

Guideline

Screw, shock absorber adjusting ring M6 5 Nm (3.7 lbf ft)

– Install the shock absorber.x ( p. 36)


9.12Adjusting the riding sagx– Remove the shock absorber.x ( p. 36)

– After removing the shock absorber, clean it thoroughly.

– Choose and mount a suitable spring.

Guideline

Spring rate

Weight of rider: 65… 75 kg (143… 165 lb.) 69 N/mm (394 lb/in)



InfoThe spring rate is shown on the outside of the spring.Smaller weight differences can be compensated by changing the spring preload.

– Install the shock absorber.x ( p. 36)

– Check the static sag of the shock absorber. ( p. 34)

– Check the riding sag of the shock absorber. ( p. 35)

– Adjust the rebound damping of the shock absorber. ( p. 33)

9.13Removing the shock absorberx– Jack up the motorcycle. ( p. 32)

100374-10

– Remove screw and lower the rear wheel with the swing arm as far as possiblewithout blocking the rear wheel. Fix the rear wheel in this position.

– Remove screw , push splash protector to the side, and remove the shockabsorber.

9.14Installing the shock absorberx

100374-11

– Push splash protector to the side and position the shock absorber. Mount andtighten screw .

Guideline

Screw, top shock absorber M12 80 Nm(59 lbf ft)

Loctite® 243™

– Mount and tighten screw .

Guideline

Screw, bottom shockabsorber

M12 80 Nm(59 lbf ft)

Loctite® 243™

InfoThe heim joint for the shock absorber at the swing arm is Teflon coated. Itmust not be greased with grease or with other lubricants. Lubricants dis-solve the Teflon coating, thereby drastically reducing the service life.



9.15Checking the basic setting of the fork

InfoFor various reasons, no exact riding sag can be determined for the forks.

100375-01

– As with the shock absorber, smaller weight differences can be compensated by thespring preload.

– However, if your fork is often overloaded (hard end stop on compression), you mustfit harder springs to avoid damage to the fork and frame.

9.16Adjusting the compression damping of the fork

InfoThe hydraulic compression damping determines the fork suspension behavior.

100377-10

– Remove protection covers .

– Turn adjusting screws clockwise until they stop.

InfoAdjusting screws are located at the bottom end of the fork legs.Make the same adjustment on both fork legs.

– Turn back counterclockwise by the number of clicks corresponding to the fork type.

Guideline

Compression damping

Comfort 26 clicks

Standard 22 clicks

Sport 18 clicks


– Mount protection covers .

9.17Adjusting the rebound damping of the fork

InfoThe hydraulic rebound damping determines the fork suspension behavior.

100376-10

– Turn adjusting screws clockwise until they stop.

InfoAdjusting screws are located at the top end of the fork legs.Make the same adjustment on both fork legs.


– Turn back counterclockwise by the number of clicks corresponding to the fork type.

Guideline

Rebound damping

Comfort 22 clicks

Standard 20 clicks

Sport 18 clicks


9.18Adjusting the spring preload of the fork

100378-01

– Turn the adjusting screws counterclockwise until they stop.

InfoMake the same adjustment on both fork legs.

– Turn back clockwise the number of turns corresponding to the fork type.

Guideline

Spring preload - Preload Adjuster

Comfort 0 turn

Standard 2 turns

Sport 4 turns

InfoTurn clockwise to increase spring preload, turn counterclockwise to reducespring preload.Adjusting the spring preload has no influence on the absorption setting ofthe rebound damping.Basically, however, you should set the rebound damping higher with ahigher spring preload.

9.19Bleeding the fork legs– Jack up the motorcycle. ( p. 32)

100379-10

– Remove bleeder screws briefly.

Any excess pressure escapes from the interior of the fork.

– Mount and tighten bleeder screws.


9.20Cleaning the dust boots of the fork legs– Jack up the motorcycle. ( p. 32)

– Loosen the fork protection. ( p. 39)

100380-10

– Push dust boots of both fork legs downwards.

InfoThe dust boots should remove dust and coarse dirt particles from the forktubes. Over time, dirt can penetrate behind the dust boots. If this dirt is notremoved, the oil seals behind can start to leak.


WarningDanger of accidents Reduced braking due to oil or grease on the brakediscs.

– Always keep the brake discs free of oil and grease, and clean them withbrake cleaner when necessary.

– Clean and oil the dust boots and inner fork tube of both fork legs.

Universal oil spray ( p. 94)

– Press the dust boots back into their normal position.

– Remove excess oil.

– Position the fork protection. ( p. 39)


9.21Loosening the fork protection

100381-10

– Remove screws and take off clamp.

– Remove screws on the left fork leg. Push the fork protection downwards.

– Remove the screws on the right fork leg. Push the fork protection downwards.

9.22Positioning the fork protection

100381-11

– Position the fork protection on the left fork leg. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

– Position the brake line and cable harness. Put the clamp on, and mount andtighten screws .

– Position the fork protection on the right fork leg. Mount and tighten the screws.

Guideline


9.23Checking the play of the steering head bearing

WarningDanger of accidents Unsafe riding behavior due to incorrect steering head bearing play.

– The steering head bearing play should be adjusted immediately in an authorized HUSABERG workshop.

InfoIf the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame canbe damaged after time.

– Jack up the motorcycle. ( p. 32)

100382-01

– Move the handlebar to the straight-ahead position. Move the fork legs to and fro inthe direction of travel.

No play should be noticeable in the steering head bearing.

» If there is noticeable play present:

– Adjust the play of the steering head bearing.x ( p. 40)

00BB00AA

0022

0011


– Move the handlebar to and fro over the entire steering range.

The handlebar must be able to move easily over the entire steering range. Noresting locations should be noticeable.

» If click positions are noticeable:

– Adjust the play of the steering head bearing.x ( p. 40)

– Check the steering head bearing and change if required.


9.24Adjusting the play of the steering head bearingx– Jack up the motorcycle. ( p. 32)

100383-10

– Loosen screw . Remove screw .

– Loosen and retighten screw .

Guideline

Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft)

– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.

– Fully tighten screw .

Guideline

Screw, top triple clamp M8 17 Nm(12.5 lbf ft)


Guideline

Screw, top steering stem M8 17 Nm(12.5 lbf ft)

Loctite® 243™

– Check the play of the steering head bearing. ( p. 39)

9.25Handlebar position

400271-11

On the upper triple clamp, there are two holes at a distance of to each other.

Hole distance A 15 mm (0.59 in)

The holes on the handlebar support are placed at a distance of from the center.

Hole distance B 3.5 mm (0.138 in)

The handlebar can be mounted in four different positions. In this way, the handlebarcan be mounted in the position that is most comfortable for the rider.

9.26Adjusting the handlebar positionx

400271-10

– Remove the four screws . Remove the handlebar clamp. Remove the handlebarand lay it to one side.

InfoProtect the motorcycle and its attachments from damage by covering them.Do not bend the cables and lines.

– Remove the two screws . Remove the handlebar support.

100384-10

– Place the handlebar support in the required position. Mount and tighten the twoscrews .

Guideline

Screw, handlebar support M10 40 Nm(29.5 lbf ft)

Loctite® 243™

InfoPosition the left and right handlebar supports evenly.


– Position the handlebar.

InfoMake sure cables and wiring are positioned correctly.

– Position the handlebar clamp. Mount and evenly tighten the four screws .

Guideline

Screw, handlebar clamp M8 20 Nm(14.8 lbf ft)

9.27Checking the gas Bowden cable route

100385-10

– The two gas Bowden cables must run parallel behind the handlebar down to theframe and into the gas Bowden cable guide.

9.28Checking the play in the gas Bowden cable

400192-10

– Move the handlebar to the straight-ahead position. Move the throttle grip back-wards and forwards to ascertain the play in the gas Bowden cable.

Play in gas Bowden cable 3… 5 mm (0.12… 0.2 in)

» If the gas Bowden cable play does not meet specifications:

– Adjust the play in the gas Bowden cable.x ( p. 41)

DangerDanger of poisoning Exhaust gases are poisonous and can result in uncon-sciousness and/or death.

– When running the engine, always make sure there is sufficient venti-lation, and do not start or run the engine in a closed space without aneffective exhaust extraction system.

– Start the engine and let it run idle. Move the handlebar to and fro over the entiresteering range.

The idle speed must not change.

» If the idle speed changes:

– Adjust the play in the gas Bowden cable.x ( p. 41)

9.29Adjusting the play in the gas Bowden cablex– Remove the fuel tank.x ( p. 63)

100386-10

– Move the handlebar to the straight-ahead position.

– Push back bellows .

– Loosen nut . Turn adjusting screw in as far as possible.

– Loosen nut . Turn adjusting screw so that there is play in the gas Bowdencable at the throttle grip.

Guideline

Play in gas Bowden cable 3… 5 mm (0.12… 0.2 in)

– Tighten nut .

– Press and hold the throttle grip in the closed setting. Turn adjusting screw outuntil there is no play in the Bowden cable .

– Tighten nut .

– Push bellows on. Check the throttle grip for smooth operation.

– Install the fuel tank.x ( p. 65)

– Check the play in the gas Bowden cable. ( p. 41)


9.30Checking for chain dirt accumulation

100387-01

– Check the chain for coarse dirt accumulation.

» If the chain is very dirty:

– Clean the chain. ( p. 42)

9.31Cleaning the chain

WarningDanger of accidents Oil or grease on the tires reduces their grip.

– Remove oil and grease with a suitable cleaning material.

WarningDanger of accidents Reduced braking due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

WarningEnvironmental hazard Problem materials cause environmental damage.

– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

InfoThe service life of the chain depends largely on its maintenance.

– Clean the chain regularly and then treat with chain spray.

Chain cleaner ( p. 93)

Offroad chain spray ( p. 93)

9.32Checking the chain tension

WarningDanger of accidents Danger caused by incorrect chain tension.

– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain canrupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the enginesprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust ifnecessary.


100388-10

– Push the chain at the end of the chain sliding component upwards to measure thechain tension .

InfoThe upper chain section must be taut.Chain wear is not always even, so you should repeat this measurement atdifferent chain positions.

Chain tension 8… 10 mm (0.31… 0.39 in)

» If the chain tension does not meet specifications:

– Adjust the chain tension. ( p. 43)



9.33Adjusting the chain tension

WarningDanger of accidents Danger caused by incorrect chain tension.

– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain canrupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the enginesprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust ifnecessary.


100388-10

– Push the chain at the end of the chain sliding component upwards to measure thechain tension .

InfoThe upper chain section must be taut.Because chain wear is not always even, you should repeat this measurementat different chain positions.

100389-10

– Loosen nut .

– Loosen nuts .

– Adjust the chain tension by turning the adjusting screws left and right.

Guideline

Chain tension 8… 10 mm (0.31… 0.39 in)

Turn adjusting screws on the left and right so that the markings on the leftand right chain adjusters are in the same position relative to the referencemarks . The rear wheel is then correctly aligned.

– Tighten nuts .

– Make sure that chain adjusters are fitted correctly on adjusting screws .

– Tighten nut .

Guideline

Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)

InfoThe wide adjustment range of the chain adjusters (32 mm) enables differentsecondary transmissions with the same chain length.Chain adjusters can be turned by 180°.


9.34Checking the rear sprocket/engine sprocket for wear

400227-01

– Check the rear sprocket/engine sprocket for wear.

» If the rear sprocket/engine sprocket are worn:

– Replace the rear sprocket/engine sprocket.

InfoWhen fitting the chain joint, always make sure that the closed sideof the joint faces forward (riding direction).The engine sprocket, rear sprocket and chain should always bereplaced together.

– Check the chain guide for tightness and wear.

1 2 3 16 17 18

000BB

00AA


9.35Checking the chain wear– Jack up the motorcycle. ( p. 32)

400523-10


– Pull on the upper part of the chain with the specified weight .

Guideline

Weight, chain wear measurement 10… 15 kg (22… 33 lb.)

– Measure the distance of 18 chain links in the lower chain section.

InfoChain wear is not always even, so you should repeat this measurement atdifferent chain positions.

Maximum distance at the longestchain section

272 mm (10.71 in)

» If the distance is greater than the specified measurement:

– Replace the chain.

InfoWhen you replace the chain, you should also replace rear sprocketand engine sprocket.New chains wear out faster on old, worn sprockets.


9.36Adjusting the chain guidex

100390-10

– Remove screws and . Take off the chain guide.

ConditionNumber of teeth: ≤ 44 teeth

– Insert nut in hole . Position the chain guide.

– Mount and tighten screws and .

Guideline

Remaining screws, chassis M6 10 Nm(7.4 lbf ft)

ConditionNumber of teeth: ≥ 45 teeth

– Insert nut in hole . Position the chain guide.

– Mount and tighten screws and .

Guideline

Remaining screws, chassis M6 10 Nm(7.4 lbf ft)

9.37Checking the brake discs

WarningDanger of accidents Reduced braking effect caused by worn brake discs.

– Have worn brake discs replaced immediately in an authorized HUSABERG workshop.

AA


400257-10

– Check the thickness of the front and rear brake discs at several places on the discto see if it conforms to measurement .

InfoWear reduces the thickness of the brake disc around the area used by thebrake linings.

Brake discs - wear limit

Front 2.5 mm (0.098 in)

Rear 3.5 mm (0.138 in)

» If the brake disc thickness is less than the specified value:

– Change the brake disc.

– Check the front and rear brake discs for damage, cracking and deformation.

» If the brake disc exhibits damage, cracking or deformation:

– Change the brake disc.

9.38Checking the free travel of the hand brake lever


– If there is no free travel on the hand brake lever, pressure builds up on the front brake in the brake system. The front brakecan fail due to overheating. Adjust free travel on hand brake lever according to specifications.

100391-10

(FE USA)– Push the hand brake lever forward and check free travel .

Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)

» If the free travel does not meet specifications:

– Adjust the basic position of the handbrake lever. ( p. 45)

100391-11

(FE EU, FE AUS)– Push the hand brake to the handlebar and check free travel .

Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)


– Adjust the free travel of the handbrake lever. ( p. 46)

9.39Adjusting the basic position of the handbrake lever (FE USA)

100391-12

– Adjust the basic setting of the handbrake lever to your hand size by turning adjust-ing screw .

InfoTurn the adjusting screw clockwise to increase the distance between thehandbrake lever and the handlebar.Turn the adjusting screw counterclockwise to decrease the distance betweenthe handbrake lever and the handlebar.The range of adjustment is limited.Turn the adjusting screw by hand only, and do not apply any force.Do not make any adjustments while riding!

– Check the free travel of the hand brake lever. ( p. 45)


9.40Adjusting the free travel of the handbrake lever (FE EU, FE AUS)

100391-12

– Adjust the free travel of the handbrake lever with adjusting screw .

InfoTurn the adjusting screw clockwise to reduce free travel. The pressure pointmoves away from the handlebar.Turn the adjusting screw counterclockwise to increase free travel. The pres-sure point moves towards the handlebar.The range of adjustment is limited.Turn the adjusting screw by hand only, and do not apply any force.Do not make any adjustments while riding!

– Check the free travel of the hand brake lever. ( p. 45)

9.41Checking the front brake fluid level


– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.Have the brake system checked in an authorized HUSABERG workshop, and do not ride any further.

WarningDanger of accidents Reduced braking due to old brake fluid.

– Have the brake fluid of the front and rear brakes changed according to the service plan in an authorized HUSABERG work-shop.

100392-10

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

– Check the brake fluid level in the viewer .

» If the brake fluid is below the MIN marking:

– Add front brake fluid.x ( p. 46)

9.42Adding front brake fluidx



WarningSkin irritations Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.

– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.






InfoNever user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed forDOT 5 brake fluid.Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!Use only clean brake fluid from a sealed container!

100393-10


– Remove screws .

– Remove cover with membrane .

– Add brake fluid to level .

Guideline


Brake fluid DOT 4 / DOT 5.1 ( p. 91)

– Position the cover with the membrane. Mount and tighten the screws.

InfoClean up overflowed or spilt brake fluid immediately with water.

9.43Checking the front brake linings

WarningDanger of accidents Reduced braking due to worn brake linings.

– Worn brake linings should be replaced immediately in an authorized HUSABERG workshop.

100394-10

– Check the brake linings for minimum thickness .

Minimum thickness ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the front brake linings.x ( p. 47)

– Check the brake linings for damage and cracking.

» If damage or cracking is visible:

– Change the front brake linings.x ( p. 47)

9.44Changing the front brake liningsx

WarningDanger of accidents Improper brake maintenance and repair.

– Always have your brake system maintained and repaired in an authorized HUSABERG workshop.






0077

0066

00




WarningDanger of accidents Reduced braking due to use of non-approved brake linings.

– Brake linings available from accessory suppliers are often not tested and approved for use on HUSABERG vehicles. Theconstruction and friction factor of the brake linings and therefore the brake power can differ considerably from the originalHUSABERG brake linings. If brake linings are used that differ from the originals, there is no guarantee that they complywith the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.




100395-10


– Remove screws .


– Press the brake caliper by hand on to the brake disc in order to press back thebrake pistons. Ensure that brake fluid does not overflow from the brake fluid reser-voir, using suction to remove it if it does.

InfoMake sure when pushing back the brake pistons that you do not press thebrake caliper against the spokes.

100396-10

– Remove locking split pins , withdraw bolt , and take out the brake pads.

– Clean the brake caliper and brake caliper support.

100397-01

– Check that leaf spring in the brake caliper and sliding plate in the brakecaliper support are seated correctly.

100398-10

– Fit the brake pads, insert the bolt, and mount the locking split pins.

– Operate the hand brake lever repeatedly until the brake linings lie on the brake discand there is a tight spot.


100399-10

– Correct the brake fluid quantity to level .

Guideline





9.45Checking the free travel of the foot brake lever


– If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brakecan fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

100400-10

– Disconnect spring .

– Move the foot brake lever backwards and forwards between the end stop and thefoot brake cylinder piston bracket and check free travel .

Guideline

Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)


– Adjust the basic position of the footbrake lever.x ( p. 49)

– Reconnect spring .

9.46Adjusting the basic position of the footbrake leverx


– If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brakecan fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

100401-10


– Loosen nut and with push rod , turn it back until you have maximum freetravel.

– To adjust the basic position of the footbrake lever individually, loosen nut andturn screw accordingly.

InfoThe range of adjustment is limited.

– Turn push rod accordingly until you have free travel . If necessary, adjust thebasic position of the footbrake lever.

Guideline

Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)

– Hold screw and tighten nut .

Guideline

Remaining nuts, chassis M8 30 Nm(22.1 lbf ft)

– Hold push rod and tighten nut .

Guideline

Remaining nuts, chassis M6 15 Nm(11.1 lbf ft)



9.47Checking the rear brake fluid level





100402-10

– Stand the vehicle upright.

– Check the brake fluid level in the viewer .

» When in the viewer an air bubble is visible:

– Add rear brake fluid.x ( p. 50)

9.48Adding rear brake fluidx











100403-10


– Remove screw cap with membrane and the O-ring.

– Add brake fluid to level .


– Mount the screw cap with the membrane and the O-ring.



9.49Checking the rear brake linings

WarningDanger of accidents Reduced braking due to worn brake linings.

– Worn brake linings should be replaced immediately in an authorized HUSABERG workshop.

100404-10

– Check the brake linings for minimum thickness .

Minimum thickness ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the rear brake linings.x ( p. 51)

– Check the brake linings for damage and cracking.

» If damage or cracking is visible:

– Change the rear brake linings.x ( p. 51)

9.50Changing the rear brake liningsx

WarningDanger of accidents Improper brake maintenance and repair.

– Always have your brake system maintained and repaired in an authorized HUSABERG workshop.








WarningDanger of accidents Reduced braking due to use of non-approved brake linings.

– Brake linings available from accessory suppliers are often not tested and approved for use on HUSABERG vehicles. Theconstruction and friction factor of the brake linings and therefore the brake power can differ considerably from the originalHUSABERG brake linings. If brake linings are used that differ from the originals, there is no guarantee that they complywith the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.





100405-10


– Remove screw cap with membrane and the O-ring.

– Press the brake caliper by hand on to the brake disc in order to press back thebrake piston. Ensure that brake fluid does not overflow from the brake fluid reser-voir, using suction to remove it if it does.

InfoMake sure when pushing back the brake piston that you do not press thebrake caliper against the spokes.

100406-10

– Remove locking split pins , withdraw bolt , and take out the brake pads.

– Clean the brake caliper and brake caliper support.

100407-10

– Check that leaf spring in the brake caliper and sliding plate in the brakecaliper support are seated correctly.

100408-01

– Fit the brake pads, insert the bolt, and mount the locking split pins.

– Operate the foot brake lever repeatedly until the brake linings lie on the brake discand there is a tight spot.

– Correct the brake fluid quantity to the MAX marking.


– Mount the screw cap with the membrane and the O-ring.


9.51Removing the front wheelx– Jack up the motorcycle. ( p. 32)

100409-01

– Press the brake caliper by hand on to the brake disc in order to press back thebrake pistons.

InfoMake sure when pushing back the brake pistons that you do not press thebrake caliper against the spokes.


100410-10

– Remove screw .

– Loosen screw .

100411-10

– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out ofthe fork.

InfoDo not pull the hand brake lever when the front wheel is removed.Always lay the wheel down in such a way that the brake disc is not dam-aged.

100412-10

WarningDanger of accidents Reduced braking due to damaged brake discs.

– Always lay the wheel down in such a way that the brake disc is not dam-aged.

– Remove spacing sleeves .

9.52Installing the front wheelx



100412-11

– Clean and grease shaft seal rings and bearing surface of the spacing sleeves.

Long-life grease ( p. 93)

– Insert the spacing sleeves.

100410-11

– Lift the front wheel into the fork, position it, and insert the wheel spindle.


Guideline

Screw, front wheel spindle M24x1.5 45 Nm(33.2 lbf ft)

– Operate the hand brake lever several times until the brake pads are lying correctlyon the brake disc.


– Pull the front wheel brake and push down hard on the fork several times to alignthe fork legs.

– Fully tighten screw .

Guideline

Screw, fork stub M8 15 Nm(11.1 lbf ft)


9.53Removing the rear wheelx– Jack up the motorcycle. ( p. 32)

100413-10

– Press the brake caliper by hand on to the brake disc in order to press back thebrake piston.

InfoMake sure when pushing back the brake piston that you do not press thebrake caliper against the spokes.

– Remove nut .

– Remove chain adjuster . Withdraw wheel spindle only enough to allow the rearwheel to be pushed forward.

– Push the rear wheel forward as far as possible. Remove the chain from the rearsprocket.

– Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of theswing arm.

InfoDo not operate the foot brake when the rear wheel is removed.Always lay the wheel down in such a way that the brake disc is not dam-aged.

100414-10

WarningDanger of accidents Reduced braking due to damaged brake discs.

– Always lay the wheel down in such a way that the brake disc is not dam-aged.

– Remove spacing sleeves .

9.54Installing the rear wheelx



100414-11

– Clean and grease shaft seal rings and bearing surface of the spacing sleeves.

Long-life grease ( p. 93)

– Insert the spacing sleeves.

100415-10

– Lift the rear wheel into the swing arm, position it, and insert the wheel spindle .

– Put the chain on.


100416-10

– Position chain adjuster . Mount nut , but do not tighten it yet.

– Check the chain tension. ( p. 42)

– Make sure that chain adjusters are fitted correctly on adjusting screws .

– Tighten nut .

Guideline

Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)

InfoThe wide adjustment range of the chain adjusters (32 mm) enables differentsecondary transmissions with the same chain length.Chain adjusters can be turned by 180°.

– Operate the foot brake lever repeatedly until the brake linings lie on the brake discand there is a tight spot.


9.55Checking the tire condition

InfoOnly mount tires approved or recommended by HUSABERG.Other tires could have a negative effect on riding behavior.The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.The front and rear wheels must be mounted with tires with similar profiles.Worn tires have a negative effect on riding behavior, especially on wet surfaces.

– Examine the front and rear tires for cuts, foreign bodies and other damage.

» If you find cuts, foreign bodies or other damage on a tire:

– Change the tire.

– Check the depth of the tread.

InfoNote local national regulations concerning the minimum tread depth.

Minimum tread depth ≥ 2 mm (≥ 0.08 in)

» If the tread depth is less than the minimum allowable depth:

– Change the tire.

9.56Checking the tire air pressure

InfoLow tire air pressure leads to abnormal wear and overheating of the tire.Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

100417-10

– Remove the dust cap.

– Check tire air pressure when tires are cold.

Tire air pressure off road

Front 1.0 bar (15 psi)

Rear 1.0 bar (15 psi)

Road tire pressure



» If the tire pressure does not meet specifications:

– Correct the tire pressure.

– Mount the dust cap.


9.57Checking the spoke tension

WarningDanger of accidents Unstable riding behavior due to loose spokes.

– If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized HUSABERG work-shop.

InfoA loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.If the spokes are too tight, they can break due to local overload.Check the spoke tension regularly, especially on a new motorcycle.

100418-10

– To check spoke tension, tap each spoke with a screwdriver.

Guideline

You should hear a high note.

Spoke nipple, front wheel M4.5 5 Nm (3.7 lbf ft)

Spoke nipple, rear wheel M5 5 Nm (3.7 lbf ft)

InfoIf you hear different tone frequencies from different spokes, this is an indi-cation of different spoke tensions.

9.58Removing the seat

100362-10

– Pull on the loop while raising the rear of the seat.

– Pull the seat back and lift it off.

9.59Mounting the seat

400514-10

– Attach the seat to the hooks on fuel tank and on the top part of subframe ,and lower it at the rear while pushing forward.

– Guide lock bolt into the lock housing and push down the rear of the seat untilthe lock bolt engages audibly.

– Finally, check that the seat is correctly mounted.

9.60Removing the batteryx

WarningRisk of injury Battery acid and battery gases cause serious chemical burns.

– Keep batteries out of the reach of children.

– Wear suitable protective clothing and goggles.

– Avoid contact with battery acid and battery gases.

– Keep the battery away from sparks or open fire. Charge only in well-ventilated rooms.

– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least15 minutes and contact a physician.

– Switch off all power consumers and switch off the engine.


– Remove the seat. ( p. 56)

100422-10

– Detach fuse box and swing it to one side.

– Detach connector and swing it to one side with connector .

– Remove screws and swing battery cover with the starter relay to one side.Swing the EFI control unit to one side.

100423-10

– Disconnect the negative and positive cables of the battery.

InfoPay attention to the contact disks between the cable sockets and batteryterminals.

– Lift battery up and out.

9.61Installing the batteryx

100423-11

– Insert battery into the battery tray with the terminals facing to the rear.

Battery (YTZ7S) ( p. 86)

100424-10

– Connect the positive and negative cables.

InfoContact disks must be mounted between battery terminals and cablesockets with the claws facing up.

– Tighten the screws.

Guideline

Screw, battery terminal M5 3 Nm (2.2 lbf ft)

100422-11

– Position the EFI control unit, hook battery cover into the battery tray and mountscrews .

– Attach connector to the battery cover and plug in connector to the starterrelay.

– Attach fuse box to the battery cover.

– Mount the seat. ( p. 56)


9.62Recharging the batteryx

WarningRisk of injury Battery acid and battery gases cause serious chemical burns.

– Keep batteries out of the reach of children.

– Wear suitable protective clothing and goggles.

– Avoid contact with battery acid and battery gases.

– Keep the battery away from sparks or open fire. Charge only in well-ventilated rooms.

– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least15 minutes and contact a physician.

WarningEnvironmental hazard Components and battery acid are a danger to the environment.

– Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.



InfoEven if there is no load on the battery, it loses power every day.The charge state and the type of charge are very important for the service life of the battery.Fast recharging with a high charge current shortens the battery's service life.If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes.The battery capacity is then reduced.If the battery is discharged from starting, it must be recharged immediately.If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed.The battery is maintenance-free, i.e., the acid level does not have to be checked.



– Disconnect the minus (negative) cable of the battery to avoid damage to the motor-cycle's electronics.

100425-10

– Connect the battery charger to the battery. Switch on the battery charger.

Battery charger (81229074000)

You can also use the battery charger to test rest potential and start potential of thebattery, and to test the generator. With this device, you cannot overcharge the bat-tery.

InfoNever remove lid .Charge the battery with at most 10% of the capacity specified on the bat-tery .

– Switch off the charger after charging. Disconnect the battery.

Guideline

Screw, battery terminal M5 3 Nm (2.2 lbf ft)

The charge current, charge voltage and charge time must not be exceeded.

Charge the battery regularly when themotorcycle is not in use.

3 months

TipIf the vehicle will not be operated for more than two weeks, we recommendtrickle charging the battery using the HUSABERG battery charger. Thecharger charges the battery fully and then maintains it in this state for theensuing period. In this way, the battery will be fully charged when you putthe vehicle back into operation.



9.63Changing the main fuse

WarningFire hazard The electrical system can be overloaded by the use of incorrect fuses.

– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

InfoThe main fuse protects all power consumers of the vehicle. It is located in the housing of the starter relay on the battery cover.



100426-10

– Detach connector .

– Remove protection covers .

100427-10

– Remove faulty main fuse .

InfoYou can recognize a faulty fuse by the burned-out fuse wire .A reserve fuse is located in the starter relay.

– Insert a new main fuse.

Fuse (58011109120)

– Plug in connector on the starter relay.

InfoIf the new fuse burns out, contact an authorized HUSABERG workshop.

– Check the functioning of the electrical equipment.

TipReplace the spare fuse so that it is available if needed.

– Attach protection covers .


9.64Changing the fuses of individual power consumers

InfoThe fuse box containing the fuses of individual power consumers is located under the seat.



100428-10

– Open fuse box cover .

00BB

00AA


100429-10

– Remove the faulty fuse.

Guideline

Fuse 1 - 10A - EFI control unit

Fuse 2 - 10A - fuel pump

Fuse 3 - 10A - high beam, low beam, parking light, tail light, license plate lamp

Fuse 4 - 10A - speedometer, horn, brake light, flasher light, radiator fan(optional)

Fuse 5 - not used

Fuse res - 10A - spare fuses

InfoYou can recognize a faulty fuse by the burned-out fuse wire .

WarningFire hazard The electrical system can be overloaded by the use of incorrectfuses.

– Use only fuses with the prescribed amperage. Never by-pass or repairfuses.

– Use spare fuses with the correct rating only.

Fuse (58011109110)

InfoIf the new fuse burns out, contact an authorized HUSABERG workshop.

TipReplace the spare fuse in the fuse box so that it is available if needed.

– Check that the power consumer is functioning properly.

– Close the fuse box cover.


9.65Checking the headlight adjustment

400558-10

– On a light-colored wall behind a horizontal area, make a mark as high as the centerof the headlight.

– Make another mark a distance under the first mark.

Guideline

Distance 5 cm (2 in)

– Stand the motorcycle at distance in from of the wall and switch on the lowbeam.

Guideline

Distance 5 m (16 ft)

– Check the headlight adjustment.

The border between light and dark must be exactly at the lower mark when themotorcycle is operational and complete with rider.

» If the boundary between light and dark does not meet specifications:

– Adjust the beam width of the headlight. ( p. 61)


9.66Adjusting the beam width of the headlight– Check the headlight adjustment. ( p. 60)

100459-10

– Adjust the beam width of the headlight by turning adjusting screw .

Guideline

The boundary between light and dark must be exactly on the lower mark for amotorcycle with a rider (mark is applied under: Checking the headlight adjust-ment).

InfoTurn clockwise to increase the beam width, turn counterclockwise to reducethe beam width.If you have a payload, you may have to correct the headlight beam width.

9.67Removing the headlight mask with the headlight– Switch off all power consumers and switch off the engine.

100460-10

– Open rubber mask strap at the fork legs.

– Tilt the headlight mask forward and detach it at catch .

– Detach connector .

– Pull bulb socket out of the high beam indicator lamp and take off the headlightmask.

9.68Installing the headlight mask with the headlight

100460-11

– Attach connector .

– Insert bulb socket into the high beam indicator lamp.

– Check the lighting function.

– Attach headlight holder at the catch and position the headlight mask.

100461-10

– Place rubber mask strap around the fork legs and close it.

InfoBrake hose must be routed in front of the headlight mask.

– Check the headlight adjustment. ( p. 60)

9.69Changing the headlight bulb

NoteDamage to reflector Keep the glass of the bulb free of grease.

– Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited onthe reflector.

– Remove the headlight mask with the headlight. ( p. 61)


100462-10

– Turn rubber cap together with the underlying bulb socket counterclockwise allthe way and remove it.

– Pull lamp socket of the parking light out of the reflector.

100463-10

– Press headlight bulb into the bulb socket lightly, turn it counterclockwise all theway and pull it out.

– Insert a new headlight bulb.

Headlight (BA20d) ( p. 86)

– Insert the rubber cap together with the bulb socket into the reflector, turn it clock-wise all the way.

– Insert the bulb socket of the parking light into the reflector.

– Install the headlight mask with the headlight. ( p. 61)

9.70Removing the spoiler– Remove the seat. ( p. 56)

100430-10

– Remove screw on the radiator.

– Remove screws on the fuel tank and take off the spoiler.

9.71Installing the spoiler

100430-11

– Position the spoiler. Mount and tighten screws .

– Mount and tighten screw on the radiator.

Guideline



9.72Removing the air filterx

NoteEngine failure Unfiltered intake air has a negative effect on the service life of the engine.

– Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.





100431-10

– Remove coarse dirt.

– Detach air filter holder at the bottom and swing it to one side. Remove the airfilter with the air filter support.

– Remove the air filter from the air filter support.

9.73Installing the air filterx

100431-10

– Mount the clean air filter onto the air filter support.

– Put in both parts together, position them and fix them with air filter holder .

InfoIf the air filter is not correctly mounted, dust and dirt can penetrate into theengine and can cause damage.


9.74Cleaning air filterx



InfoDo not clean the air filter with highly flammable substances (e.g., fuel, petroleum, solvents) as these substances will damagethe foam rubber.

– Remove the air filter.x ( p. 62)

– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

Air filter cleaning agent ( p. 93)

InfoOnly press the air filter to dry it, never wring it out.

– Oil the dry air filter with a high quality filter oil.

Oil for foam air filter ( p. 94)

– Clean the intake flange and check it for damage and tightness.

– Install the air filter.x ( p. 63)

9.75Removing the fuel tankx





– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister accordingto regulations and keep it out of the reach of children.


– Remove the spoiler. ( p. 62)


100432-10

– Remove screws .

– Pull the top of the subframe outward slightly at the front and remove it.

100433-10

– Remove screw .

100434-10

– Detach connector of the fuel pump.

100435-10

– Thoroughly clean the plug-in connection of the fuel line using compressed air.

InfoUnder no circumstances should dirt enter into the fuel line. Dirt in the fuelline will clog the fuel injection jets.

– Disconnect the plug-in connection of the fuel line.

– Mount wash cap set .

Wash cap set (81212016000)

– Carefully raise the fuel tank while detaching intake flange .

100436-10

– Carefully close intake trumpet and connection of the engine housing vent toprevent dirt from entering.


9.76Installing the fuel tankx






– Clean all parts well.

100438-10

– Position the fuel tank and route the fuel line to the front.

– Route the fuel pump cable up through the rear opening in the fuel tank and posi-tion the fuel tank in its final location.

– Pull intake flange through the front opening in the fuel tank and position it.

– Attach connector of the fuel pump.

100439-10

– Remove the wash cap set. Oil the O-ring and connect plug-in connector of thefuel line.

InfoRoute the cable and fuel line at a safe distance from the exhaust system.

100432-11

– Position the top part of the subframe.

– Mount and tighten screws .

Guideline

Screw, subframe M8 30 Nm(22.1 lbf ft)

100433-11


Guideline


– Check that the intake trumpet and the connection of the engine housing vent areclear.


– Install the spoiler. ( p. 62)

– Check the fuel system for leakage.


9.77Cooling system

400524-10

Water pump in the engine circulates the coolant.The pressure resulting from the warming of the cooling system is regulated by a valvein radiator cap . The specified coolant temperature is therefore permissible withoutdanger of function problems.

120 °C (248 °F)

Cooling is effected by the air stream.The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cool-ing effect.

9.78Checking the antifreeze and coolant level

WarningDanger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.

– Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine andcooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

WarningDanger of poisoning Coolants are poisonous and a health hazard.

– Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water andcontact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctorimmediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

400243-10

– Stand the motorcycle upright on a horizontal surface.

– Remove the radiator cap.

– Check the antifreeze of the coolant.

−25… −45 °C (−13… −49 °F)

» If the antifreeze of the coolant does not meet specifications:

– Correct the antifreeze of the coolant.

– Check the coolant level in the radiator.

Coolant level above radiator fins. 10 mm (0.39 in)

» If the level of the coolant does not meet specifications:

– Correct the coolant level.

Alternative 1

Coolant ( p. 91)

Alternative 2

Coolant (mixed ready to use) ( p. 91)

– Refit the radiator cap.


9.79Checking the coolant level





400243-10


– Remove the radiator cap.

– Check the coolant level in the radiator.

Coolant level above radiator fins. 10 mm (0.39 in)

» If the level of the coolant does not meet specifications:

– Correct the coolant level.

Alternative 1

Coolant ( p. 91)

Alternative 2



9.80Draining the coolantx





100441-10


– Place a suitable container under the water pump cover.

– Remove screw . Remove radiator cap .

– Completely drain the coolant.

– Mount and tighten screw with a new seal ring.

Guideline

Plug, water pump drain hole M6 10 Nm (7.4 lbf ft)


9.81Refilling coolantx



100442-10

– Make sure that screw is tightened.


– Pour coolant in up to measurement above the radiator fins.

Guideline

10 mm (0.39 in)

Coolant 1.00 l (1.06 qt.) Coolant ( p. 91)



– Make a short test ride.


9.82Removing the main silencer

WarningDanger of burns The exhaust system gets very hot when the vehicle is driven.

– Allow the exhaust system to cool down. Do not touch hot components.

100443-10


– Remove screws and take off the main silencer.

9.83Installing the main silencer

100443-11

– Mount the main silencer. Mount and tighten screws .

Guideline




9.84Changing the glass fiber yarn filling of the main silencerx

WarningDanger of burns The exhaust system gets very hot when the vehicle is driven.

– Allow the exhaust system to cool down. Do not touch hot components.

– Remove the main silencer. ( p. 68)

100444-10

– Remove screws of connecting cap . Remove the connecting cap, perforatedpipe and glass fiber yarn filling .

– Remove screws and take off silencer cap with stuffing yarn .

– Mount the new stuffing yarn on silencer cap and fix it with a small piece ofadhesive tape.

– Insert the silencer cap and mount and tighten the screws.

– Insert perforated piping and mount the new glass fiber yarn filling using ablunt tool.

TipTo aid you in mounting the glass fiber yarn filling, you can create a woodenor metal cone piece that is inserted into the perforated piping. This will letthe glass fiber yarn filling slide more easily into the perforated piping.

– Insert connecting cap . Mount and tighten screws .

– Install the main silencer. ( p. 68)

9.85Adjusting the basic position of the clutch lever

100445-10

– Adjust the basic setting of the clutch lever to your hand size by turning adjustingscrew .

InfoThe adjusting screw is easier to turn when you pull the clutch lever forward.Turn the adjusting screw clockwise to decrease the distance between theclutch lever and the handlebar.Turn the adjusting screw counterclockwise to increase the distance betweenthe clutch lever and the handlebar.The range of adjustment is limited.Turn the adjusting screw by hand only, and do not apply any force.Do not make any adjustments while riding!

9.86Checking the fluid level of the hydraulic clutch

InfoThe fluid level rises with increasing wear of the clutch lining disc.Do not use brake fluid.

100446-10

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.

– Remove screws .


– Check the fluid level.

Fluid level under top level of container. 4 mm (0.16 in)

» If the level of the fluid does not meet specifications:

– Correct the fluid level of the hydraulic clutch.

Hydraulic oil (15) ( p. 91)



9.87Changing the hydraulic clutch fluidx



100446-10

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.

– Remove screws .


100447-10

– Remove screws . Lift off the engine sprocket cover at the front and carefullyremove clutch slave cylinder .

InfoDo not activate the clutch lever if the clutch slave cylinder has beenremoved.

– Remove O-ring and seal .

100448-10

– Fill bleeding syringe with the appropriate hydraulic fluid.

Bleed syringe (50329050000)

Hydraulic oil (15) ( p. 91)

– On the clutch slave cylinder, remove the bleeder screw and mount the bleedingsyringe.

100449-10

– Inject the liquid into the system until it escapes from drill hole of the clutchslave cylinder without bubbles.

– To prevent overflow, drain fluid occasionally from the clutch slave cylinder reser-voir.

– Remove the bleeding syringe. Mount and tighten screws bleeder screw.

– Clean the sealing surfaces of the clutch slave cylinder and engine housing.

– Position the seal and O-ring on the clutch slave cylinder and install it.

– Mount and tighten the screws.

Guideline


– Correct the fluid level of the hydraulic clutch.

Guideline

Fluid level under top level of container. 4 mm (0.16 in)


– Check that the clutch is functioning properly.


9.88Adjusting the idle speedx

400530-11

– Idle speed adjusting screw is attached to the throttle valve body on the left side.

– Run the engine warm and push the idle speed adjusting screw all the way in.

– Set the desired idle speed by turning the idle speed adjusting screw.

Guideline

Idle speed 1,700… 1,800 rpm

InfoTurn counterclockwise to increase the idle speed.Turn clockwise to decrease the idle speed.

9.89Removing the engine guard

100450-10

– Remove screw . Remove the engine guard.

9.90Installing the engine guard

100450-10

– Attach the engine guard on the frame at the rear and swing it up and forward.Mount and tighten screw .

Guideline


9.91Checking the engine oil level

InfoThe engine oil level must be checked when the engine is cold.


400528-10

ConditionEngine is cold.

– Check the engine oil level.

The engine oil level must be within range .

Range above the middle of theviewer

10 mm (0.39 in)

» If the engine oil level is below the specified level:

– Add engine oil. ( p. 72)


9.92Adding engine oil

InfoToo little engine oil or poor-quality engine oil results in premature wear to the engine.

100451-10

– Remove screw connection and add engine oil.

Engine oil (SAE 10W/50) ( p. 91)

– Mount and tighten screw cap .



– Start the engine and let it run briefly. Stop the engine and check that it is oil-tight.


9.93Changing the engine oil and oil filter, cleaning the engine oil screenx– Remove the engine guard. ( p. 71)

– Drain the engine oil and clean the engine oil screen.x ( p. 72)

– Remove the oil filter.x ( p. 73)

– Install the oil filter.x ( p. 73)

– Fill up with engine oil.x ( p. 74)

– Install the engine guard. ( p. 71)

9.94Draining engine oil, cleaning engine oil screenx

WarningDanger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

– Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.



InfoDrain the engine oil only when the engine is warm.

– Place the motorcycle upright on a horizontal surface (not on the side stand).

100454-10

– Place a suitable container under the engine.

– Remove oil drain plug with the magnet and seal ring.


100452-10

– Remove engine oil screen plug with engine oil screen .

– Completely drain the engine oil.

100453-10

– Remove banjo bolt with the oil screen.

– Thoroughly clean the parts and sealing surfaces.

– Mount and tighten banjo bolt with the oil screen and seals.

Guideline

Banjo bolt, oil line M12 15 Nm(11.1 lbf ft)

– Oil the O-rings on the engine oil screen and insert them in the engine oil screenplug. Mount and tighten the engine oil screen plug.

Guideline

Plug, engine oil screen M17x1.5 20 Nm(14.8 lbf ft)

– Mount and tighten the oil drain plug with the magnet and seal ring.

Guideline

Oil drain plug with magnet M12x1.5 20 Nm(14.8 lbf ft)

9.95Removing the oil filterx

WarningDanger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

– Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.



– Place a suitable container under the engine.

100455-10

– Remove screws . Remove oil filter cover with the O-ring.

– Pull oil filter out of the oil filter housing.

Circlip pliers reverse (51012011000)

– Completely drain the engine oil.

9.96Installing the oil filterx

100456-10

– Insert oil filter into the oil filter housing.

– Oil O-ring of the oil filter cover.

– Mount oil filter cover .

– Mount and tighten the screws.

Guideline

Screw, oil filter cover M5 6 Nm (4.4 lbf ft)


9.97Filling up with engine oilx

InfoToo little engine oil or poor-quality engine oil results in premature wear to the engine.

100451-10

– Remove screw connection and add engine oil.

Engine oil 1.35 l (1.43 qt.) Engine oil (SAE 10W/50) ( p. 91)

– Mount and tighten screw cap .



– Start the engine and check that it is oil-tight.


TROUBLESHOOTING 75

Faults Possible cause Action

Engine doesn't crank when the elec-tric starter button is pressed

Operating error – Go through the steps of starting the engine.( p. 25)

Battery discharged – Recharge the battery.x ( p. 58)

– Check the charging voltage.x– Check the closed current.x– Check the generator.x

Main fuse blown – Change the main fuse. ( p. 59)

Starter relay defective – Check the starter relay.xStarter motor defective – Check the starter motor.x

Engine turns but does not start. Fuse 1 or 2 blown – Change the fuses of individual powerconsumers. ( p. 59)

Coupling of fuel hose connection notjoined together

– Join coupling of fuel hose connection together.

Idle speed is not set correctly – Adjust the idle speed.x ( p. 71)

Spark plug oily or wet – Clean and dry the spark plug, or change it ifnecessary.

Electrode distance (plug gap) of sparkplug too wide

– Adjust the plug gap.

GuidelineSpark plug electrode gap0.9 mm (0.035 in)

Fault in ignition system – Check the ignition system.xIgnition system defective – Check the ignition system.xShort-circuit cable in cable harnessfrayed, short-circuit button or emer-gency OFF switch defective

– Check the wiring harness. (visual check).

– Check the electrical system.

Plug-in connector of EFI controldevice, pulse generator or ignitioncoil oxidized.

– Clean the plug-in connector and treat it withcontact spray.

Fault in fuel injection system – Read out the fault memory using the HUS-ABERG diagnostic tool.x

Engine does not speed up. Fault in fuel injection system – Read out the fault memory using the HUS-ABERG diagnostic tool.x

Ignition system defective – Check the ignition coil.x– Check the spark plug connector.x– Check the ignition pulse generator.x– Check the generator.x

Engine has too little power. Air filter very dirty – Clean the air filter.x ( p. 63)

Fuel filter very dirty – Change the fuel filter.xFault in fuel injection system – Read out the fault memory using the HUS-

ABERG diagnostic tool.xExhaust system leaky, deformed ortoo little glass fiber yarn filling inmain silencer.

– Check exhaust system for damage.

– Change the glass fiber yarn filling of the mainsilencer.x ( p. 69)

Valve clearance too little – Adjust the valve clearance.xIgnition system defective – Check the ignition coil.x

– Check the spark plug connector.x– Check the ignition pulse generator.x– Check the generator.x

Engine dies during the trip Lack of fuel – Refuel. ( p. 27)

Fuse 1 or 2 blown – Change the fuses of individual powerconsumers. ( p. 59)

Engine overheats. Too little coolant in cooling system – Check the cooling system for leakage.


Too little air stream – Switch off the engine when standing.

Radiator fins very dirty – Clean radiator fins.

TROUBLESHOOTING 76

Faults Possible cause Action

Engine overheats. Foam formation in cooling system – Drain the coolant.x ( p. 67)

– Refill the coolant.x ( p. 68)

Bent radiator hose – Change the radiator hose.xThermostat defective – Check the thermostat.x

GuidelineOpening temperature: 70 °C (158 °F)

FI warning lamp (MIL) lightsup/flashes

Fault in fuel injection system – Stop the motorcycle and identify the faulty partusing the flash code.

– Check the cabling for damage and the electri-cal plug-in connections for corrosion and dam-age.

InfoSee flash code

– Read out the fault memory using the HUS-ABERG diagnostic tool.x

High oil consumption Engine vent hose bent – Route the vent hose without bends or change itif necessary.

Engine oil level too high – Check the engine oil level. ( p. 71)

Engine oil too thin (low viscosity) – Change the engine oil and oil filter, clean theengine oil screen.x ( p. 72)

Piston and cylinder worn – Piston/cylinder - determine the mounting clear-ance.x

Battery discharged Battery is not charging – Check the charging voltage.x– Check the charging current.x– Check the generator.x

Unwanted power consumer – Check the closed current.xSpeedometer values deleted (time,stop watch, lap times)

The battery in the speedometer isempty.

– Change the battery in the speedometer.

The high beam, low beam, parkinglight, tail light and license plate lampare not working.

Fuse 3 blown – Change the fuses of individual powerconsumers. ( p. 59)

The speedometer, horn, brakelight, flasher light and radiator fan(optional) are not working

Fuse 4 blown – Change the fuses of individual powerconsumers. ( p. 59)

FLASH CODE 77

Flash code FI warninglamp (MIL)

45 FI warning lamp (MIL) flashes 4x long, 5x short

Possible cause Action

Malfunction or short circuit toground in lambda probe heat-ing circuit (cylinder 1)

– Check the heating lambda probe for short circuit to ground.x


09 FI warning lamp (MIL) flashes 9x short


Input signal from pressure sen-sor, induction manifold (cylin-der 1) too low

– Check the manifold absolute pressure sensor for short circuit to ground.x




Input signal from pressure sen-sor, induction manifold (cylin-der 1) too high

– Check the manifold absolute pressure sensor for short circuit to positive.x




Input signal from intake airtemperature sensor too low

– Check the intake air temperature sensor for short circuit to ground.x




Input signal from intake airtemperature sensor too high

– Check the intake air temperature sensor for short circuit to positive.x




Input signal from coolant tem-perature sensor too high

– Check the coolant temperature sensor for short circuit to ground.x




Input signal from coolant tem-perature sensor too high

– Check the coolant temperature sensor for short circuit to positive.x




Input signal of throttle valveposition generator circuit A toolow

– Check the throttle valve sensor for short circuit to ground.x




Input signal of throttle valveposition generator circuit A toohigh

– Check the throttle valve sensor for short circuit to positive.x




Malfunction in lambda probecircuit (cylinder 1)

– Check the lambda probe for a malfunction in the circuit.x




FLASH CODE 78

Malfunction in injection valvecircuit (cylinder 1)

– Check the injection valve.x




Malfunction in ignition pulsegenerator circuit

– Check the ignition pulse generator.x




Malfunction in ignition coilcircuit (cylinder 1)

– Check the primary winding of the ignition coil.x




Interruption/short circuit toground in fuel pump controlcircuit

– Check the fuel pump for short circuit to ground.x




Input signal from roll anglesensor too low

– Check the roll angle sensor for short circuit to ground.x




Input signal from roll anglesensor too high

– Check the roll angle sensor for short circuit to positive.x

CLEANING 79

12.1Cleaning the motorcycle

NoteMaterial damage Damage and destruction of components by high-pressure cleaning equipment.

– Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri-cal components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts.



InfoIf you clean the motorcycle regularly, its value and appearance are maintained over a long period.Avoid direct sunshine on the motorcycle during cleaning.Before cleaning, the intake flange and exhaust system must be protected against contact with water. To protect the intakeflange when the fuel tank is mounted, proceed as follows:

100457-10



– Close off sleeve of the engine vent and intake trumpet .

– Mount intake flange cover and fix with filter fixing bracket .

Intake flange cover (81206005000)

InfoIf the intake flange is not closed properly, dirt and water can enter into theengine. In the worst case, this can lead to engine damage.

– When you remove the fuel tank, carefully close off the sleeve, intake trumpet andthe entire intake flange.

– Remove the fuel tank.x ( p. 63)

– First remove coarse dirt particles with a gentle water spray.

– Spray very dirty areas with a normal motorcycle cleaner and then clean with apaintbrush.

Motorcycle cleaner ( p. 93)

InfoUse warm water containing normal motorcycle cleaner and a soft sponge.

– After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.Blow off the vehicle with compressed air.

– To prevent electrical problems, treat electric contacts and switches with contactspray. Disconnect the electrical plug-in connections, blow off with compressed airand treat with contact spray.

Contact spray ( p. 93)

– Check that all closed openings are clear.

– Install the fuel tank.x ( p. 65)

– Clean the air filter.x ( p. 63)


WarningDanger of accidents Reduced braking due to wet or dirty brakes.

– Clean or dry dirty or wet brakes by riding and braking gently.

– After cleaning, ride the vehicle a short distance until the engine warms up, andthen apply the brakes.

InfoThe heat produced causes water at inaccessible positions in the engine andthe brakes to evaporate.

CLEANING 80

– Push back the protection covers on the handlebar instruments to allow water toevaporate.

– After the motorcycle has cooled off, oil or grease all moving parts and bearings.


– Treat bare metal parts (except for brake discs and exhaust system) withanti-corrosion materials.

Cleaning and polishing materials for metal, rubber and plastic ( p. 93)

– Treat all painted parts with a mild paint polish.

High-luster polish for paint ( p. 93)

(FE EU, FE AUS)– Lubricate the steering lock.

Universal oil spray ( p. 94)

PROTECTION FOR WINTER OPERATION 81

13.1Protection for winter operation

InfoIf you use the motorcycle in the winter, you can expect to encounter salt on the roads. Precautions need to be taken againstroad salt corrosion.If the vehicle has been used on salted roads, clean it with cold water. Warm water intensifies the effects of salt.

– Clean the motorcycle. ( p. 79)

– Treat the engine, swingarm and all other bare or galvanized parts (except the brake discs) with a wax-based anticorrosive.

InfoAvoid getting anticorrosive on the brake discs: this would badly affect the braking.After riding on salted roads, thoroughly wash the motorcycle with cold water and dry it well.


STORAGE 82

14.1Storage



InfoIf you want to garage the motorcycle for a longer period, take the following steps.Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, youshould do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at thestart of the new season.

– Clean the motorcycle. ( p. 79)

– Change the engine oil and oil filter, clean the engine oil screen.x ( p. 72)

– Check the antifreeze and coolant level. ( p. 66)

– Check the tire air pressure. ( p. 55)

– Remove the battery.x ( p. 56)

– Recharge the battery.x ( p. 58)

Guideline

Storage temperature of battery without direct sunlight. 0… 35 °C (32… 95 °F)

– The storage place should be dry and not subject to large temperature fluctuations.

InfoHUSABERG recommends jacking up the motorcycle.


– Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping,thus causing corrosion.

InfoAvoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced duringcombustion condenses and causes valves and exhaust system to rust.

14.2Putting into operation after storage– Remove the motorcycle from the work stand. ( p. 32)

– Install the battery.x ( p. 57)

– Refuel. ( p. 27)

– Make checks before putting into operation. ( p. 25)

– Make a test ride.

TECHNICAL DATA - ENGINE 83

Design 1-cylinder 4-stroke engine, water-cooled

Displacement (All 450 models) 449.3 cm³ (27.418 cu in)

Displacement (All 570 models) 565.5 cm³ (34.509 cu in)

Stroke (All 450 models) 63.4 mm (2.496 in)

Stroke (All 570 models) 72 mm (2.83 in)

Bore (All 450 models) 95 mm (3.74 in)

Bore (All 570 models) 100 mm (3.94 in)

Compression ratio 11.8:1

Idle speed 1,700… 1,800 rpm

Control OHC, 4 valves controlled via rocker arm, drive via tooth/wheelchain

Valve diameter, intake 38 mm (1.5 in)

Valve diameter, exhaust 32 mm (1.26 in)

Valve clearance

Exhaust at: 20 °C (68 °F) 0.12… 0.17 mm (0.0047… 0.0067 in)

Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039… 0.0059 in)

Crankshaft bearing 2 cylinder bearings

Conrod bearing Needle bearing

Piston pin bearing Not a bearing bush - DLC-plated piston pins

Pistons Forged light alloy

Piston rings 1 compression ring, 1 oil scraper ring

Engine lubrication Pressure circulation lubrication with two rotary pumps

Primary transmission 33:76

Clutch Multidisc clutch in oil bath/hydraulically activated

Transmission ratio

1st gear 14:36

2nd gear 17:32

3rd gear 19:28

4th gear 22:26

5th gear 24:23

6th gear 26:21

Generator 12 V, 210 W

Mixture preparation Electronically controlled fuel injection

Ignition Contactless controlled fully electronic ignition with digital igni-tion adjustment

Spark plug NGK LKAR 8AI - 9

Spark plug electrode gap 0.9 mm (0.035 in)

Cooling Water cooling, permanent circulation of coolant by water pump

Starting aid Electric starter

15.1Capacity - engine oil

Engine oil 1.35 l (1.43 qt.) Engine oil (SAE 10W/50) ( p. 91)

15.2Capacity - coolant

Coolant 1.00 l (1.06 qt.) Coolant ( p. 91)


TECHNICAL DATA - ENGINE TIGHTENING TORQUES 84

Screw, cable holder in generator cover M4 4 Nm (3 lbf ft) Loctite® 243™

Locking screw for bearing M5 6 Nm (4.4 lbf ft) Loctite® 243™

Oil jet, piston cooling M5 2 Nm (1.5 lbf ft) Loctite® 243™

Oil jet, rocker arm lubrication M5 2 Nm (1.5 lbf ft) Loctite® 243™

Screw, ignition pulse generator M5 6 Nm (4.4 lbf ft) Loctite® 243™

Screw, locking lever M5 6 Nm (4.4 lbf ft) Loctite® 243™

Screw, oil filter cover M5 6 Nm (4.4 lbf ft) –

Screw, oil pump cover M5 6 Nm (4.4 lbf ft) Loctite® 222

Nut, water-pump wheel M6 8 Nm (5.9 lbf ft) Loctite® 243™

Plug, water pump drain hole M6 10 Nm (7.4 lbf ft) –

Screw, camshaft bearing support M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, clutch cover M6x25 10 Nm (7.4 lbf ft) –



Screw, clutch spring M6 10 Nm (7.4 lbf ft) –

Screw, cylinder head M6 10 Nm (7.4 lbf ft) –

Screw, engine housing M6x60 10 Nm (7.4 lbf ft) –



Screw, generator cover M6x30 10 Nm (7.4 lbf ft) –

Screw, generator cover M6x50 10 Nm (7.4 lbf ft) –

Screw, generator cover (chain shaftthrough-hole)

M6x30 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, idler M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, shift lever M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, starter motor M6 10 Nm (7.4 lbf ft) –

Screw, stator bracket M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, timing chain guide rail M6 8 Nm (5.9 lbf ft) Loctite® 243™

Screw, timing chain securing guide M6 8 Nm (5.9 lbf ft) Loctite® 243™

Screw, timing chain tensioning rail M6 8 Nm (5.9 lbf ft) Loctite® 243™

Screw, torque limiter M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, valve cover M6 10 Nm (7.4 lbf ft) –

Screw, water pump cover M6x25 10 Nm (7.4 lbf ft) –

Screw, water pump cover M6x55 10 Nm (7.4 lbf ft) –

Oil jet, conrod lubrication M6x0.75 4 Nm (3 lbf ft) –

Plug, oil channel M7 9 Nm (6.6 lbf ft) Loctite® 243™

Screw, rocker arm bearing M7x1 15 Nm (11.1 lbf ft) –

Plug, crank shaft location with thickcopper disk

M8 10 Nm (7.4 lbf ft) –

Plug, oil channel M10 15 Nm (11.1 lbf ft) Loctite® 243™

Screw, engine sprocket M10 60 Nm (44.3 lbf ft) Loctite® 243™

Balancer shaft nut M10x1 40 Nm (29.5 lbf ft) –

Screw, unlocking of timing chain ten-sioner

M10x1 10 Nm (7.4 lbf ft) –

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 85

Screw, cylinder head M10x1.25 Tightening sequence:Tighten diagonally, begin-ning with the rear screw onthe chain shaft.Step 110 Nm (7.4 lbf ft)Step 230 Nm (22.1 lbf ft)Step 350 Nm (36.9 lbf ft)

lubricated with engine oil

Banjo bolt, oil line M12 15 Nm (11.1 lbf ft) –

Nut, rotor M12x1 60 Nm (44.3 lbf ft) –

Spark plug M12x1.25 15… 20 Nm (11.1…14.8 lbf ft)

–

Coolant temperature sensor at cylinderhead

M12x1.5 12 Nm (8.9 lbf ft) –

Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –

Plug, oil pressure regulator valve M12x1.5 20 Nm (14.8 lbf ft) –

Plug, SLS M12x1.5 20 Nm (14.8 lbf ft) –

Plug, rocker arm M14x1.25 20 Nm (14.8 lbf ft) –

Plug, engine oil screen M17x1.5 20 Nm (14.8 lbf ft) –

Nut, inner clutch hub M18x1.5 80 Nm (59 lbf ft) –

Nut, primary gear M20LHx1.5 120 Nm (88.5 lbf ft) Loctite® 243™

Plug, timing chain tensioner M24x1.5 30 Nm (22.1 lbf ft) –

TECHNICAL DATA - CHASSIS 86

Frame Perimeter tube frame made of chrome molybdenum steel tubing

Fork WP Suspension 4860 MXMA PA

Suspension travel

Front 300 mm (11.81 in)

Rear 335 mm (13.19 in)

Fork offset 19 mm (0.75 in)

Shock absorber WP Suspension PDS 5018 DCC

Brake system Disc brakes, brake calipers on floating bearings

Brake discs - diameter

Front 260 mm (10.24 in)

Rear 220 mm (8.66 in)

Brake discs - wear limit

Front 2.5 mm (0.098 in)

Rear 3.5 mm (0.138 in)

Tire air pressure off road



Road tire pressure



Final drive 13:38 (13:52)

Chain 5/8 x 1/4"

Rear sprockets available 38, 40, 42, 45, 48, 49, 50, 51, 52

Steering head angle 63.5°

Wheelbase 1,475±10 mm (58.07±0.39 in)

Seat height, unloaded 985 mm (38.78 in)

Ground clearance, unloaded 390 mm (15.35 in)

Weight without fuel, approx. (FE 450 EU, FE 450 AUS) 116.5 kg (256.8 lb.)

Weight without fuel, approx. (FE 570 EU, FE 570 AUS) 117 kg (258 lb.)

Weight without fuel, approx. (FE 450 USA) 113 kg (249 lb.)

Weight without fuel, approx. (FE 570 USA) 113.5 kg (250.2 lb.)

Maximum permissible front axle load 145 kg (320 lb.)

Maximum permissible rear axle load 190 kg (419 lb.)

Maximum permissible overall weight 335 kg (739 lb.)

Battery YTZ7S Battery voltage: 12 VNominal capacity: 6 AhMaintenance-free

17.1Lighting equipment

Headlight BA20d 12 V35/35 W

Parking light W2,1x9,5d 12 V5 W

Indicator lights W2x4,6d 12 V1.2 W

Flasher light BA15s 12 V10 W

Brake/tail light LED

License plate lamp W2,1x9,5d 12 V5 W

TECHNICAL DATA - CHASSIS 87

17.2Tires

Validity Front tire Rear tire

(FE EU, FE AUS) 90/90 - 21 M/C 54M M+S TTMetzeler MCE 6 DAYS EXTREME

140/80 - 18 M/C 70M M+S TTMetzeler MCE 6 DAYS EXTREME

(FE USA) 80/100 - 21 51M TTBridgestone M59

110/100 - 18 64M TTBridgestone M402

Additional information is available in the Service section under:www.husaberg.com

17.3Capacity - fuel

Total fuel tank capacity,approx.

8.2 l (2.17 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 92)

TECHNICAL DATA - FORK 88

Fork part number 14.45.7E.02

Fork WP Suspension 4860 MXMA PA

Compression damping

Comfort 26 clicks

Standard 22 clicks

Sport 18 clicks

Rebound damping

Comfort 22 clicks

Standard 20 clicks

Sport 18 clicks

Spring length with preload spacer(s) 510 mm (20.08 in)

Spring rate

Weight of rider: 65… 75 kg (143… 165 lb.) 4.2 N/mm (24 lb/in)

Weight of rider: 75… 85 kg (165… 187 lb.) 4.4 N/mm (25.1 lb/in)

Weight of rider: 85… 95 kg (187… 209 lb.) 4.6 N/mm (26.3 lb/in)

Air chamber length 110+20−30 mm (4.33+0.79

−1.18 in)

Spring preload - Preload Adjuster

Comfort 0 turn

Standard 2 turns

Sport 4 turns

Fork length 940 mm (37.01 in)

FORK OIL Fork oil (SAE 5) ( p. 91)

TECHNICAL DATA - SHOCK ABSORBER 89

Shock absorber part number 12.45.7E.02

Shock absorber WP Suspension PDS 5018 DCC

Compression damping, low-speed

Comfort 18 clicks

Standard 15 clicks

Sport 12 clicks

Compression damping, high-speed

Comfort 2 turns

Standard 1.5 turns

Sport 1 turn

Rebound damping

Comfort 26 clicks

Standard 24 clicks

Sport 22 clicks

Spring preload 10 mm (0.39 in)

Spring rate




Spring length 250 mm (9.84 in)

Gas pressure 10 bar (145 psi)

Static sag 35 mm (1.38 in)

Riding sag 105 mm (4.13 in)

Fitted length 411 mm (16.18 in)

Shock absorber oil Shock absorber oil (SAE 2.5) (50180342S1) ( p. 92)

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 90

Spoke nipple, front wheel M4.5 5 Nm (3.7 lbf ft) –

Screw, battery terminal M5 3 Nm (2.2 lbf ft) –

Screw, intake air temperature sensor M5 2 Nm (1.5 lbf ft) –

Spoke nipple, rear wheel M5 5 Nm (3.7 lbf ft) –

Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) –

Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –

Screw, ball joint of push rod on foot-brake cylinder

M6 10 Nm (7.4 lbf ft) –

Screw, front brake disc M6 14 Nm (10.3 lbf ft) –

Screw, rear brake disc M6 14 Nm (10.3 lbf ft) –

Screw, shock absorber adjusting ring M6 5 Nm (3.7 lbf ft) –

Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite® 243™

Nut, rim lock M8 10 Nm (7.4 lbf ft) –



Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) –

Screw, engine brace M8 33 Nm (24.3 lbf ft) –

Screw, exhaust clamp on manifold M8 8 Nm (5.9 lbf ft) –

Screw, fork stub M8 15 Nm (11.1 lbf ft) –

Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite® 243™

Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –

Screw, side stand fixing M8 40 Nm (29.5 lbf ft) Loctite® 243™

Screw, subframe M8 30 Nm (22.1 lbf ft) –

Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite® 243™

Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –

Engine carrying screw M10 60 Nm (44.3 lbf ft) –



Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite® 243™

Screw, bottom shock absorber M12 80 Nm (59 lbf ft) Loctite® 243™

Screw, top shock absorber M12 80 Nm (59 lbf ft) Loctite® 243™

Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) –

Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) –

Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft) –

Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –

SUBSTANCES 91

Brake fluid DOT 4 / DOT 5.1According to– DOT

Guideline– Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre-

sponding properties. HUSABERG recommends Castrol and Motorex® products.

SupplierCastrol– RESPONSE BRAKE FLUID SUPER DOT 4

Motorex®

– Brake Fluid DOT 5.1

CoolantGuideline– Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming.

HUSABERG recommends Motorex® products.

Mixture ratio

Antifreeze: −25… −45 °C (−13… −49 °F) 50 % Anti-corrosion/antifreeze50 % Distilled water

Coolant (mixed ready to use)

Antifreeze −40 °C (−40 °F)

SupplierMotorex®

– Anti Freeze

Engine oil (SAE 10W/50)According to– JASO T903 MA ( p. 95)

– SAE ( p. 95) (SAE 10W/50)

Guideline– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-

sponding properties. HUSABERG recommends Motorex® products.

Synthetic engine oil

SupplierMotorex®

– Cross Power 4T

Fork oil (SAE 5)According to– SAE ( p. 95) (SAE 5)

Guideline– Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding

properties. HUSABERG recommends Motorex® products.

SupplierMotorex®

– Racing Fork Oil

Hydraulic oil (15)According to– ISO VG (15)

Guideline– Use only hydraulic oil that complies with the specified standards (see specifications on the container) and that possesses the cor-

responding properties. HUSABERG recommends Motorex® products.

SUBSTANCES 92

SupplierMotorex®

– Hydraulic Fluid 75

Shock absorber oil (SAE 2.5) (50180342S1)According to– SAE ( p. 95) (SAE 2.5)

Guideline– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding

properties.

Super unleaded (ROZ 95 / RON 95 / PON 91)According to– DIN EN 228 (ROZ 95 / RON 95 / PON 91)

AUXILIARY SUBSTANCES 93

Air filter cleaning agentSpecification– HUSABERG recommends Motorex® products.

SupplierMotorex®

– Twin Air Dirt Bio Remover

Chain cleanerSpecification– HUSABERG recommends Motorex® products.

SupplierMotorex®

– Chain Clean 611

Cleaning and polishing materials for metal, rubber and plasticSpecification– HUSABERG recommends Motorex® products.

SupplierMotorex®

– Protect & Shine 645

Contact spraySpecification– HUSABERG recommends Motorex® products.

SupplierMotorex®

– Accu Contact

High-luster polish for paintSpecification– HUSABERG recommends Motorex® products.

SupplierMotorex®

– Moto Polish

Long-life greaseSpecification– HUSABERG recommends Motorex® products.

SupplierMotorex®

– Fett 2000

Motorcycle cleanerSpecification– HUSABERG recommends Motorex® products.

SupplierMotorex®

– Moto Clean 900

Offroad chain spraySpecification– HUSABERG recommends Motorex® products.

SupplierMotorex®

– Chain Lube 622

AUXILIARY SUBSTANCES 94

Oil for foam air filterSpecification– HUSABERG recommends Motorex® products.

SupplierMotorex®

– Twin Air Liquid Bio Power

Universal oil spraySpecification– HUSABERG recommends Motorex® products.

SupplierMotorex®

– Joker 440 Universal

STANDARDS 95

JASO T903 MADifferent technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear-lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi-cation. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore-ground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the oil as the engine. The JASOMA Standard meets these special requirements.

SAEThe SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis-cosity. The viscosity describes only one property of oil and says nothing about quality.

INDEX 96

INDEX

A

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Air filtercleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Antifreezechecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

B

Basic chassis settingchecking with rider's weight . . . . . . . . . . . . . . . . . . . . 32

Batteryinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Brake discschecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Brake fluidfront brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 46rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Brake fluid levelfront brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 46rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 50

Brake liningsfront brake, changing . . . . . . . . . . . . . . . . . . . . . . . . 47front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 47rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . . . 51rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 51

C

Chaincleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chain guideadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Chain tensionadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chain wearchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-80

Clutchfluid level, checking . . . . . . . . . . . . . . . . . . . . . . . . . 69fluid, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 69

Compression dampingfork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Compression damping, high-speedshock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 32

Compression damping, low-speedshock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 33

Coolantdraining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Coolant levelchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66-67

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

D

Dust bootscleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

E

Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Enginerunning in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Engine guardinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Engine oiladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Engine oil levelchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Engine oil screencleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Engine oil screenscleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

F

Filler capclosing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Filling upfuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Flash code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77-78Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 49free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 49

Forkbasic setting, checking . . . . . . . . . . . . . . . . . . . . . . . 37

Fork legsbleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Front wheelinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Fuel tankinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Fuseindividual power consumers, changing . . . . . . . . . . . . . 59

G

Gas Bowden cable routechecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

INDEX 97

H

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 45free travel, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 46free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 45

Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Headlightbeam width, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 61

Headlight adjustment, checking . . . . . . . . . . . . . . . . . . . . . 60Headlight bulb, changing . . . . . . . . . . . . . . . . . . . . . . . . . 61

Headlight mask with headlightinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

I

Idle speed adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . 20

K

Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

L

Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

M

Main fusechanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Main silencerchanging glass fiber yarn filling . . . . . . . . . . . . . . . . . 69installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Motorcyclecleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

O

Oil filterchanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Overview of indicator lamps . . . . . . . . . . . . . . . . . . . . . . . 13Owner's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

P

Play in gas Bowden cableadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Protection for winter operation . . . . . . . . . . . . . . . . . . . . . . 81

Putting into operationadvice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . 23after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82checks before putting into operation . . . . . . . . . . . . . . 25

R

Rear sprocket / engine sprocketchecking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Rear wheelinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Rebound dampingfork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 33

Riding sagadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

S

Seatmounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Seat release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-31Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Shock absorberinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36riding sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 35static sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 34

Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Speedometeradjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15function description . . . . . . . . . . . . . . . . . . . . . . . . . 13Setting kilometers or miles . . . . . . . . . . . . . . . . . . . . . 14Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Spoilerinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Spoke tensionchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Spring preloadfork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 35

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Steeringlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Steering head bearing playadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

T

Technical datachassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86-87chassis tightening torques . . . . . . . . . . . . . . . . . . . . . 90engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83engine tightening torques . . . . . . . . . . . . . . . . . . . 84-85fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Throttle valve bodyidle speed, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 71

Tire air pressurechecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Tire conditionchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INDEX 98

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-76Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

U

Use definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

V

View of vehicleleft front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

W

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

HUSABERG eine Division der KTM SMC AGStallhofnerstraße 35230 Mattighofen, Austriawww.husaberg.com

*3802014en*3802014en

07/2

008

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: Mitt

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Documents

FE570EU FE570AUS 2009 - jbsracingpage.co.uk Owners... · owner'smanual fe450eu fe450aus fe450usa fe570eu fe570aus fe570usa 2009 art.no.3802014en