husaberg_'04_general_service_manual.pdf

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RA_Husaberg_2004_E
“ 04
REPARATURANLEITUNG
REPAIR MANUAL
Edition 2004
MANUEL DE REPARATION
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PREFACE
This manual contains detailed instructions on repairing the engine. It was prepared according
to the state of the art for this model series. We reserve the right to make modifications based
on technical progress without making the respective corrections in this repair manual.
This manual does not contain a description of general shop or working methods. It does not
include safety rules generally observed in workshops and is based on the assumption that the
work is performed by a mechanic who has completed his vocational training.
Please read the entire manual before starting to work.
WARNING: failing to observe these instructions can be dangerous to life and limb.
CAUTION: failing to observe these instructions may damage the motorcycle/engine components
or impair the motorcycle's traffic safety.
NOTE: provides useful information.
Only use ORIGINAL HUSABERG SPARE PARTS if parts need to be replaced.
The engine will only continue to operate safely if the prescribed service work is performed
regularly and professionally.
Subject to changes in construction and design.
C by HUSABERG All rights reserved
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INDEX
A
GENERAL INFORMATION
DISMOUNTING AND MOUNTING THE ENGINE
B
DISASSEMBLING THE ENGINE
C
SERVICING THE INDIVIDUAL PARTS
D
ASSEMBLING THE ENGINE
E
ELECTRIC SYSTEM
F
FUEL SYSTEM
G
TROUBLESHOOTING
H
TECHNICAL SPECIFICATIONS
I
PERIODIC MAINTENANCE SCHEDULE
J
WIRING DIAGRAMS
K
L
M
N
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TABLE OF CONTENTS
GENERAL INFORMATION
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1
Checking the oil level . . . . . . . . . . . . . . . . . . . . . . .A1
Changing the engine oil . . . . . . . . . . . . . . . . . . . . .A2
Cleaning the oil screen . . . . . . . . . . . . . . . . . . . . . .A2
Changing the oil filter . . . . . . . . . . . . . . . . . . . . . . .A3
Checking the oil level in the hydraulic clutch . . . . .A4
Bleeding the clutch . . . . . . . . . . . . . . . . . . . . . . . . .A4
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5
Preservation for winter operation . . . . . . . . . . . . . .A5
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6
Mounting the timing chain tensioner . . . . . . . . . . .E7
Adjusting the valve clearance . . . . . . . . . . . . . . . . .E7
Mounting the oil pump . . . . . . . . . . . . . . . . . . . . . .E8
Mounting the shift mechanism . . . . . . . . . . . . . . . .E8
Mounting the kickstarter shaft . . . . . . . . . . . . . . . . .E9
Mounting the clutch . . . . . . . . . . . . . . . . . . . . . . . .E9
Mounting the clutch cover . . . . . . . . . . . . . . . . . .E11
Mounting the pressure relief valve . . . . . . . . . . . .E13
Mounting rotor and pick up . . . . . . . . . . . . . . . . .E13
ELECTRIC SYSTEM
Checking for loss of current . . . . . . . . . . . . . . . . . .F1
Dismounting/mounting the battery . . . . . . . . . . . . .F1
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . .F1
Filling the battery . . . . . . . . . . . . . . . . . . . . . . . . . .F2
Checking the starter . . . . . . . . . . . . . . . . . . . . . . . .F2
Checking the starter relay . . . . . . . . . . . . . . . . . . . .F3
Checking the main fuse . . . . . . . . . . . . . . . . . . . . . .F3
Checking the voltage regulator . . . . . . . . . . . . . . . .F4
Kokusan 4K3B dynamic generator values . . . . . . . .F4
Troubleshooting in the ignition system . . . . . . . . . .F5
CDI unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F6
Checking the ignition coil . . . . . . . . . . . . . . . . . . . .F6
Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . .F7
Checking the stator and pulse generator . . . . . . . .F7
Replacing the stator in FC models (Kokusan 4K-3A) . .F7
Replacing the stator in FE and FS models (Kokusan 4K-3B) . .F7
Static ignition values Kokusan 4K-3A/B . . . . . . . . .F8
Static generator values Kokusan 4K3B . . . . . . . . .F10
DISMOUNTING AND MOUNTING THE ENGINE
Dismounting the engine . . . . . . . . . . . . . . . . . . . . .B1
Mounting the engine . . . . . . . . . . . . . . . . . . . . . . .B5
Bleeding the cooling system . . . . . . . . . . . . . . . . . .B9
Adjusting the decompression cable . . . . . . . . . . . .B9
Adjusting the throttle cable . . . . . . . . . . . . . . . . . .B9
DISASSEMBLING THE ENGINE
Blocking the engine . . . . . . . . . . . . . . . . . . . . . . . .C1
Removing the rotor . . . . . . . . . . . . . . . . . . . . . . . . .C2
Removing the pressure relief valve . . . . . . . . . . . . .C2
Removing the clutch . . . . . . . . . . . . . . . . . . . . . . . .C3
Removing inner clutch hub . . . . . . . . . . . . . . . . . . .C4
Removing primary pinion and the idler shaft gear . .C4
Removing the oil pump . . . . . . . . . . . . . . . . . . . . .C5
Removing the chain tensioner . . . . . . . . . . . . . . . .C6
Separating the timing chain . . . . . . . . . . . . . . . . . .C6
Removing the cylinder head . . . . . . . . . . . . . . . . . .C7
Separating the housing . . . . . . . . . . . . . . . . . . . . .C7
Removing the crankshaft . . . . . . . . . . . . . . . . . . . .C8
Removing the transmission . . . . . . . . . . . . . . . . . . .C8
Removing the idler shaft . . . . . . . . . . . . . . . . . . . . .C9
FUEL SYSTEM
KEIHIN FCR-MX 39/41 . . . . . . . . . . . . . . . . . . . . . .G1
Disassembling the carburetor . . . . . . . . . . . . . . . . .G2
Choke slide and hot start knob . . . . . . . . . . . . . . .G5
Accelerator pump . . . . . . . . . . . . . . . . . . . . . . . . . .G5
Jet needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G5
Float needle valve . . . . . . . . . . . . . . . . . . . . . . . . .G5
Throttle slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G6
Assembling the carburetor . . . . . . . . . . . . . . . . . . .G6
Adjusting the throttle sensor position . . . . . . . . .G10
Checking the throttle sensor . . . . . . . . . . . . . . . .G11
Dismounting and mounting the throttle sensor . .G11
Adjusting the idle . . . . . . . . . . . . . . . . . . . . . . . . .G12
Checking/adjusting the float height . . . . . . . . . . .G13
SERVICING THE INDIVIDUAL PARTS
Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1
Left housing half . . . . . . . . . . . . . . . . . . . . . . . . . .D1
Right housing half . . . . . . . . . . . . . . . . . . . . . . . . . .D2
Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . .D3
Clutch cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4
Press out the crank pin . . . . . . . . . . . . . . . . . . . . . .D5
Press in the crank pin . . . . . . . . . . . . . . . . . . . . . . .D6
Checking the crankshaft journal . . . . . . . . . . . . . . .D7
Outer dimension of the crankshaft webs . . . . . . . .D7
Balancing the axial clearance of the crankshaft . . .D8
Nikasil cylinder coating . . . . . . . . . . . . . . . . . . . . . .D9
Measuring the piston and cylinder liner,
determining the piston mounting clearance . . . . .D9
Checking the piston . . . . . . . . . . . . . . . . . . . . . . .D10
Checking the piston ring end gap . . . . . . . . . . . .D10
Checking the oil pump for wear . . . . . . . . . . . . . .D10
Cylinder head top section . . . . . . . . . . . . . . . . . .D11
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . .D12
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D14
Timing chain tensioner . . . . . . . . . . . . . . . . . . . . .D15
Timing train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D15
Checking the clutch for wear . . . . . . . . . . . . . . . .D16
Checking the kickstarter for wear . . . . . . . . . . . . .D17
Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . .D18
Assembling the main shaft (four-speed) . . . . . . . .D19
Assembling the main shaft (six-speed) . . . . . . . . .D20
Assembling the countershaft (four/six-speed) . . .D21
Starter drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D22
Checking the freewheel. . . . . . . . . . . . . . . . . . . . .D22
Checking the freewheel hub . . . . . . . . . . . . . . . . .D22
TROUBLESHOOTING
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .H1
TECHNICAL SPECIFICATIONS
Engine 450, 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . .I1
Carburetor 450, 501 . . . . . . . . . . . . . . . . . . . . . . . . .I1
Engine 550, 650 . . . . . . . . . . . . . . . . . . . . . . . . . . . .I2
Carburetor 550, 650 . . . . . . . . . . . . . . . . . . . . . . . . .I2
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I3
Engine torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4
Chassis torques . . . . . . . . . . . . . . . . . . . . . . . . . . . .I5
Mounting clearances, engine wear limits . . . . . . . ..I6
PERIODIC MAINTENANCE SCHEDULE
FC 450, 550/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J1
FE 450 - 650e/6, FS 450, 650e/6 . . . . . . . . . . . . . . .J2
Additional work - driver . . . . . . . . . . . . . . . . . . . . . .J3
Additional work - workshop . . . . . . . . . . . . . . . . . ..J4
WIRING DIAGRAMS
FC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K1
FE models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K2
FE USA models . . . . . . . . . . . . . . . . . . . . . . . . . . . .K4
FS models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K6
Cable colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K8
ASSEMBLING THE ENGINE
Mounting the idler shaft . . . . . . . . . . . . . . . . . . . . .E1
Mounting the crankshaft . . . . . . . . . . . . . . . . . . . .E2
Mounting the cylinder head . . . . . . . . . . . . . . . . . .E4
Mounting the timing chain . . . . . . . . . . . . . . . . . . .E5
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