Husqvarna FC 450 2019 Owner's Manual
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Husqvarna FC 450 2019 Owner's Manual

Husqvarna FC 450 2019 Owner's Manual

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OWNER'S MANUAL 2019
FC 450
FX 450
Art. no. 3402242en
https://www.motorcycle-manual.com/

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Summary of Contents for Husqvarna FC 450 2019

  • Page 1 OWNER'S MANUAL 2019 FC 450 FX 450 Art. no. 3402242en https://www.motorcycle-manual.com/...
  • Page 2 https://www.motorcycle-manual.com/...
  • Page 3 DEAR HUSQVARNA MOTORCYCLES CUSTOMER Congratulations on your decision to purchase a Husqvarna motorcycle. You are now the owner of a state-of- DEAR HUSQVARNA MOTORCYCLES CUSTOMER the-art sports motorcycle that will give you enormous pleasure if you service and maintain it properly.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS 6.16 Service hour counter......22 MEANS OF REPRESENTATION......5 PREPARING FOR USE........23 Symbols used ........5 Formats used ........5 Advice on preparing for first use..23 Running in the engine ......24 SAFETY ADVICE ..........
  • Page 5 TABLE OF CONTENTS 10.7 Measuring the rear wheel dimension 11.27 Removing the main silencer....66 unloaded ..........41 11.28 Installing the main silencer....67 10.8 Checking the static sag of the 11.29 Changing the glass fiber yarn filling shock absorber ........42 of the main silencer ......
  • Page 6 TABLE OF CONTENTS 13.7 Checking spoke tension ....105 22.3 Capacities ......... 138 22.3.1 Engine oil........138 ELECTRICAL SYSTEM........106 22.3.2 Coolant ......... 138 14.1 Removing the battery ....106 22.3.3 Fuel..........138 14.2 Installing the battery ...... 107 22.4 Chassis ..........

  • Page 7: Means Of Representation 1

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interests of your own safety, have these jobs performed by an authorized Husqvarna Motorcycles workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the currently valid regulations and categories of the top international motorsport organizations. Info Only operate this vehicle in closed-off areas remote from public road traffic.

  • Page 9: Tampering Warning

    Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. Have malfunctions that impair safety immediately eliminated by an authorized Husqvarna Motorcycles work- shop. Adhere to the information and warning labels on the vehicle.

  • Page 10: Protective Clothing

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, Husqvarna Motorcycles recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks.

  • Page 11: Important Notes 3

    The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles workshop only and confirmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motor- cycles Dealer.net; otherwise, all warranty claims will be void. Damage or secondary damage caused by tam- pering with and/or conversions on the vehicle are not covered by the warranty.

  • Page 12: Customer Service

    3 IMPORTANT NOTES Customer service Your authorized Husqvarna Motorcycles dealer will be happy to answer any questions you may have regarding your vehicle and Husqvarna Motorcycles. A list of authorized Husqvarna Motorcycles dealers can be found on the Husqvarna Motorcycles website.

  • Page 13: View Of Vehicle 4

    VIEW OF VEHICLE 4 View of vehicle, front left (example) V01329-10 Hand brake lever ( p. 15) Clutch lever ( p. 15) Filler cap Air filter box cover Plug-in stand ( p. 21) (FC 450) Engine number ( p. 13) Shift lever ( p.

  • Page 14: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) V01330-10 Fork air pressure adjustment Combination switch ( p. 16) Kill switch ( p. 16) Electric starter button ( p. 16) Throttle grip ( p. 15) Fork compression adjuster Fork part number ( p.

  • Page 15: Serial Numbers 5

    SERIAL NUMBERS 5 Chassis number The chassis number is stamped on the right side of the steer- ing head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number The engine number is stamped on the left side of the engine.

  • Page 16: Shock Absorber Article Number

    5 SERIAL NUMBERS Shock absorber article number The shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 0 0 1 401948-10 https://www.motorcycle-manual.com/...

  • Page 17: Controls 6

    CONTROLS 6 Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. F00041-10 Hand brake lever (FC 450) The hand brake lever is located on the right side of the handlebar.

  • Page 18: Kill Switch

    6 CONTROLS Kill switch Kill switch is fitted on the left side of the handlebar. Possible states in basic position – In this position, the ignition • Kill switch circuit is closed and the engine can be started. pressed – In this position, the ignition circuit •...

  • Page 19: Overview Of Indicator Lamps

    Malfunction indicator lamp lights up/flashes orange – The OBD has detected an error in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized Husqvarna Motorcycles workshop. Malfunction indicator lamp flashes orange rapidly – Launch control is activated.

  • Page 20: Closing The Filler Cap

    6 CONTROLS (FX 450) – Press release button , turn the filler cap counterclock- wise, and lift it free. V01347-10 Closing the filler cap (FC 450) – Mount filler cap and turn it clockwise until the fuel tank is tightly closed. Info Run the fuel tank breather hose without kinks.

  • Page 21: Cold Start Button

    CONTROLS 6 6.10 Cold start button (FC 450) Cold start button is fitted on the bottom of the throttle valve body. K01109-10 (FX 450) Cold start button is fitted on the bottom of the throttle valve body. The injection system extends the injection time if the engine is cold and the outside temperature is low.

  • Page 22: Idle Speed Adjusting Screw

    6 CONTROLS 6.11 Idle speed adjusting screw The idle setting of the throttle valve body has a big influence on the vehicle's starting behavior, on stable idling, and on vehicle response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly.

  • Page 23: Foot Brake Lever

    CONTROLS 6 6.13 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.14 Plug-in stand (FC 450) Support for plug-in stand is the left side of the wheel spindle. The plug-in stand is used to park the motorcycle.

  • Page 24: Service Hour Counter

    6 CONTROLS 6.16 Service hour counter The run hour counter is fitted in front of the handlebar. It shows the total number of service hours of the engine. The service hour counter begins counting when the engine is started and stops when the engine is switched off. Info The value indicated by the service hour counter cannot be cleared or adjusted.

  • Page 25: Preparing For Use 7

    When using the motorcycle, remember that others may feel disturbed by excessive noise. – Ensure that the pre-delivery inspection work has been carried out by an authorized Husqvarna Motorcycles workshop. The delivery certificate and the Service and Manufacturer Warranty Booklet must be transferred with the vehicle.

  • Page 26: Running In The Engine

    7 PREPARING FOR USE Info The delivery certificate and the Service and Manufacturer Warranty Booklet are regarded as evi- dence of warranty services. – Read the entire Owner's Manual before riding for the first time. – Get to know the controls. –...

  • Page 27: Starting Power Of Lithium-Ion Batteries At Low Temperatures

    Riding at low temperatures and in snow. ( p. 27) Preparing vehicle for rides on dry sand – Mount a dust cover on the air filter. Dust cover for air filter (79006920000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01272-01 https://www.motorcycle-manual.com/...

  • Page 28: Preparing Vehicle For Rides On Wet Sand

    7 PREPARING FOR USE – Mount a sand cover on the air filter. Sand cover for air filter (79006922000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01273-01 – Clean the chain. Chain cleaner ( p. 147) –...

  • Page 29: Preparing Vehicle For Rides On Wet And Muddy Circuits

    Preparing vehicle for rides on wet and muddy circuits – Fit a rain cover on the air filter. Waterproofing device for air filter (79006921000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01274-01 – Mount the steel sprocket.

  • Page 30: Riding Instructions

    8 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 31: Activating Launch Control

    RIDING INSTRUCTIONS 8 (FC 450) – Remove the plug-in stand H02629-10 (FX 450) – Take the motorcycle off side stand and secure the side stand with rubber band – Shift the transmission to idle. 401944-10 Condition Ambient temperature: < 20 °C (< 68 °F) –...

  • Page 32: Activating Traction Control

    8 RIDING INSTRUCTIONS – Press and hold the MAP and TC buttons simultaneously. The malfunction indicator lamp flashes orange rapidly. Info The launch control is deactivated automatically for a few seconds after the vehicle has started. The launch control is also deactivated in the following cases (malfunction indicator lamp no longer flashes): if the throttle valve is closed more than 1/3 of the H02884-01...

  • Page 33: Shifting, Riding

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 34: Stopping, Parking

    8 RIDING INSTRUCTIONS – Use the braking effect of the engine on long downhill stretches. Shift back one or two gears, but do not overrev the engine when doing so. This means that significantly less braking is required and the brake sys- tem does not overheat.

  • Page 35: Refueling

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) https://www.motorcycle-manual.com/...
  • Page 36 8 RIDING INSTRUCTIONS Note Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Switch off the engine. – Open the filler cap. ( p.

  • Page 37: Service Schedule 9

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to- date service schedule can always be found on Husqvarna Motorcycles Dealer.net. Your authorized Husqvarna Motorcycles dealer will be glad to advise you.

  • Page 38: Recommended Work

    Final check: Check the vehicle for operating safety and take a test ride. ○ ● ● ● ● ● Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics tool. ○ ● ● ● ● ●...
  • Page 39 SERVICE SCHEDULE 9 Annually Every 100 operating hours Every 50 operating hours Once after 20 operating hours Once after 10 operating hours ● Perform major engine service including removing and installing engine. (Change valves, valve springs, valve spring seats, and valve spring retainers. Change the connecting rod, conrod bearing, and crank pin.

  • Page 40: 10 Tuning The Chassis

    – In the delivered condition, Husqvarna motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 75 …...

  • Page 41: Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 42: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber.

  • Page 43: Measuring The Rear Wheel Dimension Unloaded

    TUNING THE CHASSIS 10 – Turn adjusting screw clockwise up to the last perceptible click. – Turn counterclockwise by the number of clicks correspond- ing to the shock absorber type. Guideline Rebound damping (FC 450) Comfort 17 clicks Standard 15 clicks K00468-10 Sport 13 clicks...

  • Page 44: Checking The Static Sag Of The Shock Absorber

    10 TUNING THE CHASSIS 10.8 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 41) – Hold the motorcycle upright with the aid of an assistant. – Again measure the distance between the rear axle and mark- ing SAG on the rear fender using the sag gauge.

  • Page 45: Adjusting The Spring Preload Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info Note the current adjustment before changing the spring preload -–e.g. measure the spring length.

  • Page 46: Adjusting The Riding Sag

    10 TUNING THE CHASSIS 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) – Remove the shock absorber. p. 59) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 47: Adjusting The Fork Air Pressure

    Info This is due to the volume of the hose and not due to a defect in the fork airpump or the fork. Read the accompanying instructions for Husqvarna Motorcycles accessories. – Adjust the air pressure as specified. Guideline Air pressure (FC 450) 10.5 bar (152 psi)

  • Page 48: Adjusting The Compression Damping Of The Fork

    10 TUNING THE CHASSIS – Disconnect the fork airpump from the left fork leg. When disconnecting, excess pressure will escape from the hose – the fork leg itself does not lose any air. The fork airpump indicator switches off automatically after 80 seconds.

  • Page 49: Handlebar Position

    TUNING THE CHASSIS 10 – Remove protection cap – Turn adjusting screw clockwise all the way. Info Adjusting screw is located at the lower end of the right fork leg. – Turn counterclockwise by the number of clicks correspond- ing to the fork type. M01100-10 Guideline Rebound damping (FC 450)
  • Page 50 10 TUNING THE CHASSIS Main work – Remove screws . Take off the handlebar clamp. Remove the handlebar and lay it to one side. Info Cover the components to protect them against dam- age. Do not kink the cables and lines. –...

  • Page 51: Service Work On The Chassis 11

    SERVICE WORK ON THE CHASSIS 11 11.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (81329955100) Neither wheel is in contact with the ground.

  • Page 52: Bleeding The Fork Legs

    11 SERVICE WORK ON THE CHASSIS 11.3 Bleeding the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. –...

  • Page 53: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 11.5 Removing the fork protector – Remove screws and take off the clamp. – Remove screws and take off the left fork protector. – Remove screws and take off the right fork protector. S01902-10 11.6 Installing the fork protector –...

  • Page 54: Installing The Fork Legs

    11 SERVICE WORK ON THE CHASSIS – Loosen screws . Take out the left fork leg. – Loosen screws . Take out the right fork leg. S02314-10 11.8 Installing the fork legs Main work – Position the fork legs. Air release screw of the right fork leg is positioned to the front.

  • Page 55: Removing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 11.9 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) – Remove the front wheel. p. 99) – Remove the fork legs. p. 51) – Remove the start number plate.

  • Page 56: Installing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS 11.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 147) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 57 SERVICE WORK ON THE CHASSIS 11 – Tighten screws Guideline Screw, bottom triple 12 Nm (8.9 lbf ft) clamp S02319-10 – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head S02320-10 – Mount and tighten screw Guideline Screw, top 20 Nm (14.8 lbf ft)

  • Page 58: Checking The Steering Head Bearing Play

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become damaged over time.

  • Page 59: Adjusting The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 11.12 Adjusting the steering head bearing play Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) – Remove the handlebar cushion. Main work – Loosen screws – Remove screw – Loosen and retighten screw Guideline Screw, top steering...

  • Page 60: Removing The Start Number Plate

    11 SERVICE WORK ON THE CHASSIS 11.14 Removing the start number plate – Remove screw . Swivel the start number plate to one side. – Remove screw and take off the brake line guide and start number plate. V01315-10 11.15 Installing the start number plate –...

  • Page 61: Installing Front Fender

    SERVICE WORK ON THE CHASSIS 11 11.17 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis K01078-10 Finishing work – Install the start number plate. ( p. 58) 11.18 Removing the shock absorber Preparatory work...
  • Page 62 11 SERVICE WORK ON THE CHASSIS – Press angle lever toward the rear. – Press linkage lever downward. K01092-10 (FC 450) – Remove screws – Pull off foot brake cylinder from the push rod. K01093-10 (FX 450) – Remove screws –...

  • Page 63: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 – Hold the shock absorber and remove screw K01095-10 – Remove the shock absorber carefully at the bottom. K01096-10 11.19 Installing the shock absorber Main work – Carefully position the shock absorber into the vehicle from the bottom.
  • Page 64 11 SERVICE WORK ON THE CHASSIS (FC 450) – Position the foot brake cylinder. The push rod engages in the foot brake cylinder. Info Ensure that the dust boot is correctly seated. – Mount and tighten screws Guideline K01098-01 Remaining screws, 10 Nm (7.4 lbf ft) chassis (FX 450)

  • Page 65: Removing The Seat

    SERVICE WORK ON THE CHASSIS 11 Finishing work – Check the free travel of the foot brake lever. ( p. 91) – Remove the motorcycle from the lift stand. ( p. 49) 11.20 Removing the seat Caution Danger of burns The voltage regulator gets very hot when the vehicle is driven. –...

  • Page 66: Removing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V01319-10 Finishing work – Install the air filter box cover. ( p. 64) 11.22 Removing the air filter box cover –...

  • Page 67: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 11.24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. – Never start to use the vehicle without an air filter. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 68: Cleaning The Air Filter And Air Filter Box

    11 SERVICE WORK ON THE CHASSIS 11.26 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam.

  • Page 69: Installing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11 – Remove screws with the washers and take off the main silencer. V01323-10 11.28 Installing the main silencer – Position the main silencer. – Mount screws with the washers, but do not tighten yet. V01324-10 –...

  • Page 70: Removing The Right Side Cover

    11 SERVICE WORK ON THE CHASSIS Main work – Remove all the screws on the silencer cap. – Take off silencer cap and O-ring – Pull glass fiber yarn filling out of the silencer cap. – Pull glass fiber yarn filling from the inner tube.

  • Page 71: Installing The Right Side Cover

    SERVICE WORK ON THE CHASSIS 11 11.31 Installing the right side cover Main work – Attach side cover with the catches from below and push upward. – Engage the side cover in areas K01113-10 Finishing work – Mount the seat. ( p.
  • Page 72 11 SERVICE WORK ON THE CHASSIS – Remove the seat. ( p. 63) – Remove the right side cover. ( p. 68) Main work (FC 450) – Unplug connector of the fuel pump. – Pull the fuel tank breather hose off the tank lid. –...
  • Page 73 SERVICE WORK ON THE CHASSIS 11 (FX 450) – Unplug connector of the fuel pump. – Pull the fuel tank breather hose off the tank lid. – Clean plug-in connection of the fuel line thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 74: Installing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS 11.33 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...
  • Page 75 SERVICE WORK ON THE CHASSIS 11 – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis K01085-11 – Plug in connector for the fuel pump. – Remove the wash cap set and thoroughly clean the plug- in connection of the fuel line using compressed air.

  • Page 76: Checking For Chain Dirt Accumulation

    11 SERVICE WORK ON THE CHASSIS – Plug in connector for the fuel pump. – Remove the wash cap set and thoroughly clean the plug- in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 77: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) Main work – Rinse off loose dirt with a soft jet of water. –...

  • Page 78: Adjusting The Chain Tension

    11 SERVICE WORK ON THE CHASSIS 11.37 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 79: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 11 11.38 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) Main work – Shift the transmission to idle. – Check the chain, rear sprocket and engine sprocket for wear. »...
  • Page 80 11 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with, or below, the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.

  • Page 81: Checking The Frame

    – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by Husqvarna K01114-01 Motorcycles. 11.40 Checking the swingarm – Check the swingarm for damage, cracking, and deformation.

  • Page 82: Checking The Rubber Grips

    11 SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. Both throttle cables must be routed, side by side, behind the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the fuel tank contact area rubber band.

  • Page 83: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 11 11.43 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info When the adjusting screw is turned counterclockwise, the clutch lever moves away from the handlebar.

  • Page 84: Changing The Hydraulic Clutch Fluid

    11 SERVICE WORK ON THE CHASSIS Info Clean up overflowed or spilled brake fluid immediately with water. 11.45 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. –...
  • Page 85 SERVICE WORK ON THE CHASSIS 11 (FX 450) – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 145) – On the clutch slave cylinder, remove the protection cap and mount bleeding syringe with appropriate hose piece at the bleeder screw V01364-10...

  • Page 86: 12 Brake System

    12 BRAKE SYSTEM 12.1 Checking the free travel of the hand brake lever (FC 450) Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. –...

  • Page 87: Checking The Brake Discs

    Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple...

  • Page 88: Adding Front Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.
  • Page 89 BRAKE SYSTEM 12 Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.

  • Page 90: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) (FC 450) – Check the brake linings for minimum thickness ≥...
  • Page 91 BRAKE SYSTEM 12 Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Note Environmental hazard Hazardous substances cause environmental damage. –...
  • Page 92 12 BRAKE SYSTEM – Insert the new brake linings, insert pin , and mount the cotter pins Info Always change the brake linings in pairs. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

  • Page 93: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 12 – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. H02377-10 – Insert the new brake linings. – Mount pin Leaf spring engages in the groove on the pin. Info Always change the brake linings in pairs.

  • Page 94: Adjusting The Basic Position Of The Foot Brake Lever

    12 BRAKE SYSTEM – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake 3 … 5 mm (0.12 … 0.2 in) lever »...

  • Page 95: Checking The Rear Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Preparatory work –...
  • Page 96 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 97: Checking The Brake Linings Of The Rear Brake

    Checking the brake linings of the rear brake Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) (FC 450) –...

  • Page 98: Changing The Rear Brake Linings

    Changing the rear brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation.
  • Page 99 BRAKE SYSTEM 12 – Manually press the brake caliper to the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suc- tion if it does. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the...
  • Page 100 12 BRAKE SYSTEM – Manually press the brake caliper to the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suc- tion if it does. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the...

  • Page 101: Wheels, Tires 13

    WHEELS, TIRES 13 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) Main work (FC 450) – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake...

  • Page 102: Installing The Front Wheel

    13 WHEELS, TIRES – Remove spacers H00934-10 13.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 103: Removing The Rear Wheel

    WHEELS, TIRES 13 13.3 Removing the rear wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) Main work (FC 450) – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the...

  • Page 104: Installing The Rear Wheel

    13 WHEELS, TIRES (FX 450) – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.
  • Page 105 WHEELS, TIRES 13 Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surfaces of the spacers. Long-life grease ( p.

  • Page 106: Checking The Tire Condition

    Checking the tire condition Info Only mount tires approved and/or recommended by Husqvarna Motorcycles. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcy- cle.

  • Page 107: Checking Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) –...

  • Page 108: 14 Electrical System

    14 ELECTRICAL SYSTEM 14.1 Removing the battery Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. – Only charge batteries in well-ventilated rooms. –...

  • Page 109: Installing The Battery

    ELECTRICAL SYSTEM 14 14.2 Installing the battery Main work – Position the battery in the battery compartment with the ter- minals facing forward, and secure with holding bracket Battery (HJTZ5S-FP-C) ( p. 139) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis Info...
  • Page 110 14 ELECTRICAL SYSTEM Info Even when there is no load on the battery, it discharges steadily. The charging level and the method of charging are very important for the service life of the battery. Rapid recharging with a high charging current shortens the service life of the battery. If the charging current, charging voltage, or charging time are exceeded, the battery will be destroyed.

  • Page 111: Changing The Main Fuse

    ELECTRICAL SYSTEM 14 These battery chargers are only suitable for lithium iron phosphate batteries. Read the accompanying instructions for Husqvarna Motorcycles accessories. Info Never remove cover – Switch off the battery charger after charging and dis- connect from the battery.
  • Page 112 14 ELECTRICAL SYSTEM – Take off protection caps – Remove faulty main fuse Info You can recognize a faulty fuse by a burned-out fuse wire A spare fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109110) ( p.

  • Page 113: Cooling System 15

    COOLING SYSTEM 15 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 114: Checking The Coolant Level

    15 COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...

  • Page 115: Draining The Coolant

    COOLING SYSTEM 15 15.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 116: Changing The Coolant

    15 COOLING SYSTEM Main work – Make sure that screw is tightened. – Position the motorcycle upright. – Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Distance above the radi- ator fins V01327-10 Coolant 1.20 l Coolant (...
  • Page 117 COOLING SYSTEM 15 – Mount and tighten screw with a new seal ring. Guideline Screw, water pump 10 Nm (7.4 lbf ft) cover – Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Distance above the radi- V01327-10 ator fins...

  • Page 118: 16 Tuning The Engine

    16 TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 …...
  • Page 119 TUNING THE ENGINE 16 Main work (FC 450) – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop.

  • Page 120: Adjusting The Characteristic Map Of The Throttle Response

    16 TUNING THE ENGINE 16.3 Adjusting the characteristic map of the throttle response Info On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate. A guide plate with a different characteristic map is supplied. Main work –...

  • Page 121: Changing The Mapping

    Adjusting the idle speed Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) https://www.motorcycle-manual.com/...

  • Page 122: Teaching The Throttle Valve Position

    16 TUNING THE ENGINE – Run the engine until warm. The cold start button is deactivated – The cold start but- ton is in its basic position. ( p. 19) Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

  • Page 123: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 16 Info If the engine becomes too hot, perform a cool-down ride at medium revs. Then do not switch off the engine after this, but leave it running at idle speed until teaching is completed. 16.7 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position.

  • Page 124: 17 Service Work On The Engine

    17 SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...
  • Page 125 SERVICE WORK ON THE ENGINE 17 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventila- tion when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 126: Checking The Engine Oil Level

    17 SERVICE WORK ON THE ENGINE 17.2 Checking the engine oil level Info The engine oil level can be checked when the engine is cold or warm. Preparatory work – Stand the motorcycle upright on a horizontal surface. Condition The engine is cold. –...
  • Page 127 SERVICE WORK ON THE ENGINE 17 Main work – Place a suitable container under the engine. – Remove oil drain plug with the magnet and seal ring. K01068-10 – Remove screw plug with the short oil screen and the O- rings.
  • Page 128 17 SERVICE WORK ON THE ENGINE – Mount and tighten screw plug with the O-ring. Guideline Screw plug, oil M20x1.5 15 Nm (11.1 lbf ft) screen – Mount and tighten oil drain plug with the magnet and a new seal ring. Guideline Oil drain plug with M12x1.5...

  • Page 129: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 17 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 130: 18 Cleaning, Care

    18 CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 131 CLEANING, CARE 18 – Push back the protection caps of the handlebar controls to allow any water that has penetrated to evaporate. – After the motorcycle has cooled off, lubricate all moving parts and bearings. – Clean the chain. ( p.

  • Page 132: 19 Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info Husqvarna Motorcycles recommends raising the motorcycle. – Raise the motorcycle with a lift stand. ( p. 49) –...

  • Page 133: Preparing For Use After Storage

    STORAGE 19 Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and the exhaust system to rust.

  • Page 134: 20 Troubleshooting

    – Check the electrical system. – Defect in fuel injection system Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the Husqvarna Motorcycles diagnostics tool.
  • Page 135 Check the cabling for damage and lights up or flashes the electrical plug-in connections for corrosion and damage. – Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary.

  • Page 136: 21 Blink Code

    21 BLINK CODE Blink code for malfunc- tion indicator lamp 02a Malfunction indicator lamp flashes 2x per second Error level condition Teaching of throttle valve position required Blink code for malfunc- tion indicator lamp 02 Malfunction indicator lamp flashes 2x short Error level condition Crankshaft speed sensor - circuit fault Blink code for malfunc-...
  • Page 137 BLINK CODE 21 Blink code for malfunc- tion indicator lamp 33 Malfunction indicator lamp flashes 3x long, 3x short Injection valve cylinder 1 – circuit fault Error level condition Blink code for malfunc- tion indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short Ignition coil –...

  • Page 138: 22 Technical Data

    22 TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.9 cm³ (27.455 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 12.75:1 Idle speed 2,250 … 2,350 rpm Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust...

  • Page 139: Engine Tightening Torques

    TECHNICAL DATA 22 22.2 Engine tightening torques Screw, oil jet for piston cooling 2 Nm (1.5 lbf ft) ® Loctite 243™ Oil nozzle for clutch lubrication 2 Nm (1.5 lbf ft) ® Loctite 243™ Oil nozzle for timing chain lubrica- 2 Nm (1.5 lbf ft) ®...

  • Page 140: Capacities

    22 TECHNICAL DATA Oil nozzle for conrod bearing M6x0.75 2 Nm (1.5 lbf ft) lubrication Plug, oil channel 9 Nm (6.6 lbf ft) ® Loctite 243™ Screw, rocker arm bearing 15 Nm (11.1 lbf ft) Plug, timing chain tensioner 8 Nm (5.9 lbf ft) Screw plug, crankshaft location 10 Nm (7.4 lbf ft) Plug, oil channel...

  • Page 141: Chassis

    TECHNICAL DATA 22 22.4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork (FC 450) WP Suspension Upside down AER 48 Fork (FX 450) WP Suspension Upside down AER 48 Suspension travel front 310 mm (12.2 in) rear 300 mm (11.81 in) Fork offset...

  • Page 142: Tires

    110/100 - 18 64M TT Dunlop GEOMAX AT81F Dunlop GEOMAX AT81 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com 22.7 Fork 22.7.1 FC 450 Fork article number 34.18.8S.59...

  • Page 143: Shock Absorber

    TECHNICAL DATA 22 Air pressure 10.1 bar (146 psi) Fork length 950 mm (37.4 in) + 40 + 1.35 Oil capacity external mechanism ml (6.76 fl. oz.) Fork oil (SAE 4) (48601166S1) − 20 − 0.68 right p. 146) + 40 + 1.35 Oil capacity external mechanism ml (6.76...

  • Page 144: Chassis Tightening Torques

    22 TECHNICAL DATA Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 8 mm (0.31 in) Spring rate Weight of rider: 65 …...
  • Page 145 TECHNICAL DATA 22 Remaining screws, chassis 10 Nm (7.4 lbf ft) Screw, ball joint of push rod on 10 Nm (7.4 lbf ft) ® Loctite 243™ foot brake cylinder Screw, chain sliding guard 6 Nm (4.4 lbf ft) ® Loctite 243™...
  • Page 146 22 TECHNICAL DATA Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) Screw-in fitting, cooling system M24x1.5 15 Nm (11.1 lbf ft) ® Loctite 243™ Nut, rear wheel spindle M25x1.5 80 Nm (59 lbf ft) https://www.motorcycle-manual.com/...

  • Page 147: Substances 23

    SUBSTANCES 23 Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 ®...
  • Page 148 23 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 149) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...

  • Page 149: Auxiliary Substances 24

    AUXILIARY SUBSTANCES 24 Air filter cleaner Recommended supplier ® Motorex – Racing Bio Dirt Remover Chain cleaner Recommended supplier ® Motorex – Chain Clean Fuel additive Recommended supplier ® Motorex – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 150 24 AUXILIARY SUBSTANCES Preserving materials for paints, metal and rubber Recommended supplier ® Motorex – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier ® Motorex – Quick Cleaner Universal oil spray Recommended supplier ®...

  • Page 151: Standards 25

    STANDARDS 25 JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 152: 26 Index Of Special Terms

    26 INDEX OF SPECIAL TERMS Launch control Vehicles electronics functions for achieving the best possible acceleration from a standing position On-board diagnosis Vehicle system, which monitors the specified param- eters of the vehicle electronics https://www.motorcycle-manual.com/...

  • Page 153: List Of Abbreviations 27

    LIST OF ABBREVIATIONS 27 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly https://www.motorcycle-manual.com/...

  • Page 154: 28 List Of Symbols

    Malfunction indicator lamp lights up/flashes orange – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized Husqvarna Motorcy- cles workshop. Malfunction indicator lamp flashes orange rapidly – Launch control is activated.

  • Page 155: Index

    INDEX INDEX Chain guide checking ......77 Accessories ......9 Chain tension Air filter adjusting .
  • Page 156 INDEX Idle speed adjusting screw ....20 Implied warranty ..... . . 9 Figures .
  • Page 157 INDEX Starting power of lithium-ion batteries at low temperatures ......25 Rear sprocket Steering head bearing checking ......77 lubricating .
  • Page 158 *3402242en* 3402242en 03/2018 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer, https://www.motorcycle-manual.com/ www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...

This manual is also suitable for:

Fx 450 2019F2401s1 2019F2301s6 2019

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