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OWNER'S MANUAL 2020 FE 450 FE 501 Art. no. 3402343en...
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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 vehicle that will continue giving you pleasure for a long time if you maintain it properly.
TABLE OF CONTENTS TABLE OF CONTENTS 6.13 Overview of indicator lamps MEANS OF REPRESENTATION......6 (FE 501 US) ......... 21 Symbols used ........6 6.14 Opening fuel tank filler cap ....21 Formats used ........6 6.15 Closing the fuel tank filler cap..... 22 SAFETY ADVICE ..........
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TABLE OF CONTENTS Starting off .......... 39 12.5 Removing the fork protector....56 Shifting, riding........39 12.6 Installing the fork protector....57 Braking..........39 12.7 Removing the fork legs ....57 Stopping, parking ....... 40 12.8 Installing the fork legs .....
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TABLE OF CONTENTS 12.46 Installing the engine guard....89 16.3 Checking the coolant level....122 16.4 Draining the coolant ...... 122 BRAKE SYSTEM ..........90 16.5 Refilling with coolant ..... 123 13.1 Adjusting the basic position of the TUNING THE ENGINE ........125 hand brake lever .........
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TABLE OF CONTENTS STANDARDS ..........156 INDEX OF SPECIAL TERMS ......157 LIST OF ABBREVIATIONS ......158 LIST OF SYMBOLS ........159 29.1 Yellow and orange symbols....159 29.2 Green and blue symbols....159 INDEX ..............160...
1 MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. 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 understand- ing.
SAFETY ADVICE 2 Use definition – intended use (All EU models) This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehi- cle complies with the currently valid regulations and categories of the top international motorsports organi- zations.
2 SAFETY ADVICE Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
– 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.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized Husqvarna Motor- cycles dealer will be glad to advise you.
IMPORTANT NOTES 3 Manufacturer and implied warranty The work prescribed in the service schedule must only be carried out in an authorized Husqvarna Motorcy- cles workshop and confirmed in the Husqvarna Motorcycles Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.
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.
VIEW OF VEHICLE 4 View of vehicle, front left (example) F02332-10 Hand brake lever ( p. 17) Clutch lever ( p. 17) Fuel tank filler cap Air filter box cover Side stand ( p. 24) Engine number ( p. 15) Shift lever ( p.
4 VIEW OF VEHICLE View of vehicle, rear right (example) F02333-10 Fork compression adjuster Switch-off button ( p. 17) p. 18) (All EU models) Horn button ( Light switch ( p. 18) (All EU models) Turn signal switch ( p. 19) (All EU models) p.
SERIAL NUMBERS 5 Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label (All EU models) Type label is fixed to the front of the steering head. 401946-10 Key number (All EU models) Key number for the steering lock is stamped on a tag on the key ring.
5 SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub. 401947-10 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. H02222-10...
CONTROLS 6 Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. F00257-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar.
6 CONTROLS (FE 501 US) Switch-off button is fitted on the left side of the handle- bar. Possible states is in the basic position – In this • The switch-off button position, the ignition circuit is closed and the engine can be started.
CONTROLS 6 Turn signal switch (All EU models) Turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal off – The turn signal switch is in the cen- tral position. Left turn signal, on – The turn signal switch is turned to the left.
– The OBD has detected an error in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized Husqvarna Motorcycles workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.
– The OBD has detected an error in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized Husqvarna Motorcycles workshop. Fuel level warning lamp lights up orange – The fuel level has reached the reserve mark.
6 CONTROLS 6.15 Closing the fuel tank filler cap – Mount fuel tank filler cap and turn it clockwise until the release button engages. Info Route fuel tank breather hose without kinks. F02337-10 6.16 Cold start button The cold start button is fitted to the bottom of the throttle valve body.
CONTROLS 6 6.17 Idle speed adjusting screw The idle speed is adjusted using the idle speed adjusting screw Increase the idle speed by turning the idle speed adjusting screw clockwise. Decrease the idle speed by turning the idle speed adjusting screw counterclockwise.
6 CONTROLS 6.19 Foot brake lever Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 401956-10 6.20 Side stand The side stand is attached to the left side of the vehicle. 401943-10 The side stand is used for parking the motorcycle.
CONTROLS 6 6.22 Locking the steering (All EU models) Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Park the vehicle. – Turn handlebar as far as possible to the right. –...
Battery voltage of the combination instrument – Bat- tery voltage of the combination instrument is too low. Change combination instrument battery. Service – A service is due. Contact an authorized Husqvarna Motorcycles workshop. 401901-01 Setting the combination instrument Condition The motorcycle is stationary.
COMBINATION INSTRUMENT 7 – Wait for 5 seconds. Combination instrument changes to the next menu item. symbol flashes. – Press one of the buttons to select the 24h or 12h display of the clock. 401911-01 – Wait for 5 seconds. Combination instrument changes to the next menu item.
7 COMBINATION INSTRUMENT – Press and hold both buttons for 3 - 5 seconds. The Setup menu is displayed. The UNIT display flashes. – Press one of the buttons to select UNIT for the speed in kilo- meters KM/H or miles M/H. 401909-01 Adjusting the clock Condition...
COMBINATION INSTRUMENT 7 Switching off the service interval display – Press and hold the left button. off appears in the display. 401914-01 Speed, time, and DST distance 1 – Press one of the buttons until DST appears on the combina- tion instrument.
7 COMBINATION INSTRUMENT Press the left DST2 can be preset to a value between 0.0 button for 3 – and 39999.9 by pressing the buttons. 5 seconds. Press the Next display mode right button briefly. Press the DST2 is reset to 0.0. right button for 3 –...
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-sale inspection work has been carried out by an authorized Husqvarna Motorcycles workshop. You will receive a delivery certificate when the vehicle is handed over.
8 PREPARING FOR USE – Adjust basic position of the hand brake lever. ( p. 90) – Adjust the basic position of the foot brake lever. p. 96) – Adjust the basic position of the shift lever. p. 130) – Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more challenging trips.
Riding at low temperatures and in snow. ( p. 36) Preparing the vehicle for riding on dry sand – Mount the air filter dust cover. Air filter dust cover (79006920000) Info Read the fitting instructions for Husqvarna Motorcy- cles accessories. 102136-01...
8 PREPARING FOR USE – Mount the air filter sand cover. Air filter sand cover (79006922000) Info Read the fitting instructions for Husqvarna Motorcy- cles accessories. 102138-01 – Clean the chain. – Mount the steel sprocket. – Grease the chain.
M01459-01 Preparing the vehicle for riding on wet and muddy circuits – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Read the fitting instructions for Husqvarna Motorcy- cles accessories. 102137-01 – Mount the steel sprocket. –...
Straighten bent radiator fins carefully. – Check the coolant level. ( p. 122) Preparing the vehicle for low temperatures or snow – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Read the fitting instructions for Husqvarna Motorcy- cles accessories. 102137-01...
RIDING INSTRUCTIONS 9 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. –...
9 RIDING INSTRUCTIONS – Take the motorcycle off side stand and secure the side stand with rubber strap – Shift the transmission into neutral. Condition Ambient temperature: < 20 °C (< 68 °F) – Push the cold start button in all the way. 401944-10 –...
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.)
9 RIDING INSTRUCTIONS Warning Danger of accidents Moisture and dirt impair the brake system. – Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs. – On sandy, wet or slippery surfaces, use the rear brake. –...
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.)
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9 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 engine. – Open fuel tank filler cap. ( p.
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.
● Final check: Check the vehicle is roadworthy and take a test ride. ○ ● ● ● ● Read out the fault memory after the test ride using the Husqvarna Motorcycles diag- nostics tool. ○ ● ● ● ● Make a service entry in Husqvarna Motorcycles Dealer.net.
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SERVICE SCHEDULE 10 Every 135 operating hours Every 70 operating hours when used for motorsports After 20 operating hours After 10 operating hours every 12 months ● ● Perform engine service including removing and installing the engine. (Change the spark plug and spark plug connector. Change the piston. Check/measure the cylinder. Check the cylinder head.
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 compression adjuster can be seen in slow to normal compression of the...
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 compression adjuster can be seen in fast compression of the shock absorber.
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incor- rectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.
TUNING THE CHASSIS 11 Finishing work – Remove the motorcycle from the lift stand. ( p. 55) 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 48) – Hold the motorcycle upright with aid of an assistant. –...
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 Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring length.
TUNING THE CHASSIS 11 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 55) – Remove the shock absorber. p. 64) – After removing the shock absorber, clean it thoroughly. Main work –...
11 TUNING THE CHASSIS 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn white adjuster clockwise as far as it will go. Info Adjuster is located at the upper end of the left fork leg.
TUNING THE CHASSIS 11 Info Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds. 11.14 Adjusting the spring preload of the fork Preparatory work – Raise the motorcycle with a lift stand. ( p.
11 TUNING THE CHASSIS 11.16 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result. – Change the handlebar if the handlebar is damaged or bent. –...
SERVICE WORK ON THE CHASSIS 12 12.1 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.
12 SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 55) – Remove the fork protector. ( p. 56) Main work – Push dust boots of both fork legs downward.
SERVICE WORK ON THE CHASSIS 12 12.6 Installing the fork protector – Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake line, wiring harness, and clamp. Mount and tighten screws –...
12 SERVICE WORK ON THE CHASSIS 12.8 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front. Info The compression damping is located in left fork leg COMP (white adjuster). The rebound damping is located in right fork leg REB (red adjuster).
SERVICE WORK ON THE CHASSIS 12 Main work – Remove screw – Remove screw – Open cable holder in front of the left radiator and detach the clutch line. – Take off the upper triple clamp with the handlebar and set aside.
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12 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the handlebar. – Mount screw , but do not tighten yet. – Mount the clutch line with cable holder S03552-11 – Position the fork legs. Bleeder screws are positioned toward the front.
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 vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.
12 SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bear- ing. » If there is detectable play: –...
SERVICE WORK ON THE CHASSIS 12 12.13 Lubricating the steering head bearing – Remove the lower triple clamp. p. 58) – Install the lower triple clamp. p. 59) H02387-01 12.14 Removing front fender Preparatory work – Remove the headlight mask with the headlight. ( p.
12 SERVICE WORK ON THE CHASSIS 12.15 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis H03691-10 Finishing work...
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SERVICE WORK ON THE CHASSIS 12 – Press angle lever toward the rear. – Press linkage lever downward. H03694-10 (All EU models) – Disconnect the plug-in connector of the brake light switch. F02341-10 – Remove screws – Pull off foot brake cylinder from the push rod. F02342-10 –...
12 SERVICE WORK ON THE CHASSIS – Hold the shock absorber and remove screw – Remove the shock absorber carefully at the bottom. H03699-10 12.17 Installing the shock absorber Main work – Carefully position the shock absorber into the vehicle from the bottom.
SERVICE WORK ON THE CHASSIS 12 – Position the foot brake cylinder. Push rod engages in the foot brake cylinder. The dust boot is correctly positioned. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F02307-10 –...
12 SERVICE WORK ON THE CHASSIS Main work – Remove screw with the bushing. – Pull seat back and lift it off. S03559-10 12.19 Mounting the seat Main work – Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket.
SERVICE WORK ON THE CHASSIS 12 12.20 Removing the air filter box cover – Pull off the air filter box cover sideways in areas and take off toward the rear. F02345-10 12.21 Installing the air filter box cover – Attach catch of the air filter box in area and push for- ward.
12 SERVICE WORK ON THE CHASSIS Main work – Detach retaining tab . Remove air filter with air filter sup- port. – Remove air filter from air filter support. S03573-10 12.23 Installing the air filter Main work – Mount the clean air filter on the air filter support. –...
SERVICE WORK ON THE CHASSIS 12 Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 155) Info Only press the air filter to dry it, never wring it out. –...
12 SERVICE WORK ON THE CHASSIS 12.26 Installing the right side cover Main work – Attach side cover with the holding lugs from below and push upward. – Engage the side cover in areas F02344-10 Finishing work – Mount the seat. ( p.
SERVICE WORK ON THE CHASSIS 12 12.28 Installing the main silencer (All EU models) – Position the catalytic converter in the main silencer. S02101-10 – Position the main silencer. – Mount screws with the washers, but do not tighten yet. –...
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12 SERVICE WORK ON THE CHASSIS S03542-10 Main work – Remove all screws, take off silencer cap with O-ring Info Do not remove the glass fiber yarn filling. Caution Danger to health Soot particles irritate the eyes and mucuous membranes. – Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen.
SERVICE WORK ON THE CHASSIS 12 12.30 Changing the glass fiber yarn filling in the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. Info Over time, the fibers of the glass fiber yarn escape and the damper “burns”...
12 SERVICE WORK ON THE CHASSIS Finishing work – Install the main silencer. ( p. 73) 12.31 Removing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...
SERVICE WORK ON THE CHASSIS 12 – Remove screws (All EU models) – Hang the horn and horn bracket to one side. H03705-10 – Remove screw with the rubber bushing. H03704-10 – Pull both spoilers laterally off the radiator and lift off the fuel tank.
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12 SERVICE WORK ON THE CHASSIS Main work – Check throttle cable routing. ( p. 84) – Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracket. – Make sure that no cables or throttle cables are trapped or damaged.
SERVICE WORK ON THE CHASSIS 12 12.33 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 79) 400678-01 12.34 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip.
12 SERVICE WORK ON THE CHASSIS 12.35 Checking 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.
SERVICE WORK ON THE CHASSIS 12 Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55 … 58 mm (2.17 … 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks...
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12 SERVICE WORK ON THE CHASSIS – Pull on the top section of the chain with the specified weight Guideline Weight of chain wear mea- 10 … 15 kg (22 … 33 lb.) surement – Measure distance of 18 chain rollers in the lower chain section.
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SERVICE WORK ON THE CHASSIS 12 – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.
– 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 F00255-01 Motorcycles. 12.39 Checking the link fork – Check the link fork for damage, cracking, and deformation.
SERVICE WORK ON THE CHASSIS 12 Main work – Check throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the rubber strap of the fuel tank support.
12 SERVICE WORK ON THE CHASSIS (FE 501 US) – Check that screw is firmly seated. Guideline Screw, fixed 5 Nm (3.7 lbf ft) ® Loctite 243™ grip Diamond must be positioned visibly as shown in the figure. F02365-10 12.42 Adjusting the basic position of the clutch lever –...
SERVICE WORK ON THE CHASSIS 12 – Move the hydraulic clutch fluid reservoir mounted on the han- dlebar into a horizontal position. – Remove screws – Take off cover with membrane – Check the fluid level. Fluid level below container 4 mm (0.16 in) »...
12 SERVICE WORK ON THE CHASSIS – Move the hydraulic clutch fluid reservoir mounted on the han- dlebar into a horizontal position. – Remove screws – Take off cover with membrane H03713-10 – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p.
SERVICE WORK ON THE CHASSIS 12 12.46 Installing the engine guard – Attach the engine guard on the frame at the rear and swing up at the front. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis H01655-01...
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...
– 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.) – Move the brake reservoir mounted on the handlebar to a hori- zontal position.
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.) – Check the brake linings for minimum thickness ≥...
Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
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13 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Take off cover with membrane H03720-10 – Manually press the brake caliper toward the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, if necessary extract excess.
BRAKE SYSTEM 13 – Correct the brake fluid to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 ( p. 153) – Position cover with membrane – Mount and tighten screws Info Immediately clean up any brake fluid that has over- flowed or spilled with water.
Warning 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.)
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.
Checking the rear 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.) – Check the brake linings for minimum thickness ≥...
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Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
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13 BRAKE SYSTEM – Position the vehicle vertically. – Remove the cable tie on the frame protector. – Remove screw cap with membrane and the shim. H03724-01 – Manually press the brake caliper toward the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir;...
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BRAKE SYSTEM 13 – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 153) – Mount and tighten screw cap with membrane and the shim. Info Immediately clean up any brake fluid that has over- flowed or spilled with water.
14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 55) Main work – Manually press the brake caliper toward the brake disc 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 pis- tons.
WHEELS, TIRES 14 14.2 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. –...
14 WHEELS, TIRES Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pis- ton.
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WHEELS, TIRES 14 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 surface of the spacers. Long-life grease ( p.
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 pressure of the tires all have a major impact on the handling characteristic of the motorcycle.
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.) –...
15 ELECTRICAL SYSTEM 15.1 Removing the 12-V battery Note Environmental hazard 12 V batteries contain environmentally hazardous materials. – Do not dispose of 12 V batteries as household waste. – Dispose of 12 V batteries at a collection point for used batteries. Note Environmental hazard Hazardous substances cause environmental damage.
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ELECTRICAL SYSTEM 15 – Remove starter relay and fuse box from the holding bracket and hang to the side. S03578-10 – Detach wiring harness , disconnect relays and hang them to the side. S03579-10 – Remove screw and unhook the holding bracket. –...
15 ELECTRICAL SYSTEM 15.2 Installing the 12-V battery Main work – Insert the 12-V battery into the battery compartment with the terminals facing forward and secure with holding bracket 12-V battery (HJTZ5S-FP-C) ( p. 149) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft)
ELECTRICAL SYSTEM 15 – Connect positive cable to the 12-V battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) Info Contact disk must be mounted under screw and cable lug with the claws toward the battery terminal. – Slide the positive terminal cover over the positive terminal. –...
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15 ELECTRICAL SYSTEM Info Even if there is no load on the 12-V battery, it discharges each day. The charging level and the method of charging are very important for the service life of the 12-V battery. Rapid recharging with a high charging current shortens the service life of the battery. If the charging current or charging voltage are exceeded, the 12 V battery will be destroyed.
ELECTRICAL SYSTEM 15 This battery charger is only suitable for lithium iron phosphate batteries. Read the accompanying instruc- tions for Husqvarna Motorcycles accessories. Info Never remove cover – Switch off the battery charger after charging and disconnect it from the 12-V battery.
15 ELECTRICAL SYSTEM – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109120) ( p.
ELECTRICAL SYSTEM 15 Fuse 2 - 10 A - high beam, low beam, position light, tail light, license plate lamp Fuse 3 - 10 A - radiator fan, horn, brake light, turn signal Fuse 4 - 5 A - fuel pump Fuses res - 10 A - spare fuse Info A faulty fuse has a burned-out fuse wire...
15 ELECTRICAL SYSTEM – Remove screw – Detach the brake line and wiring harness from the headlight mask. – Pivot the headlight mask forwards and place it on the fender. H03748-10 (All EU models) – Detach plug-in connectors and take off the headlight mask with the headlight.
ELECTRICAL SYSTEM 15 – Position the brake line and the wiring harness in the cable guide. – Mount and tighten screw – Position the headlight mask. The holding lugs engage in the fender. H03752-10 – Secure the headlight mask with rubber straps H03749-11 Finishing work –...
15 ELECTRICAL SYSTEM Main work – Turn protection cap together with the underlying bulb socket counterclockwise all the way and remove it. – Pull bulb socket of the position light out of the reflector. H03753-10 – Pull out headlight bulb –...
ELECTRICAL SYSTEM 15 – Insert the screw and first turn counterclockwise until it engages in the thread with a small jerk. Tighten the screw lightly. Finishing work – Check that the turn signal system is functioning properly. 15.10 Checking the headlight setting –...
15 ELECTRICAL SYSTEM 15.12 Changing the combination instrument battery Preparatory work – Remove the headlight mask with the headlight. ( p. 115) Main work – Remove screws with the washers. – Pull the combination instrument upward out of the holder. H03756-10 –...
COOLING SYSTEM 16 16.1 Cooling system Water pump in the engine ensures forced circulation of 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.
16 COOLING SYSTEM Coolant ( p. 153) – Mount the radiator cap. 16.3 Checking the coolant level 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.
COOLING SYSTEM 16 Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...
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16 COOLING SYSTEM – Install the engine guard. ( p. 89)
TUNING THE ENGINE 17 17.1 Checking the throttle cable play – 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 Throttle cable play 3 …...
17 TUNING THE ENGINE Main work – 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. –...
TUNING THE ENGINE 17 – Remove guide plate from handle tube – Position the required guide plate on the grip tube. Guideline The label OUTSIDE must be visible. Marking must be positioned at marking Grey guide plate (79002014000) Alternative 1 Black guide plate (79002014100) Info The gray guide plate opens the throttle valve more...
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.) – Run the engine until warm.
TUNING THE ENGINE 17 17.6 Teaching the throttle valve position Info If the control unit detects that the throttle valve position at idle speed needs to be retaught, then the malfunction indicator lamp flashes 2x per second. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
17 TUNING THE ENGINE 17.8 Adjusting the basic position of the shift lever – Remove screw with the washers and take off shift lever 401950-12 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage gearing.
SERVICE WORK ON THE ENGINE 18 18.1 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. –...
18 SERVICE WORK ON THE ENGINE – Start the engine and check the response. 18.2 Checking the engine oil level Preparatory work – Stand the motorcycle upright on a horizontal surface. Condition The engine is cold. – Check the engine oil level. The engine oil reaches the lower edge of level viewer »...
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SERVICE WORK ON THE ENGINE 18 Main work – Place an appropriate container under the engine. – Remove oil drain plug with the magnet and seal ring. F00441-10 – Remove screw plug with the short oil screen and the O- rings.
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18 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...
SERVICE WORK ON THE ENGINE 18 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 effective exhaust extraction when starting or running the engine in an enclosed space.
19 CLEANING, CARE 19.1 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. –...
CLEANING, CARE 19 – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 155) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.
– 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. 55) –...
STORAGE 20 Info 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. 20.2 Preparing for use after storage –...
Check the electrical system. faulty – Error in the electronic fuel Read out the fault memory using the injection Husqvarna Motorcycles diagnostics tool. – Engine does not speed up Error in the electronic fuel Read out the fault memory using the...
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– 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 replace it if necessary.
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21 TROUBLESHOOTING Faults Possible cause Action – The high beam, low beam, tail Fuse 2 blown Change the fuses of individual power light, position light, and license consumers. ( p. 114) plate lamp are not working – Combination instrument, horn, Fuse 3 blown Change the fuses of individual power brake light, turn signal, and...
BLINK CODE 22 Info The blink codes are only displayed by the derestricted version of the vehicle. 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...
23 TECHNICAL DATA 23.3 Capacities 23.3.1 Engine oil Engine oil 1.2 l (1.3 qt.) Engine oil (SAE 10W/50) ( p. 153) 23.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p. 153) 23.3.3 Fuel Total fuel tank capacity, approx. (All EU models) Super unleaded (ROZ 95/RON 95/PON 91) ( p.
(FE 501 US) 80/100 - 21 51M TT 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...
TECHNICAL DATA 23 Spring length 260 mm (10.24 in) Gas pressure 10 bar (145 psi) Static sag 37 mm (1.46 in) Riding sag 110 mm (4.33 in) Fitted length 477 mm (18.78 in) Shock absorber oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p.
SUBSTANCES 24 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 ®...
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24 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 156) (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 –...
26 STANDARDS 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.
Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized Husqvarna Motorcy- cles workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.
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