Husqvarna FS 450 2015 Manuals

Manuals and User Guides for Husqvarna FS 450 2015. We have 1 Husqvarna FS 450 2015 manual available for free PDF download: Repair Manual

Husqvarna FS 450 2015 Repair Manual (249 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 73.2 MB

Table of Contents
4
Removing the Manifold
6
Installing the Manifold
6
Means of Representation
8
Symbols Used
8
Formats Used
8
Safety Advice
9
Repair Manual
9
Degrees of Risk and Symbols
9
Work Rules
9
Important Notes
10
Manufacturer and Implied Warranty
10
Operating and Auxiliary Substances
10
Spare Parts, Accessories
10
Figures
10
Serial Numbers
11
Chassis Number
11
Type Label
11
Engine Number
11
Fork Part Number
11
Shock Absorber Article Number
11
Motorcycle
12
Raising the Motorcycle with a Lift Stand
12
Removing the Motorcycle from the Lift Stand
12
Starting
12
Starting the Motorcycle for a Check
13
Fork, Triple Clamp
14
Adjusting the Compression Damping of the 9.10 Fork
14
Adjusting the Rebound Damping of the Fork
14
Bleeding the Fork Legs
15
Cleaning the Dust Boots of the Fork Legs
15
Removing the Fork Legs
15
Installing the Fork Legs
16
Removing the Fork Protector
16
Installing the Fork Protector
17
Conducting Major Fork Service
17
Conducting Minor Fork Service
17
Disassembling the Fork Legs
18
Disassembling the Cartridge
20
Disassembling the Piston Rod
22
Disassembling the Screw Cap with the Membrane Holder
24
Disassembling the Screw Sleeve
25
Checking the Fork Legs
25
Checking the Fork Legs - During a Minor Fork Service
27
Changing the Pilot Bushing
28
Assembling the Screw Sleeve
29
Assembling the Screw Cap with the Membrane Holder
29
Assembling the Piston Rod
30
Assembling the Cartridge
31
Assembling the Fork Legs
33
Bleeding and Filling the Cartridge
36
Filling the Cartridge with Nitrogen
38
Greasing the Steering Head Bearing
38
Removing the Lower Triple Clamp
39
Installing the Lower Triple Clamp
39
Checking the Steering Head Bearing Play
41
Changing the Steering Head Bearing
41
Adjusting the Steering Head Bearing Play
42
Handlebar,Controls
44
Handlebar Position
44
Adjusting the Handlebar Position
44
Adjusting the Basic Position of the Clutch Lever
44
Checking the Throttle Cable Routing
45
Checking the Play in the Throttle Cable
45
Adjusting the Play in the Throttle Cable
46
Frame
47
Checking the Frame
47
Shock Absorber, Swingarm
48
Adjusting the High-Speed Compression Damping of the Shock Absorber
48
Adjusting the Low-Speed Compression Damping of the Shock Absorber
48
Adjusting the Rebound Damping of the Shock Absorber
49
Measuring Rear Wheel Sag Unloaded
49
Checking the Static Sag of the Shock Absorber
49
Checking the Riding Sag of the Shock Absorber
50
Adjusting the Spring Preload of the Shock Absorber
50
Adjusting the Riding Sag
51
Removing the Shock Absorber
52
Installing the Shock Absorber
53
Checking the Shock Absorber Linkage
53
Servicing the Shock Absorber
55
Removing the Spring
56
Disassembling the Damper
56
Disassembling the Piston Rod
58
Disassembling the Seal Ring Retainer
59
Changing the Pilot Bushing
59
Checking the Damper
60
Removing the Heim Joint
61
Installing the Heim Joint
62
Assembling the Seal Ring Retainer
62
Assembling the Piston Rod
63
Assembling the Damper
64
Bleeding and Filling the Damper
66
Filling the Damper with Nitrogen
69
Installing the Spring
70
Checking the Swingarm
71
Removing the Swingarm
71
Installing the Swingarm
72
Changing the Swingarm Bearing
73
Exhaust
76
Removing the Main Silencer
77
Installing the Main Silencer
77
Changing the Glass Fiber Yarn Filling of the Main Silencer
77
Air Filter
79
Removing the Air Filter Box Lid
79
Installing the Air Filter Box Lid
79
Removing the Air Filter
79
Installing the Air Filter
79
Cleaning the Air Filter and Air Filter Box
80
Sealing the Air Filter Box
80
Fuel Tank, Seat, Trim
81
Opening the Filler Cap
81
Closing the Filler Cap
81
Removing the Right Side Cover
81
Installing the Right Side Cover
82
Removing the Seat
82
Mounting the Seat
82
Removing the Fuel Tank
82
Installing the Fuel Tank
83
Checking the Fuel Pressure
85
Changing the Fuel Pump
86
Changing the Fuel Filter
88
Changing the Fuel Screen
90
Mask, Fender
92
Removing the Front Fender
92
Installing the Front Fender
92
Removing the Start Number Plate
92
Installing the Start Number Plate
92
Wheels
93
Checking the Tire Air Pressure
93
Checking the Tire Condition
93
Checking the Brake Discs
94
Checking Spoke Tension
94
Checking the Rim Run-Out
95
Front Wheel
95
Removing the Front Wheel
95
Installing the Front Wheel
96
Removing the Brake Disc of the Front Brake
97
Installing the Brake Disc of the Front Brake
97
Changing the Front Wheel Bearing
97
Rear Wheel
98
Removing the Rear Wheel
98
Installing the Rear Wheel
99
Removing the Brake Disc of the Rear Brake
100
Installing the Brake Disc of the Rear Brake
100
Checking the Chain Tension
101
Adjusting the Chain Tension
101
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
102
Checking for Chain Dirt Accumulation
104
Cleaning the Chain
104
Changing the Drivetrain Kit
104
Changing the Rear Wheel Bearing
106
Wiring Harness, Battery
108
Changing the Main Fuse
108
Removing the Battery
108
Installing the Battery
109
Recharging the Battery
109
Checking the Charging Voltage
110
Checking the Open-Circuit Current
111
Checking the Capacitor
111
Checking the Starter Relay
112
Brake System
113
Checking the Front Brake Linings
113
Changing the Front Brake Linings
113
Brake Lever
115
Checking the Front Brake Fluid Level
115
Adding Front Brake Fluid
115
Changing the Front Brake Fluid
116
Checking the Rear Brake Linings
118
Changing the Rear Brake Linings
118
Checking the Free Travel of Foot Brake Lever
119
Adjusting the Basic Position of the Foot Brake Lever
120
Checking the Rear Brake Fluid Level
120
Adding Rear Brake Fluid
121
Changing the Rear Brake Fluid
121
Engine
124
Removing the Engine
124
Installing the Engine
128
Engine Disassembly
133
Preparations
133
Draining the Engine Oil
133
Removing the Clutch Push Rod
134
Removing the Oil Filter
134
Removing the Starter Motor
134
Removing the Spark Plug
134
Removing the Valve Cover
135
Removing the Alternator Cover
135
Positioning the Engine at Ignition Top Dead Center
135
Removing the Timing Chain Tensioner
136
Removing the Camshaft
136
Removing the Cylinder Head
137
Removing the Piston
137
Removing the Rotor
138
Removing the Timing Chain
138
Removing the Ignition Pulse Generator
139
Removing the Suction Pump
139
Removing the Water Pump Cover
139
Removing the Clutch Cover
140
Removing the Clutch Discs
140
Removing the Outer Clutch Hub
141
Removing the Torque Limiter
142
Removing the Starter Idler Gear
142
Removing the Shift Shaft
142
Removing the Shift Drum Locating Unit
142
Removing the Locking Lever
142
Removing the Force Pump
143
Removing the Primary Gear
144
Removing the Freewheel Gear
144
Removing the Left Engine Case Section
144
Removing the Shift Rails
145
Removing the Shift Drum
145
Removing the Shift Forks
145
Removing the Transmission Shafts
145
Removing the Crankshaft
146
Working on Individual Parts
146
Work on the Right Section of the Engine Case
146
Work on the Left Section of the Engine Case
148
Removing the Oil Pressure Regulator Valve
149
Checking Spring Length of Oil Pressure Regulator Valve
149
Installing the Oil Pressure Regulator Valve
150
Changing the Crankshaft Seal Ring in the Clutch Cover
150
Removing the Water Pump
150
Installing the Water Pump
151
Removing the Timing Chain Sprocket
152
Installing the Timing Chain Sprocket
152
Changing the Connecting Rod, Conrod Bearing, and Crank Pin
152
Checking Crankshaft Run-Out at Bearing Pin
154
Cylinder - Nikasil Coating
154
Checking/Measuring the Cylinder
154
Checking/Measuring the Piston
155
Checking the Piston Ring End Gap
155
Measuring the Piston/Cylinder Mounting Clearance
156
Checking the Oil Pumps
156
Disassembling the Autodecompressor
156
Assembling the Autodecompressor
157
Checking Camshaft
158
Checking the Timing Assembly
158
Removing the Rocker Arm
159
Removing the Valves
159
Changing Camshaft Bearing
160
Checking the Valves
160
Checking Valve Springs
161
Checking Valve Spring Seat
161
Checking the Cylinder Head
161
Checking the Rocker Arm Shafts
162
Installing the Valves
162
Installing the Rocker Arm
163
Disassembling the Antihopping Clutch
163
Preassembling the Antihopping Clutch
164
Checking the Clutch
165
Checking the Shift Mechanism
166
Preassembling the Shift Shaft
167
Disassembling the Main Shaft
168
Disassembling the Countershaft
168
Checking the Transmission
169
Assembling the Main Shaft
170
Assembling the Countershaft
171
Checking the Starter Drive
172
Checking the Freewheel
172
Removing the Freewheel
173
Installing the Freewheel
173
Engine Assembly
174
Installing the Crankshaft
174
Installing the Transmission Shafts
174
Installing the Shift Forks
174
Installing the Shift Drum
175
Installing the Shift Rails
175
Installing the Left Engine Case
175
Installing the Force Pump
176
Installing the Locking Lever
177
Installing the Shift Drum Locating Unit
178
Installing the Shift Shaft
178
Installing the Starter Idler Gear
178
Installing the Torque Limiter
178
17.5.15 Installing the Outer Clutch Hub
178
Installing the Clutch Discs
179
Installing the Clutch Cover
180
Installing the Water Pump Cover
181
Installing the Suction Pump
181
Installing the Ignition Pulse Generator
182
Installing the Timing Chain
182
Installing the Rotor
182
Installing the Piston
183
Installing the Cylinder Head
184
Installing the Camshaft
185
Installing the Timing Chain Tensioner
185
Checking the Valve Clearance
186
Adjusting the Valve Clearance
186
Installing the Alternator Cover
187
Installing the Valve Cover
187
Installing the Spark Plug
187
Installing the Starter Motor
188
Installing the Oil Filter
188
Installing the Clutch Push Rod
188
17.5.35 Installing the Oil Screens
188
Removing the Engine from the Engine
189
Assembly Stand
189
Clutch
190
Checking/Correcting the Fluid Level of the Hydraulic Clutch
190
Changing the Hydraulic Clutch Fluid
190
Antihopping Clutch
191
Adjusting the Antihopping Clutch
192
Water Pump, Cooling System
194
Cooling System
194
Checking the Antifreeze and Coolant Level
194
Checking the Coolant Level
195
Draining the Coolant
195
Refilling Coolant
196
Lubrication System
197
Oil Circuit
197
Checking the Engine Oil Level
197
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens
198
Adding Engine Oil
200
Checking the Engine Oil Pressure
200
Ignition System
202
Ignition Coil - Checking the Secondary
202
Winding
202
Checking the Spark Plug Connector
202
Alternator - Checking Stator Winding
202
Removing the Stator
203
Installing the Stator
203
Electric Starter
204
Checking the Starter Motor
204
Throttle Valve Body
205
Adjusting the Idle Speed
205
Executing the Initialization Run
205
Technical Data
207
Engine
207
Tolerance, Engine Wear Limits
207
Engine Tightening Torques
208
Capacities
209
Engine Oil
209
Coolant
209
Fuel
209
Chassis
209
Electrical System
210
Tires
210
Fork
210
Shock Absorber
211
Chassis Tightening Torques
211
Cleaning/Protective Treatment
213
Cleaning the Motorcycle
213
Storage
214
Preparing for Use after Storage
214
Service Schedule
215
Service Work (as Additional Order)
216
Wiring Diagram
219
Substances
224
Auxiliary Substances
226
Special Tools
228
Standards
243
Index
244

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Husqvarna FS 450 2015 Repair Manual (249 pages)

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