husaberg_'04_owners_manual.pdf

“ 04

BEDIENUNGSANLEITUNG

OWNERS MANUAL

Edition 2004

MANUEL D’UTILISATION

TABLE OF CONTENTS

Page

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Important limited warranty and limited guarantee

information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Page

Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . .33

How to change the handlebar position . . . . . . . . . .34

Changing the spring preloading of the shock absorber .34

Check chain tension . . . . . . . . . . . . . . . . . . . . . . . . .35

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .35

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .36

Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

General information about Husaberg disc brakes . .37

Changing the basic position the hand brake lever (FC, FE) 38

Changing the basic position the hand brake lever (FS) . . .38

Checking the brake fluid level - front brake . . . . . . .38

Refilling the front brake fluid reservoir . . . . . . . . . . .38

Checking the front brake pads . . . . . . . . . . . . . . . . .39

Replacing the front brake pads (FC/FE) . . . . . . . . . .39

Replacing the front brake pads (FS) . . . . . . . . . . . . .39

Changing the basic position of the foot brake pedal 40

Check the rear brake fluid level . . . . . . . . . . . . . . . .40

Refilling the rear brake fluid reservoir . . . . . . . . . . . .40

Checking the rear brake pads . . . . . . . . . . . . . . . . .41

Replacing the rear brake pads . . . . . . . . . . . . . . . . .41

Dismounting and mounting the front wheel . . . . . .42

Dismounting and mounting the rear wheel . . . . . . .43

Checking the shock absorption rubbers in the rear hub .44

Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .44

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Check/set distance of the magnetic sensor . . . . . . .45

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Charging the battery . . . . . . . . . . . . . . . . . . . . . . . .46

Fuse (FE/FS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Replacing headlight lamp/parking light lamp . . . . .47

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Checking the coolant level . . . . . . . . . . . . . . . . . . . .48

Bleeding the cooling system . . . . . . . . . . . . . . . . . .49

Replacing the glassfiber yarn packing of the silencer .49

Cleaning the spark arrester . . . . . . . . . . . . . . . . . . .49

Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . .50

Checking the adjustment of the hand decompression

release cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Adjusting the throttle cables . . . . . . . . . . . . . . . . . .50

Changing the original position of the clutch lever . .51

Checking the oil level of the hydraulic clutch . . . . . .51

Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . .51

Carburetor – Adjust idling . . . . . . . . . . . . . . . . . . . .52

Basic information on carburetor wear . . . . . . . . . . .52

Adjusting the mixture control screw . . . . . . . . . . . . .52

Checking the float level (float height) . . . . . . . . . . .53

Draining the float chamber of the carburetor . . . . .53

Oil Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Checking the engine oil level . . . . . . . . . . . . . . . . . .54

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Changing the engine oil . . . . . . . . . . . . . . . . . . . . . .54

Cleaning the oil screen . . . . . . . . . . . . . . . . . . . . . . .54

Changing the oil filter . . . . . . . . . . . . . . . . . . . . . . . .55

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Engine-Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . .6

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Hand decompression lever . . . . . . . . . . . . . . . . . . . . .6

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . .7

Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Headlamp switch (USA) . . . . . . . . . . . . . . . . . . . . . . .7

Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Emergency OFF switch (Australia) . . . . . . . . . . . . . . . .8

Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . .8

Tripmaster-switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Activating/deactivating the display modes . . . . . . .13

Kilometers or miles . . . . . . . . . . . . . . . . . . . . . . . . . .14

Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Fuel taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Hot start device . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Compression damping of fork . . . . . . . . . . . . . . . . . .17

Rebound damping of fork . . . . . . . . . . . . . . . . . . . .17

Damping action during compression of shock absorber 18

Rebound damping of shock absorber . . . . . . . . . . .19

Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE .20

Instructions for initial operation . . . . . . . . . . . . . . . .20

Running in the Husaberg models . . . . . . . . . . . . . . .20

DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .21

Check the following before each start . . . . . . . . . . .21

Starting when the engine is cold . . . . . . . . . . . . . . .22

Starting when the engine is warm . . . . . . . . . . . . . .22

What to do when the engine is “flooded” . . . . . . . .22

Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . .24

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

PERIODIC MAINTENANCE SCHEDULE 2004 . . . . . . . .26

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .56

MAINTENANCE WORK ON CHASSIS AND ENGINE . .30

Checking and adjusting the steering head bearing .30

Breather plug front fork . . . . . . . . . . . . . . . . . . . . . .31

Cleaning the dust sleeves of the telescopic fork . . .31

Basic suspension setup for the weight of the driver .32

Checking the shock absorber and spring . . . . . . . . .32

Determining the static sag of the shock absorber . .32

Determining the riding sag of the shock absorber .32

Checking the basic setup of the telescopic fork . . .33

Changing the spring preload on the telescopic fork 33

CLEANING, CONSERVATION, STORAGE . . . . . . . . . .58

TECHNICAL DATA - ENGINE . . . . . . . . . . . . . . . . . . . .59

TECHNICAL DATA - CHASSIS . . . . . . . . . . . . . . . . . . . .61

HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . .64

WIRING DIAGRAMM . . . . . . . . . . . . . . . . . . . . .Appendix

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INTRODUCTION

IMPORTANT

WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COM-

PLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF

INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR

BIKE PROPERLY.

IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES

THAT ARE MARKED AS FOLLOWS:

WARNING: IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY

AND YOUR LIFE.

CAUTION: IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO

PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE IS NOT ROAD-

SAFE ANYMORE.

NOTE: USEFUL INFORMATION ON HANDLING AND SERVICING YOUR

MOTORCYCLE.

Please insert the serial numbers of your motorcycle in the boxes below

Frame number:

Motor number:

Stamp of dealer:

COMSUMER INFORMATION FOR AUSTRALIA ONLY

The exhaust system on this vehicle has no owner serviceable parts. Should there be an

increase in noise or damage to any component relating to the noise reduction system,

replacement parts should be fitted by an Authorised dealer.

Tampering with noise control system prohibited

Owners are warned that the law may prohibit:

(a) The removal or rendering inoperative by any person other than for purposes of

maintenance, repair or replacement, of any device or element of design incorpora-

ted into any new vehicle for the purpose of noise control prior to its sale or delivery

to the ultimate purchaser or while it is in use; and

(b)the use of the vehicle after such device or element of design has been removed or

rendered inoperative by any person.

H USABERG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT , TECHNICAL SPECIFICATIONS , COLORS , MATERIALS , SERVI -

CES OFFERED AND RENDERED , AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT PREVIOUS ANNO -

UNCEMENT AND WITHOUT GIVING REASONS , OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTITUTING THEM

WITH OTHERS . I TSHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS ANNOUNCEMENT .

- 2 -

INTRODUCTION

We would like to congratulate you on your purchase of a Husaberg motorcycle.

You are now the owner of a state-of-the-art sport motorcycle that guarantees to

bring you lots of fun and enjoyment, provided that you clean and maintain it appro-

priately. Before you go for your first ride, be sure to read this manual carefully

and thoroughly in order to familiarize yourself with how to operate your new

motorcycle and with its characteristics, even if this means that you will have to

dedicate some of your valuable time to this task. Only by doing so will you

learn how to tune your motorcycle to your specific needs and how to protect

yourself against injury. Besides, this manual contains important information on

motorcycle maintenance. At the time this manual was typeset, it was up-to-date

with the latest state of this production series. Please note that motorcycle features

may vary according to the effective legal provisions. It cannot be completely ruled

out, however, that minor discrepancies may exist resulting from further design

upgrades of these motorcycles.This manual is an important part of your motorcycle

and should be passed on to any subsequent owner in case you decide to sell it.

The work marked with an * in the chapter "Servicing the chassis and engine" must

be performed by an authorized Husaberg dealer. If such service work becomes

necessary during a competition, it must be performed by a trained mechanic.

For your own safety, use Husaberg-approved parts and accessories only. Husaberg is not

liable for damage that arises in connection with the use of other products.

Take special care to follow the recommended run in, inspection, and maintenance

intervals. Heeding these guidelines will significantly increase the life of your

motorcycle. Be sure to have your motorcycle serviced by an authorized Husaberg

dealer to maintain the validity of your warranty.

Off-road / Supermoto motorcycle driving is a wonderful sport and we hope that you

will be able to enjoy it to the full. It may, however, involve potential problems for the

environment or lead to conflicts with others. These problems or conflicts can be

avoided if the motorcycle is used responsibly. To safeguard the future of motorcycle

sports, make sure that you use the motorcycle in accordance with the law, show that

you are environmentally conscious and respect the rights of others.

We wish you a lot of fun when driving !

HUSABERG

5230 MATTIGHOFEN, AUSTRIA

A LL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL .

- 3 -

INTRODUCTION

IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE

INFORMATION

Husaberg sports motorcycles are designed and constructed to resist the usual wear

and tear of normal use in competitions.

The motorcycles comply with the regulations and categories currently in effect with the

leading international motorcycle associations.

Observance of the service, maintenance and tuning instructions for the engine and

chassis specified in the Owner's Manual is a prerequisite for faultless operation and

the avoidance of premature wear. An improperly tuned chassis can lead to damage

and breakage of the chassis components (see chapter on checking the basic chassis

setting).

The service work described in the "Lubrication and maintenance chart" must be car-

ried out and confirmed by an authorized Husaberg dealer, otherwise your warranty

will become void.

The fuels and lubricants specified in the Owner's Manual or fluids with equivalent

specifications must be used in accordance with the maintenance schedule.

No claims can be filed under the warranty for damage or consequential damage

caused by manipulations or conversions to the motorcycle.

The use of the motorcycle under extreme conditions, e.g. on extremely muddy and

wet terrain, can lead to higher than average wear on components such as the drive

train or the brakes. In this case it may become necessary to service or replace wear

parts before the service limit specified in the maintenance schedule has been rea-

ched.

MODELS FC

FC and other “competition only“ labeled models are prohibited on public roads.

MODELS FE

“On the road“ approved models are only allowed on public roads in the original

homologated (throttled) version. Without this performance restriction (i.e. de-

throttled), these models are only allowed to be driven off-road and not on

public roads. The FE models are designed for off-road sports endurance competiti-

ons(enduro) and not suitable for predominant motocross use.

MODELS FS

The FS models are only allowed on public roads in the original homologated (thrott-

led) version. Without this performance restriction (i.e. dethrottled), these

models are only allowed to be driven in Supermoto competitions but not on

public roads.

No warranty will be assumed if the bike is used in races or competitions.

In accordance with the international quality management

ISO 9001 standard, Husaberg uses quality assurance pro-

cesses that lead to the highest possible product quality.

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