Husaberg Fe 501e 2000 2006 Workshop Service Manual
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DESCRIPTION:
This manual contains detailed instructions on repairing the engine. It was prepared according to the state of the art for this model series. We reserve the right to make modifications based on technical progress without making the respective corrections in this repair manual. This manual does not contain a description of general shop or working methods. It does not include safety rules generally observed in workshops and is based on the assumption that the work is performed by a mechanic who has completed his vocational training.
TABLE OF CONTENTS:
GENERAL INFORMATION
Oil circuitA1
Engine oil A1
Checking the oil level A1
Changing the engine oilA2
Cleaning the oil screen A2
Changing the oil filter A3
Checking the oil level in the hydraulic clutch A4
Bleeding the clutch A4
CleaningA5
Preservation for winter operation A5
Storage A5
Special toolsA6
DISMOUNTING AND MOUNTING THE
ENGINE
Dismounting the engineB1
Mounting the engineB5
Bleeding the cooling systemB9
Adjusting the decompression cableB9
Adjusting the throttle cable B9
DISASSEMBLING THE ENGINE
Blocking the engineC1
Removing the rotor C2
Removing the pressure relief valveC2
Removing the clutchC3
Removing inner clutch hub C4
Removing primary pinion and the idler shaft gear C4
Removing the oil pump C5
Removing the chain tensioner C6
Separating the timing chainC6
Removing the cylinder headC7
Separating the housingC7
Removing the crankshaft C8
Removing the transmissionC8
Removing the idler shaftC9
SERVICING THE INDIVIDUAL PARTS
Important D1
Left housing half D1
Right housing half D2
Pressure relief valveD3
Clutch coverD3
Crankshaft D4
Press out the crank pin D5
Press in the crank pin D6
Checking the crankshaft journalD7
Outer dimension of the crankshaft webs D7
Balancing the axial clearance of the crankshaftD8
Nikasil cylinder coating D9
Measuring the piston and cylinder liner,
determining the piston mounting clearanceD9
Checking the piston D10
Checking the piston ring end gap D10
Checking the oil pump for wear D10
Cylinder head top section D11
Cylinder head D12
Camshaft D14
Timing chain tensionerD15
Timing trainD15
Checking the clutch for wear D16
Checking the kickstarter for wear D17
Shift mechanism D18
Assembling the main shaft (four-speed) D19
Assembling the main shaft (six-speed)D20
Assembling the countershaft (four/six-speed)D21
Starter drive D22
Checking the freewheel D22
Checking the freewheel hub D22
ASSEMBLING THE ENGINE
Mounting the idler shaft E1
Mounting the crankshaftE2
Mounting the cylinder head E4
Mounting the timing chain E5
Mounting the timing chain tensionerE7
Adjusting the valve clearance E7
Mounting the oil pump E8
Mounting the shift mechanism E8
Mounting the kickstarter shaft E9
Mounting the clutch E9
Mounting the clutch cover E11
Mounting the pressure relief valveE13
Mounting rotor and pick upE13
ELECTRIC SYSTEM
Checking for loss of currentF1
Dismounting/mounting the battery F1
Charging the batteryF1
Filling the batteryF2
Checking the starterF2
Checking the starter relay F3
Checking the main fuse F3
Checking the voltage regulator F4
Kokusan 4K3B dynamic generator values F4
Troubleshooting in the ignition system F5
CDI unit F6
Checking the ignition coil F6
Ignition system F7
Checking the stator and pulse generator F7
Replacing the stator in FC models (Kokusan 4K-3A) F7
Replacing the stator in FE and FS models (Kokusan 4K-3B) F7
Static ignition values Kokusan 4K-3A/BF8
Static generator values Kokusan 4K3BF10
FUEL SYSTEM
KEIHIN FCR-MX 39/41 G1
Disassembling the carburetor G2
Choke slide and hot start knob G5
Accelerator pump G5
Jet needle G5
Float needle valve G5
Throttle slideG6
Assembling the carburetor G6
Adjusting the throttle sensor position G10
Checking the throttle sensor G11
Dismounting and mounting the throttle sensorG11
Adjusting the idle G12
Checking/adjusting the float heightG13
TROUBLESHOOTING
TroubleshootingH1
TECHNICAL SPECIFICATIONS 2000-
Engine / Carburetor 450, 501I1
Engine / Carburetor 550, 650I2
Chassis I3
TECHNICAL SPECIFICATIONS 2005-2007
Engine / Carburetor 450 I4
Engine / Carburetor 550, 650I5
Engine torques I6
Mounting clearances, engine wear limits I7
Chassis I8
Chassis torques I9
PERIODIC MAINTENANCE SCHEDULE
FC 450, 550/4 J1
FE 450 – 650e/6, FS 450, 650e/6 J2
Additional work – driver J3
Additional work – workshop J4
FILE FORMAT:
LANGUAGE:ENGLISH
PAGES:115
DOWNLOADABLE:YES
FILE TYPE:PDF
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]