Husaberg 450 2004 Factory Service Repair Manual

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Taper: Motorcycle

Distributeur:

UGS: 96121

Mots clés: 2004 450 Husaberg Motorcycle

Variantes de produits

Description

The FE 450 is a high-performance, single-cylinder, 4-stroke off-road motorcycle renowned for its agile handling and potent engine, making it a strong contender in the competitive enduro and motocross landscape of its era. Designed for demanding terrain, this 2004 model emphasizes raw capability and rider engagement, embodying the brand's dedication to off-road excellence. Its liquid-cooled 450cc engine, paired with a robust suspension system and hydraulic disc brakes, ensures it can tackle challenging conditions with confidence. This Factory Service Repair Manual provides comprehensive guidance for the FE 450, covering all essential aspects from routine maintenance to in-depth repairs. It details procedures for engine overhaul, carburetor tuning, transmission servicing, and suspension adjustments, along with electrical system diagnostics and troubleshooting. With its focus on technical specifications, maintenance schedules, and repair processes, this manual serves as an indispensable resource for owners and technicians seeking to maintain the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Husaberg

Model:

FE 450

Year:

Product Name:

Husaberg 450 2004 Factory Service Repair Manual

Codes

Chassis Code:

FE450

👋 Introduction

Market Position

Vehicle Segment:

High-performance Enduro/Off-road Motorcycle

Competitive Analysis

Competitors 2004:

KTM EXC 450, Yamaha WR450F, Honda CRF450X, Suzuki RM-Z450 (transitioning to 4-stroke), Kawasaki KX450F (upcoming).

Key Features Of Vehicle

Handling And Performance:

Renowned for its agile handling and potent, hard-hitting engine, making it a favorite for competitive off-road riding.

Off Road Capability:

Built for demanding terrain, featuring robust suspension and a powerful engine designed for motocross and enduro applications.

Manual Usefulness

Value Proposition:

Essential resource for owners and mechanics to maintain, diagnose, and repair the Husaberg FE 450, ensuring optimal performance and longevity.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Digital (likely PDF)

Page Count

Estimated Page Count:

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine overhaul, carburetor tuning, ignition system, cooling system, lubrication system, exhaust system.

Transmission Systems:

Clutch operation and adjustment, gearbox disassembly and assembly, shifting mechanism.

Chassis Systems:

Frame inspection and repair, suspension (front forks and rear shock absorber) service and adjustment, steering system maintenance.

Electrical Systems:

Wiring diagrams, lighting system, battery and charging system, starting system, ignition troubleshooting.

Braking Systems:

Hydraulic brake system service (master cylinders, calipers, lines), brake pad replacement, bleeding procedure.

Fuel System:

Fuel tank inspection, fuel lines, carburetor servicing (Mikuni TM40 or similar), fuel filter.

Bodywork And Trim:

Plastic panel removal and installation, seat maintenance, graphics.

Procedures Included

Maintenance Procedures:

Routine service checks, oil changes, filter replacements, spark plug replacement, chain adjustment, valve clearance checks/adjustments.

Repair Procedures:

Engine rebuilding, transmission repair, suspension fork seal replacement, carburetor overhaul, electrical component testing.

Troubleshooting Guides:

Diagnostic flowcharts for common starting, running, and electrical issues.

Technical Specifications:

Torque specifications, clearances, fluid capacities, electrical component values.

Technical Depth

Depth Of Coverage:

Comprehensive - covers everything from basic maintenance to complete engine and gearbox rebuilds.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable (typical for quality service manuals)

Print Quality

Image Resolution:

High-resolution diagrams and illustrations

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, 4-stroke

Displacement:

450 cc

Bore X Stroke:

95 mm x 63.4 mm (approximate, common for this era)

Cooling System:

Liquid-cooled

Performance

Horsepower:

Estimated 50-55 HP (at crankshaft)

Torque:

Estimated 45-50 Nm (at crankshaft)

Fuel System

Carburetor:

Mikuni TM40 (or similar flat-slide performance carburetor)

Fuel Type:

Unleaded gasoline (95 RON minimum recommended)

Ignition System

Ignition Type:

Digital CDI

Lubrication System

Oil Type Engine:

SAE 10W-40 or 10W-50 Semi-Synthetic or Fully Synthetic Motorcycle Oil

🔧 Transmission

Standard

Transmission Type:

5-speed manual

Clutch Type:

Wet, multi-plate

Optional

Gear Ratios:

Specific ratios detailed in manual, crucial for off-road performance tuning.

Features

Transmission Oil Type:

SAE 75W/80 or 75W/90 GL-4 Gear Oil (check specific manual for exact spec)

📐 Dimensions

Exterior

Wheelbase:

Approximately 1470 mm (57.9 inches)

Seat Height:

Approximately 960 mm (37.8 inches)

Weights

Dry Weight:

Approximately 107 kg (236 lbs)

Fuel Tank Capacity:

Approximately 8.5 liters (2.25 gallons)

🛡️ Safety Features

Ratings

Safety Certification:

N/A (off-road vehicles not typically crash-tested for road use)

Active Features

Braking System Type:

Hydraulic disc brakes, front and rear.

Suspension Design:

Upside-down telescopic front forks (e.g., WP) and mono-shock rear suspension, crucial for absorbing impacts.

💡 Technology Features

Infotainment

Infotainment System:

N/A (basic off-road motorcycle, no infotainment system)

Driver Assistance

Traction Control:

N/A (no electronic rider aids)

Connectivity

Connectivity Features:

Engine Management

Engine Control Unit:

ECU controls ignition timing, no advanced fuel mapping adjustments typically available without aftermarket tuning.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 10-15 hours of riding or annually (refer to manual for exact specification).

Air Filter Cleaning:

Every 5-10 hours of riding, or as needed based on riding conditions.

Valve Adjustment Interval:

Every 30-50 hours of riding (critical for performance).

Fluid Specifications

Fork Oil Type And Level:

Specific WP fork oil (e.g., 5W or 7.5W) and level (e.g., 100mm from top of inner tube when compressed) detailed in manual.

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors (50/50 mix with distilled water).

Known Issues

Common Wear Items:

Clutch plates, brake pads, wheel bearings, chain and sprockets, fork seals, valve guides (regular maintenance prevents most issues).

Carburetor Tuning Sensitivity:

Mikuni TM40 requires precise jetting and adjustment for optimal performance across different altitudes and temperatures.

Recommended Tools

Special Tools:

Torque wrench, specialized clutch holding tool, valve shim tools (if applicable), piston ring compressor.

📚 Vehicle History

Brand Heritage

Brand Origin:

Swedish motorcycle manufacturer, known for its focus on off-road performance.

Model Evolution

Previous Generations:

Husaberg has a history of developing high-performance off-road bikes, with the FE 450 model representing their continuous refinement in the 450cc class.

Production

Manufacturing Location:

Originally Sweden, later acquired by KTM and production shifted.

🏆 Awards & Recognition

Recognitions

Motocross Magazine Reviews:

Often praised in contemporary off-road magazines for its performance and handling, though specific awards for the 2004 model would need archival research.

Ratings

Customer Satisfaction:

Generally high among dedicated off-road enthusiasts who value its pure performance.