HUSABERG FC650 FS650 FE650 Service Repair Manual 1998-2007 Online

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Type: Motorcycle

Vendor:

Sku: 120468

Tags: 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 FC Models FC650 FE650 FS650 Husaberg Motorcycle Motorcycles

Product variants

Description

This manual provides comprehensive service and repair information for FC650, FS650, and FE650 models produced between 1998 and 2007. These motorcycles, known for their powerful single-cylinder engines and performance-oriented design, were engineered for demanding off-road and supermoto applications. The FC models are tailored for motocross, the FS for supermoto racing, and the FE for enduro riding, each featuring distinct characteristics to suit their intended purpose. The heritage, often linked with robust engineering and off-road prowess, is reflected in these versatile machines. This Factory Service Workshop Repair Manual in English offers in-depth guidance for owners and mechanics alike. It covers all essential aspects of vehicle maintenance and repair, including detailed procedures for engine disassembly and assembly, transmission servicing, electrical system diagnostics with wiring diagrams, chassis and suspension maintenance, brake system overhauls, and fuel and cooling system service. The manual is designed to facilitate efficient troubleshooting, part replacement, and complete vehicle overhauls, ensuring the longevity and optimal performance of your motorcycle.

🏷️ Basic Information

Identification

Make:

Husaberg

Model:

FC650, FS650, FE650

Production Years Covered:

1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007

Codes

Engine Type Identifiers:

FC (Motocross), FS (Supermoto), FE (Enduro)

👋 Introduction

Market Position

Target Audience:

Do-it-yourself owners and experienced mechanics.

Value Proposition:

An inexpensive method to maintain and repair the vehicle, avoiding costly dealership service.

Competitive Analysis

Advantage Over Alternatives:

Instant download eliminates shipping costs and wait times associated with physical manuals.

Key Features

Content Organization:

Numbered table of contents for quick information retrieval.

Diagnostic Capabilities:

Specifically highlights combined troubleshooting and electrical service with detailed wiring diagrams.

Customization:

Flexibility to print only necessary pages or the entire manual.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Workshop Repair Manual

Language:

English

Format Options:

Digital Download (PDF)

Page Count

Estimated Page Count:

Hundreds of Pages (specific count not provided, but indicates comprehensive content)

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, diagnostics, and repair. Includes internal components, lubrication, cooling, and fuel delivery.

Transmission:

Gearbox overhaul, clutch service, shifting mechanisms, and related maintenance.

Electrical System:

Wiring diagrams, troubleshooting procedures, component testing, ignition system, lighting, battery, and starting system.

Chassis And Suspension:

Frame inspection and repair, front fork service (including seal replacement, oil changes), rear shock absorber maintenance, linkage systems.

Brakes:

Hydraulic brake system service, caliper maintenance, master cylinder overhaul, bleeding procedures, pad replacement.

Fuel System:

Carburetor tuning, cleaning, and overhaul (specific carburetor model would be detailed). Fuel pump and filter service.

Cooling System:

Radiator maintenance, coolant replacement, water pump service.

Exhaust System:

Exhaust pipe and silencer inspection and replacement.

Wheels And Tires:

Tire changes, spoke tensioning (if applicable), wheel bearing service.

Procedures Included

Maintenance:

Regular service schedules, fluid changes, filter replacements, lubrication points.

Troubleshooting:

Diagnostic procedures for common and uncommon issues across all major systems, with detailed symptom-to-cause analysis.

Repair:

Step-by-step instructions for component repair, part replacement, and system overhauls.

Disassembly And Assembly:

Detailed instructions for complete teardown and reassembly of the motorcycle.

Electrical Diagnostics:

Specific guidance for identifying and rectifying electrical faults, including connector checks and wiring continuity tests.

Technical Depth

Depth Of Information:

Comprehensive; covers basic maintenance to complete engine rebuilds and advanced diagnostics.

Illustrations And Photos:

Hundreds of detailed illustrations, drawings, and photos, with enlarged inset views for critical components.

Instruction Format:

Numbered, step-by-step instructions with bold figure numbers for easy reference to illustrations.

Safety Information:

Includes critical notes, cautions, and warnings integrated within repair procedures.

📊 Manual Specifications

File Format

File Type:

Compatibility:

Compatible with all PC-based Windows operating systems and Mac.

Print Quality

Printability:

All pages are printable, allowing for individual section printing or complete manual printing.

Binding Type

Binding:

Digital Download (no physical binding, user prints as needed)

Paper Type

Paper Type:

N/A (Digital format, printing on user's choice of paper)

⚙️ Engine Specifications

Primary Engine

Engine Configuration:

Single-cylinder, four-stroke

Engine Displacement:

Approximately 650cc (exact bore and stroke for specific FC/FS/FE variants would be detailed in the manual)

Engine Variant Details:

Manual covers FC650 (Motocross), FS650 (Supermoto), and FE650 (Enduro) which may have minor differences in tuning or components.

Performance

Horsepower Range:

Expected range of 50-60 HP, depending on specific model and tuning (exact figures in manual).

Torque Range:

Significant torque delivery characteristic of large single-cylinder engines (specific figures in manual).

Fuel System

Fuel Delivery:

Carbureted (likely Keihin or Mikuni, specific model in manual).

Fuel Type:

Unleaded gasoline (Octane rating specified in manual).

🔧 Transmission

Standard

Transmission Type:

Constant-mesh, sequential manual transmission

Number Of Gears:

Typically 5 or 6 speeds (specific count and ratios in manual).

Features

Clutch Type:

Hydraulically operated, multi-plate wet clutch (details on adjustment and replacement in manual).

Final Drive:

Chain drive (maintenance and adjustment procedures in manual).

📐 Dimensions

Exterior

Style Variants:

Motocross (FC), Supermoto (FS), Enduro (FE) – differing suspension travel, wheel sizes, and tire types.

Weights

Dry Weight:

Varied by model, but typically in the range of 110-125 kg (specific figures in manual).

🛡️ Safety Features

Ratings

Safety Features Overview:

Motorcycles of this era primarily rely on rider skill and basic safety equipment; manual focuses on mechanical safety and proper operation.

Active Features

Braking System:

Hydraulic disc brakes, front and rear (specific caliper and rotor details in manual).

Passive Features

Frame Integrity:

Steel or aluminum frame construction (manual covers inspection and potential repair).

💡 Technology Features

Infotainment

Instrumentation:

Digital or analog odometer/trip meter, speedometer, and basic indicator lights. Advanced features not typically present.

Driver Assistance

Anti-lock Braking System (ABS) was not standard or widely available on these off-road/motard oriented models during this period. Manual will not cover ABS diagnostics.

Connectivity

Electronic Aids:

No electronic rider aids such as traction control or riding modes on these models.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 10-15 hours of operation or annually (specifics for engine oil, transmission oil, and clutch fluid in manual).

Spark Plug Replacement:

Refer to manual for recommended intervals based on usage.

Air Filter Cleaning:

Frequent checks and cleaning recommended, especially for off-road use (procedures in manual).

Fluid Specifications

Engine Oil Type:

High-quality motorcycle-specific 4-stroke engine oil (e.g., SAE 10W-40 or 15W-50, specific API/JASO rating in manual).

Transmission Oil Type:

Dedicated transmission oil or engine oil depending on shared lubrication (specifications in manual).

Brake Fluid Type:

DOT 4 or DOT 5.1 hydraulic brake fluid (manual will specify).

Coolant Type:

Ethylene glycol-based antifreeze mixed with distilled water (specific ratio and type in manual).

Known Issues

Common Wear Items:

Clutch plates, wheel bearings, fork seals, chain and sprockets, valve adjustments (manual details inspection and replacement).

Electrical Gremlins:

Potential for corroded connectors or failing grounds, especially with off-road use (manual's electrical section is crucial).

📚 Vehicle History

Brand Heritage

Manufacturer:

Husaberg Motorcycles, historically known for off-road performance, often with KTM influence/components during this period.

Model Evolution

Design Philosophy:

Focused on performance-oriented off-road and dual-sport motorcycles, utilizing powerful single-cylinder engines.

Production

Manufacturing Era:

Manual covers a significant developmental period for Husaberg, from its KTM acquisition era through to later models before subsequent ownership changes.

🏆 Awards & Recognition

Recognitions

Motorcycle Segment Accolades:

Husaberg models of this era were often praised for their powerful engines and capable chassis in their respective categories (motocross, enduro, supermoto). Specific awards would be model/year dependent and not directly in manual content.