Market Position:
Husaberg motorcycles, particularly in the early 2000s, were positioned as high-performance off-road and enduro machines, often favored by riders seeking raw power and specialized capabilities over mainstream brands.
Competitive Analysis:
Competed directly with other European manufacturers in the premium enduro segment, such as KTM, and to some extent, specialized models from Japanese brands. Known for their robust engines and no-nonsense off-road focus.
Key Features:
Powerful single-cylinder engines, advanced chassis design for off-road capability, robust suspension components, and a focus on performance for demanding terrain.
Coverage Areas:
Comprehensive service and repair for Husaberg FE 450 and FE 650 models of the 2004 model year.
Page Count:
Estimated 300-500 pages (typical for a complete service manual)
Illustrative Content:
Contains numerous diagrams, illustrations, and exploded views to clarify procedures.
Manual Type:
Service and Repair Manual
Language:
English (Primary for download)
Searchability:
Searchable PDF text for quick access to specific information.
Systems Covered:
Engine (top end, bottom end, valve train, lubrication, cooling), Fuel System (carburetion, fuel pump, lines), Ignition System, Exhaust System, Transmission (clutch, gearbox, shifting mechanism), Drivetrain (chain, sprockets, rear hub), Suspension (forks, shock absorber, linkage), Brakes (hydraulic system, calipers, master cylinders, rotors), Wheels and Tires, Electrical System (wiring diagrams, battery, lighting, starter, ECU), Chassis and Frame, Bodywork and Plastics, Controls (levers, cables), Troubleshooting.
Electrical System Detail:
Complete wiring diagrams, component testing procedures, troubleshooting for lighting, ignition, starting system, sensors, and ECU diagnostics.
Procedures Included:
Routine maintenance (oil changes, filter replacement, chain adjustment), complete engine disassembly and reassembly, transmission rebuild, suspension servicing (fork seal replacement, shock rebuild), brake bleeding and component replacement, carburetor tuning and cleaning, electrical diagnostics and repair, chassis component inspection and replacement, torque specifications for all fasteners, troubleshooting guides for common problems.
Engine Rebuild Detail:
Detailed steps for cylinder head removal, piston replacement, connecting rod inspection, crankshaft service, valve clearance adjustment, timing chain replacement, and oil pump servicing.
Suspension Service Detail:
Step-by-step instructions for fork disassembly, seal and bushing replacement, oil level and volume setting, shock absorber service including nitrogen charging and valving adjustments.
Chassis Component Replacement:
Procedures for steering head bearing replacement, swingarm bearing service, wheel bearing replacement, and linkage bearing maintenance.
Technical Depth:
In-depth technical information suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic adjustments to complete overhauls and complex diagnostics. Includes detailed component diagrams and exploded views.
Diagnostic Procedures:
Includes systematic troubleshooting flowcharts and diagnostic trees for common performance issues and system failures.
Torque Specifications:
Comprehensive list of torque values for critical fasteners including engine, chassis, and suspension components.
Engine Type:
Four-stroke, single-cylinder, liquid-cooled
Displacement 450:
Approximately 450cc (specific bore/stroke vary, e.g., 95mm x 63.4mm)
Displacement 650:
Approximately 650cc (specific bore/stroke vary, e.g., 100mm x 80mm)
Valvetrain:
DOHC, 4 valves per cylinder
Bore Stroke 450:
e.g., 95 mm x 63.4 mm (verify with manual)
Bore Stroke 650:
e.g., 100 mm x 80 mm (verify with manual)
Compression Ratio 450:
Approximately 12.5:1 (verify with manual)
Compression Ratio 650:
Approximately 11.8:1 (verify with manual)
Horsepower 450:
Estimated 50-55 HP (at crank, typical for the era)
Horsepower 650:
Estimated 60-65 HP (at crank, typical for the era)
Torque 450:
Estimated 45-50 Nm
Torque 650:
Estimated 55-60 Nm
Carburetor Type:
Keihin FCR (Flat CRankshaft) series (e.g., FCR41 or FCR40)
Ignition Type:
Digital CDI with variable ignition timing
Starter System:
Electric Start (Standard)
Length:
Variable based on specific model variant, but generally in line with enduro motorcycles (~2.2-2.3 meters)
Width:
Variable, typical for off-road bikes (~0.8-0.9 meters at handlebars)
Height:
Variable, typical for off-road bikes (~1.2-1.3 meters)
Dry Weight 450:
Approximately 110-115 kg
Dry Weight 650:
Approximately 115-120 kg
Fuel Capacity:
Approximately 9-10 liters (standard tank)
Oil Change Interval:
Every 10-15 hours of riding or annually. Refer to manual for exact specifications.
Air Filter Cleaning:
Every 5-10 hours of riding, or more frequently in dusty conditions.
Spark Plug Replacement:
Every 20-30 hours of riding, or as needed based on inspection.
Engine Oil Type:
High-quality synthetic motorcycle oil, SAE 10W-50 or 15W-50 (check manual for exact viscosity and API rating).
Engine Oil Capacity:
Approximately 1.3 - 1.5 liters (check manual for exact capacity).
Fork Oil Type:
Specific suspension fluid, SAE 5W or 7.5W (check manual for exact type and viscosity).
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid (check manual for precise specification).
Coolant Type:
Ethylene glycol-based coolant, mixed with distilled water at a 50/50 ratio.
Clutch Fluid Type:
Mineral oil or specific hydraulic fluid (check manual for exact type, often separate from brake fluid).
Known Issues:
Early model Husabergs could be prone to carburetor jetting sensitivity, occasional electrical gremlins if not maintained, and wear on the decompression mechanism if not properly adjusted. Regular maintenance is key. Fork seals and shock seals are common wear items on off-road bikes.
Brand Heritage:
Husaberg was a Swedish motorcycle manufacturer founded in 1987, specializing in high-performance off-road motorcycles. Known for innovation and robust engineering, it was later acquired by KTM.
Model Evolution 2004:
The 2004 models represented a refinement of their single-cylinder enduro platform, building on previous years' designs with performance enhancements and reliability improvements. Husaberg was known for its continuous development of its engine and chassis configurations.
Production Location:
Sweden (prior to KTM acquisition)
