This manual covers the FE 450, FC 450, FE 650, and FC 650 models from the 2004 production year. These motorcycles are renowned for their powerful LC4 single-cylinder engines and robust construction, designed for demanding off-road and enduro riding. With Swedish origins and later integration with another manufacturer, there is a heritage of producing high-performance, purpose-built machines that compete in specialized segments of the motorcycle market. The 450cc and 650cc displacements offer distinct performance characteristics, catering to riders who prioritize power, agility, and reliability in competitive off-road environments.
This comprehensive Factory Service Repair Workshop Manual provides detailed information on all repairs, servicing, troubleshooting, and maintenance procedures for the specified models. It covers an extensive range of systems, including the engine, fuel, ignition, lubrication, cooling, exhaust, transmission, clutch, drivetrain, suspension, brakes, wheels, tires, and electrical systems. The manual includes step-by-step instructions, detailed photos, and exploded diagrams, making it an invaluable resource for owners, mechanics, and technicians to ensure the optimal performance and longevity of their motorcycles.
Model:
FE 450 / FC 450 / FE 650 / FC 650
Engine Codes:
FE450 (LC4 single-cylinder), FC450 (LC4 single-cylinder), FE650 (LC4 single-cylinder), FC650 (LC4 single-cylinder)
Market Position:
Husaberg motorcycles, particularly the FE and FC models, occupied a niche in the off-road and enduro racing market, known for their powerful engines and robust construction. This manual caters to owners and technicians seeking in-depth knowledge for maintaining and repairing these specialized machines.
Competitive Analysis:
In 2004, Husaberg competed against other premium European off-road manufacturers like KTM, Husqvarna, and Beta, as well as Japanese brands such as Yamaha, Honda, and Suzuki in the enduro and motocross segments. The 450cc and 650cc displacements offered distinct performance characteristics, with the 650cc models often favored for torque-rich off-road riding and the 450cc for a more agile, race-oriented feel.
Key Features:
This manual is a comprehensive factory service manual, providing the same level of detail found in professional workshop manuals. Its key features include unlimited lifetime usage, compatibility across multiple devices and operating systems, and the ability to print any section or the entire document. It covers all aspects of repair, maintenance, and troubleshooting.
Coverage Areas:
All repairs, servicing, troubleshooting, maintenance procedures for the specified Husaberg models.
Page Count:
Hundreds of pages (exact count not specified, but described as 'very detailed')
Manual Type:
Factory Service Repair Workshop Manual
Format:
Digital Download (PDF compatible with computers, tablets, smartphones)
Content Type:
Service, Repair, Workshop, Troubleshooting, Maintenance
Systems Covered:
Engine, Fuel System, Ignition System, Lubrication System, Cooling System, Exhaust System, Transmission, Clutch, Drivetrain, Suspension (Front and Rear), Brakes (Front and Rear), Wheels and Tires, Electrical System (Lighting, Ignition, Charging, Starting), Frame, Bodywork, Controls, Chassis.
Procedures Included:
Routine Maintenance, Scheduled Servicing, Engine Overhaul, Transmission Repair, Clutch Service, Suspension Adjustments and Rebuilds, Brake System Bleeding and Component Replacement, Electrical Troubleshooting, Carburetor Adjustment and Rebuild, Fuel Injection System Diagnosis (if applicable to specific sub-models), Chassis Lubrication, Wheel Bearing Service, Chain Adjustment, Spark Plug Replacement, Oil and Filter Changes, Valve Clearance Adjustment, General Inspection and Repair.
Technical Depth:
Comprehensive and detailed, suitable for professional mechanics and technicians. Includes step-by-step instructions, detailed photos, and exploded diagrams for all repair and maintenance tasks.
Diagnostic Tools Required:
Manual provides troubleshooting guides that may require basic hand tools, multimeter, and diagnostic indicators specific to the bike's electrical system. No proprietary software diagnostics are implied.
Repair Procedures:
Detailed instructions for disassembly, inspection, repair, and reassembly of all major mechanical and electrical components.
Print Quality:
High-resolution, allowing for clear printing of individual pages or the entire manual.
Binding Type:
Not Applicable (Digital Download)
Paper Type:
Not Applicable (Digital Download)
Accessibility Devices:
Works on Windows, MAC computers, tablets, and smartphones.
License Terms:
Lifetime usage, no expiry dates, no renewal fees.
Searchability:
PDF format often allows for text searching of keywords, aiding in quick location of specific information.
Diagrams Photos Quality:
Hundreds of detailed photos and diagrams, including exploded views, to illustrate procedures and component relationships.
Primary Engine:
LC4 Single-Cylinder Four-Stroke Engine
Engine Displacement 450:
Approximately 450cc (specific bore and stroke required from manual)
Engine Displacement 650:
Approximately 650cc (specific bore and stroke required from manual)
Horsepower 450:
Estimated 45-55 HP (dependent on specific tune and model variant; exact figures in manual)
Horsepower 650:
Estimated 55-65 HP (dependent on specific tune and model variant; exact figures in manual)
Torque 450:
Estimated 35-40 lb-ft (dependent on specific tune and model variant; exact figures in manual)
Torque 650:
Estimated 45-55 lb-ft (dependent on specific tune and model variant; exact figures in manual)
Fuel System 450 650:
Carbureted (likely Keihin or Mikuni, specific model detailed in manual)
Cooling System:
Liquid-cooled
Lubrication System:
Wet sump with oil filter
Bore Stroke 450:
Specific bore and stroke dimensions required from manual for accurate engine rebuild specifications.
Bore Stroke 650:
Specific bore and stroke dimensions required from manual for accurate engine rebuild specifications.
Compression Ratio 450:
Typical for high-performance off-road engines; exact figures detailed in the manual.
Compression Ratio 650:
Typical for high-performance off-road engines; exact figures detailed in the manual.
Ignition System Type:
Electronic Ignition (CDI or similar, specific type detailed in manual).
Transmission Type:
6-speed Manual Transmission
Transmission Features:
Hydraulic clutch actuation (typical for Husaberg of this era)
Clutch Type:
Wet, multi-plate
Gear Ratios:
Specific gear ratios for each of the 6 speeds and the final drive ratio will be provided in the manual.
Wheelbase:
Variable depending on FE/FC designation, typically around 1470-1500 mm (exact figures in manual)
Ground Clearance:
Significant ground clearance typical for off-road motorcycles, specific figures in manual.
Dry Weight:
Approximately 115-125 kg (dependent on model and equipment, exact figures in manual)
Safety Ratings:
Not applicable for off-road competition motorcycles; safety focus is on rider protection and vehicle stability during performance riding.
Active Features:
High-performance braking systems (e.g., Brembo or Magura front and rear disc brakes), responsive suspension for stability.
Passive Features:
Sturdy frame construction, ergonomic rider controls designed for off-road use.
Infotainment Systems:
None. This is a performance off-road motorcycle focused purely on function and rider control, not creature comforts or digital displays beyond essential instrumentation.
Driver Assistance Features:
None. Rider input and skill are the primary 'assistance' systems.
Connectivity Features:
None.
Instrumentation:
Basic digital or analog instrumentation for speed, odometer, and possibly engine hour meter, as per off-road standards.
Oil Change Interval:
Typically every 10-15 hours of riding or annually, as specified in the manual.
Air Filter Cleaning:
Recommended after every few rides or in dusty conditions, as detailed in the manual.
Spark Plug Replacement:
As per manual recommendations, often tied to engine hours or specific mileage.
Valve Clearance Check:
Typically every 30-50 hours of riding; crucial for engine performance and longevity (exact intervals in manual).
Engine Oil Type:
High-quality synthetic motorcycle oil, e.g., Motorex 4T 10W-50 or equivalent (specific API and JASO ratings in manual).
Engine Oil Capacity:
Approximately 1.5-1.8 liters (exact capacity in manual).
Coolant Type:
Ethylene glycol based coolant with anti-corrosion additives, typically a 50/50 mix with distilled water (specific type in manual).
Brake Fluid Type:
DOT 4 or DOT 5.1 brake fluid (as specified by caliper manufacturer, usually in manual).
Clutch Fluid Type:
DOT 4 or DOT 5.1 brake fluid for hydraulic clutch systems (as specified, in manual).
Known Issues General:
Common issues for performance off-road bikes of this era can include carburetor tuning, suspension seal leaks, clutch wear, and electrical connections. The manual will provide diagnostic procedures for these and other potential problems.
Maintenance Schedule Details:
The manual provides detailed maintenance schedules for various riding conditions, from light use to competitive enduro racing, covering all critical components.
Oil Filter Part Number:
Specific part numbers for oil filters (e.g., for the engine oil and potentially a separate oil screen) will be listed in the manual; common brands for this era include K&N or Hiflofiltro.
Air Filter Part Number:
Specific part numbers for air filters (e.g., foam or paper) will be listed in the manual; common brands include Twin Air or K&N.
Torque Specifications:
Crucial torque values for critical fasteners (e.g., cylinder head bolts, wheel nuts, suspension components) will be detailed for proper assembly.
Brand Heritage:
Husaberg was founded in Sweden in 1988 by former Husqvarna engineers. The brand quickly established a reputation for high-performance, purpose-built off-road motorcycles. In 2003, KTM acquired Husaberg.
Model Evolution:
The FE (Four-stroke Enduro) and FC (Four-stroke Competition/Cross Country) lines represented Husaberg's commitment to the four-stroke off-road market. The 2004 models likely featured refinements and updates from previous years, leveraging the KTM acquisition for improved components and manufacturing.
Production Location:
Sweden/Austria (post-KTM acquisition)
Brand Recognitions:
Husaberg models were consistently recognized for their performance and innovative designs within the off-road motorcycle community, frequently winning shootouts and earning praise from specialized media.
Performance Ratings:
High performance ratings for engine power, suspension travel and damping, and chassis handling in off-road conditions.
