Primary Coverage:
Comprehensive service, repair, and maintenance for all 2004 Husaberg FE/FC 450 and 650 models.
Secondary Coverage:
Mechanical and electrical systems, including engine, transmission, chassis, suspension, brakes, and electrical components.
Estimated Page Count:
Detailed, but not specified. Expected to be extensive given the A-Z coverage.
Type:
Workshop Service Repair Manual
Language:
English (implied by typical market for this manual type and description)
Engine:
Complete engine overhaul, cylinder head, valve train, pistons, crankshaft, camshafts, lubrication system, cooling system, fuel system, emissions control, ignition system.
Transmission:
Clutch operation and repair, manual transmission (gearbox) disassembly, inspection, and assembly, including gear ratios and shift mechanisms.
Chassis And Suspension:
Frame inspection, front forks (including internal components, seals, and oil changes), rear shock absorber, linkage, swingarm, bearings.
Brakes:
Front and rear brake systems (hydraulic), caliper service, master cylinder, brake lines, bleeding procedures, pad replacement, rotor inspection. ABS not typically featured on these models.
Electrical:
Wiring diagrams, lighting system, ignition system, starter system, charging system (stator, rectifier/regulator), battery maintenance, instrument panel functions, troubleshooting electrical faults.
Fuel And Emissions:
Carburetor (if applicable) service and tuning, fuel pump operation, fuel filter replacement, emissions control systems specific to the model year and region.
Bodywork:
Fairing removal and installation, seat, fuel tank, fenders, exhaust system removal and installation.
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning/replacement, spark plug inspection and replacement.
Tune Up:
Carburetor synchronization (if applicable), ignition timing verification, valve clearance adjustment.
Engine Rebuild:
Complete engine disassembly, component inspection, measuring tolerances, reassembly procedures, gasket and seal replacement.
Suspension Service:
Fork seal replacement, fork oil level and type specification, rear shock servicing (if user-serviceable).
Electrical Troubleshooting:
Diagnosis of electrical faults using wiring diagrams, continuity testing, voltage checks.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Engine Removal Installation:
Detailed steps for removing and reinstalling the entire engine from the motorcycle frame.
Tightening Torques:
Essential torque specifications for all critical fasteners to ensure proper assembly and prevent component failure.
Valve Timing:
Procedures for setting valve timing using timing marks on camshafts and crankshafts.
Chain Routing Sprocket Timing:
Guidance on correct chain routing and timing marks for camshaft and crankshaft sprockets.
Depth:
Extensive, covering all aspects from basic maintenance to complete engine and component rebuilds. Suitable for professional mechanics and skilled DIY enthusiasts.
Diagnostic Capabilities:
Covers comprehensive troubleshooting guides for various mechanical and electrical issues, enabling accurate diagnosis.
Scope:
Complete A-Z coverage, meaning no critical repair or maintenance procedure is omitted.
Type:
Four-stroke, single-cylinder (specific engine configurations may vary slightly between 450 and 650cc).
Displacement 450:
Approximately 449cc (actual displacement may vary based on specific engine variant).
Displacement 650:
Approximately 652cc (actual displacement may vary based on specific engine variant).
Horsepower Torque:
Specific figures not provided in product information, but typical for performance off-road engines of this era. Consult specific model specifications for exact data.
Carburetion:
Likely utilizes a high-performance carburetor (e.g., Keihin FCR series) for optimal air-fuel mixture. Manual will detail tuning and maintenance.
Oil Type:
Refer to manual for specific engine oil viscosity (e.g., SAE 10W-40 or 15W-50) and capacity. Likely a dedicated motorcycle 4-stroke oil with JASO MA/MA2 certification.
System Type:
Liquid-cooled, with radiator and fan. Manual will cover coolant type, capacity, and bleeding procedures.
Oil Change:
Refer to manual for specific intervals, typically every 15-30 engine hours or based on mileage/usage conditions.
Valve Clearance:
Crucial for performance and engine longevity. Intervals often range from 100-300 engine hours, dependent on usage. Manual provides precise checks and adjustment procedures.
Engine Oil:
Specific viscosity and API/JASO ratings will be detailed. Expect high-quality synthetic or semi-synthetic motorcycle oil.
Coolant:
Proprietary or standard motorcycle coolant mixtures with anti-corrosion and anti-freeze properties. Manual will specify type and mixture ratio.
Brake Fluid:
DOT 4 or DOT 5.1 is common for hydraulic brake systems. Manual will confirm the correct specification.
Fork Oil:
Specific weight (viscosity) of fork oil will be provided, crucial for proper damping characteristics.
Common Wear Items:
Clutch plates, valve seats, piston rings, fork seals, wheel bearings, and chain/sprockets are common wear items on performance off-road motorcycles. The manual will guide on inspection and replacement.
Electrical Connections:
Corrosion on electrical connectors, particularly in off-road environments, can lead to intermittent issues. The manual aids in diagnosis and repair.
