"04 Edition 2004 BEDIENUNGSANLEITUNG OWNERS MANUAL MANUEL D'UTILISATION TABLE OF CONTENTS Page INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Important limited warranty and limited guarantee information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine-Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . .6 Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Hand decompression lever . . . . . . . . . . . . . . . . . . . . .6 Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . .7 Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Headlamp switch (USA) . . . . . . . . . . . . . . . . . . . . . . .7 Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Emergency OFF switch (Australia) . . . . . . . . . . . . . . . .8 Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . .8 Tripmaster-switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Activating/deactivating the display modes . . . . . . .13 Kilometers or miles . . . . . . . . . . . . . . . . . . . . . . . . . .14 Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Fuel taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Hot start device . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Compression damping of fork . . . . . . . . . . . . . . . . . .17 Rebound damping of fork . . . . . . . . . . . . . . . . . . . .17 Damping action during compression of shock absorber 18 Rebound damping of shock absorber . . . . . . . . . . .19 Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE .20 Instructions for initial operation . . . . . . . . . . . . . . . .20 Running in the Husaberg models . . . . . . . . . . . . . . .20 DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .21 Check the following before each start . . . . . . . . . . .21 Starting when the engine is cold . . . . . . . . . . . . . . .22 Starting when the engine is warm . . . . . . . . . . . . . .22 What to do when the engine is "flooded" . . . . . . . .22 Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . .24 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 PERIODIC MAINTENANCE SCHEDULE 2004 . . . . . . . .26 MAINTENANCE WORK ON CHASSIS AND ENGINE . .30 Checking and adjusting the steering head bearing .30 Breather plug front fork . . . . . . . . . . . . . . . . . . . . . .31 Cleaning the dust sleeves of the telescopic fork . . .31 Basic suspension setup for the weight of the driver .32 Checking the shock absorber and spring . . . . . . . . .32 Determining the static sag of the shock absorber . .32 Determining the riding sag of the shock absorber .32 Checking the basic setup of the telescopic fork . . .33 Changing the spring preload on the telescopic fork 33 Page Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . .33 How to change the handlebar position . . . . . . . . . .34 Changing the spring preloading of the shock absorber .34 Check chain tension . . . . . . . . . . . . . . . . . . . . . . . . .35 Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .35 Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .36 Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 General information about Husaberg disc brakes . .37 Changing the basic position the hand brake lever (FC, FE) 38 Changing the basic position the hand brake lever (FS) . . .38 Checking the brake fluid level - front brake . . . . . . .38 Refilling the front brake fluid reservoir . . . . . . . . . . .38 Checking the front brake pads . . . . . . . . . . . . . . . . .39 Replacing the front brake pads (FC/FE) . . . . . . . . . .39 Replacing the front brake pads (FS) . . . . . . . . . . . . .39 Changing the basic position of the foot brake pedal 40 Check the rear brake fluid level . . . . . . . . . . . . . . . .40 Refilling the rear brake fluid reservoir . . . . . . . . . . . .40 Checking the rear brake pads . . . . . . . . . . . . . . . . .41 Replacing the rear brake pads . . . . . . . . . . . . . . . . .41 Dismounting and mounting the front wheel . . . . . .42 Dismounting and mounting the rear wheel . . . . . . .43 Checking the shock absorption rubbers in the rear hub .44 Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .44 Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Check/set distance of the magnetic sensor . . . . . . .45 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Charging the battery . . . . . . . . . . . . . . . . . . . . . . . .46 Fuse (FE/FS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Replacing headlight lamp/parking light lamp . . . . .47 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Checking the coolant level . . . . . . . . . . . . . . . . . . . .48 Bleeding the cooling system . . . . . . . . . . . . . . . . . .49 Replacing the glassfiber yarn packing of the silencer .49 Cleaning the spark arrester . . . . . . . . . . . . . . . . . . .49 Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . .50 Checking the adjustment of the hand decompression release cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Adjusting the throttle cables . . . . . . . . . . . . . . . . . .50 Changing the original position of the clutch lever . .51 Checking the oil level of the hydraulic clutch . . . . . .51 Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . .51 Carburetor ­ Adjust idling . . . . . . . . . . . . . . . . . . . .52 Basic information on carburetor wear . . . . . . . . . . .52 Adjusting the mixture control screw . . . . . . . . . . . . .52 Checking the float level (float height) . . . . . . . . . . .53 Draining the float chamber of the carburetor . . . . .53 Oil Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Checking the engine oil level . . . . . . . . . . . . . . . . . .54 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Changing the engine oil . . . . . . . . . . . . . . . . . . . . . .54 Cleaning the oil screen . . . . . . . . . . . . . . . . . . . . . . .54 Changing the oil filter . . . . . . . . . . . . . . . . . . . . . . . .55 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .56 CLEANING, CONSERVATION, STORAGE . . . . . . . . . .58 TECHNICAL DATA - ENGINE . . . . . . . . . . . . . . . . . . . .59 TECHNICAL DATA - CHASSIS . . . . . . . . . . . . . . . . . . . .61 HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . .64 WIRING DIAGRAMM . . . . . . . . . . . . . . . . . . . . .Appendix -1- ENGLISH INTRODUCTION IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS: WARNING: IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE. ENGLISH CAUTION: IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE IS NOT ROADSAFE ANYMORE. NOTE: USEFUL INFORMATION ON HANDLING AND SERVICING YOUR MOTORCYCLE. Please insert the serial numbers of your motorcycle in the boxes below Frame number: Motor number: Stamp of dealer: COMSUMER INFORMATION FOR AUSTRALIA ONLY The exhaust system on this vehicle has no owner serviceable parts. Should there be an increase in noise or damage to any component relating to the noise reduction system, replacement parts should be fitted by an Authorised dealer. Tampering with noise control system prohibited Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and (b)the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT, TECHNICAL SPECIFICATIONS, COLORS, MATERIALS, SERVICES OFFERED AND RENDERED, AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS, OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTITUTING THEM WITH OTHERS. IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS ANNOUNCEMENT. HUSABERG -2- INTRODUCTION We would like to congratulate you on your purchase of a Husaberg motorcycle. You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately. Before you go for your first ride, be sure to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new motorcycle and with its characteristics, even if this means that you will have to dedicate some of your valuable time to this task. Only by doing so will you learn how to tune your motorcycle to your specific needs and how to protect yourself against injury. Besides, this manual contains important information on motorcycle maintenance. At the time this manual was typeset, it was up-to-date with the latest state of this production series. Please note that motorcycle features may vary according to the effective legal provisions. It cannot be completely ruled out, however, that minor discrepancies may exist resulting from further design upgrades of these motorcycles.This manual is an important part of your motorcycle and should be passed on to any subsequent owner in case you decide to sell it. The work marked with an * in the chapter "Servicing the chassis and engine" must be performed by an authorized Husaberg dealer. If such service work becomes necessary during a competition, it must be performed by a trained mechanic. For your own safety, use Husaberg-approved parts and accessories only. Husaberg is not liable for damage that arises in connection with the use of other products. Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle. Be sure to have your motorcycle serviced by an authorized Husaberg dealer to maintain the validity of your warranty. Off-road / Supermoto motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full. It may, however, involve potential problems for the environment or lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle is used responsibly. To safeguard the future of motorcycle sports, make sure that you use the motorcycle in accordance with the law, show that you are environmentally conscious and respect the rights of others. We wish you a lot of fun when driving ! HUSABERG 5230 MATTIGHOFEN, AUSTRIA ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL. © by HUSABERG Alle Rechte vorbehalten -3- ENGLISH INTRODUCTION IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION Husaberg sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations. Observance of the service, maintenan ...