HUSABERG FC 470 e User manual

INDEX
1
1
2
3
4
5
6
7
8
9
11
10
12
SAFETY AND PRECAUTIONS Page 4-
GENERAL INFORMATION Page 6-
MAINTENANCE SCHEDULE Page 9-
CONTROLS Page 12-
WIRING DIAGRAMS Page 33-
INTRODUCTION Page 2-
STARTING PROCEDURE Page 15
ENGINE Page 16- A LUBRICATION SYSTEM
B IGNITION
C AIR FILTER
D VALVE ADJUSTMENT
WHEELS & BRAKES Page 23- A WHEELS
B CHAIN
C BRAKES
SUSPENSION Page 29- A SUSPENSION
B STEERING HEAD
C SWINGARM
FUEL & COOLING Page 20- A CARBURETTOR
B FUEL
C COOLING SYSTEM
CLUTCH & DECOMPRESSION Page 22

INTRODUCTION
2
1
1
Please read and observe the following:
Warning
If the engine has to be running during any maintenance, make sure that the area is
properly ventilated. Never run the engine in a closed area though the exhaust fumes
are posionous and thus hazardous to your health and life.
Warning
Although the battery is of a sealed construction, please take care. The electrolyte contains
sulfuric acid and you must protect your eyes, skin and clothing if such fluid is assumed
to be leaking or likewise exposed. In case of contact, wash and flush thoroughly with
water and contact medical help if needed, especially if your eyes have been exposed to
the fluid.
Warning
Fuel is extremely flammable and explosive under certain conditions. Do not smoke or
expose the fuel to open fire or sparks.
SERVICE CONDITIONS:
1. Always use original Husaberg parts.
2. Use the special Husaberg tools when required.
3. Install new gaskets, o-rings, circlips etc whenever possible.
4. Always clean all parts thoroughly before assembly.
5. All screws, nuts and bolts etc. are in the metric system. Do not use incorrect tools.
Endurovägen, S-695 72 SWEDEN
www.husaberg.se
[email protected]
PRINT & COPY RIGHTS
The material and information included in this Owner’s Manual are all of the latest editions
available at the time of the printing.
Husaberg Motor AB reserves the right to make changes regarding the products at any
time without prior notice.
This Owner’s Manual is subject to corrections without prior notice.
No part of this Owner’s Manual may be reproduced without written permission

INTRODUCTION
3
1
1
Always put the motorcycle on a stable centerstand
whenever removing either front or rear wheel.
ATTENTION:
Never ride your motorcycle under the influence of
alcohol, drugs, barbiturates or any other kind of medical
treatments hazardous to your riding performance.
ATTENTION:
Never ride in a too low or too high gear -
Never let the engine run for more than one minute while stationary
It may cause severe mechanical damages
ATTENTION:
ATTENTION:
Service more frequently when
riding under hard conditions
ATTENTION:
Do not use a highpressure jet-cleaning
equipment on surfaces around
bearings and other fragile components.
WARNING:
Do not check the coolant
level while the engine is hot.
ATTENTION:
Less clearances than the required
cause severe engine damages
Dear client,
We feel ourselves privileged and honoured to be the supplier of your choice of motorcycle. We
know for sure that our product will give you years of fun and performance though the Husabergs
are based upon decades of experience in racing and a dedication hard to find elsewere. You’re
bound to feel this through the inborn lively spirit of your bike.
Although mainly designed and constructed for competition purposes it is still very rider-friendly
but due to the design the product needs careful and proper maintenannce. In order to get the
most out of your "beast" and before any use of the motorbike; we highly recommend you to
carefully read this Owner's Manual through. We also recommend you to pay your outmost
attention to the following page regarding safety and precautions and always remember the
fundamental base of all activities on two wheels:
- "Do not overestimate your capabilities, follow the domestic regulations and do think about
your surroundings"
Although the Owner's Manual is put together and written in a way that will make it possible for
an average mechanical experienced person to take care of the maintenance, we recommend
you to let an authorized Husaberg dealer take care of at least the parts we’ve mentioned under:
Also, part of the maintenance has to be performed by an authorized dealer in order to fulfill the
terms of warranty.
If you follow the advice regarding the set-up and of course also regarding the vital maintenance
of the motorcycle; the Husaberg of yours will provide a maintained level of performance (read:
joy and satisfaction - the reason to your choice of brand).
The personnel of Husaberg Motor AB Sweden

SAFETY AND PRECAUTIONS
4
2
2
Never ride your motorcycle under the influence of
alcohol, drugs, barbiturates or any other kind of medical
treatments hazardous to your riding performance.
ATTENTION:
SAFETY
PROTECTION:
Always protect yourself with adequat clothing and protective apparel.
Always wear a helmet, goggles and boots.
MOTORCYCLE:
The motorcycle may become dangerous to ride if it is modified or if any other parts than
original Husaberg parts are used. The use of other parts than original makes the warranty
no longer valid.
Always keep your motorcycle in a safe state and in the best of conditions.
Regular cleaning and maintenance are extremely vital in order to avoid any mechanical
damages hazardous to you and/or your surroundings.
TRANSPORTATION:
Always transport your bike upright in order to avoid any leakages of oil and/or fuel. Such
fluids may increase the risk of fire. Always make sure that the bike is properly fastened
in a safe and firm position during transportation.
RIDING:
Always check the motorcycle for any deterioration/damages and any necessary
adjustments before you start the motorcycle (see "Pre-ride inspection").
Though the Husaberg motorcycle has a very high level of performance; always ride
with care and do not overestimate your capabilities. Get to know your Husaberg
motorcycle really well before you try to get the most out of it.
Never lend your motorcycle to any other rider unless you are sure that he/she is fully
capable of handling it.
Always obey all local and federal regulations and laws valid within the territory.
Never ride in terrain unfamiliar to you unless inspected and guaranteed by the local
authorities.
PRE-RIDE INSPECTION:
Make it a habit to give your motorcycle an inspection before and after every ride.
Always check all bolts and nuts and tighten if necessary - All for your own safety.
A clean and well lubricated bike makes for a safer ride as well as a higher value of the
machine. The Pre-ride Inspection Checklist on the next page is to be regarded as a
brief summary of the main important items to be controlled and, if necessary; to be
adjusted or replaced.

SAFETY AND PRECAUTIONS
5
2
2
PRE-RIDE INSPECTION CHECK LIST
Engine oil Check the level and fill up if necessary.
Check for any leakages in the casing.
Ignition Check the sparkplug cap/HV lead for damages.
Radiator Check the coolant level and fill up if necessary.
Check for leakages and/or damages of the cells and hoses
and attachments.
Airfilter Clean, or if necessary, replace the filter
Carburettor Check the function of the throttle/cable and adjust/replace
any damaged parts if necessary.
Adjust the idling- and/or mixture screw if necessary.
After every time the motorbike has been washed drain the
float chamber of the carburettor.
Clutch Check the function and for any leakages.
Decompression Check the function of the manual and the semi-automatic
decompression lever and adjust if necessary (non-electrical
starter models only).
Chain Check and adjust/replace the chain if necessary.
Check the sprockets and replace if necessary.
Suspension Check the operation of the front fork and the shock absorber
and adjust if necessary.
Check and tighten the swingarm if necessary.
Wheels Check the air pressure of the tyres and fill up if necessary.
Check the spokes and tighten if necessary.
Brakes Check the level of brakefluid and fill up if necessary.
Check for any leakages and the function of the brakes.
Adjust levers and/or replace hoses/pads if necessary.
Fuel Check the level and fill up if necessary.
Check for any leakages in the fuel lines.
Steering Check the clearance of the steering head bearings and
adjust if necessary.
Controls Check the function of the speedometer or odometer (if
incl.in equipment).
Lighting Check the functions of the front-, tail-, and brake lights
(and any occuring turn signals).

GENERAL INFORMATION
6
3
3
SPECIFICATIONS
SUBJECT/MODEL FE 400 e FE 501 e FE 650 e FS 400 e FS 650 e FS 400 c FS 650 c FC 470/6 FC 550/4 FC 550/6 FC 470 e FX 470 e FX 650 e Displacement 399cc 501cc 644cc 399cc 644cc 399cc 644cc 472cc 550cc 550cc 472cc 472cc 644cc Bore x Stroke (mm) 92 x 60,1 95 x 70,7 100 x 82,0 92 x 60,1 100 x 82,0 92 x 60,1 100 x 82,0 100 x 60,1 100 x 70,0 100 x 70,7 100 x 60,1 100 x 60,1 100 x 82,0 Compression ratio 12,5:1 11,8:1 11,0:1 12,5:1 11,0:1 12,5:1 11,0:1 12,4:1 12,7:1 12,7:1 12,4.1 12,4:1 11,0:1 Start system Electrical and kick-starter Kick-starter Electrical and kick-starter Decompression system Three separate ones; one activated by the kickstart lever, one activated by the camshaft and one activated by a lever on the handlebar Decomp. cable clearance 2mm ± 1mm / 0,08 in ± 0,04 in. Engine Liquid cooled single cylinder 4-stroke, SOHC-4 valves, counter balancer Valve clearance Intake and Exhaust: 0,10mm / 0,004 in. Lubrication system Orbit oil pump and reed valve controlled. High pressure jet spray of piston and connecting rod, pressure lubrication of connecting rod bearing and rocker arms. Oil screen and micro filter Engine oil 1,0 Litre Synthetic SAE 5W-50 API SG/CF (minimum SAE 10W-50) Ignition system SEM Dynamic Force Control, DFC™, Dual Ignition Curves; High & Low. A load sensitive digital system with six sensors Spark plug - Spark plug gap NGK DCPR8E - 0,6 mm / 0,025 in. Alternator 12 V 70 + 70 W Not available 12 V 70 + 70 W Air intake system Single foam filter Carburettor (DELLORTO) PHM 38 PHM 40 PHM 40 PHM 38 PHM 40 PHM 40 PHM 40 PHM 40 PHM 40 PHM 40 PHM 40 PHM 40 PHM 40 Fuel RON 98 (octane), unleaded Exhaust system Chrome plated steel pipes, 2 into 1 collector, Aluminium/steel silencer. USA versions, except FC and FSc models, equipped with spark arresters Coolant 1,3 Litre of 50% Anti-freeze, with corrosion inhibitor, and 50% water Clutch Hydraulic, 7 friction- and 8 mating plates in oil bath Clutch hydraulic oil Mineral oil SAE 2-7W Wear limit clutch discs 19,6 mm / 0,772 in. Primary transmission Spur gears, ratio 29/78 - 2,690 Gearbox 6-speed 6-speed 6-speed 6-speed 6-speed 6-speed 6-speed 6-speed CR 4-speed 6-speed CR 6-speed CR 6-speed 6-speed
Ratios 1st: 14/33 - 2,357 2nd: 17/30 - 1,765 3rd: 19/26 - 1,368 4th: 23/25 - 1,087 5th: 24/22 - 0,917 6th: 27/20 - 0,741 (6th CR: 25/21-0,840)
Secondary transmission D.I.D. 520 O-ring chain Sprockets front/rear 13/48 15/48 15/42 15/42 15/42 15/42 15/42 13/42 15/42 15/48 13/48 13/48 15/42 Wear limit drive chain 272 mm - 18 chain reels (tensioned, center distance between reels) Frame Heat treated BTR / 25CrMo4 steel Caster 28,5° Weight (dry) 109,8 kg 110,1 kg 110,9 kg 111,9 kg 113,1 kg 105,7 kg 106,8 kg 103,5 kg 103,5 kg 103,9 kg 109,6 kg 109,6 kg 110,4 kg
242 lb. 243 lb. 244 lb. 247 lb. 249 lb. 233 lb. 235 lb. 228 lb. 228 lb. 229 lb. 242 lb. 242 lb. 243 lb.

GENERAL INFORMATION
7
3
3
SPECIFICATIONS
SUBJECT/MODEL FE 400 e FE 501 e FE 650 e FS 400 e FS 650 e FS 400 c FS 650 c FC 470/6 FC 550/4 FC 550/6 FC 470 e FX 470 e FX 650 e Rims Front EXCEL 1.60 x 21” BEHR 3.50 x 17” EXCEL 1.60 x 21” EXCEL 1.60 x 21”
Rear EXCEL 2.15 x 18” BEHR 4.25 x 17” EXCEL 2.15 x 19” EXCEL 2.15 x 18”
Tyres (MICHELIN)Front 90/90-21” 120/60-17” 80/100-21” 90/90-21”
Rear 140/80-18” 150/60-17” 110/100-19” 130/80-18”
Tyre pressure (cold) Offroad Front 0,8 bar / 12,0 psi 0,8 bar / 12,0 psi
Rear 0,8 bar / 12,0 psi 0,8 bar / 12,0 psi
Tarmac Front 1,0 bar / 14,5 psi 2,2 bar / 31,9 psi
Rear 1,0 bar / 14,5 psi 2,0 bar / 29,0 psi
Suspension (WP) Front MXMA 4860-HBG E ø 48 mm MXMA 4860-HBG S ø 48 mm MXMA 4860-HBG MX ø 48 mm
Rear PDS 5018-HBG E PDS 5018-HBG S PDS 5018-HBG MX
Wheel travel Front 295 mm / 11,6 in. 260 mm / 10,2 in. 295 mm / 11,6 in.
Rear 320 mm / 12,6 in. 287 mm / 11,3 in. 320 mm / 12,6 in.
Front fork oil WP SAE 5 Brakes Front BREMBO BERINGER BREMBO
Hydraulic twin piston floating caliper Hydraulic four piston floating caliper Hydraulic twin piston floating caliper
ø 260 mm Inox steel disc ø 310 mm Plated cast iron disc ø 260 mm Inox steel disc
Rear BREMBO hydraulic single piston floating caliper, ø 220 mm Inox steel disc
Brake fluid DOT 4 Wear limit brake pads 1,5 mm / 0,06 in. Head light Alt. A 12 V 65/50 W - P43t Not applicable
Alt. B 12 V 45/40 W - BA20d Not applicable
Tail / Stop light 12 V 21/5 W - BAY 15d Not applicable Parking light 12 V 4 W - BA9s Not applicable Turn signal lights 12 V 10 W - BA15s Not applicable Speedometer light 12 V 2 W - BA7s Not applicable Battery / Main fuse 12 V 8 Ah / 15 A Not applicable Wheel base - Width 1490 mm / 58,66 in. - 810 mm / 31,89 in. Seat height 930 mm / 36,61 in. 870 mm / 34,25 in. 930 mm / 36,61 in. Ground clearance 380 mm / 14,96 in. 320 mm / 12,60 in. 380 mm / 14,96 in. Overall length 2200 mm / 86,61 in. 2150 mm / 84,65 in. 2200 mm / 86,61 in.

GENERAL INFORMATION
8
3
3
1. Flywheel puller -
Article No. 270028-01
2. Flywheel holder -
Article No. 270030-01
4. Tool kit -
Article No. 390029-01
CARBURETTOR STD. JETTINGS
3. Air bleeding syringe -
Article No. 270032-01
Street ECE
MODEL/SUBJECT
Exploded view number
Main
jet
# 6
Needle
jet
# 4
Needle
# 3
Needle
clip pos.
# 26
Pilot
jet
# 7
Throttle
# 2
Float
valve
# 9
Mixture
screw
# 33
Start
jet
# 8
185 DR 270 K 51 #3 33 40 300
185 DR 272 K 51 #3 35 40 300
190 DR 272 K 51 #3 40 40 300
110 DR 266 K 51 #2 48 40 300
110 DR 264 K 35 #4 33 40 300
100 DR 266 K 51 #3 33 40 300
190 DR 270 K 51 #3 38 40 300
195 DR 268 K 35 #3 33 40 300
195 DR 270 K 35 #3 33 40 300
185 DR 270 K 51 #3 33 40 300
190 DR 272 K 51 #3 40 40 300
110 DR 266 K 51 #2 48 40 300
100 DR 266 K 51 #3 33 40 300
190 DR 270 K 51 #3 38 40 300
195 DR 270 K 35 #3 33 40 300
180 DR 272 K 35 #3 33 40 300
190 DR 272 K 51 #3 40 40 300
185 DR 266 K 35 #3 33 30 300
190 DR 270 K 51 #3 33 40 300
185 DR 266 K 35 #3 33 30 300
190 DR 272 K 51 #3 33 40 300
185 DR 266 K 35 #3 33 30 300
2 turns
1½ turns
1½ turns
½ turn
½ turn
½ turn
2 turns
1½ turns
1½ turns
2 turns
1½ turns
½ turn
½ turn
2 turns
1½ turns
1½ turns
1½ turns
1½ turns
1½ turns
1½ turns
1½ turns
1½ turns
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
Enduro
Enduro
ECE
Enduro
USA
Super Motard
Super Motard
Super Motard
Street USA
Super Motard
Competition
Cross Country
Motocross
FE 400 e
FE 501 e
FE 650 e
FE 400 e
FE 501 e
FE 650 e
FE 400 e
FE 501 e
FE 650 e
FS 400 e
FS 650 e
FS 400 e
FS 650 e
FS 400 e
FS 650 e
FS 400 c
FS 650 c
FX 470 e
FX 650 e
FC 470
FC 550
FC 470 e
Street

GENERAL INFORMATION
9
3
3
4MAINTENANCE SCHEDULE
C: Clean - I: Inspect - R: Replace - *Maximum 12 months interval
Chassis - FE and FSe models
Chassis - FC, FSc and FX models
SRUOH/TCEJBUSSRUOH/TCEJBUS SRUOH/TCEJBUS SRUOH/TCEJBUSSRUOH/TCEJBUS
55
5
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*liokroftnorF RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
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RR RR
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RR RR
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R
RR RR
R
RR
*diulfekarB RR
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RR RR
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R
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R
RR RR
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R
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II II
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sgnihsubrebrosbakcohS II
I
II II
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II II
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II II
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II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II
sgniraebdaehgnireetS II
I
II II
I
II II
I
II II
I
II
sgniraebleehW II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II
SRUOH/TCEJBUSSRUOH/TCEJBUS SRUOH/TCEJBUS SRUOH/TCEJBUSSRUOH/TCEJBUS
010101010102020202020303030303040404040405050505050606060606070707070708080808080909090909001001 001 001001011011 011 011011021021 021 021021031031 031 031031041041 041 041041051051 051 051051061061 061 061061071071 071 071071081081 081 081081091091 091 091091002002 002 002002
*liokroftnorF RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR
*diulfekarB RR
R
RR RR
R
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R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
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sgnihsub/sgniraebmragniwS II
I
II II
I
II II
I
II II
I
II
sgnihsubrebrosbakcohS II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II
sgniraebdaehgnireetS II
I
II II
I
II II
I
II II
I
II
sgniraebleehW II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II
TORQUE VALUES
5 NmOil filter cover screws
5 Nm Apply a threadlock liquidReed valve screws
5 NmValve inspection cover screws
5 Nm
Waterpump cover screws
SUBJECT TORQUE NOTE
5 NmIntake manifold screws
10 NmCrankcase screws
8 NmStator screws
10 Nm
Exhaust pipe screws
10 NmGearshift lever screw
10 Nm Apply a threadlock liquidKick start lever screw
10 NmValve cover screws
12 NmOil drain plug
12 NmValve adjustment lock nuts
12 Nm
Spark plug
15 NmFront fork triple clamp screws lower (M8)
Standard torque values M8 M10
25 Nm 40 Nm
M12
40 Nm
M16
125 Nm
44 NmCylinderstud nuts
50 Nm Left-hand threadFlywheel nut
80 Nm Apply a threadlock liquidIntermediate gear wheel nut
110 Nm Apply a threadlock liquidPrimary gear wheel nut
125 NmSwingarm shaft nuts
M6
10 Nm
M5
8 Nm
M4
6 Nm
20 NmFront fork triple clamp screws upper (M8)
25 Nm Apply a threadlock liquidUpper timing sprocket screws

MAINTENANCE SCHEDULE
10
4
4
SRUOH/TCEJBUSSRUOH/TCEJBUS SRUOH/TCEJBUS SRUOH/TCEJBUSSRUOH/TCEJBUS
55
5
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RALUGERRALUGER RALUGER RALUGERRALUGER
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RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR
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C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC
retliforcimliO RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
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I
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R
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**noitingI/rotanretlA II
I
II II
I
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I
II II
I
II II
I
II II
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II II
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II II
I
II II
I
II II
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II II
I
II II
I
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sgnilaes&sediug.lcnisevlaV II
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nip&sgnir.lcninotsiP RR
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R
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I
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RR II
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scsid.lcnimsinahcemhctulC II
I
II II
I
II II
I
II II
I
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***/**rotterubraC C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I
msinahcemtratskciK II
I
II II
I
II
msinahcemtfihsraeG II
I
II II
I
II
msinahcemleehweerF:LE II
I
II II
I
II
SGNIRAEBSGNIRAEB SGNIRAEB SGNIRAEBSGNIRAEB
dorgnitcennoC RR
R
RR
tfahsknarC RR
R
RR RR
R
RR
tfahsniamxobraeG II
I
II RR
R
RR
tfahsyradnocesxobraeG II
I
II RR
R
RR
murdtfihS II
I
II RR
R
RR
tfahsmaC II
I
II RR
R
RR
etalperusserphctulC II
I
II RR
R
RR
leehwraegtratskciK II
I
II RR
R
RR
leehwraegetaidemretnI II
I
II RR
R
RR
smrarekcoR RR
R
RR RR
R
RR RR
R
RR RR
R
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.labretnuoctfahsetaidemretnI RR
R
RR RR
R
RR RR
R
RR RR
R
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recnalabretnuoC RR
R
RR RR
R
RR RR
R
RR RR
R
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dorgnitcennoC RR
R
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smrarekcoR II
I
II II
I
II
tfahstratskciK II
I
II II
I
II
tfahshctulC II
I
II RR
R
RR II
I
II RR
R
RR
Engine - FC, FSc and FX models
Please observe: Riding under hard conditions demands more frequent maintenance
C: Clean - I: Inspect - R: Replace
* Maximum 12 months interval - ** Clean whenever the engine has been washed - *** I(R): Especially needle and needle jet

MAINTENANCE SCHEDULE
11
4
4
SRUOH/TCEJBUSSRUOH/TCEJBUS SRUOH/TCEJBUS SRUOH/TCEJBUSSRUOH/TCEJBUS
010101010102020202020303030303040404040405050505050606060606070707070708080808080909090909001001 001 001001011011 011 011011021021 021 021021031031 031 031031041041 041 041041051051 051 051051061061 061 061061071071 071 071071081081 081 081081091091 091 091091002002 002 002002
RALUGERRALUGER RALUGER RALUGERRALUGER
lioenignE RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
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CC CC
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CC CC
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CC CC
C
CC CC
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CC CC
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C
CC CC
C
CC CC
C
CC CC
C
CC CC
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CC CC
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retliforcimliO RR
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scsid.lcnimsinahcemhctulC II
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***/**rotterubraC C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I
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Engine - FE and FSe models
Please observe: Riding under hard conditions demands more frequent maintenance
C: Clean - I: Inspect - R: Replace
* Maximum 12 months interval - ** Clean whenever the engine has been washed - *** I(R): Especially needle and needle jet

CONTROLS
12
5
5
IDENTIFACTION NUMBERS
The Vehicle Identification Number is placed on
the right side of the steering head (Fig. 5A-1).
The Engine Number is placed on the right side of
the engine, just below the cylinder (Fig. 5B-1).
STEERING LOCK
The lock (if incl. in equipment) is placed on the
right side of the steering head (Fig. 5A-2).
We recommend you to follow the conditions of
your insurance regarding the use of anti-theft
devices.
IGNITION LOCK
The ignition lock is either placed to the right of
any speedometer (Fig. 5C-1) or in a separat
bracket.
The first position, maximum counter-clockwise,
means that the engine can not be started. No
lights in function.
The second position, clockwise, means that the
engine can be started with the kick starter but
not with the electrical starter. Available lights in
function.
The third position, clockwise, means that the
engine can be started with both the kick starter
and the electrical starter. Available lights in
function.
Fig.
5A
Fig.
5B
Fig.
5C

CONTROLS
13
5
5
Fig. 5E Combination switch Type I:
1- Headlight switch
(Off - Low - High beam)
2- Turn signal switch
3- Horn button
4- Engine shortcircuit button
5- Clutch lever
Fig. 5F Combination switch Type II:
1- Headlight switch
(Off - Low - High beam)
2- Horn button
3- Engine shortcircuit button
Fig. 5G 1- Engine shortcircuit button
(Motocross models)
Fig. 5H 1- Clutch lever adjustment knob
2- Oil reservoir hydraulic clutch
3- Decompression lever
4- Decompression lever adjustment
Fig.
5E
Fig.
5F
Fig.
5G
Fig.
5H

CONTROLS
14
5
5
Fig. 7A
LOW HIGH
Fig.
5I
Fig.
5K
Fig.
5L
Fig 5I 1- Twistgrip
2- Front brake lever
3- Electrical starter button
(if it is an electrical starter model,
otherwise the button having no
function)
4- Dual ignition curve switch
Fig. 5L 1- Speedometer
(If included in equipment)
2- Highbeam indicator lamp
3- Turn signal indicator lamp
4- Trip meter knob
Fig. 5K 1- Reservoir front brake fluid
2- Brake fluid inspection window
3- Throttle wire adjustment
Fig 5J Low- Normal conditions
High- Starts and heavy conditions
Fig.
5J

STARTING PROCEDURE
15
6
ON OFF
RESERVE
In order to ensure an easy start the
following must be correctly adjusted:
The valve clearances, the idling speed,
the spark plug gap and the mixture
screw of the carburettor.
ATTENTION:
ATTENTION:
Do not drain all of the battery capacity
6
Kick starter models:
Follow the checklist on page 5.
Turn the fuel taps (Fig. 6A-1 & 6B-1) to position
ON (Fig. 6D).
Cold engine: Turn the choke lever (Fig 6A-2) to
position ON (Fig. 6C-1) by pulling it downwards
and twisting it 90° (Fig. 6C-2).
Warm engine: Choke lever should be in OFF
position.
Put the gearshift lever into neutral.
With the throttle fully closed, make a distinct and
long kick all the way through the operational orbit
of the kick start lever. If the engine does not start,
let the kick start lever return all the way back in
order to provide the maximum distance for the
kick start lever and also activating the additional
semi-automatic decompression system.
Cold engine: Warm the engine up (the throttle a
little bit opened) with the choke on until it runs
smoothly.
Engine idling, pull the clutch lever fully towards
the handlebar and engage the 1st gear by
pushing the gearshift lever downwards. Open the
throttle slightly at the same time as you slowly
and gently release the clutch lever.
Shift the gears as soon as adequate rpms have
been achieved.
Electrical starter models:
Follow the checklist on page 5.
Turn the fuel taps (Fig. 6A-1) to position ON (Fig.
6B-1).
Cold engine: Turn the choke lever (Fig 6A-2) to
position ON (Fig. 6B-2) by pulling it downwards
and twisting it 90°.
Warm engine: Choke lever should be in OFF
position.
Put the gearshift lever into neutral.
With the throttle fully closed, push the electrical
start button.
Cold engine: Warm the engine up (the throttle a
little bit opened) with the choke on until it runs
smoothly.
Engine idling, pull the clutch lever fully towards
the handlebar and engage the 1st gear by
pushing the gearshift lever downwards.
Open the throttle slightly at the same time as
you slowly and gently release the clutch lever.
Shift the gears as soon as adequate rpms have
been achieved.
The electrical start models are all equipped with
kick starters. Follow the instructions above: ”Kick
starter models”, if used.
Fig.
6A
Fig.
6B
Fig.
6C
Fig.
6D

ENGINE
16
7
ATTENTION:
Take care - the oil could be very hot
ATTENTION:
Service more frequently when
riding under hard conditions
OIL LEVEL
Oil and filter change and cleaning of oil screen:
The oil is preferably changed while the engine is
warm.
Drain the oil by removing the oil drain plug (Fig.
7A-1, wrench No. 13) and the attached oil screen.
Remove the cover of the microfilter by removing
the ignition cable clamp (Fig. 7A-2, wrench No. 8)
and the two allen screws (Fig. 7A-3, allen key No.
4) and pull out the cover and filter by using one M
6 screw as a puller into the center of the cover.
Lubricate the surface of the cover's O-rings and
the O-ring of the new microfilter (Fig. 7B-2, 7B-3).
Insert the microfilter in reverse order of
disassembly.
Refit the oil drain plug and the attached, well
cleaned, oil screen.
Refill the engine with the adequate amount of oil;
1,0 litre, through the filler hole (Fig. 7C-1). Correct
level of oil as shown (Fig. 7C-2 & 7D)
Whenever checking the oil level the motorcycle/
engine has to be in an upright position.
LUBRICATION SYSTEM:
Always use a synthetic oil of a well-known brand,
viscosity SAE 5W-50.
Depending on the basic design of the engine;
competition purposes = equal to a small sized
engine thus giving a small capacity of oil, it is vital
that the oil is frequently changed.
Packed into the crate of a totally new motorcycle
is an additional microfilter. The filter installed in
the engine and the engine oil have to be changed
after the first two hours of operation. The oil screen
has to be fully cleaned at the same time.
After the first change of oil and filter, including
cleaning of the oil screen, the intervals are
maximum 5 hours (Motocross, Super Motard
Competition and Cross Country models) or 10
hours (all other models) regarding change of oil
and cleaning of the screen and every 25/50 hours
regarding exchange of the microfilter.
After every 100 hours the reed valve of the
lubication system has to be inspected and
cleaned.
7 A
Fig.
7A
Fig.
7B
Fig.
7C
Fig.
7D

ENGINE
17
7
Fig.
7E
Fig.
7F
Fig.
7G
Fig.
7H
7 B
IGNITION:
The ignition system is a CDI-system without any
contact-breaker to change or any other moving
parts apart from the flywheel. However, the system
has to be frequently checked and cleaned for a
maximum of durability and performance.
The inside of the ignition cover, the stator, the
flywheel and the surroundings are preferably
cleaned after every time the motorcycle has been
used and/or washed (cover removal; three allen
screws, allen key No.5). Due to the heat of the
engine a condensation is built up around the stator
and flywheel which could cause the system to
work improperly. Check the surface of the cover
for any damages in order to avoid any leakages.
Frequently check the spark plug (Fig. 7E-1) for
wear and the colour of the electrode coating (spark
plug wrench, article No. 270007-01). The colour
ought to be pale brown. A dark or black colour
means that the carburettor's setting is on the rich
side and a light or white colour means that it is
too lean (see "FUEL & COOLING -
CARBURETTOR”).
Check also the spark plug electrode gap. The
correct electrode gap is 0,6 mm.
Recommended spark plug is NGK DCPR8E.
Tightening torque 12 Nm.
Ignition timing:
Remove the inspection cover (Fig. 7F-1).
Put the engine in TDC position (see ”ENGINE -
VALVE ADJUSTMENT”).
The ignition is propely set if the right mark on the
flywheel (Fig. 7G/H-2) is aligned with the mark on
the stator (Fig. 7G-1).
If the ignition needs to be adjusted, remove the
cover, slightly undo the three screws of the stator
(Fig. 7H-1) and adjust the stator.
Tighten the screws.

ENGINE
18
7
Fig.
7I
Fig.
7J
ATTENTION:
Service more frequently when
riding under hard conditions
7 C
AIRFILTER:
To avoid any engine damages or lack of power
the air filter has to be frequently cleaned or
replaced.
Always use a well-known brand of filter oil after
cleaning. Use an airfilter cleaning solvent of a
well-known brand.
Always check the surface of the filter attachment
and the filter basket for any damages.
Always check the surfaces behind the filter for
any loose particles and carefully clean the
surfaces.
Airfilter removal:
Remove the seat (Fig. 7I-1, one quick release
screw on top of the seat).
Remove the wing nut (Fig. 7J-1) holding the
airfilter and airfilter basket (Fig. 7J-2).
Pull the airfilter basket out of the airfilter.
Wash the filter carefully.
Soak the filter in filter oil and squeeze it slightly
for any superfluous oil.
Put the airfilter basket into the filter.
Assembly in reverse order of disassembly.

ENGINE
19
7
Fig.
7L
Fig.
7M
Fig.
7K
ATTENTION:
Service more frequently when
riding under hard conditions
7 D
VALVES:
The clearances between the valve adjustment
screws and the valve stems have to be checked
after 2 hours of operation if the engine is brand
new or any parts of the valves, valve seats or
rockerarms have been changed.
The interval between the checks of the clearences
is after that every 10 hours (Motocross, Super
Motard Competition and Cross Country models)
or 20 hours (all other models).
Valve adjustment:
Remove the fuel tank (see "FUEL & COOLING
- FUEL").
Put the engine in TDC position on compression
stroke: Remove the ignition cover, install a dial
indicator into the spark plug hole (Fig. 7K-1) and
turn the flywheel (wrench No. 17), clockwise, in
order to find the upper position of the piston.
Remove the two valve inspection covers (Fig.
7L-1, 2, allen key No. 4) including the gaskets.
Check the clearances of the valves; 0.10 mm on
both the intake valves as well as the exhaust
valves. Adjust if necessary by releasing the lock
nut (Fig. 7M-1, wrench No. 10) and then by
adjusting the screw (Fig. 7M-2) into the adequate
clearance.
Refit in the reverse order of disassembly.
Replace the gaskets of the inspection covers if
necessary.

FUEL & COOLING
20
8
ATTENTION:
Service more frequently when
riding under hard conditions
Carburettor setting:
To ensure an easy start of the engine, a high
level of performance and a reduction of any risk
of engine damages, the carburettor has to be
correctly set and adjusted.
The carburettor has an idling screw (Fig. 8C-1)
and a mixture screw (Fig. 8C-2) that have to be
properly adjusted. In order to carry out a proper
adjustment of these, the engine has to be warm.
With the twistgrip fully closed, turn the idling
screw to a position that makes the engine run
smoothly at idling speed (approximately 1600-
1800 rpm).
Adjust the mixture screw to a position of a
maximum idling speed.
If the engine now runs in a too high idling speed
unscrew the idling screw until a satisfying idling
speed is established.
A guideline regarding the mixture screw is 1½-
2½ turns from the bottom position of the screw.
Depending on the altitude and the humidity, the
adjustment may have to be changed whenever
riding under various conditions.
CARBURETTOR:
Always make sure that the throttle (Fig. 8A-1)
returns to a fully closed position.
Always make sure that the twistgrip and cable
move easily.
Always keep the twistgrip and cable well cleaned
and lubricated. The tube on top of the carburettor
(Fig. 8A-2) is a point of deterioration to the cable
and thus a vital part of the cable to be inspected.
Always make sure of a 1-2 mm clearance in the
twistgrip. Adjustment is done by removing the
dust protection (Fig. 8B-1), releasing the lock nut
(Fig. 8B-2) and adjusting the adjustment screw
(Fig. 8B-3).
Fig.
8A
Fig.
8B
Fig.
8C
8 A
Always check the intake manifold (Fig. 8C-6) and
the airfilter tube (Fig. 8C-5) for any cracks and/
or leakages and replace if necessary.
Always keep the shaft of the choke lever (Fig.
8C-3) well lubricated.
Always check that the overflow tubes (Fig. 8C-4)
on each side of the carburettor are positioned in
a vertical position straight from the outlets and
not crossed nor hanging over the carburettor.
Always ensure that an appropriate fuel is used
(minimum 98 octane) in order to get the most
out of the motorcycle and to ensure a proper
function of the engine.