User Manuals: Husqvarna FE 501 2014 Off-Road Motorcycle

Manuals and User Guides for Husqvarna FE 501 2014 Off-Road Motorcycle. We have 1 Husqvarna FE 501 2014 Off-Road Motorcycle manual available for free PDF download: Repair Manual

Husqvarna FE 501 2014 Repair Manual (337 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 75.66 MB

Table of Contents
4
Removing the Shift Rails
6
Means of Representation
9
Symbols Used
9
Formats Used
9
Safety Advice
10
Repair Manual
10
Degrees of Risk and Symbols
10
Work Rules
10
Important Notes
11
Manufacturer and Implied Warranty
11
Operating and Auxiliary Substances
11
Spare Parts, Accessories
11
Figures
11
Serial Numbers
12
Chassis Number
12
Key Number (FE EU/AU)
12
Engine Number
12
Fork Part Number
13
Shock Absorber Article Number
13
Motorcycle
14
Raising the Motorcycle with a Lift Stand
14
Removing the Motorcycle from the Lift Stand
14
Starting
14
Starting the Motorcycle for a Check
15
Fork, Triple Clamp
16
Adjusting the Compression Damping of the Fork
16
Adjusting the Rebound Damping of 9 the Fork
16
Bleeding the Fork Legs
17
Cleaning the Dust Boots of the Fork Legs
17
Loosening the Fork Protector
18
Positioning the Fork Protector
18
Removing the Fork Legs
18
Installing the Fork Legs
19
Removing the Fork Protector
20
Installing the Fork Protector
20
Performing a Fork Service
20
Removing the Spring
23
Disassembling the Cartridge
24
Disassembling the Piston Rod
26
Disassembling the Hydrostop Unit
27
Disassembling the Seal Ring Retainer
28
Checking the Fork Legs
28
Assembling the Seal Ring Retainer
30
Assembling the Hydrostop Unit
30
Assembling the Piston Rod
31
Assembling the Cartridge
32
Assembling the Fork Legs
34
Lubricating the Steering Head Bearing
38
Removing the Lower Triple Clamp
39
Installing the Lower Triple Clamp
40
Checking the Play of the Steering Head Bearing
42
Changing the Steering Head Bearing
42
Adjusting the Steering Head Bearing Play
44
7 Handlebar,Controls
45
Handlebar Position
45
Adjusting the Handlebar Position
45
Adjusting the Basic Position of the Clutch Lever
46
Checking the Routing of the Throttle Cable
46
Checking the Play in the Throttle Cable
47
Adjusting the Play in the Throttle Cable
47
Frame
49
Removing the Engine Guard
49
Installing the Engine Guard
49
Checking the Frame
49
Shock Absorber, Swingarm
50
Adjusting the High-Speed Compression Damping of the Shock Absorber
50
Adjusting the Low-Speed Compression Damping of the Shock Absorber
50
Adjusting the Rebound Damping of the Shock Absorber
51
Measuring Rear Wheel Sag Unloaded
52
Checking the Static Sag of the Shock Absorber
52
Checking the Riding Sag of the Shock Absorber
53
Adjusting the Spring Preload of the Shock Absorber
53
Adjusting the Riding Sag
54
Removing the Shock Absorber
55
Installing the Shock Absorber
56
Checking the Shock Absorber Linkage
56
Servicing the Shock Absorber
58
Removing the Spring
59
Disassembling the Damper
60
Disassembling the Piston Rod
61
Disassembling the Seal Ring Retainer
62
Changing the Pilot Bushing
63
Checking the Damper
64
Removing the Heim Joint
65
Installing the Heim Joint
66
Assembling Seal Ring Retainer
66
Assembling the Piston Rod
67
Assembling the Damper
69
Bleeding and Filling the Damper
71
Filling Damper with Nitrogen
74
Installing the Spring
75
Checking the Swingarm
76
Checking the Swingarm Bearing for Play
76
Removing the Swingarm
77
Installing the Swingarm
78
Changing the Swingarm Bearing
80
Exhaust
83
Removing the Manifold
83
Installing the Manifold
85
Removing the Main Silencer
86
Installing the Main Silencer
87
Changing the Glass Fiber Yarn Filling in the Main Silencer
87
11 Air Filter
89
Removing the Air Filter Box Cover
89
Installing the Air Filter Box Cover
89
Removing the Air Filter
89
Installing the Air Filter
90
Cleaning the Air Filter and Air Filter Box
90
Sealing the Air Filter Box
91
12 Fuel Tank, Seat, Trim
92
Opening Filler Cap
92
Closing Filler Cap
92
Removing the Right Side Cover
93
Installing the Right Side Cover
93
Removing the Seat
93
Mounting the Seat
93
Removing the Fuel Tank
94
Installing the Fuel Tank
95
Changing the Fuel Screen
97
Changing the Fuel Filter
98
Changing the Fuel Pump
100
Checking the Fuel Pressure
102
13 Mask, Fender
104
Removing Front Fender
104
Installing Front Fender
104
Removing the Headlight Mask with the Headlight
105
Installing the Headlight Mask with the Headlight
105
14 Wheels
106
Checking the Tire Air Pressure
106
Checking the Tire Condition
106
Checking the Wheel Bearing for Play
107
Checking the Brake Discs
108
Checking Spoke Tension
108
Checking the Rim Run-Out
109
Front Wheel
110
Removing the Front Wheel
110
Installing the Front Wheel
111
Removing the Front Brake Disc
111
Lnstalling the Front Brake Disc
112
Changing Front Wheel Bearing
112
Rear Wheel
113
Removing the Rear Wheel
113
Installing the Rear Wheel
114
Removing the Rear Brake Disc
115
Installing the Rear Brake Disc
115
Checking the Chain Tension
116
Adjusting the Chain Tension
116
Checking the Chain, Rear Sprocket, Motor Sprocket, and Chain Guide
117
Checking for Chain Dirt Accumulation
120
Cleaning the Chain
120
Changing the Drivetrain Kit
120
Changing the Rear Wheel Bearing
122
15 Wiring Harness, Battery
125
Changing the Fuses of Individual Power Consumers
125
Changing the Main Fuse
126
Checking the Starter Relay
126
Removing the Battery
127
Installing the Battery
128
Recharging the Battery
128
Checking the Charging Voltage
130
Checking the Open-Circuit Current
130
Brake System
131
Checking the Front Brake Linings
131
Changing the Front Brake Linings
131
Checking the Free Travel of the Hand Brake Lever
133
Adjusting the Basic Position of the Hand Brake Lever (FE 501 US)
134
Adjusting Free Travel of Hand Brake Lever (FE EU/ AU)
134
Checking the Front Brake Fluid Level
135
Adding Front Brake Fluid
135
Changing the Front Brake Fluid
136
Checking the Rear Brake Linings
138
Changing the Rear Brake Linings
138
Brake Lever
141
Adjusting the Basic Position of the Foot Brake Lever
142
Checking the Rear Brake Fluid Level
142
Adding Rear Brake Fluid
143
Changing the Rear Brake Fluid
144
17 Lighting System, Instruments
147
Adjusting the Combination Instrument
147
Adjusting the Kilometers or Miles
148
Adjusting the Clock
148
Setting the Wheel Circumference
149
Adjusting the Service Display
149
Checking the Headlight Setting
150
Adjusting the Headlight Range
150
18 Engine
151
Removing the Engine
151
Installing the Engine
156
Engine Disassembly
161
Preparations
161
Draining the Engine Oil
161
Removing the Clutch Push Rod
162
Removing the Oil Filter
162
Removing the Starter Motor
163
Removing the Spark Plug
163
Removing the Valve Cover
163
Removing the Alternator Cover
164
Positioning the Engine at Ignition Top Dead Center
164
Removing the Timing Chain Tensioner
165
Removing the Camshaft
165
Removing the Cylinder Head
166
Removing the Piston
166
Removing the Rotor
166
Removing the Timing Chain Guide Rail
167
Removing the Timing Chain Tensioning Rail
167
Removing the Timing Chain Securing Guide
167
Removing the Timing Chain
168
Removing the Ignition Pulse Generator
168
Removing the Suction Pump
168
Removing the Water Pump Cover
169
Removing the Clutch Cover
169
Removing the Clutch Discs
170
Removing the Primary Gear Nut
171
Removing the Outer Clutch Hub
171
Removing the Torque Limiter
172
Removing the Starter Idler Gear
172
Removing the Shift Shaft
172
Removing the Shift Drum Locating Unit
172
Removing the Locking Lever
173
Removing the Oil Pump Gear Wheels
173
Removing the Force Pump
174
Removing the Primary Gear
174
Removing the Freewheel Gear
174
Removing the Left Section of the Engine Case
175
Removing the Shift Drum
176
Removing the Shift Forks
176
Removing the Transmission Shafts
176
Removing the Crankshaft
177
Working on Individual Parts
177
Work on the Right Section of the Engine Case
177
Working on the Left Section of the Engine Case
179
Removing the Oil Pressure Regulator Valve
181
Checking Spring Length of Oil Pressure Regulator Valve
181
Installing the Oil Pressure Regulator Valve
182
Removing the Crankshaft Seal Ring in the Clutch Cover
182
Installing the Crankshaft Seal Ring in the Clutch Cover
182
Removing the Water Pump
182
Installing the Water Pump
183
Removing the Timing Chain
184
Sprocket
184
Installing the Timing Chain
184
Changing the Connecting Rod, Conrod Bearing and Crank Pin
185
Checking Crankshaft Run-Out at Bearing Pin
187
Cylinder - Nikasil ® Coating
187
Checking/Measuring the Cylinder
187
Checking/Measuring the Piston
188
Checking the Piston Ring End Gap
189
Measuring the Piston/Cylinder Mounting Clearance
189
Checking the Oil Pumps
190
Disassembling the Autodecompressor
190
Assembling the Autodecompressor
191
Checking Camshaft
192
Checking the Timing Assembly
192
Removing the Rocker Arm
193
Removing the Valves
193
Changing the Camshaft
194
Bearing
194
Checking the Valves
195
Checking Valve Springs
195
Checking Valve Spring Seat
196
Checking the Cylinder Head
196
Checking the Rocker Arm Shafts
197
Installing the Valves
197
Installing the Rocker Arm
198
Checking the Clutch
199
Checking the Shift Mechanism
200
Preassembling the Shift Shaft
201
Disassembling the Main Shaft
202
18.4.38 Assembling the Main Shaft
202
Disassembling the Countershaft
204
Assembling the Countershaft
204
Checking the Transmission
205
Checking the Starter Drive
207
Removing the Freewheel
208
Checking the Freewheel
208
Installing the Freewheel
208
Engine Assembly
209
Installing the Crankshaft
209
Installing the Transmission Shafts
209
Installing the Shift Forks
210
Installing the Shift Drum
210
Installing the Shift Rails
211
Installing the Left Engine Case
211
Installing the Freewheel Gear
212
Installing the Primary Gear
212
Installing the Force Pump
212
Installing the Oil Pump Gear Wheels
213
Installing the Locking Lever
213
Installing the Shift Drum Locating Unit
214
Installing the Shift Shaft
214
Installing the Starter Idler Gear
214
Installing the Torque Limiter
214
Installing the Outer Clutch Hub
215
Installing the Primary Gear Nut
215
Installing the Clutch Discs
216
Installing the Clutch Cover
218
Installing the Water Pump Cover
218
Installing the Suction Pump
219
Installing the Ignition Pulse Generator
219
Installing the Timing Chain
220
Installing the Timing Chain Securing Guide
220
Installing the Timing Chain Tensioning Rail
220
Installing the Timing Chain Guide Rail
220
Installing the Rotor
221
Installing the Piston
221
Installing the Cylinder Head
223
Installing the Camshaft
224
Installing the Timing Chain Tensioner
224
Checking the Valve Clearance
225
Adjusting the Valve Clearance
225
Installing the Alternator Cover
226
Installing the Valve Cover
226
Installing the Spark Plug
227
Installing the Starter Motor
227
Installing the Oil Filter
227
Installing the Clutch Push Rod
228
Installing the Oil Screen
228
Removing the Engine from the Engine Assembly Stand
229
19 Clutch
230
Checking/Correcting the Fluid Level
230
Changing the Hydraulic Clutch Fluid
231
20 Water Pump, Cooling System
232
Cooling System
232
Checking the Antifreeze and Coolant Level
232
Checking the Coolant Level
233
Draining the Coolant
234
Refilling Coolant
234
Lubrication System
236
Oil Circuit
236
Checking the Engine Oil Level
236
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens
237
Adding Engine Oil
239
Checking the Engine Oil Pressure
240
22 Ignition System
242
Ignition Coil - Checking the
242
Secondary Winding
242
Checking the Spark Plug Connector
242
Winding
242
Removing the Stator
243
Installing the Stator
244
23 Electric Starter
245
Checking the Starter Motor
245
Throttle Valve Body
246
Adjusting the Idle Speed
246
Executing the Initialization Run
246
25 Technical Data
248
Engine
248
Tolerance, Engine Wear Limits
249
Engine Tightening Torques
250
Capacities
252
Engine Oil
252
Coolant
252
Fuel
252
Chassis
252
Electrical System
253
Tires
253
Fork
254
Shock Absorber
254
Chassis Tightening Torques
255
26 Cleaning, Care
257
Cleaning the Motorcycle
257
Checks and Maintenance Steps for Winter Operation
258
27 Storage
259
Preparing for Use after Storage
260
28 Service Schedule
261
Service Work (as Additional Order)
262
Fe Eu)
264
29 Wiring Diagram
265
Fe Eu)
266
Fe Eu)
268
Fe Eu)
270
Fe Eu)
272
Fe Eu)
274
Fe Eu)
276
Fe Eu)
278
Fe Au)
280
Fe Au)
282
Fe Au)
284
Fe Au)
286
Fe Au)
288
Fe Au)
290
Fe Au)
292
Fe Au)
294
Fe 501 Us)
296
Fe 501 Us)
298
Fe 501 Us)
300
Fe 501 Us)
302
Fe 501 Us)
304
Fe 501 Us)
306
30 Substances
308
Auxiliary Substances
310
32 Special Tools
312
Standards
329
34 List of Abbreviations
330
Index
331

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Husqvarna FE 501 2014 Repair Manual (337 pages)

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