The FE 450 is a high-performance, single-cylinder, 4-stroke off-road motorcycle renowned for its agile handling and potent engine, making it a strong contender in the competitive enduro and motocross landscape of its era. Designed for demanding terrain, this 2004 model emphasizes raw capability and rider engagement, embodying the brand's dedication to off-road excellence. Its liquid-cooled 450cc engine, paired with a robust suspension system and hydraulic disc brakes, ensures it can tackle challenging conditions with confidence. This Factory Service Repair Manual provides comprehensive guidance for the FE 450, covering all essential aspects from routine maintenance to in-depth repairs. It details procedures for engine overhaul, carburetor tuning, transmission servicing, and suspension adjustments, along with electrical system diagnostics and troubleshooting. With its focus on technical specifications, maintenance schedules, and repair processes, this manual serves as an indispensable resource for owners and technicians seeking to maintain the optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: Husaberg Model: FE 450 Year: 2004 Product Name: Husaberg 450 2004 Factory Service Repair Manual Codes Chassis Code: FE450 👋 Introduction Market Position Vehicle Segment: High-performance Enduro/Off-road Motorcycle Competitive Analysis Competitors 2004: KTM EXC 450, Yamaha WR450F, Honda CRF450X, Suzuki RM-Z450 (transitioning to 4-stroke), Kawasaki KX450F (upcoming). Key Features Of Vehicle Handling And Performance: Renowned for its agile handling and potent, hard-hitting engine, making it a favorite for competitive off-road riding. Off Road Capability: Built for demanding terrain, featuring robust suspension and a powerful engine designed for motocross and enduro applications. Manual Usefulness Value Proposition: Essential resource for owners and mechanics to maintain, diagnose, and repair the Husaberg FE 450, ensuring optimal performance and longevity. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: Digital (likely PDF) Page Count Estimated Page Count: 300+ 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, carburetor tuning, ignition system, cooling system, lubrication system, exhaust system. Transmission Systems: Clutch operation and adjustment, gearbox disassembly and assembly, shifting mechanism. Chassis Systems: Frame inspection and repair, suspension (front forks and rear shock absorber) service and adjustment, steering system maintenance. Electrical Systems: Wiring diagrams, lighting system, battery and charging system, starting system, ignition troubleshooting. Braking Systems: Hydraulic brake system service (master cylinders, calipers, lines), brake pad replacement, bleeding procedure. Fuel System: Fuel tank inspection, fuel lines, carburetor servicing (Mikuni TM40 or similar), fuel filter. Bodywork And Trim: Plastic panel removal and installation, seat maintenance, graphics. Procedures Included Maintenance Procedures: Routine service checks, oil changes, filter replacements, spark plug replacement, chain adjustment, valve clearance checks/adjustments. Repair Procedures: Engine rebuilding, transmission repair, suspension fork seal replacement, carburetor overhaul, electrical component testing. Troubleshooting Guides: Diagnostic flowcharts for common starting, running, and electrical issues. Technical Specifications: Torque specifications, clearances, fluid capacities, electrical component values. Technical Depth Depth Of Coverage: Comprehensive - covers everything from basic maintenance to complete engine and gearbox rebuilds. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable (typical for quality service manuals) Print Quality Image Resolution: High-resolution diagrams and illustrations Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke Displacement: 450 cc Bore X Stroke: 95 mm x 63.4 mm (approximate, common for this era) Cooling System: Liquid-cooled Performance Horsepower: Estimated 50-55 HP (at crankshaft) Torque: Estimated 45-50 Nm (at crankshaft) Fuel System Carburetor: Mikuni TM40 (or similar flat-slide performance carburetor) Fuel Type: Unleaded gasoline (95 RON minimum recommended) Ignition System Ignition Type: Digital CDI Lubrication System Oil Type Engine: SAE 10W-40 or 10W-50 Semi-Synthetic or Fully Synthetic Motorcycle Oil 🔧 Transmission Standard Transmission Type: 5-speed manual Clutch Type: Wet, multi-plate Optional Gear Ratios: Specific ratios detailed in manual, crucial for off-road performance tuning. Features Transmission Oil Type: SAE 75W/80 or 75W/90 GL-4 Gear Oil (check specific manual for exact spec) 📐 Dimensions Exterior Wheelbase: Approximately 1470 mm (57.9 inches) Seat Height: Approximately 960 mm (37.8 inches) Weights Dry Weight: Approximately 107 kg (236 lbs) Fuel Tank Capacity: Approximately 8.5 liters (2.25 gallons) 🛡️ Safety Features Ratings Safety Certification: N/A (off-road vehicles not typically crash-tested for road use) Active Features Braking System Type: Hydraulic disc brakes, front and rear. Suspension Design: Upside-down telescopic front forks (e.g., WP) and mono-shock rear suspension, crucial for absorbing impacts. 💡 Technology Features Infotainment Infotainment System: N/A (basic off-road motorcycle, no infotainment system) Driver Assistance Traction Control: N/A (no electronic rider aids) Connectivity Connectivity Features: N/A Engine Management Engine Control Unit: ECU controls ignition timing, no advanced fuel mapping adjustments typically available without aftermarket tuning. 🔧 Maintenance Service Intervals Oil Change Interval: Every 10-15 hours of riding or annually (refer to manual for exact specification). Air Filter Cleaning: Every 5-10 hours of riding, or as needed based on riding conditions. Valve Adjustment Interval: Every 30-50 hours of riding (critical for performance). Fluid Specifications Fork Oil Type And Level:...