The FE 450 and FE 650 models from 2004 represent a lineage of high-performance off-road motorcycles, renowned for their robust engineering and specialized capabilities. These machines were positioned in the premium enduro segment, competing with other European manufacturers and appealing to riders seeking raw power and exceptional handling for demanding terrain. Key features include powerful four-stroke, single-cylinder, liquid-cooled engines with DOHC valve trains, available in approximately 450cc and 650cc displacements, equipped with Keihin FCR carburetors and electric start. Their design emphasizes advanced chassis and suspension components for superior off-road performance, making them a choice for serious enthusiasts. This comprehensive service and repair manual provides in-depth technical information for the 2004 FE 450 and FE 650. It covers a wide array of systems, including detailed procedures for engine (top end, bottom end, valve train, lubrication, cooling), fuel, ignition, exhaust, transmission, drivetrain, suspension, brakes, wheels, electrical systems, and chassis. The manual offers routine maintenance guidance, complete disassembly and reassembly instructions, troubleshooting techniques, and essential torque specifications. With numerous diagrams and exploded views, this resource is designed to assist owners, mechanics, and technicians in maintaining, diagnosing, and repairing these specialized off-road motorcycles effectively. 🏷️ Basic Information Identification Make: Husaberg Model: FE 450 / FE 650 Year: 2004 Codes Chassis Code: Likely FE450E4, FE650E4 (specific codes vary by region/variant) 👋 Introduction Market Position Market Position: Husaberg motorcycles, particularly in the early 2000s, were positioned as high-performance off-road and enduro machines, often favored by riders seeking raw power and specialized capabilities over mainstream brands. Competitive Analysis Competitive Analysis: Competed directly with other European manufacturers in the premium enduro segment, such as KTM, and to some extent, specialized models from Japanese brands. Known for their robust engines and no-nonsense off-road focus. Key Features Key Features: Powerful single-cylinder engines, advanced chassis design for off-road capability, robust suspension components, and a focus on performance for demanding terrain. 📋 Manual Details Coverage Areas Coverage Areas: Comprehensive service and repair for Husaberg FE 450 and FE 650 models of the 2004 model year. Page Count Page Count: Estimated 300-500 pages (typical for a complete service manual) Illustrative Content: Contains numerous diagrams, illustrations, and exploded views to clarify procedures. Manual Type Manual Type: Service and Repair Manual Language Language: English (Primary for download) Format Format: PDF Download Searchability: Searchable PDF text for quick access to specific information. 📖 Manual Coverage Systems Covered Systems Covered: Engine (top end, bottom end, valve train, lubrication, cooling), Fuel System (carburetion, fuel pump, lines), Ignition System, Exhaust System, Transmission (clutch, gearbox, shifting mechanism), Drivetrain (chain, sprockets, rear hub), Suspension (forks, shock absorber, linkage), Brakes (hydraulic system, calipers, master cylinders, rotors), Wheels and Tires, Electrical System (wiring diagrams, battery, lighting, starter, ECU), Chassis and Frame, Bodywork and Plastics, Controls (levers, cables), Troubleshooting. Electrical System Detail: Complete wiring diagrams, component testing procedures, troubleshooting for lighting, ignition, starting system, sensors, and ECU diagnostics. Procedures Included Procedures Included: Routine maintenance (oil changes, filter replacement, chain adjustment), complete engine disassembly and reassembly, transmission rebuild, suspension servicing (fork seal replacement, shock rebuild), brake bleeding and component replacement, carburetor tuning and cleaning, electrical diagnostics and repair, chassis component inspection and replacement, torque specifications for all fasteners, troubleshooting guides for common problems. Engine Rebuild Detail: Detailed steps for cylinder head removal, piston replacement, connecting rod inspection, crankshaft service, valve clearance adjustment, timing chain replacement, and oil pump servicing. Suspension Service Detail: Step-by-step instructions for fork disassembly, seal and bushing replacement, oil level and volume setting, shock absorber service including nitrogen charging and valving adjustments. Chassis Component Replacement: Procedures for steering head bearing replacement, swingarm bearing service, wheel bearing replacement, and linkage bearing maintenance. Technical Depth Technical Depth: In-depth technical information suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic adjustments to complete overhauls and complex diagnostics. Includes detailed component diagrams and exploded views. Diagnostic Procedures: Includes systematic troubleshooting flowcharts and diagnostic trees for common performance issues and system failures. Torque Specifications: Comprehensive list of torque values for critical fasteners including engine, chassis, and suspension components. 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Print Quality Print Quality: High-resolution scans ensuring clarity of text and diagrams for printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled Displacement 450: Approximately 450cc (specific bore/stroke vary, e.g., 95mm x 63.4mm) Displacement 650: Approximately 650cc (specific bore/stroke vary, e.g., 100mm x 80mm) Valvetrain: DOHC, 4 valves per cylinder Bore Stroke 450: e.g., 95 mm x 63.4 mm (verify with manual) Bore Stroke 650: e.g., 100 mm x 80 mm (verify with manual) Compression Ratio 450: Approximately 12.5:1 (verify with manual) Compression Ratio 650: Approximately 11.8:1 (verify with manual) Performance Horsepower 450: Estimated 50-55 HP (at crank, typical for the era) Horsepower 650: Estimated 60-65 HP (at crank,...