2019 HUSQVARNA DUAL-SPORT BIKES

Husqvarna will have four dual-sport models for 2019. The FE250, FE350, FE450 and FE501 have been released. The information below is from Husqvarna’s technical department.

2019 Husqvarna FE501.
2019 Husqvarna FE501.

FEATURES AND BENEFITS – CHASSIS

Frame

The hydro-formed, laser-cut and robot-welded frame is expertly crafted using the latest production techniques. Its flex character is specifically tailored to benefit suspension functionality, handling and comfort. The frame is fitted with standard protectors and an engine protector that mounts directly, for superior protection and durability. On the TE 250i/300i models, the upper frame tube integrates the oil filler cap for easy access when filling.

Modern production techniques → high quality standards
Tailored flex characteristics → optimum suspension functionality, handling & comfort
Integrated oil filler cap for TE 250i/300i → simple oil refills

2019 Husqvarna FE450.
2019 Husqvarna FE450.

Composite carbon fiber subframe

The composite subframe is a design unique to Husqvarna Motorcycles, showcasing pioneering technologies and innovation. This 3-piece component is made up of 30% carbon fiber making it remarkably light 1.4 kg (~ 3. lbs). Specific care is taken to engineer a calculated rigidity for optimal handling and rider ergonomics.

3-piece subframe → composite materials
Carbon fiber construction → 1.4 kg (~ 3. lbs) overall weight
Specific rigidity → benefits handling and ergonomics

2019 Husqvarna FE350.
2019 Husqvarna FE350.

Swingarm

The hollow, cast aluminum swingarm is designed to offer optimal stiffness and reliability while adding the minimum possible weight. The machining above the rear axle allows the chain adjuster markings to be seen from above for easy adjustment.

Optimal stiffness & reliability in a lightweight construction
Easy chain adjustment & maintenance

WP Xplor 48 front fork

With a new setting to further perfect handling, the WP Xplor 48 front fork is developed by WP Suspension for off-road and dual-sport riding. The forks consist of an open cartridge layout with a spring in each circuit and split damping functions. Compression can be adjusted from the left side and rebound on the right via clickers on the top of the tubes. Additionally, the standard adjuster offers easy pre-load adjustment without the use of tools.

WP Xplor 48 front fork → new setting for MY19
Easy access clicker dials → simple & fast clicker settings
Pre-load adjuster → tool-less pre-load adjustment

2019 Husqvarna FE250.
2019 Husqvarna FE250.

CNC machined triple clamps

Featuring an offset of 22 mm, the black-anodized CNC machined triple clamps offer premium quality standard on all Husqvarna off-road and dual-sport models. The triple clamps are expertly crafted using superior techniques and materials to provide high levels of quality and reliability. The handlebar mounts can be moved between 2 positions and the handlebar itself can move inside the mounts to be lower or higher. These 4-directions adjustment allows for customizable ergonomics.

CNC aluminum → finest quality & reliability
Adjustable handlebar position → adjustable ergonomics

WP rear shock

Matched to the front fork, The WP DCC rear shock features a new setting. It is developed to provide advanced damping characteristics while keeping to a compact and lightweight design. With a pressure balance inside the shock making the stroke more seamless, this offers greater rider comfort and handling. The corrugated outer contour of the reservoir improves cooling. The component is also fully adjustable and matched to a linkage system.

WP rear shock → new setting for MY19
Lightweight system → conforming to the compact design
Pressure balance → consistent damping
Linkage system → specific geometry for optimum results

Footpeg mount

The Husqvarna frame features a smart, self – cleaning footpeg mount that prevents the build-up of dirt collected through deep ruts or muddy terrain. Featuring an off-road specific grip pattern, the large footpegs are positioned 6mm higher than on the MX models to further increase ground clearance over rocks and ruts.

Footpeg mount → prevents mud & dirt build-up
Larger footpegs → perfect grip & control with off-road specific pattern.

Magura hydraulic clutch

The reliable, high quality, German-made clutch system guarantees even wear, near maintenance-free operation and perfect action in every condition. With its play constantly compensated, the pressure point and function of the clutch remain identical in cold or hot conditions as well as over time.

Magura hydraulic clutch → perfect action in every condition
High quality German craftsmanship → reliable & consistent action

Magura brakes

Offering the highest level of braking performance, the Magura braking system is specifically tailored to deliver a sensitive and progressive feel for off-road and on-road riding. The 260mm front and 220mm rear waved brake discs by GSK keep weight to a minimum and offer complete braking confidence.

Magura brake callipers & high-performance GSK discs
Superior stopping power with unsurpassed sensitivity

ProTaper handlebar

The ProTaper handlebar is second to none for function and style. Manufactured to exacting standards, it features class-leading fatigue resistance while adding minimal weight. The ProTaper logos are chemically applied while being scratch and peel resistant.

ProTaper handlebar → class-leading function & style

ODI grips and throttle assembly

The ODI lock-on clutch grip does not require gluing, while the vulcanized throttle grip features an integrated throttle mechanism. The assembly has easy free-play adjustment and, by changing a cam, throttle progression can be altered on all 4-strokes.

Throttle assembly & ODI grips
Allows for throttle progression adjustment
Easy grip mounting without glue

Exhaust system

The exhaust systems are expertly designed to deliver the optimum performance while adhering to noise limits. Crafted from lightweight and strong aluminum, the lightweight mufflers are positioned closely to the center of gravity to improve handling. Specifically designed to match key engine characteristics, the 2-stroke exhaust systems deliver top-level performance while keeping weight to a minimum.

Exhaust systems → mass-centralization, low weight and optimal performance

Electric start and Li-ion battery

All TE and FE models continue to feature an electric starter as standard. For MY19 the system uses a new generation compact Li-ion battery produced by a different supplier to guarantee the quality and reliability.

New Li-ion battery → high quality and reliability

Integrated cooling system and radiators

The radiators are expertly crafted using high strength aluminum. CFD (computational fluid dynamics) is used to channel air through the radiators efficiently and provide optimal cooling in all conditions. Integrated into the frame the cooling system increases heat dissipation by channelling coolant through the frame while eliminating the need for additional hoses. Protecting against flying debris the radiator protectors also act as a brace that diverts energy from impacts to the frame. Cooling fans are fitted standard on all 4-stroke models.

Integrated cooling → maximum efficiency in minimum space
Radiator protectors → protection from debris & falls
Standard fan on all 4-stroke models

Fuel tank

All models feature a fuel tank made of translucent plastic so the fuel level can be checked quickly and easily. Their capacity is 10L (2.64 US Gal) for the TE 150 and 8.5L (2.24 US Gal) for all 4-stroke models. The TE 250i/300i tanks have a 9.25L (2.44 US Gal) capacity and like the 4-stroke models house an integrated fuel pump and fuel level sensor. All fuel tanks feature a quick release fuel cap for quick refuelling.

Translucent fuel tank → large capacity for extended running times
Quick release fuel cap → quick & easy refuelling

Airbox and tool-less air filter access

The airbox is designed with precisely positioned inlet ducts aimed at preventing air deformation and ensuring maximum airflow and filter protection. The air filter is easily accessed, without tools, by removing the left side panel. Easy maintenance is guaranteed by the Twin Air filter and filter cage design that features a simple fail proof mounting system for safe and accurate installation.

Airbox → maximum air flow & filter protection
Filter mounting system → safe & accurate protection from dirt
Tool-less filter access → easy & fast maintenance

Wheels

Black high-strength alloy rims by D.I.D are matched with CNC machined hubs using lightweight spokes and silver anodized aluminum nipples. The D.I.D logo is laser-engraved for unsurpassed durability.

Lightweight & reliable construction → minimum unsprung weight

Tires

The off-road and dual-sport range features Continental TKC 80 tires. The TKC 80 tires offer advanced grip in a wide variety of terrain.

Continental TKC 80 tires → advanced grip in all conditions

Bodywork

With a distinctive and futuristic bodywork highlighting the off-road and dual-sport range, the striking pearl blue and electric yellow graphics stylishly adorn Husqvarna’s Swedish heritage. Providing superior comfort and control, the advanced ergonomics allow the rider to perform at their peak for extended periods of time.

Bodywork → distinctive looks, modern colors & graphics
Advanced ergonomics → confidence-inspiring riding position in all riding conditions

FEATURES AND BENEFITS – ENGINES

Engine management system (EMS)

All FE models feature electronic fuel injection.  With the help of a gear sensor, power delivery is tailored for each gear.

Gear sensor → specific power delivery for each gear

Throttle body

The 4-stroke range features a 42 mm Keihin throttle body. The injector is placed accordingly to ensure the most efficient flow of fuel into the combustion chamber. The throttle cable is mounted directly without a throttle linkage providing more immediate throttle response and feeling.

42 mm body for all FE models → injector positioned for optimal flow

Map switch & traction control

For the MY19 2-stroke models the switch allows for selection between the standard ignition timing and a slightly retarded timing, to be used in low traction conditions. The system functions by analyzing throttle input from the rider and the rate at which RPM increases in the engine. If the RPM increases too quickly, the ECU will register a loss of grip thus reducing the amount of power to the rear wheel for maximum traction.

Standard map switch → alter engine characteristics depending on conditions
2-strokes → option to select different ignition timings

 

FE 250 / FE 350 – FEATURES AND BENEFITS

2019 Husqvarna FE250.
2019 Husqvarna FE250.

FE 250 / FE 350 – BENEFITS

Class leading performance & weight
Centralized mass for top-level handling & maneuverability
Advanced electronics for unsurpassed usability
Hydraulic clutch & reliable gearbox for precise & smooth shifting
Dependable electric start

 

Engine

The DOHC 250cc and 350cc engines are second to none in terms of versatility and performance. All major components and shaft arrangements are carefully positioned to best suit the performance and handling characteristics of each model. Retaining its torquey nature the FE 250 engine makes the bike accessible to both professionals and amateurs. As for the FE 350 engine, it offers a significant boost of power and torque giving the bike 450-rivalling power.

Engine design → light & compact for optimized mass-centralization
FE 250 engine → accessible for all skill levels
FE 350 engine → 450 rivalling power-to-weight ratio

Cylinder head

Featuring polished camshafts with DLC coated finger followers the DOHC design on both engines transmits minimal friction and improves overall performance. Added to the design are lightweight titanium valves (FE 250 intake: titanium Ø32.5mm, exhaust steel Ø26,5mm; FE 350 intake Ø36.3mm, exhaust Ø29.1mm).

Cylinder head → minimum drag for maximum performance
Lightweight titanium valves
Polished camshafts
Finger followers with DLC coating → minimal friction

Cylinder and piston

The cylinders (78mm bore for the FE 250 and 88mm bore for the FE 350) feature lightweight forged bridged-box-type pistons by CP. As a result, the low oscillating masses deliver exceptional power, high revs and a very wide power band. The compression ratios are 12.8:1 for the FE 250 and 12.3:1 for the FE 350.

Lightweight pistons → reduce oscillating masses
Forged bridged-box-type pistons → high performance and reliability

Crankshaft

The plain big end bearings feature two force-fitted bearing shells ensuring maximum reliability and durability while guaranteeing long service intervals of 135 hours.

Plain big end bearing with force-fitted bearing shells → 135-hour service interval

Counter balancer shaft

In order to counteract the rotational force of the crankshafts and reduce vibration, both engines use multifunctional counter balancer shafts, which also drive their water pumps and timing chains.

Multifunctional counter balancer shaft → reduced vibrations, compact design

Crankcases

The FE 250/350 engines are designed to be compact while centralizing rotating masses. As a result, their crankcases are engineered to house the shaft arrangements at the ideal center of gravity. The casings are manufactured using a high-pressure die cast production process, resulting in thin wall thickness while retaining exceptional reliability. The iconic Husqvarna logo adorns the bronze finished crankcase covers.

Crankcases → light and compact, mass-centralization
High pressure die cast production → thin walls for less weight but same strength

Gearbox

The FE 250 and FE 350 feature 6-speed gearboxes with specific wide-range off-road and dual-sport type gearing. Additionally, no-dirt gear levers prevent dirt build up allowing the mechanisms to spring back into place to guarantee perfect control in all conditions.

6-speed gearbox → off-road and dual-sport specific ratios

DDS clutch

Both models feature DDS (Dampened Diaphragm Steel) clutches. The exclusive characteristics of this system includes a single diaphragm steel pressure plate instead of traditional coil springs making the clutch pull very light. The integrated damping system improves traction and durability. The clutch basket is a single-piece CNC machined steel component that allows the use of thin steel liners and contributes to the compact design of the engines. Magura hydraulic systems ensure perfect action in all conditions.

DDS clutch → compact and durable
Magura hydraulic system → perfect clutch modulation

FE 450 / FE 501 – FEATURES AND BENEFITS

2019 Husqvarna FE501.
2019 Husqvarna FE501.

The FE 501 is the most powerful Husqvarna dual-sport
Intuitive & confidence-inspiring riding experience
Exclusive DDS clutch with Magura hydraulics for smooth & light clutch action
Electric starter & compact Li-ion battery

Engine

Delivering high levels of performance, the 450cc and 510.9cc power plants are more advanced than ever. The FE 450 engine weighs only 29.7 kg, while the FE 501 engine weighs 30.1kg.
Engine → lightweight, compact & powerful
Class leading electronics → Keihin EFI

Cylinder head

The compact SOHC cylinder heads are designed to offer the maximum performance at the minimum possible weight. The camshafts on each model actuate four lightweight valves (intake: titanium Ø40mm, exhaust steel Ø33mm) through very robust rocker arm systems.
SOHC → compact engine design

Cylinder and piston

The lightweight aluminum cylinders feature a 95mm bore housing a lightweight, forged Konig bridge-box-type pistons. This combination produces very little oscillating masses, significantly reducing vibration and increasing rider comfort. The compression ratio on both models is 11.8:1

Lightweight aluminum cylinder → 95mm bore
Lightweight forged bridged-box-type piston → high performance, less oscillating masses

Crankshaft

Plain big end bearings comprising of two force-fitted bearing shells ensure maximum reliability and durability, guaranteeing long service intervals of 135 hours.

Plain big end bearing & force-fitted bearing shells → increased durability & service intervals

Counter balancer shaft

In order to counteract the rotational force of the crankshaft and reduce vibration, the FE 450/FE 501 engines use multifunctional counter balancer shafts which also drive their water pumps.

Multifunctional counter balancer shaft → reduced vibrations, compact design

Crankcases

The crankcases are designed to house the shaft arrangements and internals of the engines in the best possible position, centralizing masses for a lightweight handling feel. High-pressure die cast production processes result in a thin but reliable wall thickness while keeping weight to a minimum.

Design → mass-centralization, lightweight handling
High pressure die cast production → thin walls for reduced weight and similar strength

Gearbox

The lightweight 6-speed gearboxes ensure smooth and precise shifting thanks to low friction coatings on the shifting forks. The gear levers feature a design that prevents dirt build-up and keeps the lever’s tip in their original position even in the toughest conditions. Gear sensors allow for specific engine maps for each gear.

6-speed gearbox → Lightweight
Fork coating → smooth & precise shifting
Gear sensor → specific engine maps for each gear

DDS clutch

The FE 450 / FE 501 engines feature DDS (Dampened Diaphragm Steel) clutches. The exclusive characteristics of this system include a single diaphragm steel pressure plate instead of traditional coil springs making clutch pull very light. The integrated damping systems improve traction and durability. The clutch baskets are single-piece CNC machined steel components that allow the use of thin steel liners and contributes to the compact design of the engines. The Magura hydraulic systems ensure perfect action in all conditions.

DDS clutch → compact, with better modulation & improved durability
Magura hydraulic system → perfect clutch modulation

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