How to Change the Oil in a 2002 Husaberg FE400 — MotoSport.com Guide

Shop parts for a 2002 Husaberg FE400 Dirt Bike.

Keeping your 2002 Husaberg FE400 running in peak condition means performing regular maintenance tasks such as oil changes. This robust how-to blog covers everything you need to change the oil on your FE400, including recommended tools, a detailed step-by-step process, and important model-specific tips every owner should know.

Tools & Supplies Needed

  • Socket set (metric, as all bolts are metric)
  • Allen wrenches (metric)
  • Drain pan (to catch used oil)
  • New oil filter (OEM recommended)
  • Replacement engine oil (1,050ml Motorex or equivalent high-quality 4-stroke engine oil)
  • Shop rags or paper towels
  • Small brush or toothbrush (for cleaning filters)
  • Funnel (for filling oil)
  • New crush washer (for drain plug, optional but recommended)
  • Torque wrench (to ensure proper bolt tightening)
  • Latex or nitrile gloves (recommended)

2002 Husaberg FE400 Specific Call-outs

  • This model uses a mesh oil filter and a cartridge oil filter. Both should be cleaned or replaced at each oil change.
  • The oil capacity is approximately 1,050ml, but always check the sight glass or dipstick after filling – never overfill.
  • If you notice a few fine metal flakes in the mesh filter, especially on a lower-kilometre bike, it is usually normal; however, excessive flakes can indicate engine wear and should be monitored closely.
  • The mesh oil screen has a large hole at one end and a small hole at the other. The large hole end goes into the engine casing first; the small end is near the sump plug.

Step-by-Step Oil Change Instructions

  1. Warm Up the Engine
    • Start the FE400 and let it idle for a few minutes. This helps the oil thin out, making it easier to drain completely.
  2. Position the Bike
    • Use a bike stand to keep the FE400 upright and stable. Place a drain pan underneath the engine.
  3. Remove the Drain Plug
    • Use a socket or Allen wrench (check your owner's manual for the exact size) to remove the drain plug from the bottom of the engine.
    • Allow all old oil to drain into the pan. Inspect the oil for excessive metal flakes or contaminants.
    • Optional: Replace the crush washer on the drain plug for a better seal.
  4. Remove and Clean the Mesh Oil Filter/Screen
    • Locate and unscrew the mesh oil filter cover (often located beside or near the drain plug).
    • Carefully remove the mesh filter. Clean it thoroughly using a brush and parts cleaner.
    • Check for excess debris or metal; a few fine flakes are typically normal during break-in or limited wear.
    • Install the large hole end of the mesh filter into the engine casing first; the small end should face the sump plug when you reinstall it.
  5. Replace the Cartridge Oil Filter
    • Remove the oil filter cover using the correct tool. Note the position and orientation of the old oil filter.
    • Replace with a new oil filter. Lightly oil the rubber gasket or o-ring if your filter uses one.
    • Reinstall the cover securely without over-torquing the bolts (refer to your manual for specs).
  6. Reinstall the Drain Plug & Mesh Filter Cover
    • Once the oil has completely drained and parts are cleaned, reinstall the drain plug. Tighten to manufacturer's specification using a torque wrench.
    • Reinstall the mesh filter cover securely.
  7. Refill with Fresh Oil
    • Using a funnel, add 1,050ml of high-quality 4-stroke engine oil (such as Motorex, as per Husaberg recommendations).
    • Do not overfill. Always use the oil sight glass or dipstick to ensure the oil level is correct.
  8. Check for Leaks & Final Inspection
    • Start the engine and let it idle for 1–2 minutes. Turn off and recheck the oil level.
    • Inspect under the bike for leaks around the drain plug and filters.
    • Top up oil if necessary, always avoiding overfilling.
  9. Dispose of Used Oil Properly
    • Take used oil to a local recycling facility or auto parts store that accepts oil for recycling.

Additional Model-Specific Advice for the 2002 FE400

  • Always use original Husaberg parts for best performance and longevity.
  • Ensure all bolts and fittings are torqued to spec. Over-tightening may damage the magnesium engine cases.
  • If the bike has been sitting for a long time or you see excessive residue in the oil, check that all O-rings and gaskets are in good condition before reassembly.
  • The parts manual recommends cleaning all components thoroughly before reassembly for best results and component longevity.

Final Thoughts & Maintenance Reminder

Changing the oil on your 2002 Husaberg FE400 is a straightforward process when following the correct procedure and using the right tools. Regular oil changes will help maximize the life and performance of your machine. Stick to a maintenance schedule outlined in your owner's manual, and always keep an eye out for unusual wear signs, leaks, or performance changes.

This guide is proprietary to MotoSport.com and intended for informational purposes. Always consult your owner's manual for precise specifications for your individual bike.

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Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your motorcycle's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.