Husqvarna 125 TC EU Owner'S Manual Download Page 45

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11 SERVICE WORK ON THE CHASSIS

L01632-10

Main work

–

Push air filter holder

toward the air filter at position

and detach it at end

Swing the air filter holder to one side and remove the air filter with the air filter sup-

port.

–

Remove the air filter from the air filter support.

11.27

Cleaning the air filter and air filter box

Warning

Environmental hazard

Hazardous substances cause environmental damage.

–

Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Do not clean the air filter with fuel or petroleum since these substances attack the foam.

Preparatory work

–

Remove the air filter box lid. (

p. 42)

–

Remove the air filter.

(

p. 42)

L00944-10

Main work

–

Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

Info

Only squeeze the air filter to dry it; never wring it out.

–

Oil the dry air filter with a high quality filter oil.

–

Clean the air filter box.

–

Clean the intake flange and check it for damage and tightness.

Finishing work

–

Install the air filter.

(

p. 43)

–

Install the air filter box lid. (

p. 42)

11.28

Installing the air filter

L00943-10

Main work

–

Mount the clean air filter on the air filter support.

–

Grease the air filter in area

L01632-11

–

Insert both parts together, position them, and fasten them using air filter holder

area

The arrow of marking

faces up.

Info

If the air filter is not correctly mounted, dust and dirt can enter the engine and

cause damage.

Finishing work

–

Install the air filter box lid. (

p. 42)

Summary of Contents for 125 TC EU

Page 1: ...OWNER S MANUAL 2014 125 TC EU 250 TC EU Art no 3402001en ...

Page 2: ......

Page 3: ...ifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice Husqvarna accepts no liability for deliv ery options deviations from illustrations and descriptions as well as misprints and other errors The models portrayed partly c...

Page 4: ...THE CHASSIS 26 10 1 Checking the basic chassis setting with the rider s weight 26 10 2 Compression damping of shock absorber 26 10 3 Adjusting the low speed compression damping of the shock absorber 26 10 4 Adjusting the high speed compression damping of the shock absorber 27 10 5 Adjusting the rebound damping of the shock absorber 27 10 6 Measuring the sag of the unloaded rear wheel 28 10 7 Check...

Page 5: ...oke tension 68 14 COOLING SYSTEM 70 14 1 Cooling system 70 14 2 Radiator cover 70 14 3 Installing the radiator cover 70 14 4 Removing the radiator cover 71 14 5 Checking the antifreeze and coolant level 71 14 6 Checking the coolant level 72 14 7 Draining the coolant x 72 14 8 Refilling with coolant x 73 15 TUNING THE ENGINE 75 15 1 Checking the play in the throttle cable 75 15 2 Adjusting the play...

Page 6: ...ding In the interest of your own safety have these jobs performed by an authorized Husqvarna workshop There your motorcycle will be opti mally cared for by specially trained experts using the special tools required Identifies a page reference more information is provided on the specified page 1 2 Formats used The typographical and other formats used are explained below Specific name Identifies a s...

Page 7: ...er that will lead to environmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new v...

Page 8: ... is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts After you complete the repair or service work check the operating safety of the vehicle 2 8 Environment If you use your motorcycle responsibly you can ensure that problems and conflicts do not occur To protect th...

Page 9: ... Husky Power parts for your vehicle can be found on the Husqvarna website International Husqvarna website www husqvarna motorcycles com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chas sis is properly carried out as described in the Owner s Manual Incorrect adjustment and tuning of the engine and chass...

Page 10: ...4 VIEW OF VEHICLE 8 4 1 View of the vehicle from the left front example L01903 10 1 Filler cap 2 Air filter box lid 3 Fuel tap p 13 4 Choke p 13 5 Shift lever p 13 6 Plug in stand p 14 ...

Page 11: ...r p 11 2 Kill switch p 11 3 Fork compression adjustment 4 Throttle grip p 11 5 Hand brake lever p 11 6 Shock absorber rebound adjustment 7 Level viewer for brake fluid rear 8 Shock absorber compression adjustment 9 Foot brake lever p 14 10 Kick starter p 14 11 Fork rebound adjustment ...

Page 12: ...ering head 5 3 Engine number 401949 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 5 4 Fork part number 401947 10 The fork part number 1 is stamped on the inner side of the fork stub 5 5 Shock absorber part number 0 0 1 1 401948 10 The shock absorber part number 1 is stamped on the top of the shock absorber above the adjusting ring on the engine side ...

Page 13: ...ke lever 1 is located on the right side of the handlebar The hand brake lever is used to activate the front brake 6 3 Throttle grip L01908 11 Throttle grip 1 is fitted on the right side of the handlebar 6 4 Kill switch B01827 10 The kill switch 1 is fitted on the left side of the handlebar Possible states Kill switch in basic position In this position the ignition circuit is closed and the engine ...

Page 14: ...tions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clot...

Page 15: ...of the carburetor Activating the choke function frees an opening in the carburetor through which the engine can draw extra fuel This creates a richer fuel air mixture as is required for a cold start Info If the engine is warm the choke function must be deactivated Possible states Choke function activated The choke lever is pulled out to the stop Choke function deactivated The choke lever is pushed...

Page 16: ...ed on the right side of the engine The top part can be swiveled 6 12 Foot brake lever L01905 11 Foot brake lever 1 is located in front of the right footrest The foot brake lever is used to activate the rear brake 6 13 Plug in stand L00936 10 The holder for plug in stand 1 is on the left side of the wheel spindle The plug in stand is used to park the motorcycle Info Remove the plug in stand before ...

Page 17: ...ake your foot off the foot brake lever when you are not braking Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info When using your motorcycle remember that others ...

Page 18: ...ecessary to inspect or replace parts before the next scheduled service Seal the air filter box x p 44 Clean the air filter and air filter box x p 43 Info Check the air filter approx every 30 minutes Additionally secure the rubber grip p 52 Check the electrical connector for humidity and corrosion and to ensure it is firmly seated If humidity corrosion or damage is found Clean and dry the connector...

Page 19: ...ly replace the piston every 10 operating hours 7 5 Preparations for riding on wet sand 600872 10 Check the radiator cap Value on the radiator cap 1 8 bar 26 psi If the displayed value does not equal the setpoint value Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system component...

Page 20: ...lign bent radiator fins 7 7 Preparations for riding at high temperatures and low speeds 600872 10 Check the radiator cap Value on the radiator cap 1 8 bar 26 psi If the displayed value does not equal the setpoint value Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system componen...

Page 21: ...now B00437 01 Mount the rain cover for the air filter Rain cover for air filter 77206921100 Info Observe the Husky Power fitting instructions Adjust the carburetor jetting and setting Info The recommended carburetor tuning is available from your authorized Husq varna workshop ...

Page 22: ...he fuel supply 8 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Note Engine failure High engine speeds in cold engines have a negative effect on the...

Page 23: ...abrupt throttle opening increases fuel consumption To shift down brake and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time Guideline 2 min Avoid frequent and longer slipping of the clutch This heats the engine oil the engine a...

Page 24: ...st Note Material damage Damage to or destruction of components due to excessive load The side stand is only designed for the weight of the motorcycle Do no sit on the motorcycle when it is resting on the side stand The side stand or the frame may become damaged and the motorcycle may fall over Brake the motorcycle Shift gear to neutral Press and hold the kill switch while the engine is idling unti...

Page 25: ... rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Switch off t...

Page 26: ...g hand lever chain and check for smooth operation x Check correct the fluid level of the hydraulic clutch p 53 Check the front brake fluid level p 57 Check the free travel of the hand brake lever p 56 Check the play of the steering head bearing p 38 Change the piston and check the cylinder x Change the piston and check the cylinder under difficult riding conditions x Change the spark plug and spar...

Page 27: ...Change the front brake fluid x Change the rear brake fluid x Change the hydraulic clutch fluid x p 54 Grease the steering head bearing x p 39 Check set the carburetor components x Service the shock absorber x Change the connecting rod conrod bearing and crank pin x Check the transmission and shift mechanism x Change all engine bearings x One time interval Periodic interval ...

Page 28: ...peed refer to the compression speed of the rear wheel suspension and not to the vehicle speed The high speed setting for example affects the compression when landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example affects the compression when riding over long ground swells the rear wheel suspension compresses more slowly These two ranges can be adju...

Page 29: ...d setting can be seen during the fast compression of the shock absorber L01620 11 Turn adjusting screw 1 all the way clockwise with a socket wrench Info Do not loosen fitting 2 Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed 125 TC EU Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Compression damping high speed 250 ...

Page 30: ...work Measure the distance as vertically as possible between the rear axle and a fixed point such as a mark on the side cover Note down the value as dimension A Finishing work Remove the motorcycle from the lift stand p 33 10 7 Checking the static sag of the shock absorber 400989 10 Measure distance A of the unloaded rear wheel p 28 Hold the motorcycle upright with the aid of an assistant Measure t...

Page 31: ...ed parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized Husqvarna work shop will be glad to help Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Preparatory work Raise the motorcycle with the lift stand p 33 Remove the right side cover p 45 Remove the ...

Page 32: ...ight of rider 65 75 kg 143 165 lb 51 N mm 291 lb in Weight of rider 75 85 kg 165 187 lb 54 N mm 308 lb in Weight of rider 85 95 kg 187 209 lb 57 N mm 325 lb in Info The spring rate is shown on the outside of the spring Finishing work Install the shock absorber x p 41 Install the main silencer p 44 Install the right side cover p 45 Remove the motorcycle from the lift stand p 33 Check the static sag...

Page 33: ...ks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing Mount protection caps 1 10 13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior B00295 10 Remove protection caps 1 Turn adjusting screws 2 clockwise all the way Info Adjusting screws 2 are located at the bottom end of the fork legs Make the same adj...

Page 34: ...material fatigue and the handlebar can break Always replace handlebar B00375 10 Remove screws 1 Remove the handlebar clamp Remove the handlebar and lay it to one side Info Protect the motorcycle and its attachments against damage by covering them Do not bend the cables and lines Remove screws 2 Remove the handlebar support Place the handlebar support in the required position Mount and tighten scre...

Page 35: ...t side of the wheel spin dle Info Remove the plug in stand before riding 11 3 Bleeding the fork legs Preparatory work Raise the motorcycle with the lift stand p 33 L01910 10 Main work Release bleeder screws 1 Any excess pressure escapes from the interior of the fork Tighten the bleeder screws Finishing work Remove the motorcycle from the lift stand p 33 11 4 Cleaning the dust boots of the fork leg...

Page 36: ...ection downwards 11 6 Positioning the fork protection B01849 11 Position the fork protection on the left fork leg Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line Position the clamp and mount and tighten screws 2 Position the fork protection on the right fork leg Mount and tighten the screws Guideline Remaining screws chassis M6 10 Nm 7 4 lb...

Page 37: ...ine Screw bottom triple clamp M8 12 Nm 8 9 lbf ft 800191 11 Position the brake caliper and mount and tighten screws 4 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Position the brake line Put the clamp on and mount and tighten screws 5 Finishing work Install the front wheel x p 65 11 9 Removing the fork protector x Preparatory work Raise the motorcycle with the lift stand p ...

Page 38: ...11 11 Removing the lower triple clamp x Preparatory work Raise the motorcycle with the lift stand p 33 Remove the front wheel x p 65 Remove the fork legs x p 34 Remove the start number plate p 39 Remove the front fender p 40 L01912 10 Main work Take off cable holder 1 in front of the left radiator Remove screw 2 Remove screw 3 Take off the upper triple clamp with the handlebar and set it aside Inf...

Page 39: ...ed Slide on protective ring 2 and O ring 3 L01913 10 Position the upper triple clamp with the steering Mount screw 4 but do not tighten yet L01914 10 Position the fork legs Bleeder screws 5 face toward the front Info Grooves are milled into the side of the upper end of the fork legs The sec ond milled groove from the top must be flush with the top edge of the upper triple clamp L01915 10 Tighten s...

Page 40: ...ely and are routed correctly Check the play of the steering head bearing p 38 Remove the motorcycle from the lift stand p 33 11 13 Checking the play of the steering head bearing Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play Adjust the steering head bearing play without delay Your authorized Husqvarna workshop will be glad to help Info If the bike i...

Page 41: ... Main work Loosen screws 1 Remove screw 2 Loosen and retighten screw 3 Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Tighten screws 1 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw 2 Guideline Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Finishing work Check the pla...

Page 42: ...age Position brake line 2 in the brake line guide 11 18 Removing the front fender Preparatory work Remove the start number plate p 39 B01876 10 Main work Remove screws 1 and 2 Remove the front fender 11 19 Installing the front fender B01876 10 Main work Position the front fender Mount and tighten screws 1 and 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the start...

Page 43: ...1 21 Installing the shock absorber x L01664 10 Main work Insert the shock absorber from above Position the shock absorber Mount and tighten screw 1 Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 L01669 11 Position the angle lever and linkage lever Mount and tighten screw cap 2 Guideline Nut linkage lever to angle lever M14x1 5 80 Nm 59 lbf ft Mount and tighten screw 3 Guidel...

Page 44: ...10 Release catch 1 pull off the air filter box lid sideways in areas A and B and remove toward the rear 11 25 Installing the air filter box lid L01918 10 Position the air filter box lid and catch 1 Engage the air filter box lid in areas A and B Engage catch 1 11 26 Removing the air filter x Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never oper...

Page 45: ...box lid p 42 Remove the air filter x p 42 L00944 10 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Info Only squeeze the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil Clean the air filter box Clean the intake flange and check it for damage and tightness Finishing work Install the air filter x p 43 Ins...

Page 46: ...lling the main silencer L01634 10 Main work Mount the main silencer with rubber sleeve 1 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the right side cover p 45 11 32 Changing the glass fiber yarn filling of the main silencer x Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to c...

Page 47: ... cover L01635 10 Remove screw 1 Pull off the side cover in area A sideways and remove it toward the rear 11 34 Installing the right side cover L01635 10 Position the side cover and engage in area A Mount and tighten screw 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 35 Removing the fuel tank x Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or b...

Page 48: ...he fuel tank vent line B01810 01 Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank 11 36 Installing the fuel tank x Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediatel...

Page 49: ...g the chain for dirt 400678 01 Check the chain for heavy soiling If the chain is very dirty Clean the chain p 47 11 38 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of o...

Page 50: ...nent upwards to measure chain tension A Info The bottom chain section 1 must be taut Chain wear is not always even repeat this measurement at different chain positions Chain tension 55 58 mm 2 17 2 28 in If the chain tension does not meet specifications Adjust the chain tension p 48 Finishing work Remove the motorcycle from the lift stand p 33 11 40 Adjusting the chain tension Warning Danger of ac...

Page 51: ... 33 11 41 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle with the lift stand p 33 400227 01 Main work Shift gear to neutral Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Change the drivetrain kit x Info The engine sprocket rear sprocket and chain should always be changed together 400987 1...

Page 52: ...in line with or below the chain sliding piece Change the chain sliding piece x Check the chain sliding piece for tightness If the chain sliding piece is loose Tighten the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 401760 01 Check the chain guide for wear Info Wear can be seen on the front of the chain guide If the light part of the chain guide is worn Change the c...

Page 53: ...ing and deformation If the swingarm shows signs of damage cracking or deformation Change the swingarm x Info A damaged swingarm must always be changed Repair of the swingarm is not authorized by Husqvarna 11 44 Checking the routing of the throttle cable Preparatory work Remove the seat p 42 Remove the fuel tank x p 45 L01920 10 Main work 125 TC EU Check the routing of the throttle cable The thrott...

Page 54: ...the handlebar for damage and wear and to ensure they are firmly seated If a rubber grip is damaged worn or loose Change and secure the rubber grip Rubber grip adhesive 00062030051 p 102 11 46 Additionally securing the rubber grip Preparatory work Check the rubber grip p 52 401198 01 Main work Secure the rubber grip at two points using the securing wire Securing wire 54812016000 Wire twister forcep...

Page 55: ...correcting the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining discs L00953 10 125 TC EU Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Check the fluid level Fluid level under top edge of container 4 mm 0 16 in If the level of the fluid does not meet specificat...

Page 56: ...syringe 4 L00953 11 Inject the liquid into the system until it escapes from bore hole 6 of the master cylinder without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount and tighten the bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level under top level of container 4 mm 0 16 in Position the cove...

Page 57: ...without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount and tighten the bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level under top level of container 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws ...

Page 58: ...d brake lever moves away from the handlebar When the adjusting screw is turned counterclockwise the hand brake lever moves closer to the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 12 3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Ch...

Page 59: ...akage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized Husqvarna workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flus...

Page 60: ...ck the brake linings for damage and cracking If damage or cracking is visible Change the front brake linings x p 58 12 7 Changing the front brake linings x Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized Husqvarna workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avo...

Page 61: ...sure that brake fluid does not flow out of the brake fluid reservoir extracting it by suction if it does Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes Remove cotter pins 4 pull out pin 5 and remove the brake linings Clean the brake caliper and brake caliper support 100397 01 Check that leaf spring 6 in the brake caliper and sliding pl...

Page 62: ...ng Adjust the free travel on foot brake lever according to specifications L01905 10 Disconnect spring 1 Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel A Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the basic position of the foot brake lever x...

Page 63: ...ized Husqvarna workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized Husqvarna workshop will be glad to help Preparatory work Check the rear brake linings p 62 L01805 10 Main work Stand the vehicle upright Check the brake fluid level in the view...

Page 64: ... the membrane and the O ring Info Clean up overflowed or spilt brake fluid immediately with water 12 12 Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized Husqvarna workshop will be glad to help B01843 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 0...

Page 65: ...livery and the war ranty shall be void Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid ...

Page 66: ...unted on the piston side of the brake lining Operate the foot brake lever several times until the brake linings are lying correctly against the brake disc and there is a pressure point B01903 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 100 Mount and tighten screw cap 1 with membrane 2 and the O ring Info Clean up overflowed or spilt brake fluid immediately with water ...

Page 67: ...e the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not damaged L00214 10 Remove spacers 3 13 2 Installing the front wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them...

Page 68: ... work Press the brake caliper onto the brake disc by hand in order to push back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut 1 Remove chain adjuster 2 Withdraw wheel spindle 3 only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the re...

Page 69: ...heck the chain tension p 48 Tighten nut 4 Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 18 in enables different secondary ratios with the same chain length Chain adjusters 3 can be turned by 180 Operate the foot brake lever several times until the brake linings are lying correctly against the brake disc and there is a pressur...

Page 70: ... and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the dust cap Check the tire air pressure when the tires are cold Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi If the tire pressure does not meet specifications Correct the tire pressure Mount the dust cap 13 7 Checking the spoke tension Warning...

Page 71: ...ension varies Correct the spoke tension x Check the spoke torque Guideline Spoke nipple front wheel M4 5 5 6 Nm 3 7 4 4 lbf ft Spoke nipple rear wheel M4 5 5 6 Nm 3 7 4 4 lbf ft Torque wrench with various accessories in set 58429094000 ...

Page 72: ...t operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions 120 C 248 F Cooling is effected by the air stream The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect 14 2 Radiator cover L01811 10 The radiator cover is mounted in front of the left radiator between the radiator shield and radiator The radiator cover...

Page 73: ...d cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal low...

Page 74: ...motorcycle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level A above the radiator fins 10 mm 0 39 in If the level of the coolant does not meet specifications Correct the coolant level Alternative 1 Coolant p 100 Alternative 2 Coolant mixed ready to use p 100 Mount the radiator cap 14 7 Draining the coolant x Warning Danger of scalding Dur...

Page 75: ... water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of chil dren L01925 10 125 TC EU Make sure that screw 1 is tightened Position the motorcycle upright Completely fill the radiator with coolant Coolant 1 2...

Page 76: ...o For all of the air to be able to escape from the cooling system the vehicle must be raised at the front If the cooling system is poorly de aerated its cooling power will be reduced and the engine may overheat Return the vehicle to the horizontal position L01926 10 Fill the radiator completely with coolant Mount radiator cap 2 Run the engine until it is warm Check the coolant level p 72 ...

Page 77: ...on system Start the engine and let it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable x p 75 15 2 Adjusting the play in the throttle cable x Preparatory work Remove the seat p 42 Remove the fuel tank x p 45 Check the routing of the throttle cable p 51 L01807 10 Main work Move the ha...

Page 78: ...nd part load setting and if it abruptly reaches full power at a high rpm the carburetor setting is too rich or the float level is too high or the float needle valve is leaky Part load range C Operation with the throttle slide partially open This range is influenced by the jet needle form and position The idle setting influences the engine tuning in the lower range and the main jet influences the e...

Page 79: ...inning Following extreme air temperature or altitude changes adjust the idle speed again 15 5 Emptying the carburetor float chamber x Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the f...

Page 80: ... 10 p 78 Soft better rideability Change the ignition curve from Soft to Performance 125 TC EU Connect plug in connection 1 Figure L01900 10 p 78 Performance better performance Change the ignition curve from Performance to Soft 250 TC EU Turn lever 1 to position II Figure L01818 10 p 12 Soft better rideability Change the ignition curve from Soft to Performance 250 TC EU Turn lever 1 to position I F...

Page 81: ...ng with yellow marking Auxiliary spring mounted at the factory with medium tuning standard for good rideability Auxiliary spring with green marking Auxiliary spring contained in the separate enclosure for softer performance Auxiliary spring with red marking Auxiliary spring contained in the separate enclo sure for more aggressive performance The engine characteristic can be influenced by different...

Page 82: ...ide them into the clutch cover together Auxiliary spring with yellow marking 54637072300 Auxiliary spring with green marking 54837072100 Auxiliary spring with red marking 54837072000 The recess in spring insert 5 engages in the angle lever Info Screw 6 must not be turned as this would worsen the engine characteristic Check the O ring in the cap Position the cap Mount and tighten the screws Guideli...

Page 83: ...t Add gear oil x p 83 Mount and tighten the screw in the opening used to check the gear oil level Guideline Screw gear oil level check M6 10 Nm 7 4 lbf ft L01815 12 250 TC EU Remove screw 1 from the opening used to check the gear oil level Check the gear oil level A small quantity of gear oil should flow out of the opening If gear oil does not flow out Add gear oil x p 83 Mount and tighten the scr...

Page 84: ...plug thoroughly Clean the sealing area on the engine Mount the gear oil drain plug with magnet 1 and the seal ring and tighten Guideline Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Mount gear oil drain plug 2 with the seal ring and tighten Guideline Gear oil drain plug M10x1 15 Nm 11 1 lbf ft L01817 10 250 TC EU Remove the gear oil drain plug with magnet 1 Completely drain the gear o...

Page 85: ...01711 10 Main work 125 TC EU Remove screw 1 from the opening used to check the gear oil level L01815 12 250 TC EU Remove screw 1 from the opening used to check the gear oil level L01663 11 Remove screw cap 2 Add gear oil until it emerges from the opening used to check the gear oil level engine oil 15W 50 p 100 Mount and tighten the screw in the opening used to check the gear oil level Guideline 12...

Page 86: ...16 SERVICE WORK ON THE ENGINE 84 Start the engine and check that it is oil tight ...

Page 87: ...ry dirty areas with a normal motorcycle cleaner and then clean with a soft brush Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with water first After rinsing the motorcycle with a gentle water spray allow it to dry thoroughly Empty the carburetor float chamber x p 77 Remove the plug from the exhaust system ...

Page 88: ... start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Refuel p 23 Clean the motorcycle p 85 Change the gear oil x p 81 Check the antifreeze and coolant level p 71 Empty the carburetor float chamber x p 77 Check the tire air pressure p 68 Store the vehicle in a dry location that is not subject to large fluctuations in tempe...

Page 89: ...tem defective Check the ignition coil x Check the spark plug connector x Engine does not speed up Carburetor running over because float needle dirty or worn Check set the carburetor components Loose carburetor jets Check set the carburetor components Fault in ignition system Check the ignition system x Engine has too little power Fuel feed interrupted Check the fuel tank breather Clean the fuel ta...

Page 90: ...as ket Bent radiator hose Change the radiator hose x Incorrect ignition point due to loose stator Adjust the ignition x White smoke emission steam in exhaust gas Damaged cylinder head or cylinder head gasket Check the cylinder head or cylinder head gas ket Gear oil exits at the vent hose Too much gear oil added Check the gear oil level p 81 Water in the gear oil Damaged shaft seal ring or water pu...

Page 91: ...ignition adjustment type Kokusan Ignition point BTDC 1 4 mm 0 055 in Spark plug NGK BR9 ECMVX Spark plug electrode gap 0 60 mm 0 0236 in Starting aid Kick starter 20 1 2 250 TC EU Design 1 cylinder 2 stroke engine water cooled with reed intake and exhaust control Displacement 249 cm 15 19 cu in Stroke 72 mm 2 83 in Bore 66 4 mm 2 614 in Exhaust valve Beginning of adjustment 5 600 rpm Exhaust valve...

Page 92: ...ing lever M5 6 Nm 4 4 lbf ft Loctite 243 Screw water pump wheel M5 6 Nm 4 4 lbf ft Loctite 243 Adjustment cable exhaust control M6 10 Nm 7 4 lbf ft Loctite 243 Bleeder screw cylinder head M6 10 Nm 7 4 lbf ft Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch slave cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw clutch spring M6 10 Nm 7 4 lbf ft Screw engine case M6 10 Nm 7 4 lbf ft Screw exhaust c...

Page 93: ... 243 Screw bearing retainer M6 10 Nm 7 4 lbf ft Loctite 243 Screw clutch cover M6 10 Nm 7 4 lbf ft Screw control flap exhaust control M6 10 Nm 7 4 lbf ft Loctite 243 Screw engine case M6x40 10 Nm 7 4 lbf ft Screw engine case M6x55 10 Nm 7 4 lbf ft Screw engine case M6x60 10 Nm 7 4 lbf ft Screw exhaust flange M6 8 Nm 5 9 lbf ft Screw gear oil level check M6 10 Nm 7 4 lbf ft Screw intake flange reed...

Page 94: ... 79 in Shock absorber WP Suspension 5018 BAVP DCC Brake system Disc brakes brake calipers on floating bearings Brake discs diameter Front 260 mm 10 24 in Rear 220 mm 8 66 in Brake discs wear limit Front 2 5 mm 0 098 in Rear 3 5 mm 0 138 in Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Secondary ratio 125 TC EU 13 50 Secondary ratio 250 TC EU 13 48 Chain 5 8 x 1 4 Rear sprocke...

Page 95: ...4 2 N mm 24 lb in Weight of rider 75 85 kg 165 187 lb 4 4 N mm 25 1 lb in Weight of rider 85 95 kg 187 209 lb 4 6 N mm 26 3 lb in Gas pressure 1 2 bar 17 psi Fork length 940 mm 37 01 in Oil capacity per cartridge 195 ml 6 59 fl oz Fork oil SAE 4 48601166S1 p 100 Oil capacity fork leg without cartridge 360 ml 12 17 fl oz Fork oil SAE 4 48601166S1 p 100 20 6 2 250 TC EU Fork part number 14 18 7N 53 ...

Page 96: ... 65 75 kg 143 165 lb 45 N mm 257 lb in Weight of rider 75 85 kg 165 187 lb 48 N mm 274 lb in Weight of rider 85 95 kg 187 209 lb 51 N mm 291 lb in Spring length 260 mm 10 24 in Gas pressure 10 bar 145 psi Static sag 30 mm 1 18 in Riding sag 100 mm 3 94 in Fitted length 486 mm 19 13 in Shock absorber oil p 101 SAE 2 5 20 7 2 250 TC EU Shock absorber part number 18 15 7N 53 Shock absorber WP Suspens...

Page 97: ...2 Nm 8 9 lbf ft Screw chain sliding piece M8 15 Nm 11 1 lbf ft Screw engine brace M8 33 Nm 24 3 lbf ft Loctite 2701 Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw side stand attachment M8 45 Nm 33 2 lbf ft Loctite 2701 Screw subframe M8x20 30 Nm 22 1 lbf ft Loctite 2701 Screw subframe M8x30 30 Nm 22 1...

Page 98: ...ZG Needle position 5th position from top Main jet 200 Info If the engine is not running smoothly use a smaller main jet 20 9 3 250 TC EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number BS8_0 Needle position 4th position from top Jet needle N1EH N1EG N1EI Main jet 158 155 160 Idling jet 42 40 Starting jet 85 Idle air adjusting screw Open 2 turns Throttle slide 6 5 with cut out 20...

Page 99: ...Carburetor tuning 20 10 1 Carburetor tuning 125 TC EU 401762 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Info Not for sandy surfaces ...

Page 100: ...TA 98 20 10 2 Carburetor tuning 250 TC EU 401764 01 M FT ASL Sea level TEMP Temperature ASO Open idle air adjusting screw IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Info Not for sandy surfaces ...

Page 101: ...neral carburetor tuning x 0 0 4 4 0 0 3 3 0 0 5 5 0 0 2 2 0 0 1 1 B00075 10 1 5 Needle position from top The five possible needle positions are shown here The carburetor tuning depends on the defined ambient and operating conditions ...

Page 102: ...tection 40 C 40 F engine oil 15W 50 Standard classification JASO T903 MA p 103 SAE p 103 15W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the correspond ing properties Engine oil 2 stroke Standard classification JASO FC p 103 Guideline Only use high grade 2 stroke engine oil of a reputable brand Fully synthetic Fork...

Page 103: ...unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 Super unleaded 95 octane mixed with 2 stroke engine oil 1 60 Standard classification DIN EN 228 JASO FC p 103 1 60 Mixture ratio 1 60 Engine oil 2 stroke ...

Page 104: ...22 AUXILIARY SUBSTANCES 102 High viscosity grease Recommended supplier SKF LGHB 2 Rubber grip adhesive 00062030051 Recommended supplier KTM Sportmotorcycle AG GRIP GLUE ...

Page 105: ... In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis cosity The viscosity describes only one property of oil and says nothing about quality JASO FC JASO FC is a cla...

Page 106: ...uid level checking correcting 53 fluid changing 54 Clutch lever 11 basic position adjusting 52 Compression damping fork adjusting 31 Compression damping high speed shock absorber adjusting 27 Compression damping low speed shock absorber adjusting 26 Coolant draining 72 refilling 73 Coolant level checking 71 72 Cooling system 70 Customer service 7 D Difficult operating conditions dry sand 16 high t...

Page 107: ...lift stand 33 removing from lift stand 33 O Operating substances 7 Owner s Manual 6 P Plug in stand 14 Preparing for use advice on first use 15 after storage 86 checks and maintenance work when preparing for use 20 Protective clothing 6 R Radiator cover 70 installing 70 removing 71 Rear sprocket checking 49 Rear wheel installing 67 removing 66 Rebound damping fork adjusting 31 shock absorber adjus...

Page 108: ...assis 92 chassis tightening torques 95 engine 89 engine tightening torques 90 fork 93 shock absorber 94 tires 93 Throttle cable play adjusting 75 checking 75 Throttle cable routing checking 51 Throttle grip 11 Tire air pressure checking 68 Tire condition checking 67 Transport 22 Troubleshooting 87 88 Type label 10 U Use definition 5 V View of vehicle front left side 8 rear right 9 W Warranty 7 Wor...

Page 109: ... 3402001en 3402001en 11 2013 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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