Husqvarna 2009 TC 250 Workshop Manual Download Page 32

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D.2

Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

Saddle removal.............................................................................................D.4

Tank removal (TC) ........................................................................................D.4

Tank removal (TE - TXC) ..............................................................................D.5

Valve clearance adjustment ..........................................................................D.6

Throttle cable adjustment (TC) .....................................................................D.7

Throttle cable adjustment (TE - TXC) ...........................................................D.8

Enrichener lever play adjustment (TE - TXC) ...............................................D.8

Carburettor adjustment (TC).........................................................................D.9

Idle adjustment (TC) .....................................................................................D.9

Idle adjustment (TE - TXC) ...........................................................................D.9

Clutch plate replacement ............................................................................D.10

Hydraulic clutch lever adjustment and fluid level check

............................D.11

Front brake lever adjustment and fluid level check

....................................D.12

Rear brake pedal adjustment .....................................................................D.13

Rear brake pedal free play adjustment.......................................................D.14

Rear brake fluid level check

.......................................................................D.14

Engine oil level check .................................................................................D.15

Engine oil replacement and mesh filters-filter cartridge cleaning

or replacement............................................................................................D.16

Coolant level check ....................................................................................D.17

Coolant replacement ..................................................................................D.17

Air filter check (TC)

.....................................................................................D.18

Air filter check (TE - TXC)

...........................................................................D.19

Air filter cleaning

.........................................................................................D.19

Installation ..................................................................................................D.20

Secondary drive chain adjustment .............................................................D.21

Chain lubrication .........................................................................................D.22

Removal and cleaning ................................................................................D.22

Washing a chain without O-rings ................................................................D.22

Lubricating a chain without O-rings ............................................................D.22

Lubricating an O-ring chain ........................................................................D.22

Suspension setup according to track condition ..........................................D.23

Rear shock absorber adjustment................................................................D.24

Shock absorber spring preload adjustment ................................................D.25

Shock absorber compression and rebound damping adjustment ..............D.26

Shock absorber springs ..............................................................................D.26

MARZOCCHI front fork adjustment (TC 2009) ...........................................D.27

KAYBA front fork adjustment (TC - TE - TXC / 2010) .................................D.28

KAYBA front fork springs ............................................................................D.29

MARZOCCHI front fork springs ..................................................................D.30

Steering bearing clearance adjustment ......................................................D.31

Steering angle adjustment ..........................................................................D.31

Changing handlebar position and height ....................................................D.32

Supply hose check (TC) .............................................................................D.33

Supply hose check (TE – TXC) ..................................................................D.33

Silencer sound deadening material replacement .......................................D.34

Exhaust system check ................................................................................D.35

Summary of Contents for 2009 TC 250

Page 1: ...Workshop Manual TC 250 2009 TC 250 2010 TE 250 2010 TXC 250 2010 USA only Part N 8000 H1489 10 2009 ...

Page 2: ... any errors or omissions in this manual and reserves the right to make changes to reflect on going product development Illustrations in the ma nual may differ from actual components No reproduction in full or in part without written authorisation 1st edition 10 2009 ...

Page 3: ...MOTORCYCLES S R L BMW Group Technical Service Via Nino Bixio 8 21024 Varese Italy tel 39 0332 75 61 11 tel 39 0332 756 558 www husqvarna motorcycles com Workshop Manual TC 250 ZKHA300AAAV050001 TC 250 USA ZKHTC250 AV000001 TE 250 ZKHA300AAAV050001 TE 250 USA ZKHTE250 AV000001 TXC 250 ZKHTX250 AV000001 1 Chassis serial number TC 250 2009 TC 250 2010 250 2010 TXC 250 2010 USA only ...

Page 4: ...ion of the problem and ask the appropriate questions to clearly identify problem symptoms diagnose the problem and identify the causes clearly This manual provides basic background information that must be supplemented with the operator s expertise and specific training available through HUSQVARNA held at regular periods plan ahead before starting work gather any spare parts and tools to avoid unn...

Page 5: ...D General Procedures E Engine Disassembly F Engine Overhaul G Engine Reassembly H Front Suspension I Rear Suspension J Brakes L Electrical System M Engine Cooling N KIT Installation Instructions O Hydraulically Controlled Clutch P Optional Components Q Fuel Injection System S Special Tools W Tightening Torque Figures X Chassis and Wheels Y NOTES Unless otherwise specified data and specifications a...

Page 6: ......

Page 7: ...b 1 b Part N 8000 H1489 10 2009 IMPORTANT NOTICES Section ...

Page 8: ... whether off road or on the track ALWAYS remember that these motorcycles are specifically designed for racing i e for usage conditions significantly different from those experienced in regular road use IMPORTANT VEHICLE CONFIGURATION as outlined below is a prerequisite for the war ranty to remain valid A STANDARD MOTORCYCLE FOR ROAD USE DERATED B RACING MOTORCYCLE FOR RACING USE FULL POWER RATING ...

Page 9: ...A 1 A Part N 8000 H1489 10 2009 GENERAL INFORMATION Section ...

Page 10: ...3 Timing system A 3 Fuel system A 3 Lubrication A 3 Cooling A 3 Ignition system A 3 Starter A 3 Drive and Transmission A 3 Chassis A 4 Suspension A 4 Brakes A 4 Wheels A 4 Tyres A 5 Electrical components location A 5 Overall dimensions Weight A 6 Capacities A 7 ...

Page 11: ...iator and electric fan TE TXC Ignition system Electronic capacitive TC or inductive TE TXC discharge ignition with adjustable advance digital control Spark plug type NGK CR9EB Spark plug electrode gap 0 7 0 8 mm Starter TC Kick start with automatic decompressor Starter TE TXC Electric starter and kick start with automatic decompressor Drive and transmission Clutch oil bath multiple disc clutch hyd...

Page 12: ...draulic front fork with advanced axle tube diameter 50 mm rebound and compression damping adjustment travel mm 300 Front TC TE TXC 2010 KAYABA upside down telescopic hydraulic front fork with advanced axle tube diameter 48 mm rebound and compression damping adjustment Travel mm 300 Rear Light alloy rising rate swinging arm and SACHS hydraulic monoshock with coil spring DUAL adjustment for spring p...

Page 13: ...ion TXC The ignition system includes the following elements Generator on the inner side of L H crankcase half cover Electronic ignition coil under the fuel tank Electronic control unit under the fuel tank Voltage regulator under the fuel tank Spark plug on cylinder head 12V 450W starter motor behind the engine cylinder Solenoid starter on the left of rear chassis M A Q S sensor pressure throttle p...

Page 14: ...assis Electric fan Two 15A fuses and one 20A fuse on right side of rear chassis Coolant temperature sensor Lambda sensor Headlamp with 12V 35W twin halogen bulb and 12V 3W parking light bulb LED tail light with stop light bulb 12V 10W turning indicator bulbs Fuel pump inside the fuel tank Odometer Overall dimensions Weight Kerb weight without fuel TC 95 Kg 209 4 lb Kerb weight without fuel TE 102 ...

Page 15: ...ld weather TC 325 cu cm TXC 325 cu cm TE 100 mm Rear shock absorber oil CASTROL SYNTHETIC FORK OIL 5W Coolant CASTROL MOTORCYCLE COOLANT 0 9 litres Front brake fluid CASTROL RESPONSE SUPER DOT 4 Rear brake fluid CASTROL RESPONSE SUPER DOT 4 Clutch fluid CASTROL RESPONSE SUPER DOT 4 Drive chain lubrication CASTROL CHAIN LUBE RACING Grease lubrication CASTROL LM GREASE 2 Electric contact protection ...

Page 16: ......

Page 17: ...B 1 B Part N 8000 H1489 10 2009 MAINTENANCE Section ...

Page 18: ...C C S VALVE SPRINGS C X VALVE SPRING RETAINERS VALVE COLLETS C X VALVE BUCKETS C X CAMSHAFT C TIMING CHAIN C S TIMING CHAIN SLIDER C S TIMING DRIVEN GEAR C X TIMING DRIVE GEAR C X TIMING CHAIN TENSIONER C INTAKE COUPLING C S COMPLETE CYLINDER C S C X COMPLETE PISTON S C S COMPLETE CONNECTING ROD S CRANKCASE BEARINGS S ENGINE OIL S C S OIL PUMP C OIL FILTER MESH FILTER S P S P OIL PUMP TO CRANKCASE...

Page 19: ...SPARK PLUG P S SPARK PLUG CAP C CARBURETTOR P R CARBURETTOR THROTTLE VALVE C AIR FILTER P L RADIATORS C WATER HOSES AND CLAMPS C RADIATORS TO WATER PUMP HOSE C COOLANT C X FOOTPEGS PINS SPRINGS C X REAR CHASSIS MNTG BOLTS ENGINE MNTG BOLTS C C SIDE STAND C CHAIN GUIDE ROLLER BEARINGS C STEERING HEAD BOTTOM YOKE WITH STEM L FRONT FORK R HANDLEBAR MOUNTS AND FASTENERS C C REAR SWINGING ARM BUSHING C...

Page 20: ...ATING SERVICE SERVICE SERVICE SERVICE SERVICE COUPON COUPON COUPON COUPON COUPON PART AFTER FIRST EVERY EVERY EVERY EVERY EVERY REPLACE SEE 3 HOURS 4h MX 8h EN 8h MX 16h EN 16h MX 32h EN 32h MX 64h EN 40h MX 80h EN AS REQUIRED PAGE THROTTLE CABLES C L X FRONT BRAKE DISC C X FRONT BRAKING SYSTEM FLUID C S REAR BRAKE DISC C X REAR BRAKING SYSTEM FLUID C S BRAKE PADS C X MASTER CYLINDER TO BRAKE CALL...

Page 21: ... COMPLETE CONNECTING ROD S CRANKCASE BEARINGS S ENGINE OIL AND OIL FILTER S S S OIL PUMP C OIL FILTER MESH FILTER S P S P OIL PUMP TO CRANKCASE OIL FEED C PRIMARY DRIVE GEAR PAIR C X CLUTCH HUB C X CLUTCH PLATES C S X CLUTCH PRESSURE PLATE C CLUTCH SPRINGS C X CLUTCH PUSHROD C TRANSMISSION SPROCKET C S STARTER GEARS C X SCHEDULED MAINTENANCE CHART TO BE CARRIED OUT AT THE HUSQVARNA DEALER AFTER FI...

Page 22: ... MOUNTS WITH FASTENERS C C REAR SWINGING ARM BUSHING C REAR CHAIN SLIDER C X REAR SUSPENSION LINKAGE BUSHINGS C X CHAIN GUIDE CHAIN GUARD C C X ROLLER CAGES LINKAGE PINS OF REAR SUSP L REAR SHOCK ABSORBER C COMPLETE THROTTLE CONTROL C L COMPLETE CLUTCH CONTROL C R THROTTLE CABLES C L X FRONT BRAKE DISC C X FRONT BRAKING SYSTEM FLUID C S SCHEDULED MAINTENANCE CHART TO BE CARRIED OUT AT THE HUSQVARN...

Page 23: ...EEL SPOKE TENSION C C WHEEL HUB BEARINGS C X REAR CHAIN SPROCKET S SPROCKET BOLT TIGHTENING C C C SECONDARY DRIVE CHAIN C L C L S TORQUE OF NUTS AND BOLTS C C SCHEDULED MAINTENANCE CHART TO BE CARRIED OUT AT THE HUSQVARNA DEALER AFTER FIRST 1000 KM PART REPLACE AS REQUIRED EVERY 5000 KM EVERY 10000 KM LEGEND S REPLACE C CHECK C CHECK CLEARANCE P CLEAN R OVERHAUL L GREASE LUBRICATE NOTES REPLACE GA...

Page 24: ......

Page 25: ...C 1 C Part N 8000 H1489 10 2009 TROUBLESHOOTING Section ...

Page 26: ...ged Clean 2 Fuel cock clogged Clean 3 Fuel feed pipe clogged Clean 4 Filter on carburettor fitting dirty Clean 5 Floater valve or floaters faulty Replace 6 Linkage is blocking floater valve Release Carburettor floods TC 1 High fuel level in bowl Adjust 2 Floater valve or floaters worn or stuck open Replace or release Engine stalls 1 Fouled spark plug Clean easily 2 Electronic control unit faulty R...

Page 27: ... position 1 Weak or broken selector return spring Replace 2 Worn shifter forks Replace Transmission jumps out of gear 1 Worn sliding gear dogs Replace 2 Worn gear grooves Replace 3 Worn dog slots in gears Replace 4 Worn selector shaft splines Replace 5 Damaged shifter fork shafts Replace Engine has low power 1 Dirty air filter Clean 2 Carburettor main jet clogged or is the wrong size TC Clean or R...

Page 28: ...s 1 Insufficient oil in fork legs Top up too soft 2 Fork oil viscosity too low Change 3 Weak fork springs Replace 4 Weak rear shock absorber spring Replace 5 Improperly set rear shock absorber Adjust Front rear wheel 1 Bent wheel rim Replace shakes 2 Worn wheel hub bearings Replace 3 Incorrect spoke tension Adjust 4 Wheel axle nut loose Tighten 5 Worn rear swinging arm bearings Replace 6 Improperl...

Page 29: ...es not charge or 1 Cables running to voltage regulator improperly connected or Connect correctly or is not providing enough charge shorted replace 2 Voltage regulator faulty Replace 3 Generator coil faulty Replace Generator overcharges battery 1 Voltage regulator faulty Replace Battery does not hold charge 1 Battery terminals dirty Clean TE TXC Starter motor 1 Battery is flat Charge does not start...

Page 30: ......

Page 31: ...D 1 D SETTINGS AND ADJUSTMENTS Part N 8000 H1489 10 2009 Section ...

Page 32: ...nt replacement D 17 Air filter check TC D 18 Air filter check TE TXC D 19 Air filter cleaning D 19 Installation D 20 Secondary drive chain adjustment D 21 Chain lubrication D 22 Removal and cleaning D 22 Washing a chain without O rings D 22 Lubricating a chain without O rings D 22 Lubricating an O ring chain D 22 Suspension setup according to track condition D 23 Rear shock absorber adjustment D 2...

Page 33: ...D 3 SETTINGS AND ADJUSTMENTS Part N 8000 H1489 10 2009 ...

Page 34: ...d extract the saddle Tank removal TC Close the fuel cock 2 and loosen the clamp 3 on the hose running to the carburettor Detach hose 4 from carburettor making sure to drain any fuel in the hose into a container Remove the screws 5 and the side panels Remove the retaining screw 6 and then the tank 7 together with the scoops ...

Page 35: ...nd the side panels Remove the tank retaining screw 2 Lift the tank and disconnect the fuel pump connector from the main wiring har ness Disconnect the supply hose 3 from the outlet fitting 4 on the fuel pump located in the rear bottom section of the tank Remove the tank 5 together with the scoops ...

Page 36: ...rough the holes 4 Use a feeler gauge to make sure clearance is 0 15 mm on the INTAKE side and 0 20 mm on the EXHAUST side If not so remove the shim from under the valve bucket and measure its thick ness Depending on what you find replace the shim with a new shim with the required thickness to achieve correct clearance replacement shims are available in a 1 60 mm to 2 60 mm thickness range in 0 05 ...

Page 37: ...rease play or tighten to increase it tighten back the lock ring nut 3 Operation with damaged throttle cable could result in an unsafe riding condition Exhaust gas contains poisonous carbon monoxide Never run the engine indoors When replacing the throttle cables 1 and 2 make sure a 10 mm length of each cable protrudes over the clip length A as shown in the picture Refit the protection cover B using...

Page 38: ...after replacing the cables 4 and 5 Refit the cover 1 and tighten the screw Operation with damaged throttle cable could result in an unsafe riding condition Exhaust gas contains poisonous carbon monoxide Never run the engine indoors To replace the cables you will need to remove the fuel tank as described in the relevant paragraph Enrichener lever play adjustment TE TXC The lever 1 holder features a...

Page 39: ...1 until achieving suitable idle speed setting Idle adjustment TC Adjust the carburettor with warm engine and with the throttle control in closed position Proceed as follows Turn the idle speed adjuster screw 1 located on the left hand side of the vehicle until setting idle RPM as required turn clockwise to increase the speed and counter clockwise to reduce it Idle adjustment TE TXC Adjust the carb...

Page 40: ...med with the motorcycle leaning to the left there is no need to drain engine oil Remove the brake pedal 1 Remove the six retaining screws 2 and the clutch cover 3 Using an 8 mm wrench unscrew the six screws 4 securing the clutch springs Remove springs pressure plate 5 with bearing 6 and clutch actuator plate 7 ...

Page 41: ...t least 0 1 in The lever position can be adjusted to suit the rider hand size To decrease the lever distance from the handgrip rotate the adjuster B CLOCKWISE To increase the lever distance from the handgrip rotate the adjuster B COUN TER CLOCKWISE Fluid level is checked as follows Remove screws 1 cover 2 and rubber diaphragm from the control Keep the control cylinder 3 in a horizontal position an...

Page 42: ... will let air into the system hence an extension of the lever stroke If the brake lever feels mushy when pulled there may be air in the brake line or the brake may be defective CHECK THE BRAKING SYSTEM see Section L Too much brake lever free play may reduce braking action CHECK BRAKE PAD THICKNESS see Section L Do not spill brake fluid onto any painted surface or lens for example lights lens Do no...

Page 43: ... adjusted according to individual needs For adjusting proceed as follows Loosen the screw 1 Turn the cam 2 in order to raise or lower the brake pedal within the range available A When finished tighten the screw 1 Once this adjustment is completed adjust the free play of the pedal following the instructions provided in paragraph Rear brake pedal free play adjustment ...

Page 44: ...r cylinder linkage 4 to increase or decrease free play Tighten the nut 3 at the end of the operation When the free play requirement is not met the brake pads will be subjected to an early wear that may lead to TOTAL BRAKE INEFFECTIVENESS If the brake pedal feels mushy when pulled there may be air in the brake line or the brake may be defective CHECK THE BRAKING SYSTEM see Section L Rear brake flui...

Page 45: ... Keeping the motorcycle level and upright check the oil level through the inspec tion window 1 on the right crankcase Make sure level is up to window midline 1 To top up remove the filler cap 2 Have this operation made with warmed up engine Be careful not to touch hot engine oil ...

Page 46: ...ilter 4 drain the oil and clean the plug mag net Wash the filter 4 with petrol and refit it into its seat Unscrew the screws 5 and remove cover 6 together with filter 7 Change the filter 7 and refit the assembly making sure to fit the Belleville washer 8 in the correct position Refit the drain plug 3 25 Nm 2 5 Kgm 33 89 ft lb and the oil sump guard A Fill with the specified quantity of oil For rec...

Page 47: ...this occurs wash off with water Coolant replacement Place a vessel on the L H side of the cylinder under the hose 1 Remove the drain hose A as follows Unscrew the two screws C Release the spring D Loosen the clamp 2 on the hose 1 and detach the hose from the engine SLOWLY open the cap 3 of the right hand radiator and lean the motorcycle to the left to let the coolant drain into the vessel When fin...

Page 48: ... ADJUSTMENTS Air filter check TC Turn the rear fixing 1 counter clockwise remove it and extract the saddle re leasing it from the front retaining screw Remove the screw 3 remove the complete air filter 4 and separate filter 5 from rear chassis 6 ...

Page 49: ...filter 5 from intake silencer 6 Air filter cleaning Wash the filter with a specific detergent see Capacities table in Section A then dry it fully wash filter with gasoline only in case of need Plunge the filter in special oil for filters see Capacities table in Section A then wring it to drain superfluous oil Do not use fuel or a low flash point solvent to clean the filtering element A fire or exp...

Page 50: ...aling When refitting the filter into its housing make sure to position it with the tab A pointing upwards and edge B at the left bottom corner of the filter housing Refit any parts you have removed An improperly positioned filter might let dirt or dust into the engine leading to early wear of piston rings and cylinder A Upper side B Left hand side ...

Page 51: ...heel three turns In this condition the chain should be neither taut nor slack Fig A Quick adjustment Fig B Insert a 35 mm socket a or a shim of the same size at the position shown in the figure and check that the lower section C of the chain is slightly taut If it is not proceed as follows Loosen the wheel axle nut 1 on the right hand side using a 27 mm socket wrench Loosen the check nuts 2 on bot...

Page 52: ...uel or especially trichloroethylene dry and lubricate the chain to avoid oxidisation Lubricating a chain without O rings After drying dip the chain in Molybdenum Disulphide chain lubricant if possible or in warm high viscosity engine oil if warmed up oil will be more fluid Lubricating an O ring chain Lubricate all metallic and rubber O ring elements using a brush and engine oil with SAE 80 90 visc...

Page 53: ... rebound settings Work on the spring preload to lower the motorcycle riding height rear end MUDDY GROUND Front fork set compression harder or replace the standard spring with a harder spring Shock absorber harder compression and rebound settings or replace the standard spring with a harder spring Work on the spring preload to lift the motorcycle riding height rear end Changing the springs front an...

Page 54: ...easure distance A 2 Sit on the motorcycle in normal riding position with full riding gear on 3 Have someone else measure distance A again 4 The difference between these two measurements is the distance the rear end settles when the rider sits on the motorcycle RIDER SAG Recommended rider sag is 100 mm with a cold shock absorber and 95 mm with a warm shock absorber 5 To achieve correct rider sag fo...

Page 55: ...nscrew the retaining screws 2 and remove the right hand side panel 3 2 Clean lock ring nut 4 and adjuster ring nut 5 of the spring 6 3 Either with a hook wrench or an aluminium punch loosen the lock ring nut 4 Turn the adjuster ring nut as required 5 Adjust preload to suit your weight or riding style and tighten the lock ring nut firmly tightening torque 50 Nm 5 Kgm 67 8 ft lb 6 Reassemble the R H...

Page 56: ...sed position Then turn them back the number of clicks speci fied above In order to obtain a smooth braking efficiency turn the adjusters counter clock wise Vice versa to obtain a harder braking action B REBOUND Standard setting 18 clicks 2 clicks To reset the standard setting turn lower adjuster 2 clockwise until reaching fully closed position Then turn it back by the mentioned clicks In order to ...

Page 57: ...ction b REBOUND TOP ADJUSTER Standard setting 20 clicks To reset standard setting turn adjuster C clockwise to reach the fully closed position then turn it back by the mentioned clicks In order to obtain a smooth braking action turn the adjuster counter clockwise Vice versa to obtain a harder braking action c BLEEDING to carry out after each competition or monthly Set the motorcycle on a central s...

Page 58: ...ng action REBOUND Fig b TC TXC LOWER ADJUSTER TE TOP ADJUSTER KAYABA 9 clicks TC TXC 2010 KAYABA 10 clicks TE 2010 To reset standard setting turn adjuster C clockwise to reach the fully closed position then turn it back by the mentioned clicks In order to obtain a smooth braking action turn the adjuster counter clockwise Vice versa to obtain a harder braking action BLEEDING Fig a b to carry out af...

Page 59: ...D 29 SETTINGS AND ADJUSTMENTS Part N 8000 H1489 10 2009 KAYABA front fork springs STANDARD TC TXC 2010 K 4 4 N mm spring part no 8000 H2669 TE 2010 K 4 2 N mm spring part no 8000 H2690 ...

Page 60: ...D 30 Part N 8000 H1489 10 2009 SETTINGS AND ADJUSTMENTS MARZOCCHI front fork springs STANDARD K 4 8 N mm spring spacer part no 8000 H1994 ...

Page 61: ...nt to rear motion to feel for play If any play is detected adjust as follows Loosen the steering head tube nut 1 Loosen the four bolts 3 that secure the fork legs to the steering head Turn the steering head tube ring nut 2 clockwise using the special key until achieving correct play adjustment Tighten the steering head tube nut 1 to 8 9 Kgm 78 4 88 3 Nm Tighten the four bolts 3 on the steering hea...

Page 62: ...r clamp bolts 3 and 4 and then remove the handlebar upper 1 and lower 2 clamps a Changing handlebar position Rotate the lower clamp by 180 to move handlebar position forward or back ward 10 mm 0 04 in b Changing handlebar height Remove the lower spacer A and replace the screw 4 with a 65 mm long screw When finished tighten the bolts 3 to 2 75 3 05 kgm 27 30 Nm 19 9 22 lb ft and the bolts 4 to 2 0 ...

Page 63: ... as described in Section E Supply hose check TE TXC Remove saddle and side panels as described in Section E Remove the tank 1 retaining screw 2 Lift the tank 2 and check the hose 3 running from the pump 4 to the throttle body 5 To replace the hose squeeze the two retainer tabs 6 at one end of the hose and detach hose Repeat at the other end of the hose ...

Page 64: ...ch on the outside and a 10 mm T wrench on the inside remove the silencer retaining screw 4 Remove the spring 5 and then the screw 8 using an 8 mm T wrench remove the silencer Remove the six rear rivets 6 the clamp and the exhaust end cap 7 Remove the inner pipe and replace the sound deadening material Reassemble the L H side panel and the saddle If the silencer proves hard to remove tap lightly wi...

Page 65: ...TINGS AND ADJUSTMENTS Part N 8000 H1489 10 2009 Exhaust system check Remove exhaust system components as described in Section E Check pipes 1 and 2 silencer 3 for cracks or damage replace if cracked or damaged ...

Page 66: ......

Page 67: ...E 1 E Part N 8000 H1489 10 2009 GENERAL PROCEDURES Section ...

Page 68: ...stem removal E 8 Fuel tank scoop and spoiler removal TC E 10 Fuel tank scoop and spoiler removal TE TXC E 13 Fuel pump removal TE TXC E 16 Solenoid starter removal TE TXC E 17 CDI electronic control unit removal E 18 Voltage regulator removal TE TXC E 18 Ignition coil removal E 19 Clutch hose removal E 20 Horn removal TE E 20 Electric cooling fan removal TE TXC E 21 Secondary drive chain removal E...

Page 69: ...ection describes the operations preliminary to engine removal Please note that in order to gain access to certain motorcycle components rear shock absorber electrical parts wiring etc it may be necessary to partially remove some parts RIGHT HAND SIDE LEFT HAND SIDE ...

Page 70: ... in the relevant paragraph Loosen the retaining screws 1 and remove the side panels 2 and 3 Battery removal TE TCX Remove the saddle as described in the relevant paragraph First remove the BLACK negative cable 8 mm Allen wrench then the RED positive cable when reassembling first connect the RED positive cable then the BLACK negative cable remove the battery 1 from its housing ...

Page 71: ...box 3 at the carburettor end Remove the upper fixing 4 and lower fixings 5 on both sides of the rear chassis using a 10 mm ring wrench Pull the rear chassis 6 rearwards together with mudguard and air box and detach it from the main chassis Removing the rear chassis complete with mudguard and air box TE TXC Remove the following parts in the order given saddle side panels fuel tank silencer and batt...

Page 72: ... Part N 8000 H1489 10 2009 GENERAL PROCEDURES Disconnect the connector 4 of the tail light unit TE Detach relays 5 and fuses 6 on the right hand side of the motorcycle Detach the breather hose 7 from the air filter 8 ...

Page 73: ...ES Unscrew the clamp 9 connecting air filter 8 to throttle body 10 Remove the four screws 11 of the rear chassis 12 using a 10 mm ring wrench Pull the rear chassis 12 rearwards together with mudguard and air box and detach it from the main chassis ...

Page 74: ...S Exhaust system removal Remove the saddle as described in the relevant paragraph Remove the left hand side panel as described in the relevant paragraph Using an 8 mm T wrench on the outside and a 10 mm T wrench on the inside remove the silencer 4 retaining screw 1 ...

Page 75: ... Part N 8000 H1489 10 2009 GENERAL PROCEDURES Remove the spring 2 and the screw 3 using an 8 mm T wrench slide out the silencer 4 Disconnect the Lambda sensor connector 7 and shear the wiring clips TE TXC ...

Page 76: ...E 10 Part N 8000 H1489 10 2009 GENERAL PROCEDURES Loosen the two bolts 5 and remove the exhaust pipe 6 Fuel tank scoop and spoiler removal TC ...

Page 77: ...s described in the relevant paragraph Remove the breather hose 1 from the steering stem Turn the ring nut of the fuel cock 2 counter clockwise to shut off fuel supply and loosen the clamp 3 on the hose running to the carburettor Detach the hose at carburettor end and let fuel drain into a pan Loosen the fuel tank retaining screw 6 ...

Page 78: ...00 H1489 10 2009 GENERAL PROCEDURES Remove the screws 4 retaining the scoops to the fuel tank Remove the scoops 7 and the screws 5 retaining the spoilers 8 to the radiators Remove the spoilers and slide out the tank ...

Page 79: ... 8000 H1489 10 2009 GENERAL PROCEDURES Fuel tank scoops and spoiler removal TE TXC Remove the saddle as described in the relevant paragraph Remove the side panels as described in the relevant paragraph Remove the breather hose 1 Loosen the fuel tank retaining screw 2 ...

Page 80: ...rt N 8000 H1489 10 2009 GENERAL PROCEDURES Remove the screws 3 retaining the scoops to the fuel tank Remove the scoops 4 and the screws 5 retaining the spoilers 6 to the radiators and then remove the spoilers ...

Page 81: ...H1489 10 2009 GENERAL PROCEDURES Disconnect the fuel pump connector 7 from the main wiring harness Lift the tank and disconnect the hose 8 from the fuel pump outlet fitting 9 in the bottom section of the tank Slide out the tank 10 ...

Page 82: ...ank as described in the relevant paragraph Remove the tank filler cap and pour the fuel contained in the tank into a ves sel of adequate capacity Use an Allen wrench to loosen the 6 screws 1 and remove the pump 2 WARNING On assembly make sure that the pump O ring 3 is correctly po sitioned in its seat ...

Page 83: ...saddle and left hand side panel in this order as outlined in the relevant paragraphs Disconnect the negative and positive cables of the battery Disconnect the starter motor positive cable 1 from the solenoid starter Disconnect the connector 2 and remove the solenoid starter 3 from its mount ...

Page 84: ... as described in the relevant paragraphs Detach the connector 1 from the CDI electronic control unit 2 and take the control unit together with its vibration mount out of the chassis Voltage regulator removal TE TXC Remove the electronic control unit as described in the relevant paragraph Disconnect the connector 1 ...

Page 85: ...489 10 2009 GENERAL PROCEDURES Loosen the two retaining screws 2 and remove the regulator 3 Ignition coil removal Remove saddle and fuel tank as described in the relevant paragraphs Remove the spark plug cap 1 Remove the retaining screws 2 and then the coil 3 ...

Page 86: ... engine Drain any oil left in the hose On assembly bleed the clutch system as de scribed in Section P Horn removal TE Remove saddle and fuel tank in this order as outlined in the relevant para graphs Loosen the screw 1 securing the spoiler to the right hand radiator Disconnect the two connectors 2 and remove the horn 3 with its bracket ...

Page 87: ...0 2009 GENERAL PROCEDURES Electric cooling fan removal TE TXC Remove saddle fuel tank and scoops in this order as outlined in the relevant paragraphs Disconnect the connector 1 Loosen the screw 2 and remove the electric fan 3 ...

Page 88: ...ews 1 sprocket guard 2 clip 3 master link 4 and chain 5 Engine removal Remove the saddle as described in the relevant paragraph Remove the side panels as described in the relevant paragraph Remove the fuel tank as described in the relevant paragraph Remove the exhaust system as described in the relevant paragraph Slacken the drain screw 1 and drain fuel into a vessel TC ...

Page 89: ...from the intake coupling and extract it from the right hand side of the motorcycle TE TXC Disconnect the connectors 4 and 5 from the throttle body 6 Loosen the clamps 7 and 8 Push the intake coupling 9 towards the rear end of the motorcycle to re lease the throttle body 6 and then extract it from the right hand side of the motorcycle Place a vessel on the left hand side of the cylinder under the e...

Page 90: ...connecting the radiators to the engine Drain all fluid Slacken the clamp 13 and disconnect the hose 14 connecting the radiator to the water pump Remove the oil sump guard place a pan under the engine and remove the oil filler cap 15 remove the oil drain plug 16 with a 12 mm wrench and drain the oil ...

Page 91: ...CEDURES Remove the spark plug cap 17 Remove the clamp 18 and disconnect the hose 19 from the cylinder head cover Remove the chain as described in the relevant paragraph Remove the chain guide plate 20 unscrewing the screw 21 with an 8 mm wrench ...

Page 92: ...three screws 22 and remove the clutch actuator 23 TC Remove the clip 24 that holds clutch hose and wiring harness together Disconnect the connector 25 that connects wiring harness 26 to control unit TE TXC Remove the water temperature sensor connector 27 Remove the ground cables 28 ...

Page 93: ... the starter motor Disconnect the gear sensor connector 30 and the ignition connectors 31 Shear the clips securing engine wiring to chassis to release the wiring har nesses To remove the brake lever 32 use an 8 mm wrench to loosen the master cylinder linkage 33 and a 6 mm Allen wrench to loosen the central screw 34 Remove the lever ...

Page 94: ...E 28 Part N 8000 H1489 10 2009 GENERAL PROCEDURES Loosen the upper retaining screw 35 of the shock absorber 36 with a 14 mm wrench Remove the guards 37 on both sides shearing the clips 38 ...

Page 95: ... right hand side Loosen the swinging arm axle nut 40 using a 22 mm wrench pull out the axle from the right hand side of the engine and pull the swinging arm rearwards to facilitate engine removal Lift the engine tilt it to the left and remove it from the motorcycle Place the engine on a rotating stand to perform the procedures described in Sections F G H ...

Page 96: ...cooling fan TE TXC as described in the relevant paragraph Place a pan under the hose 1 to collect coolant then loosen the clamp 2 detach the hose 1 and drain all coolant Loosen the clamp 3 and disconnect the hose 4 from the left hand radiator 5 Loosen the clamp 6 and disconnect the hose 7 from the right hand radiator 8 Remove the plastic grids 9 from the radiators Remove the clamp 10 and disconnec...

Page 97: ...e the left hand radiator 5 Loosen the screws 13 and remove the right hand radiator 8 Thermostat removal TE TXC Remove the fuel tank and the left hand spoiler as outlined in the relevant paragraph Loosen the three clamps 1 securing the thermostat 2 Disconnect the hoses 3 and remove the thermostat 2 ...

Page 98: ......

Page 99: ...F 1 F Part no 8000 H1489 10 2009 ENGINE DISASSEMBLY Section ...

Page 100: ... removal F 15 Kick start pedal removal F 16 Sprocket removal F 16 Oil filter removal F 18 Clutch cover removal F 19 Clutch disassembly F 20 Slider removal F 23 Kick start disassembly F 23 Starter motor removal TE TXC F 25 Starter motor disassembly TE TXC F 27 Starter drive disassembly TE TXC F 27 Oil pump disassembly F 30 Gear shift pedal and selector assembly removal F 31 Primary drive gear remov...

Page 101: ...NGINE DISASSEMBLY Layout of engine components 1 Throttle body TE TXC Carburettor TC 2 Cylinder head cover 3 Cylinder head 4 Chain tensioner 5 Cylinder 6 Starter motor TE TXC 7 Head lubrication pipe 8 Oil filter 9 Clutch cover 10 Kick start lever 11 Water pump 12 Alternator cover 13 Sprocket ...

Page 102: ... Cylinder head cover removal Remove the two retaining screws 1 10 mm wrench and remove the head cover 2 with its gasket Camshaft removal Remove the six retaining screws 1 of the alternator cover 2 4 mm Allen wrench and remove the cover with its gasket ...

Page 103: ...F 5 Part no 8000 H1489 10 2009 ENGINE DISASSEMBLY To remove the gear sensor 3 loosen the two screws 4 8 mm wrench and its pushrod and spring ...

Page 104: ...g a 17 mm wrench bring the piston to T D C at the end of the compres sion stroke in this condition the two holes 5 and the two marks 6 on the gears must be positioned as shown in the figure Cover parting line A is visible through the holes 4 INTAKE EXHAUST ...

Page 105: ...park plug 7 16 mm wrench and the head lubrication pipe 8 unscrewing the drilled screw 9 12 mm wrench Remove the screws 10 4 mm wrench and the screws 11 5 mm wrench from both clamps 12 and 13 and remove them Remove the intake camshaft 14 and the exhaust camshaft 15 ...

Page 106: ...E DISASSEMBLY Water pump body removal Remove the four screws 1 securing pump body 2 to head 4 mm Allen wrench and remove pump body Water pump disassembly Loosen the screw 1 to disassemble the pump Loosen the nut 2 to remove the impeller 3 ...

Page 107: ...NGINE DISASSEMBLY Remove the oil seal 4 and slide off the gear 5 together with the bearing 6 Remove the circlip 7 and remove the bearing 6 from the gear 5 On assembly make sure the centring pins 8 are correctly located in their seats ...

Page 108: ...graph Remove the camshafts as described in the relevant paragraph Remove the chain tensioner 1 as follows Loosen the screw 2 with an 8 mm wrench Turn the screw 3 fully clockwise with a flat head screwdriver until locking it so as to release the spring Loosen the two screws 4 using an 8 mm wrench and remove the chain tensioner 1 ...

Page 109: ...ng clip 5 using a screwdriver Loosen the two screws 6 using a Phillips screwdriver and remove the timing drive shaft 7 while holding the gear 8 with your hand Support the gear 8 using a screwdriver or a punch unwrap the chain 9 and remove the gear Let the chain drop into the engine ...

Page 110: ... confusing them on assembly three bolts are 112 5 mm long one 10A is 104 5 mm long Remove the cylinder head 11 and its gasket 12 Be careful not to lose the locating pins positioned between head and cylinder Valve removal Remove the four valve buckets 1 and the shims 2 Mark them with their positions to ensure correct assembly in the original position ...

Page 111: ...oo much or they will weaken Mark all parts to ensure that they are refitted in their original positions on assembly If the valve collets have caused burrs on the valve stems remove them before removing the valves Remove the seals A from the valve guides Remember that seals must be replaced on assembly Compress the springs using the valve spring compressor 1 Remove valve collets 2 spring retainer 3...

Page 112: ... DISASSEMBLY Cylinder removal Remove the front slider 1 of the timing chain pulling it upwards Remove the cylinder 2 with its gasket 3 Piston removal Remove the piston pin retaining rings 1 slide out the piston pin 2 and remove the piston 3 ...

Page 113: ...740 1 2 TE TXC Part no 8000 H1489 10 2009 ENGINE DISASSEMBLY Flywheel removal Loosen the rotor 2 nut 1 17 mm wrench Remove the rotor 2 using the puller 3A part no 8000 H2146 and the puller 3B part no 8000 H1559 ...

Page 114: ...0 2009 ENGINE DISASSEMBLY Remove the key 4 from the crankshaft Kick start pedal removal Remove the pedal retaining bolt 1 12 mm wrench the washer and the pedal 2 Sprocket removal Lift the tab of the lock washer 1 using a chisel ...

Page 115: ...F 17 Part no 8000 H1489 10 2009 ENGINE DISASSEMBLY Loosen the nut 2 using a 22 mm wrench and remove sprocket 3 and spacer 4 ...

Page 116: ... ENGINE DISASSEMBLY Oil filter removal Loosen the drilled nut 1 and disconnect the hose 2 from the oil pump cover 3 Loosen the three screws 4 using an 8 mm wrench Remove the cover 3 together with its filter 5 and Belleville washer 6 ...

Page 117: ...9 Part no 8000 H1489 10 2009 ENGINE DISASSEMBLY Clutch cover removal Remove the nine screws 1 and the screw 2 securing the cover 3 8 mm wrench and remove the cover 3 Remove the gasket 4 and the bushings 5 ...

Page 118: ...E DISASSEMBLY Clutch disassembly Remove the six retaining screws 2 and the clutch cover 3 Using an 8 mm wrench unscrew the six screws 4 securing the clutch springs Remove springs pressure plate 5 with bearing 6 and clutch actuator plate 7 ...

Page 119: ...GINE DISASSEMBLY Remove the plates 8 lubricate the new plates with engine oil and install them always start with a friction plate Remove the clutch pushrod 9 from the opposite side of the engine Straighten the tab of the lock washer 10 ...

Page 120: ...no 8000 H1489 10 2009 ENGINE DISASSEMBLY Remove the nut 11 22 mm wrench using the clutch removal tool A part no 8000 79015 Remove the washer 10 Remove hub 12 washer 13 and clutch housing 14 Remove the bushing 15 ...

Page 121: ... Slider removal Use a 5 mm Allen wrench to loosen the screw 1 and remove the slider 2 Kick start disassembly Release the spring 1 from the casing 2 and remove the complete shaft assembly 3 Be careful not to lose the washer 11 located on the crank case ...

Page 122: ...2009 ENGINE DISASSEMBLY Remove the snap ring 4 the washer 5 and the timing drive gear 6 Disassemble the shaft as shown in the diagram On assembly make sure that the dot 7 on shaft end 8 and the dot 9 on the ratchet 10 are aligned ...

Page 123: ...09 ENGINE DISASSEMBLY Starter motor removal TE TXC Remove the exhaust pipe as described in the relevant paragraph Disconnect the positive power supply cable 1 loosening the hexagonal head screw 8 mm wrench Unscrew the four screws 2 using a 4 mm Allen wrench ...

Page 124: ...MBLY Slide the starter motor 3 towards the rear end of the motorcycle to remove it WARNING Upon assembly check the gasket 4 for damage and replace it if needed Make sure to position it correctly with the gasket hole 5 matching the hole 6 in the starter motor flange ...

Page 125: ...F 27 Part no 8000 H1489 10 2009 ENGINE DISASSEMBLY Starter motor disassembly TE TXC Separate the starter motor 1 from the starter drive 2 Starter drive disassembly TE TXC ...

Page 126: ...MBLY Remove flywheel and starter motor as outlined in the relevant paragraph Disassemble the starter motor as outlined in the relevant paragraph Remove the cap 1 using a 10 mm Allen wrench Remove the circlip 2 and the bearing 3 with the bevel gear ...

Page 127: ...10 2009 ENGINE DISASSEMBLY Place the wormshaft 4 assembly in a vice with aluminium jaws loosen the nut 5 using a 10 mm T wrench and slide out the wormshaft 4 Remove the freewheel 6 Remove the needle roller bearing 7 and the thrust ring 8 ...

Page 128: ...crews 1 using a 4 mm Allen wrench and remove pump body 2 and gasket Remove the pump rotors 3 and 4 and extract the drive pin 5 to release the gear 6 Remove drive gear 7 and oil suction stub 8 Make sure to align the rotor dots 9 on assembly Gear shift pedal and selector assembly removal ...

Page 129: ...the shaft Remove the retaining screw 2 of the gear shift pedal 1 8 mm wrench and slide the pedal from the selector shaft Remove the selector shaft 3 from the right hand side Remove the two screws 4 4 mm Allen wrench and 8 mm wrench secur ing the selector retaining plate 5 and remove retaining plate and ratchet mechanism 6 ...

Page 130: ...8000 H1489 10 2009 ENGINE DISASSEMBLY Remove the bolt 7 of the selector drum 8 12 mm wrench Release the ratchet 10 spring 9 and remove retaining ring 11 washer 12 and ratchet 10 Be careful not to lose the roller 13 ...

Page 131: ...F 33 Part no 8000 H1489 10 2009 ENGINE DISASSEMBLY Primary drive gear removal Loosen the central nut 1 using a 22 mm wrench Remove primary gear 2 and water pump drive gear 3 ...

Page 132: ...LY Crankcase disassembly Remove the nine screws 1 from the left crankcase 2 8 mm wrench Important the screws 1 are not all the same length Refer to figure A on assembly to ensure correct installation FIG A a1 6x60 mm a2 6x55 mm a3 6x70 mm a4 6x90 mm ...

Page 133: ... left crankcase half 4 Tap the output shaft 5 with a rubber hammer at intervals during removal to keep the crankcase half from getting stuck Gearbox disassembly Remove the shaft 1 of the output shaft shifter forks Release the shifter forks 2 and 3 from the drum 4 and remove the forks making sure to collect the drive bushings 5 Remove the drum 4 ...

Page 134: ...o 8000 H1489 10 2009 ENGINE DISASSEMBLY Remove the retaining ring 5 and then the shaft 6 of the input shaft shifter fork 7 Remove the input shaft 8 and output shaft 9 being careful not to lose any shims if fitted ...

Page 135: ... Slide the puller 1 part no 8000 A7015 over the right end of the crank shaft Secure the puller to the crankcase half and remove the crankshaft 2 from the opposite side Bring the crankshaft in the required position and remove the crank pin 3 from one of the flywheel halves 4 ...

Page 136: ...F 38 Part no 8000 H1489 10 2009 ENGINE DISASSEMBLY Remove connecting rod 5 and needle roller bearing 6 from the flywheel half Turn the flywheel half and remove the crank pin 3 ...

Page 137: ...G 1 G Part N 8000 H1489 10 2009 ENGINE OVERHAUL Section ...

Page 138: ...13 Piston ring to cylinder clearance G 13 Piston ring to groove clearance G 14 Big end axial clearance G 14 Crankshaft G 15 Crankshaft straightness G 15 Crankshaft G 15 Clutch G 16 Friction plate to clutch housing clearance G 17 Clutch spring G 17 Oil pump G 19 Shifter forks and gears G 20 Selector drum G 20 Drive bushing roundness G 20 Carburettor overhaul TC G 21 Keihin carburettor setting TC G ...

Page 139: ...ces must be within the specified tolerance A tight fit will lead to seizure as moving parts heat up whereas a loose fit will cause annoying vibration resulting in early wear of moving parts Cylinder head Remove fouling deposits from the combustion chamber using a rounded scraper Do not use sharp tools or you might damage valve seats and spark plug thread Check the machined surface of the cylinder ...

Page 140: ...r similar tool Remove the valve and measure the width X of the seating face If width is greater than 1 2 mm 0 0472 in the seat needs to be refaced The standard width measured as shown of the seating face of the valve is x 0 6 0 7 mm 0 0236 0 0275 in for INTAKE valves x 0 7 0 8 mm 0 0275 0 0314 in for EXHAUST valves Valves cannot be ground and must be replaced if damaged Valve guide INTAKE EXHAUST ...

Page 141: ...to each other using a suitably positioned dial gauge Intake valve normal clearance 0 008 0 035 mm Service limit 0 05 mm 0 0019 in Exhaust valve normal clearance 0 018 0 045 mm Service limit 0 08 mm 0 0031 in Valve guide replacement Make sure that the cylinder head is not damaged Heat up the head in a furnace at 170 C for 30 minutes Remove the valve guide from the cylinder head using a suitable pun...

Page 142: ...r the guide with oil before installation Ream the valve guide using a suitable reamer and lubricate with cutting fluid Rotate the reamer when extracting it to avoid scoring the valve guide When a valve guide is changed the valve seat must be refaced Check clearance again as outlined above Refit the sealing rings 1 Valve ...

Page 143: ... limit 0 05 mm Valve head out of round place valve on a V block and check with a dial gauge at right angles to the head while turning the valve Service limit 0 03 mm Valve spring Check free length L Replace springs if they exceed the service limit Intake Spring 1 L1 25 4 mm Service limit 23 9 mm Spring 2 L2 21 4 mm Service limit 19 9 mm Exhaust Spring 1 L2 22 6 mm Service limit 21 1 mm Spring 2 L2...

Page 144: ...ckets 1 slides freely in their seats If not so replace them Valve installation Smear valve guides and stems with oil before installation Install spring seat 1 and springs 2 place spring a at head end and finally the spring retainer 3 Use tool no 8000 A7317 to compress the valve springs and install the valve collets 4 Do not compress the springs too much and avoid damage to the cylinder head ...

Page 145: ...e stem lightly with a plastic hammer and an aluminium punch to help the valve collets become seated Tap the valve stem tip to avoid pushing the valve off centre Valve leak check Check the valves for proper sealing before assembling the cylinder head to the engine ...

Page 146: ...g or distortion STANDARD L SERVICE LIMIT 140 mm 142 5 mm 5 51 in 5 61 in Timing chain and gears At each engine overhaul check gear teeth and chain rollers for wear If gear teeth are badly worn change both gears and the chain Hold the chain taut to take out any slack and measure across 20 links 21 pins If any one gear or the chain is worn beyond the specified limit replace both gears and the chain ...

Page 147: ...per and out of round Max taper wear limit 0 05 mm Max out of round wear limit 0 05 mm If cylinder is worn beyond these limits replace both cylinder and piston The liner undergoes a special hardening treatment and cannot be ground Piston Clean off any carbon deposits from piston crown and grooves Perform a careful visual inspection of the piston and check its dimensions There should be no signs of ...

Page 148: ... Cylinder diameter Measure inside diameter Dc with an internal bore micrometer 25 mm 0 9842 in below the edge distance A Piston diameter Measure piston diameter Dp 7 mm 0 2755 in above skirt edge distance B Clearance is calculated as follows Dc Dp Piston pin The piston pin 1 must be perfectly smooth with no signs of scoring dents or bluing due to overheating ...

Page 149: ...ston pin Piston ring to cylinder clearance Insert the piston ring at the bottom of the bore where minimum wear occurs taking care to position it squarely and measure end gap Piston ring to cylinder clearance PISTON RING MOUNTING CLEARANCE H SERVICE LIMIT A 0 15 0 30 mm 0 00591 0 01182 in 0 45 mm 0 01773 in B 0 2 0 7 mm 0 00788 0 02758 in 0 85 mm 0 03349 in ...

Page 150: ...o small end clearance A 0 019 0 01 mm SERVICE LIMIT 0 050 mm Big end side clearance B 0 018 0 030 mm SERVICE LIMIT 0 070 mm Big end axial clearance Measure axial clearance A between crankshaft 1 and connecting rod 2 using a feeler gauge Compare measured clearance with the table below PISTON RING MOUNTING CLEARANCE H SERVICE LIMIT A 0 02 0 06 mm 0 00078 0 02362 in 0 09 mm 0 00354 in B 0 01 0 18 mm ...

Page 151: ...e in good condition Crankshaft straightness Place the crankshaft 1 on a stand 2 with two dial gauges 3 positioned on the journals Turn the crankshaft and measure runout STANDARD SERVICE LIMIT than 0 02 mm 0 00078 in than 0 04 mm 0 0015 in If measured runout exceeds 0 04 mm 0 0016 in the crankshaft must be straightened or replaced Crankshaft ...

Page 152: ...hould show no signs of bluing scoring or distortion Measure the thickness of friction plates Plate thickness when new 3 0 mm 0 1181 in Service limit 2 9 mm 0 1141 in Clutch pack thickness 29 4 mm 1 1574 in Place each friction and steel plate on a surface plate and check for distortion using a feeler gauge Use a feeler gauge Service limit 0 2 mm ...

Page 153: ...d clearance exceeds the service limit replace clutch plates or housing and repeat measurement If measurement is still outside the service limit replace the complete clutch assembly Clutch spring Measure the free length L of each spring with a calliper New spring L 37 3 mm 1 4685 in Service limit 35 mm 1 3779 in Change any spring that is outside the service limit STANDARD SERVICE LIMIT 0 30 0 50 mm...

Page 154: ...e the part 5 Clutch hub Check the steel plate slots for signs of wear or failure If any are found replace the part 6 Clutch housing Check the friction plate slots for signs of wear or failure Check the needle roller bearing seats for signs of wear If any are found replace the part 7 Primary drive gear pair Check gear teeth for signs of wear or failure If any are found replace the part ...

Page 155: ...g a 4 mm Allen wrench and remove pump body 2 and gasket Remove the pump rotors 3 and 4 and extract the drive pin 5 to release the gear 6 Check gear 6 and rotors 4 for wear Replace if worn Smear the rotors with oil and make sure to align the rotor dots 9 on assembly Use a new gasket ...

Page 156: ...f the three gears is outside the service limit measure the width of gear groove and fork thickness to determine which component needs to be replaced Shifter fork to groove clearance new fork and gear 0 22 0 37 mm 0 008661 0 014566 in Service limit 0 5 mm 0 019685 in Selector drum Check the grooves A for wear or dents and make sure the selector drum is not bent worn or damaged Drive bushing roundne...

Page 157: ...hat the slide valve is in good condition It should slide freely in its housing without too much play Check that taper needle and main nozzle are in good condition Check the needle valve for proper sealing Keihin carburettor setting TC 1 Main jet 190 2 Idle jet 38 3 Starting jet 72 4 Main air jet 200 5 Throttle valve 15 M 6 Taper needle groove OBDVR 6 7 Air screw turned out 1 1 2 turns 8 Idle air j...

Page 158: ... loosen the screw 1 until achieving suitable idle speed setting NOTES If the engine is difficult to start the idle jet may be the wrong size When this is the case turn in the screw 2 to the fully closed position If engine RPM does not change you need to install a smaller jet If the engine stalls before reaching the fully closed position when you tighten the screw 2 you need a larger jet Change the...

Page 159: ... petroleum based solvent Blow all holes and jets with compressed air Never use metal wire 2 Check Main jet 1 Idle jet 2 Main nozzle 9 Idle screw 7 Starting jet 3 Main air jet 4 Idle air jet 8 If damaged replace If dirty clean NOTE Clean using petroleum based solvent Blow all holes and jets with compressed air Never use metal wire ...

Page 160: ...c If worn a replace needle If dirty clean Throttle valve TC Check that the valve moves freely Repair or replace if stuck Insert the throttle valve 5 into carburettor body and make sure that it moves freely Taper needle TC Check the taper needle 6 If bent or worn replace Standard setting 6th groove ...

Page 161: ... on the needle will affect the measurement Measure the distance of the bowl mating face to the top edge of the floater with a calliper NOTE The floater arm should be resting but not pressing on the needle If floater height is not as specified check valve seat and valve If either one is worn replace both if both parts are in good condition adjust floater height bending the tab b on the floater Chec...

Page 162: ...he fuel from the carburettor floater bowl close the cock tightening the ring nut 1 Insert the end of the hose 2 in a pan slacken the drain screw 3 at the bottom of the bowl and re tighten it after draining all fuel WARNING Never release fuel into the environment or let the engine run in doors ...

Page 163: ...H 1 H Part N 8000 H1489 10 2009 ENGINE REASSEMBLY Section ...

Page 164: ...H 22 Output shaft 5 SPEED H 23 Crankcase assembly H 24 Gear shift control assembly H 29 Kick start assembly H 33 Timing chain and primary drive assembly H 34 Clutch assembly H 37 Sprocket installation H 39 Flywheel installation TC H 40 Flywheel and starter motor installation TE TXC H 41 Flywheel installation TC H 42 Assemble the starter motor 7 H 42 Piston ring installation H 43 Piston and cylinde...

Page 165: ... calculated for a certain life We recommend replacing the bearings especially those exposed to heavy loading also considering that checking them for wear is not an easy procedure These recommendations are in addition to the dimensional checks of individual components specified in the relevant section see Section G ENGINE OVERHAUL Cleaning all components thoroughly is critical to reliability bearin...

Page 166: ...H 4 Part N 8000 H1489 10 2009 ENGINE REASSEMBLY Assembly and lubrication instructions CRANK ALTERNATOR LUBRICATION LEFT CRANKCASE HALF ...

Page 167: ...ft lb 3A TE TXC M5 L35 6 Nm 0 6 Kgm 4 43 ft lb 3B TC M5 L25 6 Nm 0 6 Kgm 4 43 ft lb 3B TE TXC M5 L35 6 Nm 0 6 Kgm 4 43 ft lb 19 M5x0 8 L12 Loctite 270 or 272 8 Nm 0 8 Kgm 5 9 ft lb 49 M5 L8 6 Nm 0 6 Kgm 4 43 ft lb LUBRICATION POINTS NOTES LUBRICANT INSTALLATION INSTRUCTIONS A Degrease B Apply engine oil on installation E Line up stator mark with cover mark G WATER RESISTANT grease O Engine oil ...

Page 168: ...H 6 Part N 8000 H1489 10 2009 ENGINE REASSEMBLY Assembly and lubrication instructions GEARBOX GEAR SHIFT CONTROL ...

Page 169: ... 23A M6 L13 LOCTITE 243 8 Nm 0 8 Kgm 5 9 ft lb 23B M6 L14 LOCTITE 243 8 Nm 0 8 Kgm 5 9 ft lb 24 M5x0 8 L12 6 Nm 0 6 Kgm 4 43 ft lb 48 M6 L20 8 Nm 0 8 Kgm 5 9 ft lb LUBRICATION POINTS NOTES LUBRICANT INSTALLATION INSTRUCTIONS D Install with open end pointing to engine centre O Engine oil O G Engine oil or WATER RESISTANT grease ...

Page 170: ...H 8 Part N 8000 H1489 10 2009 ENGINE REASSEMBLY Assembly and lubrication instructions GEARBOX GEAR SHIFT CONTROL ...

Page 171: ... 23A M6 L13 LOCTITE 243 8 Nm 0 8 Kgm 5 9 ft lb 23B M6 L14 LOCTITE 243 8 Nm 0 8 Kgm 5 9 ft lb 24 M5x0 8 L12 6 Nm 0 6 Kgm 4 43 ft lb 48 M6 L20 8 Nm 0 8 Kgm 5 9 ft lb LUBRICATION POINTS NOTES LUBRICANT INSTALLATION INSTRUCTIONS D Install with open end pointing to engine centre O Engine oil O G Engine oil or WATER RESISTANT grease ...

Page 172: ...H 10 Part N 8000 H1489 10 2009 ENGINE REASSEMBLY Assembly and lubrication instructions CLUTCH KICK START LUBRICATION RIGHT CRANKCASE HALF ...

Page 173: ...using Loctite 5205 19 M5 L12 LOCTITE 270 or 272 6 Nm 0 6 Kgm 4 43 ft lb 26 M8 X 1 25 Al 8 Nm 0 8 Kgm 5 9 ft lb 27 M5 L16 8 Nm 0 8 Kgm 5 9 ft lb 28 M5 x 0 8 L20 6 Nm 0 6 Kgm 4 43 ft lb 29 M6 x 1 LOCTITE 243 8 Nm 0 8 Kgm 5 9 ft lb 30 M8 x 1 25 LOCTITE Alt 272 25 Nm 2 55 Kgm 18 44 ft lb 31 M6 L14 LOCTITE Alt 272 8 Nm 0 8 Kgm 5 9 ft lb 32 M6 L10 LOCTITE Alt 243 8 Nm 0 8 Kgm 5 9 ft lb 40 M6 L20 8 Nm 0 ...

Page 174: ...H 12 Part N 8000 H1489 10 2009 ENGINE REASSEMBLY Assembly and lubrication instructions RIGHT CRANKCASE COVER ...

Page 175: ...ue figures LUBRICATION POINTS NOTES LUBRICANT INSTALLATION INSTRUCTIONS O Engine oil O G Engine oil or WATER RESISTANT grease 27 M5 L16 6 Nm 0 6 Kgm 4 43 ft lb 33 M6 L22 8 Nm 0 8 Kgm 5 9 ft lb 34 M6 x 1 L50 8 Nm 0 8 Kgm 5 9 ft lb 35 M6 x 1 L20 8 Nm 0 8 Kgm 5 9 ft lb ...

Page 176: ...H 14 Part N 8000 H1489 10 2009 ENGINE REASSEMBLY Assembly and lubrication instructions HEAD CYLINDER PISTON TIMING SYSTEM WATER PUMP SPARK PLUG ...

Page 177: ... 0 8 Kgm 5 9 ft lb 37 Special flanged screw L 31 3 8 Nm 0 8 Kgm 5 9 ft lb 38 M5 x 0 8 L8 LOCTITE 243 6 Nm 0 6 Kgm 4 43 ft lb 39 M10 x 1 25 5 Nm 0 5 Kgm 3 69 ft lb 40 M10 L104 5 40 Nm 4 Kgm 29 5 ft lb 41 M10 L104 5 40 Nm 4 Kgm 29 5 ft lb 42 M6 L20 8 Nm 0 8 Kgm 5 9 ft lb 43 M4 L10 3 Nm 0 3 Kgm 2 21 ft lb 44 M5 L25 6 Nm 0 6 Kgm 4 43 ft lb 45 M4 L12 LOCTITE 243 3 Nm 0 3 Kgm 2 21 ft lb 46 M5 LOCTITE 27...

Page 178: ...engine oil and insert it into the flywheel half 2 WARNING Position the crank pin 1 so that hole F is lying on the same axis as connecting rod 4 and flywheel half 2 Fit the needle roller bearing 3 and lubricate it the engine oil Install the connect ing rod 4 and the second flywheel half 5 and align the two flywheel halves using a square ...

Page 179: ...ywheel halves When driving the pin observe the specified distance B Measure connecting rod axial clearance in the flywheels It should be 0 25 0 43 mm Measure crankshaft runout at the bearing locations C Runout must not exceed 0 02 mm Straighten the crankshaft using a copper hammer A 0 25 0 43 mm 0 0098 0 0169 in B 0 5 mm 0 02 in Aligned with flywheel half ...

Page 180: ...H 18 Part N 8000 H1489 10 2009 ENGINE REASSEMBLY Input shaft Output shaft ...

Page 181: ...ng and then install the washer 3 and the retaining ring 4 The washer must be placed between gear and retaining ring Fit 3rd gear 5 retaining ring 6 and washer 7 Fit the roller cage 8 Fit 4th gear 9 Fit 2nd gear 10 Fit the circlip 11 B with 5th gear engaged C with 4th gear engaged D lubricate with MOLYKOTE G n plus ...

Page 182: ... 4th gear 5 and retaining ring 6 Fit the washer 7 Fit roller cage 8 and 3rd gear 9 Fit washer 10 and retaining ring 11 Apply MOLYKOTE G n plus on the 3rd gear 9 Fit 5th gear 13 and washer 14 Fit roller cage 15 1st gear 16 and washer 12 A with 1st gear engaged B with 3rd gear engaged C with 2nd gear engaged D lubricate with MOLYKOTE G n plus ...

Page 183: ...H 21 Part N 8000 H1489 10 2009 ENGINE REASSEMBLY Input shaft Output shaft ...

Page 184: ...bushing and then install the washer 3 and the retaining ring 4 The washer must be placed between gear and retaining ring Fit 3rd 4th gear 5 retaining ring 6 and washer 7 Fit the roller cage 8 Fit 6th gear 9 Fit 2nd gear 10 Fit the circlip 11 B with 5th gear engaged and 5th gear in contact with 1st gear C with 4th gear in contact with 6th gear ...

Page 185: ...nd retaining ring 13 Apply MOLYKOTE G n plus on the 4th gear 11 Fit 5th gear 14 and washer 15 Fit roller cage 16 1st gear 17 and washer 18 A Control dimension with 1st gear engaged and 1st gear butted up on the shaft B Control dimension with 4th gear engaged and 4th gear butted up against shaft washer and circlip C Control dimension with 3rd gear engaged and 1st and 3rd gears and their washers and...

Page 186: ...tool no 8A00 90662 Heat up to around 125 C and drive the ball bearings into each crankcase half using a suitable driver tool Fit the retaining plates 1 and 2 to the crankcase bearings 5 Nm 0 5 Kgm 3 6 ft lb Loctite 272 for crankshaft bearing retaining plate 1 11 Nm 1 1 Kgm 7 9 ft lb Loctite 272 for right hand bearing retaining plate 2 ...

Page 187: ...REASSEMBLY Install the input and output shaft assembly making sure the output shaft 3 shim is in place Lubricate the three shifter forks 4 with engine oil and install them Make sure the bushings 5 are correctly in place grease the bushings ...

Page 188: ...lector drum 6 into its seat Install the fork shafts 7 and 8 and make sure the forks move freely Make sure the fork bushings 5 are correctly located in the drum grooves 6 Insert the circlip 9 of the input shaft fork shaft Rotate the selector drum to test operation ...

Page 189: ...LY Heat up the crankshaft bearing 10 and install the crankshaft 11 Make sure both crankcase locating bushings 12 are in place Apply a layer of LOCTITE 5205 on the right crankcase mating surface 13 making sure not to obstruct the oil passage hole 14 ...

Page 190: ...a plastic hammer Tighten the screws 15 using an 8 mm wrench 10 Nm 1Kgm 7 25 ft lb Make sure to fit the screws in the correct positions according the specified pattern see Section F paragraph Crankcase disassembly Cover the upper section of the engine with a cloth a sponge or the like to prevent screws or other parts from accidentally falling into the engine ...

Page 191: ...12 mm wrench apply Loctite 243 and tighten to 20 Nm 2 0 Kgm 14 5 ft lb Install ratchet 2 spring 3 washer 4 and circlip 5 Install the selector drum 6 making sure the tab 7 locates in the recess 8 and secure drum with its screw 9 Apply Loctite 243 tighten to 20 Nm 2 0 Kgm 14 5 ft lb use 12 mm wrench Engage the spring 3 ...

Page 192: ...bly 10 together with the plate making sure ratchets and springs are in the correct positions Tighten the upper screw 11 using a 4 mm Allen wrench Loctite 243 10 Nm 1 0 Kgm 7 2 ft lb Tighten the lower screw 12 using an 8 mm wrench Loctite 243 10 Nm 1 0 Kgm 7 2 ft lb Turn the engine over and install the gear shift lever oil seal 13 and its circlip 14 ...

Page 193: ...t lever shaft is positioned correctly Check the gear shift lever shaft 16 and the slot of the gear selector mechanism for signs of wear Lubricate the shaft with engine oil and insert the shaft 16 into the crankcase so that the fork 17 slides over the ratchet detent and the spring 18 locates to its abutment pin ...

Page 194: ...H 32 Part N 8000 H1489 10 2009 ENGINE REASSEMBLY Install the gear shift lever 19 and operate the gearbox manually 8 mm wrench 8 Nm 0 8 Kgm 5 8 ft lb ...

Page 195: ...ease plate 1 use a 4 mm wrench 8 Nm 0 8 Kgm 5 8 ft lb Loctite 243 Fit the complete shaft assembly 2 to its seat B in the crankcase making sure the ratchet is correctly positioned on the shaft marks lined up and insert the spring end 3 into the hole D Fit transmission gear 4 washer 5 and snap ring 6 ...

Page 196: ... chain slider 1 tighten the screw 2 using a 5 mm wrench 10 Nm 0 1 Kgm 7 3 ft lb Loctite 243 and make sure the slider moves freely Fit the oil pump drive gear 3 making sure the side with the dot is facing out side Fit the primary drive double gear 4 making sure to line up the timing dot A with the shaft dot B ...

Page 197: ...H 35 Part N 8000 H1489 10 2009 ENGINE REASSEMBLY Install the timing chain 5 Refit the bushing 6 Refit the clutch housing 7 ...

Page 198: ...00 H1489 10 2009 ENGINE REASSEMBLY Place a dummy gear 8 or an aluminium shim between clutch housing 7 gear and double gear 4 and then tighten the primary drive shaft nut 9 use a 22 mm wrench 100 Nm 10 Kgm 72 50 ft lb ...

Page 199: ...Part N 8000 H1489 10 2009 ENGINE REASSEMBLY Clutch assembly Install washer 1 hub 2 lock washer 3 and nut 4 Use the suitable tool 5 to prevent rotation and tighten to 60 Nm 6 Kgm 43 5 ft lb use a 22 mm wrench ...

Page 200: ...ate and keep alternating between friction and steel plates the last to go in should be a steel plate Fit actuator plate 7 thrust bearing 8 thrust washer 9 pressure plate 10 and springs 11 Tighten the spring screws 12 gradually in a cross pattern 5 Nm 0 5 Kgm 3 6 ft lb Turn the engine over Install the clutch pushrod 13 ...

Page 201: ...ten the screws 2 use an 8 mm wrench 5 5 Nm 0 55 Kgm 4 ft lb Fit the spacer 3 with the grooved side facing inwards Install sprocket 4 lock washer 5 and nut 6 Hold the sprocket 4 with the suitable tool 7 to prevent rotation and tighten the nut 6 use a 22 mm wrench 100 Nm 10 Kgm 72 5 ft lb Bend the tabs of the lock washer ...

Page 202: ...ded in swirling oil and captured by the magnets Fit the tab 1 into the crankshaft and refit the rotor 2 Hold the rotor 2 to prevent rotation and place an aluminium shim or dummy gear between the primary drives gears on the right side again to prevent rotation Tighten the nut 3 to 75 Nm 7 5 Kgm 54 3 ft lb Use a 17 mm wrench ...

Page 203: ...l rotor to remove any debris suspended in swirling oil and captured by the magnets Fit the tab 1 to the crankshaft Lubricate needle roller bearing 2 and thrust ring 3 with engine oil and install them making sure the thrust ring slots are pointing outwards Lubricate the freewheel 4 with engine oil and refit it ...

Page 204: ...the starter motor 7 check for free clockwise rotation of the freewheel 4 while holding the rotor 5 steady Assemble the starter motor 7 WARNING On assembly check the gasket 8 for damage and re place it if needed Make sure to position it correctly with the gasket hole 9 matching the hole 10 in the starter motor flange Fit the starter motor 7 into place Tighten the bevel drive screws 11 using a 4 mm ...

Page 205: ... C1 Top oil rail end gap position C1 Oil rail spacer end gap position C1 Bottom oil rail end gap position Piston and cylinder installation Remove the rubber protection 1 Install a new cylinder foot gasket 2 Assemble piston 3 to connecting rod 4 lubricate with engine oil and fit the piston pin retaining rings 5 Make sure the arrow mark on the piston is pointing to the front end Make sure that the l...

Page 206: ...H 44 Part N 8000 H1489 10 2009 ENGINE REASSEMBLY Lubricate the cylinder liner 7 with engine oil and slide it over the piston rings Make sure to collect the timing chain 8 Position the slider 9 ...

Page 207: ...able below Remove spacers and screws 10 and fit the appropriate head gasket Cylinder head gasket selection table Bring piston to T D C at the end of the compression stroke measure distance A between piston crown and head gasket mating face and select the appropriate gasket according to the table below CONDITION see diagram A Gasket thickness Gasket part no 1 piston lower than cylinder mating face ...

Page 208: ... supporting the timing chain 2 with a screwdriver Tighten the head bolts 3 gradually in a cross pattern to 40 Nm 4 Kgm 29 ft lb use a 12 mm wrench WARNING Refit each of the bolts 3 and 3a in its original position Bolt 3 119 5 mm long Bolt 3a 104 5 mm long TC Refit the cap 4 with its gasket use a 5 mm Allen wrench Loctite 243 20 Nm 2 0 Kgm 14 5 ft lb TE TXC Refit the water temperature sensor 4A use...

Page 209: ...on removal Check the bearings of the timing drive upper gear 7 and replace them if needed The gear 7 requires no timing Refit the gear 7 with its shaft 8 and gasket 9 Tighten the screws 10 with a Phillips screwdriver 4 Nm 0 4Kgm 2 9 ft lb Loctite 243 Push the gear until exposing the groove and fit the retaining ring 11 ...

Page 210: ...n assembly position the screw 13a at the uppermost position and fit the ground rings 14 before tightening IMPORTANT Do not confuse the screws and do not tighten the screw 13a unless you have fitted the ground rings RISK OF CYLINDER FAILURE Release the chain tensioner 12 using a screwdriver turn counter clockwise Water pump installation Refit the water pump 1 with its gasket Avoid using excessive f...

Page 211: ...the spark plug hole Turn the crankshaft manually until bringing the piston to Top Dead Centre Refit intake camshaft 2 and exhaust camshaft 3 with the gears positioned as shown in the figure Cover parting line A is visible through the holes 4 Make sure that the bushings 5 are in place in the covers ...

Page 212: ...er gauge 8 to check clearance between valve buckets and cam lobes Correct values are as follows intake 15 hundredths exhaust 20 hundredths If the value is outside the limit remove the covers and replace the shims under the valve buckets with shims of the appropriate size so as to achieve correct clearance Replacement shims are available in a 1 60 mm to 2 60 mm thickness range in 0 05 mm increments...

Page 213: ...crews 2 use a 4 mm Allen wrench 6 Nm 0 6 Kgm 4 3 ft lb Loctite 272 Insert the cable guide 3 into its seat in the cover and tighten the two retaining screws 4 of the pick up sensor 5 with its plate 6 Nm 0 6 Kgm 4 3 ft lb Loctite 272 Install the flywheel cover 7 with its gasket and tighten the six screws 8 to 6 Nm 0 6 Kgm 4 3 ft lb Make sure the two centring bushings 6 are in place ...

Page 214: ...1489 10 2009 ENGINE REASSEMBLY Neutral sensor installation Refit pin 1 and spring 2 Check the O ring 3 of the sensor 4 Refit the sensor 4 and tighten the screws 5 using an 8 mm wrench 5 5 Nm 0 55 Kgm 4 ft lb Loctite 243 ...

Page 215: ...ing UP Tighten the screws 2 with the wire clip 3 placed on the upper screw Cylinder head cover spark plug oil feed hose installation Position the central seal 1 Fit the head cover 3 with its gasket to the head 2 Tighten the screws 4 and 4a 8 Nm 0 8 Kgm 5 9 ft lb Screw 4 L 23 4 mm Screw 4a L 31 3 mm Install the spark plug 10 12 Nm 1 1 23 Kgm 7 2 8 9 ft lb ...

Page 216: ...1 and its shaft 2 Check the O rings of the oil suction stub 3 and replace them if needed Refit the oil suction stub 3 Refit the centring bushings 4 Refit the gasket 5 Manually check for correct installation and operation of the pump 6 and make sure the crankshaft sealing ring 7 is in the correct position ...

Page 217: ... lb Make sure pump gear and drive gear engage correctly Check the O ring 10 for damage and replace it if needed Refit the spring 11 of the oil filter 12 Refit the oil filter into its housing and tighten the screws 13 using an 8 mm wrench 5 5 Nm 0 55 Kgm 3 98 ft lb WARNING When assembling filter to cover make sure to fit the filter oil seal A first onto the cover 6 ...

Page 218: ...ain plug Fit the oil filter 1 and tighten the cap 2 into place with its gasket using a 12 mm wrench 25 Nm 2 5 Kgm 18 44 ft lb Oil feed hose installation Refit the hose 1 and tighten the drilled screws 2 with their seals using a 12 mm wrench 8 Nm 0 8 Kgm 5 9 ft lb ...

Page 219: ...ion Install the gear shift pedal 1 and tighten the screw 2 using an 8 mm wrench 8 Nm 0 8 Kgm 5 8 ft lb Check the pedal 1 for damage Refit the kick start pedal 3 and tighten the screw 4 using a 12 mm wrench 25 Nm 2 5 Kgm 18 44 ft lb Loctite 272 Make sure that the pedal does not foul the cover ...

Page 220: ... ft lb Refit the coolant hoses with their clamps Refit the rear brake pedal with its bolt 41 6 Nm 4 2 Kgm 30 7 ft lb Loctite 243 Refit the side guards of the chassis Refit the carburettor Refittheexhaustsystem piperetainingscrews 10 4Nm 1Kgm 7 7ft lb exhaust pipe retaining screws use an 8 mm wrench 8 4 Nm 0 8 Kgm 5 8 ft lb Refit the fuel tank together with the scoops Refit the fuel tank front reta...

Page 221: ...I 1 I Part N 8000 H1489 10 2009 FRONT SUSPENSION Section ...

Page 222: ...nce I 32 Cleaning the fork legs I 33 Disassembly I 33 Assembly I 33 Bleeding I 34 Draining oil I 35 Cartridge removal I 36 Checking and changing cartridge and compression valve setting I 36 Cartridge removal I 36 Rebound adjuster servicing I 38 Disassembly I 38 Assembly I 38 Compression valve servicing I 39 Disassembly I 39 Assembly I 39 Cartridge assembly I 40 Separating inner and outer tube seal...

Page 223: ...I 3 Part N 8000 H1489 10 2009 FRONT SUSPENSION ...

Page 224: ...ck under the engine and see that the front wheel is lifted from the ground and then proceed as follows remove the screws 1 and the brake line clamp on the left hand side remove the six screws 2 and the fork leg guards remove the brake calliper from the L H fork leg loosening the two retaining screws 3 remove the front wheel as described in Section Y ...

Page 225: ...89 10 2009 FRONT SUSPENSION loosen the bolts 4 that secure the fork legs to steering head and bottom yoke remove the fork legs Refit fork legs and front wheel as described in Section Y Set height A back to original value ...

Page 226: ...e plated and TIN coated OUTER TUBES CNC machined aluminium alloy anodised and polished in side SLIDING BUSHES Teflon coated stiction free SEALS Computer designed sealing rings ensure maximum sealing on compression and minimal friction on rebound SPRINGS Steel springs different spring rates K available See Table for more detailed information OIL Special KAYABA formulation prevents foaming and retai...

Page 227: ...7 Part N 8000 H1489 10 2009 FRONT SUSPENSION Front suspension TC TXC Front suspension is handled by a KAYABA upside down telescopic hydraulic fork with advanced axle and 48 mm legs Wheel travel is 300 mm ...

Page 228: ...slacken the cap nuts before removing the fork legs from the motorcycle Drain oil from the damper unit Clamp the wheel axle carrier in a vice and loosen the adjuster screw Push down the inner tube Slip the tool shown in the figure between wheel axle carrier and cartridge nut Hold the nut with a wrench and remove the adjuster screw Be careful not to hurt your fingers ...

Page 229: ... cartridge Remove the bottom valve assembly from the cartridge Hold the cartridge octagonal nut with the suitable tool to prevent rotation Use a similar tool in the octagonal recess of the bottom valve assembly Use a key to slacken the bottom valve assembly Check the O rings on the bottom valve assembly for damage Replace as required ...

Page 230: ...upside down and allow at least 20 minutes for oil to drain Remove the dust seal using a flat head screwdriver Remove the retaining ring using a flat head screwdriver Pull the inner tube until separating it from the outer tube Note to facilitate removal quickly but carefully pump the tubes back and forth until separating them ...

Page 231: ... rebound adjuster Replace damaged O rings Replace the complete assembly do not reuse it Check the spring Replace it if outside diameter is damaged or exceedingly worn Free length is 449 mm 17 7 in or less Check the inner tube Replace if distorted Never attempt to repair or reuse a distorted fork tube If the tube shows surface defects sand the surface If repair is not possible replace the tube Neve...

Page 232: ... tube cover tube edge with plastic as shown in the figure This will avoid damage to the oil seal lip Fit metal bushing and washer to outer tube using an appropriate installer Fit the oil seal to the outer tube and push it home using an appropriate in staller Make sure that the retaining ring groove inside the outer tube is fully visible Install the retaining ring Make sure that the retaining ring ...

Page 233: ...ot play between dust seal and outer tube Refit the cartridge Tighten the nut all the way onto the rebound adjuster rod Make sure rebound adjuster rod thread length is at least 15 mm 0 6 in Fill the cartridge with the specified oil Pump the piston rod up and down repeatedly to remove any air from the cyl inder ...

Page 234: ...lve assembly installed check that the piston rod is fully extended Hold the cartridge octagonal nut to prevent rotation Use a similar tool in the octagonal recess of the bottom valve assembly Tighten the bottom valve assembly to 29 Nm 21 4 ft lb using a wrench Hold the cartridge with the piston rod end pointing downwards as shown in the figure Pump the piston rod up and down a dozen times to help ...

Page 235: ...parts Please note that excess oil may flow out from the hole located before the res ervoir If you see no oil flowing out it means that there isn t enough oil in the car tridge Add oil to the cartridge before refitting it Drain excess oil from the reservoir Clean off any excess oil from the cartridge Install spring guide and spring on the cartridge Insert the cartridge into the inner tube ...

Page 236: ...rtridge nut Insert the rebound adjuster rod into the piston rod and tighten the adjuster screw Be careful not to hurt your fingers Tighten the adjuster screw all the way in Make sure that there is some play between the bottom edge of the adjuster screw and the upper edge of the nut Tighten nut and adjuster to 28 Nm 20 6 ft lb using a wrench ...

Page 237: ...NT SUSPENSION Clamp the wheel axle carrier in a vice and tighten the adjuster screw onto the carrier to 55 Nm 40 5 ft lb Fill the outer tube with the specified quantity of oil Tighten the cylinder onto the outer tube to 29 Nm 21 4 ft lb ...

Page 238: ...0 H1489 10 2009 FRONT SUSPENSION Front suspension TE Front suspension is handled by a KAYABA upside down telescopic hydraulic fork with advanced axle and 48 mm legs Wheel travel is 300 mm Front suspension Mod TE 2010 ...

Page 239: ...te it is good practice to moderately slacken the cap nuts before removing the fork legs from the motorcycle Loosen the fork cap nut and the nut with a wrench Remove top cap nut spring retainer spring and rebound adjuster rod Drain the oil Pump the piston rod up and down to drain oil from the cylinder ...

Page 240: ...I 20 Part N 8000 H1489 10 2009 FRONT SUSPENSION Remove nut spring guide O ring and collar bushing Hold the cartridge top end steady Loosen and remove the bottom valve assembly ...

Page 241: ...I 21 Part N 8000 H1489 10 2009 FRONT SUSPENSION Take the cartridge out of the outer tube Remove the dust seal using a flat head screwdriver ...

Page 242: ...l separating them Remove the sealing rings and the metal rings mounted on the inner tube Do not reuse any metal parts after removal Replace them with new components Replace damaged sealing rings Washer and retaining ring may be reused if they are not damaged Check the rebound adjuster rod for distortion or damage Replace as required Loosen and remove the bottom valve assembly Replace damaged O rin...

Page 243: ...air is not possible replace the tube Never reuse an inner tube if scored or showing bulges on the outer surface Check the outer tube Replace the tube is any distortion is detected or if the sliding surface is dam aged Mount sealing rings and metal parts on the inner tube See the figure below for the installation sequence Note 1 Grease the edge of the sealing ring Note 2 Before sliding the sealing ...

Page 244: ...er tube and push it home using an appropriate in staller Make sure that the retaining ring groove inside the outer tube is fully visible Install the retaining ring Make sure that the retaining ring is fully seated in the groove inside the outer tube Fit the dust seal to the outer tube Make sure that there is not play between dust seal and outer tube ...

Page 245: ...I 25 Part N 8000 H1489 10 2009 FRONT SUSPENSION Insert the cartridge into the outer tube Hold the cartridge top end into place Tighten the bottom valve assembly to 55 Nm 40 5 ft lb ...

Page 246: ... in portion of the rebound adjuster rod protrudes from the piston rod Oil filling Fill with the specified quantity of oil Fill the damper unit with the specified quantity of oil Slowly pump the piston rod up and down to help oil reach all points of the car tridge Note if you haven t drained all oil from the damper unit on disassembly follow the procedure outlined below Filling oil to specified lev...

Page 247: ...p and down to help oil reach all points of the cartridge Note add oil if level in the damper unit is too low Finally top up to the upper edge of the outer tube Allow the fork leg to rest until no more air bubbles can be seen then top up oil to specified level Insert the rebound adjuster rod into the piston rod Insert spring and spring guide retainer and tighten the cap nut Tighten fork cap nut and...

Page 248: ...H1489 10 2009 FRONT SUSPENSION Front suspension Front suspension is handled by a MARZOCCHI USD telescopic upside down hydraulic fork with advanced axle and 50 mm legs Wheel travel is 300 mm Front suspension Mod TC 2009 ...

Page 249: ...ted OUTER TUBES CNC machined aluminium alloy anodised and pol ished inside SLIDING BUSHES Teflon coated stiction free SEALS Computer designed sealing rings ensure maximum sealing on compression and minimal friction on re bound SPRINGS Steel springs different spring rates K available See Table for more detailed information OIL Special MARZOCCHI formulation prevents foam ing and retains same viscosi...

Page 250: ... Sealing ring 16 Dust seal 19 Spring 24 Rebound adjuster rod 25 Rod 26 37 Washer return spring 33 Rebound damping piston washers 35 Cartridge case 39 Compression piston 41 Compression valve washers 43 Compression valve 44 Inner tube 46 Top sliding bushing 48 Bottom nut 53 Spring preload adjuster 70 Wheel axle carrier 71 Rebound adjuster 72 Rebound adjuster taper needle In the next figure moving pa...

Page 251: ...e compo nents with the tip of the screwdriver Use only genuine Marzocchi parts Before servicing the front fork make sure to have a Marzocchi service kit for your fork if applicable available including the neces sary parts for a complete fork service or overhaul Perform service in a clean orderly well lit environment Avoid servicing the fork outdoors Make sure the work area is free from metal filin...

Page 252: ...rod changes to setting 2 Adjuster screw stuck 2 Remove and clean adjuster screw 3 Debris in oil 3 Change oil and thoroughly clean internal components of fork 4 Valves clogged by debris 4 Change oil and thoroughly clean internal components of fork Fork feels too soft 1 Low oil level 1 Top up to correct level regardless of setting 2 Spring too soft or unserviceable 2 Replace spring 3 Oil viscosity t...

Page 253: ... 44 before disassembly Prise the dust seal 16 off the outer tube 11 with a small screwdriver taking care not to scratch or damage inner and outer tube Slide the dust seal over the inner tube and blow the inner side of the dust seal and its seat in the outer tube with compressed air Lubricate the dust seal and the visible surface of the sealing ring with silicone based grease WARNING Any bugs stick...

Page 254: ...gs Both fork legs should be bled monthly or after each race You can tell that a fork needs bleeding when SAG decreases or when the suspension feels hard as the additional pressure introduced by air increases preload You will need a small pin punch to perform this procedure Air bleed valves are located on the top caps of each fork leg If the fork is not operating properly or movement is becoming le...

Page 255: ...amp the fork leg 11 in a vice Fully unscrew the cap nut 1 from the inner tube using a 4 mm pin wrench Slowly push down the outer tube 11 over the inner tube Take the fork leg 11 out of the vice and tilt it into a pan with suitable capacity to drain oil pump the fork repeatedly to help all oil drain out Look at the appearance thickness and quality of drained oil to assess the condition of seals and...

Page 256: ...load spacer 17 out of the outer tube 11 Checking and changing cartridge and compression valve setting Cartridge disassembly Turn the rebound adjuster to fully closed position fully clockwise Clamp the cartridge 21 in a vice as shown in the diagram using the suitable protector R5155 Loosen the compression valve unit 43 with a 21 mm wrench Remove the complete compression valve unit 43 Take the cartr...

Page 257: ...pply adhesive tape over the threaded end of the rod 25 Apply one turn only stretching the tape taut and do not overlap it Push the rod 25 towards the cartridge until sliding it out Damper and compression valve can be fully serviced Overhaul and setting procedures for damper and compression valve are covered in paragraphs 4 7 2 4 7 3 Check the piston ring for wear Forcartridgeandcompressionvalveass...

Page 258: ...rent specifications The by pass washers 30 control compression damping When needed the fork s compression response may be tuned by choosing washers 30 with different specifications WARNING Use only genuine Marzocchi washers and pistons Do not make changes to fork components Replace the piston ring 31 if needed Slide spring 26 and by pass washer or washer stack 30 over rod end Hold the spring compr...

Page 259: ...r part with different specifications WARNING Use only genuine Marzocchi washers and pistons Do not make changes to fork components Replace the piston O ring 40 if needed Install the compression washer or washer stack 41 and the piston 39 with its O ring 40 on the compression valve Slide the spring 37 and the by pass washer 38 over the screw 36 Hold the spring compressed and tighten the screw 36 on...

Page 260: ...ase if needed Piston should fit without interference Remove the adhesive tape from rod end 25 Turn the rebound adjuster to fully closed position fully clockwise Tighten check nut 27 and rebound adjuster 24 finger tight onto the threaded end of the rod 25 Hold the rebound adjuster 24 using a 17 mm open end wrench and tighten the check nut 27 with another 17 mm open end wrench to the specified torqu...

Page 261: ...ough one complete stroke When done you will see the bladder collapse near the 4 radial holes in the cartridge case Slowly push in the rod 25 by about 50 mm until the bladder is no longer col lapsed at the four holes Remove the cartridge from the vice Clamp the cartridge in the vice in a vertical position using the suitable protector R5198AC in such a manner as to block off the 4 holes in the bladd...

Page 262: ... Clamp the cartridge 21 in the vice as shown in the diagram using the suitable protector R5155 Screw the compression valve unit all the way home and tighten to the speci fied torque using a 21 mm open end wrench see Tightening Torque Figures table Check for correct oil quantity Check as follows pump the rod through several full strokes checking for smooth motion Also the rubber bladder should be s...

Page 263: ...pull hard to separate the tubes Sealing ring 14 retainer 13 and bottom pilot bushing 12 are removed from the outer tube in the process Remove the top pilot bushing 46 manually If hard to remove slip the tip of a flat head screwdriver into the bushing slot to aid removal Remove bottom pilot bushing 12 retainer 13 sealing ring 14 retaining ring 15 and dust seal 16 from the inner tube WARNING Never r...

Page 264: ...6 retaining ring 15 sealing ring 14 retainer 13 and bottom pilot bushing 12 WARNING The sealing ring 14 has a mounting position Its concave end must be facing the retainer 13 Remove the adhesive tape from inner tube end and clean off any adhesive sticking to the tube Insert the top pilot bushing 12 manually If hard to insert slip the tip of a flat head screwdriver into the bushing slot to aid inst...

Page 265: ...your hands Cartridge assembly Insert preload spacer 17 and spring 19 into the inner tube Spring preload can be adjusted as described in paragraph 5 2 Insert the complete damper unit 21 into the outer tube 11 Clamp the wheel axle carrier 70 in a vice Press on the top cap nut until pushing the cartridge bottom end out of the axle carrier Tighten the bottom nut 48 to the specified torque using a 21 m...

Page 266: ...r tube to the specified torque see Tightening Torque Figures table using a 4 mm pin wrench Restore original settings see page I 45 Installing the fork on the motorcycle WARNING Fork installation must be in compliance with Husqvarna specifications for steering braking system and wheel installation Improper installation may put the safety of the rider at risk For correct fork operation the wheel mus...

Page 267: ...ion work on one adjuster at a time and note any changes you make and the improvements achieved WARNING Never attempt to turn the adjusters beyond their limits Rider sag adjustment Rider sag how far the suspension settles under rider s weight is determined by the spring rate of the spring How to measure sag Sag is measured as follows Lift the front end of the motorcycle so that the wheel is off the...

Page 268: ...n minor damage do not use the fork and contact a Marzocchi service centre without delay Do not distort the metal ring Rebound adjustment Rebound damping is adjusted by turning the adjuster R The rebound adjuster controls rebound speed after the fork is compressed Each fork leg has its adjuster at the bottom of the axle carrier Proper rebound setting improves motorcycle stability and enables the wh...

Page 269: ...tting will give less stability which calls for a smoother riding style To adjust compression damping always start from the fully closed posi tion adjuster turned fully clockwise and note the number of clicks Each setting position is identified by a click Adjust turning the adjuster with a flat head screwdriver Turn the adjuster C clockwise to increase compression damping and keep compression trave...

Page 270: ......

Page 271: ...J 1 J Part N 8000 H1489 10 2009 REAR SUSPENSION Section ...

Page 272: ...n J 6 Reservoir cap with its valve removal J 7 Piston assembly inspections J 9 Seal replacement J 9 Checking the setting J 10 Reservoir replacement J 11 Floating piston removal J 12 Shock absorber assembly J 12 Driving the cap onto the body J 14 Shock absorber damping adjustment J 15 Disassembling and servicing the swinging arm J 16 Servicing the swinging arm shaft J 17 Servicing the rear suspensi...

Page 273: ...J 3 Part N 8000 H1489 10 2009 REAR SUSPENSION Rear shock absorber TIGHTENING TORQUE FIGURES 1 2 52 4 Nm 5 35 Kgm 38 6 ft lb Lubrication points grease ...

Page 274: ...r suspension is made up of a shock absorber a linkage system and a swinging arm The spring preload of the shock absorber can be adjusted to suit riding and terrain conditions Hydraulic damping is also adjustable using outer adjuster screws Periodically check all components for wear ...

Page 275: ...dle side panels silencer and rear chassis see Section E General Procedures Loosen the front clamp 1 of the intake coupling Remove the front bolt 2 securing the suspension linkage to the chassis the bottom 3 and top 4 shock absorber mounting bolts and remove the shock absorber 5 IMPORTANT On assembly fit the bottom locking nut 3 of the shock absorber on the LEFT SIDE ...

Page 276: ...amp the shock absorber in a vice taking care to avoid distorting it Slacken lock ring nut and ring nut spring retainer and spring Measure spring free length SERVICE LIMIT 245 1 5 mm SMR 255 1 5 mm TE TXC 250 255 1 5 mm TE TC TXC 450 510 Change the spring if length is outside the service limit Shock absorber inspection Visually inspect the shock absorber and look for oil leaks or other issues Repla...

Page 277: ...are Prise out the retaining ring using two small screwdrivers Take care not to dam age the inner surface To remove the retaining ring first prise one end of the ring out of its groove Then slide out the other end slip the tip of a screwdriver between ring and reservoir and prise off with the other screwdriver Take out the retaining ring Check the grooves in reservoir body for burrs If any burrs ar...

Page 278: ...ENSION Place the shock absorber on a bench Unscrew or knock out the cover depend ing on the model Once the tank cap is removed push the rod guide down into the body so as to expose the circlip groove and remove the circlip with a screwdriver ...

Page 279: ...eplace the reservoir floating piston Pour the oil into a clean pan and leave it to settle Piston assembly inspections 1 Check the seal for wear or damage replace if worn or damaged 2 Check the O ring on the rod guide Replace if scored 3 Check the surface of the chrome plated rod for dents or scoring If any dam age is found seal and DU bush will be damaged as well and you will need to replace the r...

Page 280: ...he suspension is not operating properly and you need to adjust compression damping loosen the knob dowel heat with an air gun before loosening Proceed as follows loosen the ring nut with the suitable key slide off all parts noting their positions to ensure correct assembly ...

Page 281: ...htening the cap to 30 Nm 3 kgm 29 2 ft lb It is strictly forbidden to change the compression washers This could cause the shock absorber to explode while in service Reservoir replacement In the event the reservoir needs to be replaced heat the area near the threaded end with an air gun and loosen using suitable equipment Replace the reservoir O ring Grease the O ring being careful not to smear the...

Page 282: ...damage Shock absorber assembly Wash the shock absorber body thoroughly with a degreasing product Make sure it is fully dry Blow with compressed air if needed Clamp the shock absorber eye in a vice with aluminium or bronze jaws or use a shop rag to protect the eye Fill 70 80 cu cm 4 3 4 9 cu in of oil into the shock absorber body Insert the complete piston rod into the shock absorber body taking ca...

Page 283: ...rly 2 cm 0 8 in below shock body edge Pump the rod up and down through 5 6 cm 2 2 4 in strokes four or five times to expel any air trapped under the piston Pump slowly or the floating piston might become displaced due to cavita tion or compression Top up with oil up to the circlip groove while slowly setting the rod so the bumper is level with the groove Hold the rod steady and slide the rod guide...

Page 284: ...and check for oil or air leaks Drive the cap onto the body Refitting bumper and washer If you have replaced the bumper clamp the rod in a vice with bronze or aluminium jaws apply Loctite to the mount and tighten to about 50 Nm Refit the spring and set to initial preload using ring nut and lock ring nut All liability is disclaimed for any damage resulting from procedures other than those described ...

Page 285: ...nd 3 clockwise until reaching fully closed position Then turn them back the number of clicks specified above In order to obtain a smooth braking action turn the adjuster screws counter clockwise Vice versa to obtain a harder braking action B REBOUND Standard setting 18 clicks 2 clicks To reset the standard setting turn lower adjuster screw 2 clockwise until reach ing fully closed position Then tur...

Page 286: ...xle B There is no need to loosen the chain tensioners 6 on the swinging arm in this way the chain tension will re main unchanged after reassembly Extract the complete wheel C keeping the spacers located at the hub sides Remove the shock absorber 7 as described at page J 3 Remove the swinging arm shaft nut 8 and then the swinging arm Check swinging arm straightness and manually check the roller cag...

Page 287: ...ink With drop link 1 and drag link 2 still in place connected to swinging arm and chassis respectively rock them both back and forth in all directions to check for radial and axial clearance Some axial clearance in the drop drag link is required for the swinging arm to achieve the ideal position for proper operation If any radial clearance is detected remove the part from swinging arm or chassis a...

Page 288: ...n slider Check the wear of the above mentioned elements and replace them when necessary Check the chain guide alignment and remember that a bent element can cause chain early wear In this case chain might unwrap from the sprocket 1 Chain roller 2 Chain guide 3 Chain slider a Master link clip ...

Page 289: ...L 1 L Part N 8000 H1489 10 2009 BRAKES Section ...

Page 290: ...N 8000 H1489 10 2009 BRAKES Braking system L 3 Brake disc L 4 Checking brake pads for wear replacing the pads L 5 Bleeding the front braking system L 6 Bleeding the rear braking system L 7 Changing the fluid L 8 ...

Page 291: ...calliper connected to a master cylinder with a fluid reservoir 1 Front brake lever 2 Front brake master cylinder with fluid reservoir 3 Front brake line 4 Front brake calliper 5 Front brake disc 6 Rear brake fluid reservoir 7 Rear brake line 8 Rear brake calliper 9 Rear brake disc 10 Rear brake master cylinder 11 Rear brake control pedal ...

Page 292: ...r 260 mm Front brake disc thickness when new 3 0 mm Wear limit 2 5 mm Rear brake disc diameter 240 mm Rear brake disc thickness when new 4 0 mm Wear limit 3 5 mm Disc warpage must not exceed 0 15 mm check disc mounted on the rim with a dial gauge To remove the disc from the wheel rim you need to loosen the four retaining screws Onassembly cleanallmatingsurfacesthoroughlyandtightenthescrews to the ...

Page 293: ... they cannot be cleaned satisfactorily PADS REMOVAL Remove clips 1 Slide out pins 2 Remove pads Do not work the brake lever or pedal while removing the pads PADS INSTALLATION Install new brake pads Reassemble the two pins 2 and the clips 1 The above procedure eliminates the need to bleed the braking system after replacing the pads Simply operate the control lever several times until bringing the p...

Page 294: ... tighten the bleed valve Top up fluid level A and refit rubber gaiter and reservoir cover 2 Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure Brake fluid is corrosive In the event of contact with eyes rinse with abundant water Motorcycle handlebar must be turned to the left during the bleeding procedure This will keep the master cylinder reserv...

Page 295: ... first then slightly close the valve Release the pedal and wait a few seconds Repeat the process until you see only fluid coming out of the hose Tighten the bleed valve to the specified torque and check fluid level B in the reservoir before refitting the cap A If the bleeding procedure was performed correctly the pedal will no longer have that mushy feel If not so repeat the procedure Fluid level ...

Page 296: ...taminants such as dirt water etc into the reservoir Do not keep the reservoir open without its cover longer than neces sary this would increase the risk of contamination Handle the fluid with care to avoid damage to painted parts Do not mix two brands of fluid This would reduce boil over point leading to loss of braking efficiency or degrading of rubber parts Replacement procedure is as follows Ta...

Page 297: ...nd fill the reservoir with fresh fluid Loosen the bleed valve operate lever or pedal tighten the valve keeping lever or pedal pressed and then release quickly Repeat the process until the circuit is full and you can see clear fluid coming out of the plastic hose now tighten the bleed valve Top up with fluid up to level A or B and refit rubber gaiter and reservoir cover After changing the fluid you...

Page 298: ...L 10 Part N 8000 H1489 10 2009 BRAKES Periodicallychecktheconnectinghoses C and D seeScheduledMaintenance Chart Section B replace worn or cracked hoses ...

Page 299: ...M 1 M Part N 8000 H1489 10 2009 ELECTRICAL SYSTEM Section ...

Page 300: ......

Page 301: ...LATOR RECTIFIER WIRING DIAGRAM M 22 ELECTRICAL STARTING SYSTEM TE TXC M 23 STARTING SYSTEM INSPECTION M 24 Starter motor inspection TE TXC M 24 Starter motor test curves TE TXC M 24 Solenoid starter inspection TE TXC M 24 Checking coil windings resistance M 25 Electronic control unit ECU M 26 Spark plug M 26 Gear position sensor inspection GPS Gear Position Sensor M 27 Carburettor throttle valve p...

Page 302: ... chassis ground cables M 46 Electrical system ground M 46 Wiring connection to voltage regulator TE TXC M 46 Connection of relays and fuses TE TXC M 47 Electric fan connection TE TXC M 47 Injector connection TE TXC M 47 Ignition coil connection TE TXC M 47 Fuel pump connector position TE TXC M 48 MAQS connector TE TXC M 48 Engine water temperature connector M 48 TE TXC M 48 Lambda sensor position ...

Page 303: ... Colour coding key B Blue Br Brown Bk Black G Green Gr Grey O Orange P Pink R Red Sb Sky blue V Violet W White Y Yellow Key to wiring diagram 1 Electronic control unit 2 Alternator 3 Spark plug 4 Gear sensor 5 Electronic ignition coil 6 Carburettor TPS 7 Engine kill ...

Page 304: ...26 Ignition switch 28 Speed sensor 29 Solenoid valve relay 30 DC relay 31 Lambda sensor 32 Air temperature sensor 40 33 Coolant temperature sensor 34 Pressure sensor 40 35 Fuel pump 37 Fuses 38 Power relay 39 Control unit interface 40 M A Q S 34 24 32 Colour coding key B Blue B Bk Blue Black Bk Black Br Brown Br Bk Brown Black Br R Brown Red Br W Brown White G Green G Bk Green Black G Gr Green Gre...

Page 305: ...ic fan relay 17 Lambda sensor 18 Air temperature sensor 25 19 Coolant temperature sensor 20 Pressure sensor 25 21 Fuel pump 22 Fuses 23 Power relay 24 Control unit interface 25 M A Q S 14 18 20 Colour coding key B Blue Bk Black Br Brown Br Bk Brown Black Br W Brown White G Green G Gr Green Grey G R Green Red Gr Grey Gr B Grey Blue Gr Bk Grey Black O Orange O Bk Orange Black O G Orange Green R Red ...

Page 306: ...n TC The ignition system includes the following elements Generator 1 on the inner side of L H crankcase half cover Electronic ignition coil 2 under the fuel tank Electronic control unit 3 under the fuel tank Spark plug 4 on cylinder head Throttle position sensor 5 on carburettor ...

Page 307: ... system includes the following elements Generator 1 on the inner side of L H crankcase half cover Electronic ignition coil 2 under the fuel tank Electronic control unit 3 under the fuel tank Spark plug 4 on cylinder head Voltage regulator 5 under the fuel tank over the electronic control unit 3 ...

Page 308: ...he cylinder Solenoid starter 7 on left side of rear chassis M A Q S sensor air temperature pressure throttle position 8 on throttle body The electrical system includes the following elements 12V 7Ah battery 9 under the saddle Turning indicators flasher 10 on left side of rear chassis ...

Page 309: ...e of rear chassis Relay 13 light system turning indicators horn on right side of rear chas sis Fuses 14 15 16 on rear mudguard right side Fuse 14 15A coil injection system fuel pump Fuse 15 15A dashboard parking lights control unit Fuse 16 20A electric fan light system turning indicators horn Electric fan 17 Coolant temperature sensor 18 Lambda sensor 19 ...

Page 310: ...Part N 8000 H1489 10 2009 ELECTRICAL SYSTEM Headlamp 20 with 12V 35 35W twin halogen bulb and 12V 5W parking light bulb LED tail light 21 Turning indicators 22 12V 10W bulbs Fuel pump 23 inside the fuel tank ...

Page 311: ...n system includes the following elements Generator 1 on the inner side of L H crankcase half cover Electronic ignition coil 2 under the fuel tank Electronic control unit 3 under the fuel tank Spark plug 4 on cylinder head Voltage regulator 5 under the fuel tank over the electronic control unit 3 ...

Page 312: ...t N 8000 H1489 10 2009 ELECTRICAL SYSTEM 12V 350W starter motor 6 behind the cylinder Solenoid starter 7 on left side of rear chassis M A Q S sensor air temperature pressure throttle position 8 on throttle body ...

Page 313: ...7Ah battery 9 under the saddle Relay 10 coil injection system fuel pump on right side of rear chassis Relay 11 solenoid valve on right side of rear chassis Fuses 12 13 14 on rear mudguard right side Fuse 12 15A coil injection system fuel pump Fuse 13 15A control unit Fuse 14 20A electric fan Electric fan 15 ...

Page 314: ...H1489 10 2009 ELECTRICAL SYSTEM Coolant temperature sensor 16 Lambda sensor 17 Fuel pump 18 inside the fuel tank Checking generator stator windings resistance Disconnect the stator coil connector from the wiring and measure resistance with a meter ...

Page 315: ...ross the terminals of the connector 1 correct value is about 0 6 If resistance is outside the specified limits replace the complete generator Generator no load performance TC 1 Secondary winding voltage under no load conditions 2 Battery charging current 3 Light voltage 4 RPM AT EACH ENGINE OVERHAUL CLEAN FLYWHEEL ROTOR TO REMOVE ANY DEBRIS SUSPENDED IN SWIRLING OIL AND CAP TURED BY THE MAGNETS Ge...

Page 316: ...l generates a strong spark across the spark plug electrodes The digital electronic ignition system allows for timing curve adjustment accord ing to these factors ENGINE RPM POSITION OF CARBURETTOR THROTTLE VALVE GEAR ENGAGED This system ensures optimal engine performance under any operating conditions The ignition will keep the engine running even in the event of a throttle valve or gear sensor ma...

Page 317: ... and is controlled by the ECU Ignition timing is accurately determined based on engine RPM and accelerator position In addition to these key parameters inputs from the intake air temperature and pressure sensor and from the coolant sensor are also used to control ignition timing Key 1 Electronic control unit 2 Alternator 3 Voltage regulator 6 Injector 10 Cooling fan 13 L H switch 15 Tail light 16 ...

Page 318: ...tor 3 Voltage regulator 4 Injector 7 Cooling fan 8 Battery 9 Solenoid starter 10 Starter motor 11 Spark plug 12 Gear sensor 13 HT coil 14 Throttle position sensor 25 15 R H switch 16 Electric fan relay 17 Lambda sensor 18 Air temperature sensor 25 19 Coolant temperature sensor 20 Pressure sensor 25 21 Fuel pump 22 Fuses 23 Power relay 24 Control unit interface 25 M A Q S 14 18 20 ...

Page 319: ...lternated current generated by the alternator is converted into direct cur rent by the voltage regulator rectifier The voltage regulator rectifier serves a dual purpose it provides overvoltage protection for the battery and converts alternated current into direct current All components listed above help keep voltage constant and protect the battery against overloading CHARGING SYSTEM WIRING DIAGRA...

Page 320: ...easure voltage across the positive and negative terminal of the battery using a meter the battery must be charged when performing this test If reading is outside a 12 5 14 5 V range check generator and voltage regulator rectifier as described in the relevant paragraph Voltage regulator rectifier inspection TE TXC With the ignition on and the battery charged 12 5 13 V start the engine if bat tery v...

Page 321: ... ELECTRICAL SYSTEM ELECTRICAL STARTING SYSTEM TE TXC The starting system is composed of Battery 16 Solenoid starter 17 Starter motor 18 R H switch 25 Clutch microswitch 27 TE Ignition switch 26 TE Fuses 37 For a description of wires and components please see the key to the wiring diagram ...

Page 322: ...m 0 35 Kgm 2 5 ft lb Starter motor test curves TE TXC 1 Output power W 2 Torque TQ 3 RPM N rpm x 1000 4 Light voltage V 5 Charging current A Solenoid starter inspection TE TXC Disconnect the cables at the battery negative terminal to avoid possible short circuits during disassembly Disconnect the starter relay connector A Disconnect the starter motor and battery positive cable wires at relay end A...

Page 323: ...dary winding resistance 19 5 K 20 at 20 C without spark plug cap cable Capacitive coil for carburetted TC 250 Primary winding resistance 0 3 15 at 20 C Secondary winding resistance 6 3 K 20 at 20 C without spark plug cap cable If resistance is outside the specified limits replace the coil Also check the resistance of the terminal cap contacting the spark plug Terminal cap resistance 4 5 5 5 K 5 at...

Page 324: ...he coil A gap that is too narrow may cause difficulties when accelerating when idling or poor performance at low speed Clean off any dirt around spark plug base before removing the spark plug It is good practice to closely inspect the spark plug after removal as any deposits on it and the colour of the insulator provide useful indications on spark plug heat rating carburetion ignition and the gene...

Page 325: ...to the connector hole for the WHITE BLACK gear sensor wire 2 The lever 3 is placed on the left hand side of the engine After each gear shift it automatically returns to the horizontal position First gear is engaged by pushing the lever downwards for other gears push it upwards Check the read ings provided in the relevant table TC A NEUTRAL open circuit B 1st 556 568 C 2nd 817 833 D 3rd 1 48 1 51 K...

Page 326: ...t the meter to the Ohm scale and disconnect the carburettor sensor connec tor 1 from the main wiring harness Connect the meter probes to the terminals of the YELLOW A and BLACK B wires and check that your readings match the values given in the table a throttle twistgrip CLOSED 890 990 b throttle twistgrip FULLY OPEN KEIHIN MX 37 MX 41 3 4 4 4 K 5 ...

Page 327: ...BLACK negative cable remove the battery 1 from its housing Check using a voltmeter that battery voltage is not less than 12 5 V If it is not so the battery needs to be charged Using a battery charger with a constant voltage first connect the RED positive cable to the battery positive terminal then the BLACK negative cable to the battery negative terminal At a constant voltage level of 14 4 V apply...

Page 328: ...on the wall at the same height When the low beam is on the upper edge between dark and lit zone should be at 9 10th of the height of headlamp centre from ground Beam height can be raised or lowered turning the screw 1 Headlamp bulbs replacement Proceed as follows to reach the headlamp bulbs remove the upper retaining screw securing headlamp fairing to dashboard bracket A slide the headlamp fairing...

Page 329: ... 3 Once the tail light has been replaced reverse the above procedure to reas semble Be careful not to overtighten the screws Number plate bulb replacement Loosen screw 1 and remove the number plate bulb 2 from the mudguard Extract the bulb holder 3 with the bulb 4 from the housing Pull the bulb 4 to detach it from bulb holder Once the tail light has been replaced reverse the above procedure to rea...

Page 330: ...h TC Left hand switch TE 1 High beam flasher self cancelling 2 High beam switch Low beam switch 3 Left hand turning indicators self cancelling Right hand turning indicators self cancelling To deactivate the turning indicators press the control lever after it is returned to the centre 4 Horn Colour coding key B Blue Bk Black B Bk Blue Black B W Blue White G Green G Bk Green Black G W Green White Gr...

Page 331: ...H01041 B Bk Br Y Sb Br Part N 8000 H1489 10 2009 ELECTRICAL SYSTEM Right hand switch TE TXC 1 Engine start button 2 Engine start stop switch Colour coding key B Blue Br Brown Br Bk Brown Black Y Sb Yellow Sky blue ...

Page 332: ...another fuse with a different rating Never use a wire or other makeshift repair techniques instead of installing a new fuse SEMICONDUCTOR PARTS Be careful to never drop parts that incorporate a semiconductor such as the ECU or the voltage regulator rectifier Closely follow the relevant instructions when inspecting these parts An improper procedure may lead to severe damage ...

Page 333: ...ard functions and reset functions use the SCROLL button A The functions available in the sequence are as follows 1 SPEED ODO 2 SPEED CLOCK 3 SPEED TRIP 4 SPEED LAP TIMER 5 SPEED RPM engine r p m numerical value 1 SPEED ODO IMPORTANT In the event of a FUEL INJECTION SYSTEM MALFUNCTION the word FAIL appears on the right side of the dashboard display see page 14 When this is the case contact your HUS...

Page 334: ...h or 299 mph TRIP 1 distance maximum value 999 9 km or 621 31 mi data will be lost after disconnecting the battery To reset TRIP push the SCROLL button A and hold for more than 3 sec onds 4 SPEED LAP TIMER STP figure 4 SPEED speed maximum value 299 Km h or 299 mph STP 1 miles kilometres covered time Reading from 0 00 to 99 59 59 data will be lost after disconnecting the bat tery To activate the fu...

Page 335: ...ority over any other indication NEUTRAL when running speed is under 20 Km h a Neutral condition is indi cated by a letter N placed before the speed value FAIL a FUEL INJECTION SYSTEM MALFUNCTION indicated by the word FAIL appearing in the right hand portion of the dashboard display Warning lights panel TXC The motorcycle is fitted with a small warning lights panel with two warning lights 1 Red war...

Page 336: ... incorrect no load performance of generator see paragraph Generator no load performance 5 voltage regulator malfunction see paragraph Voltage regulator rectifier inspection a battery overload indicates 1 faulty voltage regulator see paragraph Voltage regulator rectifier inspec tion 2 faulty battery see paragraph Current loss at the battery STARTING SYSTEM TE TXC If the starter motor does not start...

Page 337: ...M 39 Part N 8000 H1489 10 2009 ELECTRICAL SYSTEM 1 Engine stop button 2 Coil 3 Control unit 4 Main wiring harness 5 Carburettor throttle position sensor 6 Gear sensor Wiring TC ...

Page 338: ...uctions TC HT coil position 1 TC Connect the HT coil as shown in the figure Fuel injection control unit position 2 TC Electronic control unit installed with the flat side down Securing engine stop button ground cable to chassis TC The ground cable of the engine stop button is secured to the coil screw 3 ...

Page 339: ...RICAL SYSTEM Control unit connection TC Connect the control unit connector 4 as shown Ignition coil connection TC Connect the ignition coil connectors 5 as shown Gear sensor cable connection TC Connect the gear sensor connector 6 as shown ...

Page 340: ... wiring TC Strap wiring to chassis with three clips 7 as shown in the figure Securing the engine stop button cable TC Secure the engine stop button cable 8 with two clips 9 Securing the wiring TC Secure the ignition and gear sensor wiring loom to the clutch hose ...

Page 341: ...M 43 TE H00973 TXC H00974 Part N 8000 H1489 10 2009 ELECTRICAL SYSTEM Wiring TE TXC ...

Page 342: ...CTRICAL PARTS INSTALLATION INSTRUC TIONS TE TXC Coil position TE TXC Connect the HT coil as shown in the figure Relay 1 and fuses 2 position TE TXC On right side of motorcycle Turning indicators flasher 3 TE and solenoid starter position TE TXC On left side of motorcycle ...

Page 343: ...oltage regulator with heat grease Securing the starter motor solenoid starter cable TE TXC Connect the starter motor solenoid starter cable 7 as shown in the figure Securing the engine ground to chassis and engine ground to battery cables 8 TE TXC The engine ground to chassis and engine ground to battery cables are secured to the timing chain tensioner screw Battery negative cable routing TE TXC R...

Page 344: ...jection coil Securing the engine ground chassis ground cables 10 Electrical system ground Secure the engine ground chassis ground cable and the wiring harness ground eye terminal to the coil retaining screw Wiring connection to voltage regulator TE TXC Connect the connector 11 to the regulator Pay attention to the routing of radia tor breather hose and throttle cables ...

Page 345: ...e marked DC to relay 14 TE only fuses Connect the cable marked POW to fuse 15 Connect the cable marked MAN to fuse 16 Connect the cable marked FAN TXC to fuse 17 Connect the cable marked DC FAN TE to fuse 17 Electric fan connection TE TXC Connect the electric fan connector 18 Injector connection TE TXC Connect the connector 19 to the throttle body Ignition coil connection TE TXC Connect the igniti...

Page 346: ...as shown MAQS connector TE TXC Connect the connector 22 as shown Engine water temperature connector TE TXC Connect the engine water temperature connectors 23 to the thermostat Lambda sensor position and connector TE TXC Tighten the Lambda sensor 24 in the corresponding seat Connect the Lambda sensor connector 25 as shown ...

Page 347: ...onnection flasher contactor Route the rear end of the wiring 28 as shown in the figure Connect the tail light turning indicators connector 29 TE Connect the connector 30 to the flasher TE Connect the connector 31 to the solenoid starter Air box cable routing Route the wiring harness as shown Secure it with the suitable clip 32 Clip installation on fuse holders Install the suitable clips 33 on the ...

Page 348: ...ting of steering head tube wiring Secure the wiring harness with the suitable clip 34 Dashboard bracket connectors TE Secure the dashboard 35 and diagnostic 36 connector using the suitable clips Fit the cap 37 to the diagnostic connector 36 Headlamp front turning indicators STOP connection TE Connect the headlamp unit to the connector 38 Connect the connectors 39 to the turning indicators Connect ...

Page 349: ...uble map connector cap TE Fit the cap to the double map connector Speed sensor and ignition switch connectors TE Connect the speed sensor connector Connect the connector 41 of the ignition switch 42 Horn connector TE Connect the connector 43 to the horn ...

Page 350: ...as shown in the figure Securing the wiring harness to rear chassis left side Secure wiring harness with a clip as shown in the figure Securing the wiring harness to the chassis Strap wiring harness to chassis on right and left side with clips as shown in the figure Securing the wiring harness Position the GPS and Pick Up connectors 27 as shown ...

Page 351: ...s shown 26 Securing the wiring harness Secure the ignition gear sensor and Lambda sensor wiring loom to the clutch hose with two clips Securing the wiring harness Secure the ignition and gear sensor wiring loom to the clutch hose Securing the wiring harness Secure the front wiring loom with two clips as shown ...

Page 352: ...pening of the muffler b Clutch and front brake levers handgrips handlebar switches c Air filter intake d Steering head wheel bearings e Rear suspension drag drop link In addition to these precautions NEVER ALLOW HIGH PRESSURE AIR OR WATER to get in contact with any ELECTRICAL PARTS the INJECTION FUEL FEEDING SYSTEM and especially the electronic control unit 1 ...

Page 353: ...N 1 N Part N 8000 H1489 10 2009 ENGINE COOLING Section ...

Page 354: ...N 2 Part N 8000 H1489 10 2009 ENGINE COOLING Coolant level check N 3 Cooling circuit TC N 4 Engine cooling system overhaul TC N 5 Cooling circuit TE TXC N 6 Engine cooling system overhaul TE TXC N 7 ...

Page 355: ...e worst scenario crankshaft damage may result If the event of engine overheating check that the radiator is full Level in the radiator must be checked from cold see Section D In the event you need to check level when the engine is hot be sure to discharge pressure gradually The radiator cap 1 has a pressure relief position to depressurize the system safely Failure to follow the above instructions ...

Page 356: ...p located to the left of the head and two down draft radiators 1 Radiator cap 2 Right hand radiator 3 Left hand radiator 4 Fitting 5 Water pump 6 Breather hose 7 Radiator connecting pipe 8 Radiators to cylinder head pipe 9 Water pump to fitting pipe 10 Fitting to left hand radiator pipe 11 Fitting to right hand radiator pipe ...

Page 357: ...hten any bent fins to ensure free flow of air If the cooling mass is clogged or damaged no more than 20 of its surface must be affected If damage exceeds this limit the radiator must be replaced Periodically check the connecting hoses see Section B Scheduled Maintenance Chart this will avoid coolant leakage and consequent engine seizure If hoses show cracks swelling or hardening due to sheaths des...

Page 358: ...centrifugal pump located to the left of the head and two down draft radiators 1 Radiator cap 2 Right hand radiator 3 Left hand radiator 4 Thermostat 5 Water pump 6 Breather hose 7 Radiator connecting pipe 8 Radiators to cylinder head pipe 9 Water pump to fitting pipe 10 Thermostat to radiators pipe 11 Cooling fan ...

Page 359: ...ighten any bent fins to ensure free flow of air If the cooling mass is clogged or damaged no more than 20 of its surface must be affected If damage exceeds this limit the radiator must be replaced Periodically check the connecting hoses see Section B Scheduled Maintenance Chart this will avoid coolant leakage and consequent engine seizure If hoses show cracks swelling or hardening due to sheaths d...

Page 360: ......

Page 361: ...O 1 O Part N 8000 H1489 10 2009 KIT INSTALLATION INSTRUCTIONS Section ...

Page 362: ...INSTRUCTIONS Carburettor KIT TC D 3 Central engine guard TE TC TXC O 6 Start hook kit TC TXC O 7 Left muffler guard TE O 9 Battery bracket and battery TE TXC O 10 Turning indicators KIT TE O 11 REAR TURNING INDICATORS O 12 Rear view mirrors TE O 16 ...

Page 363: ...ock 2 counter clockwise to shut off fuel supply and loosen the clamp 3 on the hose running to the carburettor Detach the hose at carburettor end and let fuel drain into a pan Remove the fuel tank retaining screw 4 push the front end of the scoops slightly upwards and release them from the spoilers on the radiators Remove the fuel tank together with the scoops ...

Page 364: ...arburettor rearwards to release it from the intake coupling and extract it from the right hand side of the motorcycle Remove the lower retaining screw 7 of the carburettor bowl remove the bowl and drain all fuel Remove the floater bowl A Replace the standard jets with the those included in the KIT for jet locations see exploded view at next page WARNING This kit is for racing use only ...

Page 365: ...O 5 Part N 8000 H1489 10 2009 KIT INSTALLATION INSTRUCTIONS The kit includes TC 1 Idle jet 40 45 1 Main jet 170 180 185 195 200 ...

Page 366: ...O 6 Part N 8000 H1489 10 2009 KIT INSTALLATION INSTRUCTIONS Central engine guard TE TC TXC Part No Description Qty 1 Central engine guard F M6x15 mm screw 1 G Ø7xØ9xØ4 8 mm 1 Secure guard as shown ...

Page 367: ...O 7 Part N 8000 H1489 10 2009 KIT INSTALLATION INSTRUCTIONS Start hook kit TC TXC Part No Description Qty A Ring 1 B Hook 1 C M4x8 mm screw 4 D M5x16 mm screw 1 ...

Page 368: ... fig 6 Hold the hook in place and trace the drilling pattern with a bit through the four screw mounting holes Remove the hook from the fork guard and drill four holes with a Ø 4 5 mm bit keeping the bit perpendicular to fork guard surface Insert the hook into the fork guard and secure it with the four screws C Loosen the four screws 5 that secure the right fork leg and remove it from the yokes Rem...

Page 369: ...O 9 Part N 8000 H1489 10 2009 KIT INSTALLATION INSTRUCTIONS Left muffler guard TE Install the guard 1 using the screw 2 M8x20 mm that secures the rear chassis 3 at the rear end ...

Page 370: ... INSTALLATION INSTRUCTIONS Battery bracket and battery TE TXC Remove the saddle Install the bracket as shown in the figure Connect the RED positive cable first and then the BLACK negative cable Secure the battery in place with its strap ...

Page 371: ...icator 1 piece cable L 115 150 mm 2 Front R H indicator 1 piece cable L 115 150 mm 3 Rear L H indicator 1 piece cable L 315 350 mm 4 Rear R H indicator 1 piece cable L 315 350 mm 5 Front M6x16 mm screw 2 pieces 6 Rear M6x20 mm screw 2 pieces 7 M6 nut 4 pieces 8 Flasher 1 piece 9 Flasher bracket 1 piece ...

Page 372: ...rt N 8000 H1489 10 2009 KIT INSTALLATION INSTRUCTIONS REAR TURNING INDICATORS Remove the saddle and the L H side panel Fit the flasher to the bracket and secure it using the side retaining screw of the air box ...

Page 373: ...and disconnect its cables from the main wiring har ness Insert the turning indicator cables into the hole in the number plate hold er TE secure the indicator with the M6x20 mm screw and its nut Route the indicator cables through mudguard and number plate holder as shown in the picture ...

Page 374: ...or cables through the rubber gaiter and refit it into place Connect the indicator and tail light cables to the main wiring harness refer to the wiring diagram included in the Owner s Manual Refit the tail light The instructions provided for the right turning indicator also apply to the left indicator on the opposite side ...

Page 375: ...ly secure the number plate holder to the support as shown in the figure 1 Number plate holder 1 piece 2 M5x16 mm screw 2 pieces 3 Bushing 2 pieces 4 Ø5 3xØ15x1 mm washer 2 pieces 5 M5 nut 2 pieces 6 Reflector 1 piece 7 Ø4 3xØ12x0 8 mm washer 2 pieces 8 M4 nut 2 pieces ...

Page 376: ...O 16 Part N 8000 H1489 10 2009 KIT INSTALLATION INSTRUCTIONS Rear view mirrors TE Fit the rear view mirrors to the clamps of the front brake and clutch levers ...

Page 377: ...P 1 P Part N 8000 H1489 10 2009 HYDRAULICALLY CONTROLLED CLUTCH Section ...

Page 378: ...P 2 Part N 8000 H1489 10 2009 HYDRAULICALLY CONTROLLED CLUTCH Hydraulic clutch system P 3 Draining clutch fluid P 4 Clutch master cylinder servicing P 5 Bleeding the clutch system P 6 ...

Page 379: ...haft a to the gearbox input shaft b via the gear on the clutch housing 8 The clutch housing accommodates friction plates 9 and steel plates 10 that operate the clutch hub 11 secured to the gearbox input shaft 1 Clutch master cylinder 2 Clutch lever 3 Master cylinder to piston hose 4 Pushrod 5 Piston assembly 6 Pressure plate 7 Bleed fitting 8 Clutch housing with clutch ring gear 9 Steel plate 10 F...

Page 380: ...LICALLY CONTROLLED CLUTCH Draining clutch fluid Connect a plastic hose to the bleed valve 1 and the loosen the valve turning it back 1 or 2 turns Remove reservoir cap 2 and gasket 3 and operate the control lever 4 until draining all fluid ...

Page 381: ...g Drain the circuit detach the master cylinder from the left side of the handlebar and take it apart Replace all seals reassemble the master cylinder and refit it to the handlebar Reconnect the hose and fill fresh fluid into the reservoir bleed the system as described in the relevant paragraph ...

Page 382: ...erate the lever 4 repeatedly until the fluid flowing out of the hose looks clear and free of air bubbles now tighten the bleed valve Top up fluid level A and refit rubber diaphragm 3 and reservoir cover 2 Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure Hydraulic fluid is corrosive In the event of contact with eyes rinse with abundant water Mo...

Page 383: ...Q 1 Q Part N 8000 H1489 10 2009 OPTIONAL COMPONENTS Section ...

Page 384: ...D0096837 CHAIN SPROCKET Z 50 1 8C0096837 CHAIN SPROCKET Z 49 1 2 8000A7126 TRANSMISSION SPROCKET Z 12 1 OPTIONAL COMPONENTS TC Pos Part No Description 1 8F0096837 CHAIN SPROCKET Z 52 1 8C0096837 CHAIN SPROCKET Z 49 1 8D0096837 CHAIN SPROCKET Z 50 1 8000A7126 TRANSMISSION SPROCKET Z 12 1 OPTIONAL COMPONENTS TE ...

Page 385: ...1489 10 2009 OPTIONAL COMPONENTS Pos Part No Description 1 8F0096837 CHAIN SPROCKET Z 52 1 8C0096837 CHAIN SPROCKET Z 49 1 8D0096837 CHAIN SPROCKET Z 50 1 2 8000A7126 TRANSMISSION SPROCKET Z 12 1 OPTIONAL COMPONENTS TXC ...

Page 386: ......

Page 387: ...S 1 S Part N 8000 H0368 10 2009 FUEL INJECTION SYSTEM Section ...

Page 388: ...0 2009 FUEL INJECTION SYSTEM INJECTION FUEL FEEDING SYSTEM TE TXC S 3 Operation Manual for DIAGNOSTIC TOOL SOFTWARE KIT for injection fuel feeding system TE TXC S 4 Fuel pump inspection TE TXC S 6 Relay inspection TE TXC S 7 ...

Page 389: ...he intake manifold Engine coolant temperature Atmospheric pressure in the intake manifold in current location and at cur rent altitude Throttle opening Lean or rich mixture LAMBDA sensor Battery voltage Sensor power supply unit Gear shift position Fuel injection pulse width Ignition coil Lambda sensor heater The DIAGNOSTIC TOOL SOFTWARE KIT see pages S 3 S 4 provides a tool to check these paramete...

Page 390: ...D to the connector C and the serial port E of your PC turn the ignition key F to ON and set the right switch G to RUN start the Diagnostic Tool software you have installed and perform the re quired tests If the throttle body H has been removed and or replaced the TPS will need to be re initialised using options TPS idle setting see Operation Manual and Feedback Correction Operation Manual For Feed...

Page 391: ...n number VIN and engine number engine no of the motorcycle If ECU is replaced the new ECU will only report engine service hours NOTES The green neutral light ONLY turns on when the ignition key is set to ON and the right switch to RUN When the ignition key is turned to the ON position the front and rear lights and the display light up Left switch functions and the stop light can ONLY be selected w...

Page 392: ... in the sensor and then set the meter to the Impedance scale and measure across the BLUE and WHITE wires Correct value is as follows 1 3 KOhm 10 at 20 C B pump operation Connect the RED and BLACK wires to a power supply unit with constant 12V output and make sure that the pump runs Never keep the pump connected to the power supply unit for more than 3 seconds in a row ...

Page 393: ...elays 1 located on the R H side of the chassis A Set the meter to the Impedance scale and check the energiser coil for proper operation Reading should be 80 Ohm 10 at 20 C B Set the meter to Continuity mode and check the circuit is open C Feed the coil from a power supply unit with stable 12V output and make sure that the circuit closes ...

Page 394: ......

Page 395: ...W 1 W Part N 8000 H1489 10 2009 SPECIAL TOOLS Section ...

Page 396: ...7345 Jig TC 8000 A7345 Jig TE TXC 6 8000 H1807 USB pen drive 7 8000 A7317 Valve installation removal tool 8 8000 A1625 Dial gauge mount 11 8000 79015 Clutch hub tool 13 1519 84701 Spring hook 16 8000 95749 Spark plug tool 22 8B00 A9634 Diagnostic Tool Software Kit 23 8B00 H0237 Reflash Tool Kit for additional ECU mappings with motorcycle in the RACING CONFIGURA TION see Section O Vehicle not meeti...

Page 397: ...se causing damage to motorcycle and injury to rider An overtightened nut or screw might become damaged its thread might strip or the nut screw might fail and work itself loose Listed in the table are the tightening torque figures for the most important nuts and screws which have determined in accordance with thread diameter pitch and specific application These figures are obtained after cleaning t...

Page 398: ... Screw TEF M6 L20 Chain tensioner 8 Nm 0 8 Kgm Special M6x1 screw Slider use LOCTITE 243 8 Nm 0 8 Kgm Crankcase Screw TSEI M5 L12 Crankshaft bearing plate LOCTITE 270 or LOCTITE 272 6 Nm 0 6 Kgm Screw TEF M5x0 8 CH8 L8 For oil seal retaining plate 6 Nm 0 6 Kgm Screw TSEI M6 L10 Desmo bearing plate use LOCTITE 270 or LOCTITE 243 8 Nm 0 8 Kgm Selector spring pin M8x1 25 Use LOCTITE 270 or LOCTITE 27...

Page 399: ... 6 Nm 0 6 Kgm Short nut M6x1 Gear to starter motor shaft LOCTITE 243 3 9 Nm 0 5 Kgm Screw TCEI M5 L20 Bevel drive body 6 Nm 0 6 Kgm Screw TEF M8 L 15 Kick start lever LOCTITE 272 25 Nm 2 55 Kgm Gearbox Nut M16x1 Sprocket 90 Nm 9 2 Kgm Gear shift control Selector drum rtng screw M8x1 25 Use LOCTITE 270 or LOCTITE 243 25 Nm 2 55 Kgm Screw TSEI M6 L14 Selector rtng plate LOCTITE 243 8 Nm 0 8 Kgm Scre...

Page 400: ...IGURES 5 CHASSIS 99669 1 Nm 0 73756 ft lb NOTE Unless otherwise specified standard torque values for the different thread sizes are as follows M5x0 8 5 6 6 2 Nm 0 57 0 63 Kgm 4 1 4 5 ft lb M6x1 7 6 8 4 Nm 0 80 0 85 Kgm 5 8 6 1 ft lb M8x1 25 24 26 Nm 2 4 2 6 Kgm 17 3 18 8 ft lb ...

Page 401: ...X 5 Part N 8000 H1489 10 2009 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES 5 HANDLEBAR AND CONTROLS 99669 TIGHTENING TORQUE FIGURES 5 FRONT SUSPENSION 99669 1 Nm 0 73756 ft lb 1 Nm 0 73756 ft lb ...

Page 402: ...X 6 Part N 8000 H1489 10 2009 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES 5 REAR SUSPENSION 99669 1 Nm 0 73756 ft lb ...

Page 403: ...X 7 Part N 8000 H1489 10 2009 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES 5 FAIRINGS AND MUDGUARDS 99669 1 Nm 0 73756 ft lb TIGHTENING TORQUE FIGURES 5 ELECTRICAL SYSTEM 99669 1 Nm 0 73756 ft lb ...

Page 404: ...X 8 Part N 8000 H1489 10 2009 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES 5 FUEL SYSTEM 99669 1 Nm 0 73756 ft lb TIGHTENING TORQUE FIGURES 5 WHEELS AND BRAKES 99669 1 Nm 0 73756 ft lb ...

Page 405: ... 2009 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES 5 EXHAUST 99669 TIGHTENING TORQUE FIGURES 5 INSTRUMENTS 99669 1 Nm 0 73756 ft lb 1 Nm 0 73756 ft lb TIGHTENING TORQUE FIGURES 5 COOLING SYSTEM 99669 1 Nm 0 73756 ft lb ...

Page 406: ... 3 ft lb Steel screws on brass copper aluminium M5 4 Nm 0 4 Kgm 3 ft lb Steel screws on iron steel M5 6 Nm 0 6 Kgm 4 4 ft lb Steel screws on plastic with metal spacers M6 6 5 Nm 0 65 Kgm 4 8 ft lb Steel screws on brass copper aluminium M6 6 5 Nm 0 65 Kgm 4 8 ft lb Steel screws on iron steel M6 10 5 Nm 1 Kgm 7 7 ft lb Steel screws on brass copper aluminium M8 16 Nm 1 6 Kgm 11 8 ft lb Steel screws o...

Page 407: ...Y 1 Y Part N 8000 H1489 10 2009 CHASSIS AND WHEELS Section ...

Page 408: ... wheel installation Y 7 Rear wheel Y 8 Rear wheel removal Y 9 Tightening torque figures Y 9 Wheel servicing Y 10 Wheel axle warpage Y 10 Axle runout over 100 mm Y 10 Wheel spokes Y 11 Wheel rim warpage Y 11 Rear chain sprocket secondary drive sprocket and chain Y 12 Tightening torque figures Y 12 Checking chain and sprockets for wear Y 13 ...

Page 409: ...s reported below to determine whether the chassis needs realigning or replacing A badly damaged chassis must be replaced AXIS X Y X Y A 576 7 22 7 440 5 17 34 555 2 440 5 B 460 18 11 423 16 65 425 435 5 C 442 17 40 259 10 19 425 270 D 394 2 15 52 337 2 13 27 369 342 5 E 311 12 24 23 2 0 91 274 8 4 9 G 262 5 10 33 81 5 3 2 200 148 6 I 65 5 2 57 170 6 69 65 200 L 20 0 78 335 4 13 20 14 335 4 M 84 8 ...

Page 410: ...ication points lubricant 1 Steering bearings grease Check the assemblies shown in the figure for cracks or damage If any are found replace the part A ENGINE MOUNTING BOLTS B REAR CHASSIS MOUNTING BOLTS C CHAIN GUIDE ROLLER BEARING D FOOTPEGS PINS SPRINGS ...

Page 411: ... TAKASAGO Excel lightalloy 1 6x21 TC Make type and size of tyre Pirelli 51R MT 32A or Dunlop D756 80 100 x 21 TE TXC Make type and size of tyre Michelin EnduroComp 3or Pirelli MT83 Scorpion 90 90 x 21 TE USA Make type and size of tyre Metzeller Karoo 90 90 x 21 Cold tyre pressure TC 0 9 1 0 Kg sq cm TE TXC racing 0 9 1 0 Kg sq cm TE road use 1 1 Kg sq cm ...

Page 412: ...e ground Loosen the bolts 1 holding the wheel axle 2 to the front fork mounts Hold the head of the wheel axle in place and unscrew the bolt 3 on the opposite side draw the wheel axle out Do not operate the front brake lever when the wheel has been re moved this causes the calliper pistons to move outwards After removal lay down the wheel with brake disc on top ...

Page 413: ... H fork leg during this operation the wheel should be turned Tighten the screw 3 on the fork L H side but DO NOT lock it Now pump for a while pushing the handlebar downwards until you are sure that the fork legs are perfectly aligned Lock the screws 1 on the R H leg 10 4 Nm 1 05 Kgm 7 7 ft lb the screw 3 on the L H side 51 45 Nm 5 25 Kgm 38 ft lb the screws 1 on the L H leg 10 4 Nm 1 05 Kgm 7 7 ft...

Page 414: ...rims TAKASAGO Excel light alloy 1 85x19 TE TXC Make type and size of wheel rims TAKASAGO Excel light alloy 2 15x18 TE USA Make type and size of tyre Metzeller Karoo 140 80x18 TC Make type and size of tyre Pirelli NHS 57 MT 320 Pirelli MT 83 Scorpion 120x90x18 Cold tyre pressure TC 0 8 0 9 Kg sq cm TE TXC racing 0 8 0 9 Kg sq cm TE road use 1 0 Kg sq cm ...

Page 415: ... chain tensioners 2 in this way the chain tension will remain un changed after reassembly Extract the complete rear wheel keeping the spacers located at the hub sides To reassemble reverse the above procedure remembering to insert the brake disc into the calliper Do not operate the rear brake pedal when the wheel has been re moved this causes the calliper pistons to move outwards After removal lay...

Page 416: ...ard the bearings after removal Never reuse them Before installing the new bearings check to ensure the seat is clean and shows no grooves or scratches Lubricate the seat before installing the bearing Drive the bearing into place using the special installer that only applies pressure to the outer race Fit the spacer and the other bearing Check for perfect alignment as you slide the axle into place ...

Page 417: ...ch as a screwdriver a clear crisp sound indicates proper tightening a dull sound means that the spokes need to be tightened Wheel rim warpage The table below reports the allowed limits for wheel rim warpage Exceeding runout or out of round are generally due to worn bearings When this is the case replace the bearings If this does not solve the problem change the wheel rim or the wheel Standard Max ...

Page 418: ...e shows the profiles of a normally worn and an exceedingly worn sprocket 1 Normal wear 2 Exceeding wear If the sprocket is exceedingly worn replace it after loosening the six screws that retain it to the hub Chain and sprockets must always be replaced as a set Tightening torque figures 3 34 3 Nm 3 5 Kgm 25 3 ft lb LOCTITE 243 ...

Page 419: ...ink Check the transmission sprocket for damage or wear When worn down like the sprocket shown in the figure it must be replaced Wheelmisalignmentcausesabnormalwear makingthemotorcycle unsafe to ride Dirt caked on sprockets and chain collected while riding on muddy or wet terrain increases chain tension If you expect to ride on muddy or wet terrain slacken the chain a bit Riding on muddy terrain si...

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Summary of Contents for 2009 TC 250

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Husqvarna 2009 TC 250, Workshop Manual, Page: 32 / 420

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Summary of Contents for 2009 TC 250

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