Husqvarna 2014 TE 125 EU Owner'S Manual Download

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12 SERVICE WORK ON THE CHASSIS

12.28

Removing the main silencer

Warning

Danger of burns

The exhaust system gets very hot when the vehicle is driven.

–

Allow the exhaust system to cool down. Do not touch hot components.

Preparatory work

–

Remove the right side cover. (

p. 55)

L01633-10

Main work

–

Remove screws

–

Pull the main silencer off of the manifold at rubber sleeve

12.29

Installing the main silencer

L01634-10

Main work

–

Mount the main silencer with rubber sleeve

–

Mount and tighten screws

Guideline

Remaining screws, chassis

10 Nm (7.4 lbf ft)

Finishing work

–

Install the right side cover. (

p. 55)

12.30

Changing the glass fiber yarn filling of the main silencer

Warning

Danger of burns

The exhaust system gets very hot when the vehicle is driven.

–

Allow the exhaust system to cool down. Do not touch hot components.

Info

Over time, the fibers of the glass fiber yarn filling escape and the damper "burns" out.

Not only is the noise level higher, the performance characteristic changes.

Preparatory work

–

Remove the right side cover. (

p. 55)

–

Remove the main silencer. (

p. 54)

Summary of Contents for 2014 TE 125 EU

Page 1: ...OWNER S MANUAL 2014 TE 125 EU TE 250 EU TE 250 AUS TE 250 USA TE 300 EU TE 300 AUS TE 300 USA Art no 3402005en ...

Page 2: ......

Page 3: ...odify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice Husqvarna accepts no liability for delivery options deviations from illustrations and descriptions or misprints and other errors The model...

Page 4: ...etting the service display 23 7 8 Speed time and DST distance 1 24 7 9 Speed time and DST2 distance 2 24 7 10 AVG average speed ART operating hours and ODO total distance covered 24 8 PREPARING FOR USE 25 8 1 Advice on first use 25 8 2 Running in the engine 26 8 3 Preparing the vehicle for difficult riding conditions 26 8 4 Preparing for rides on dry sand 27 8 5 Preparing for rides on wet sand 27 ...

Page 5: ...cking the brake discs 67 13 5 Checking the front brake fluid level 67 13 6 Adding front brake fluid x 67 13 7 Checking the front brake linings 68 13 8 Changing the front brake linings x 69 13 9 Checking the free travel of the foot brake lever 70 13 10 Adjusting the basic position of the foot brake lever x 70 13 11 Checking the rear brake fluid level 71 13 12 Adding rear brake fluid x 71 13 13 Chec...

Page 6: ...al system 110 22 6 Tires 110 22 7 Fork 110 22 7 1 TE 125 110 22 7 2 TE 250 300 110 22 8 Shock absorber 111 22 8 1 TE 125 111 22 8 2 TE 250 300 111 22 9 Chassis tightening torques 112 22 10 Carburetor 113 22 10 1 TE 125 113 22 10 2 TE 250 EU 113 22 10 3 TE AUS 113 22 10 4 TE 250 USA 114 22 10 5 TE 300 EU 114 22 10 6 TE 300 USA 114 22 11 Carburetor tuning 115 22 11 1 Carburetor tuning TE 125 x 115 2...

Page 7: ...rstanding In the interest of your own safety have these jobs performed by an authorized Husqvarna workshop There your motorcycle will be opti mally maintained by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page 1 2 Formats used The following typographical formats are used Specific name Identifies a proprieta...

Page 8: ...rred to at the relevant passages Info The vehicle has various information and warning labels at prominent locations Do not remove information warning labels If they are missing you or others may not recognize dangers and may therefore be injured 2 3 Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropria...

Page 9: ...y an authorized Husqvarna workshop Adhere to the information and warning labels on the vehicle 2 6 Protective clothing Warning Risk of injury Missing or poor protective clothing presents an increased safety risk Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing that is in good condition and meets the legal ...

Page 10: ... will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as needed If you would like to know more about the vehicle or have questions on the material you read please contact an authorized Husqvarna dealer The Owner s Manual is an important component of the vehicl...

Page 11: ...na website www husqvarna motorcycles com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chas sis is properly carried out as described in the Owner s Manual Incorrect adjustment and tuning of the engine and chassis can lead to damage and breakage of components Use of the vehicle under difficult conditions ...

Page 12: ...4 VIEW OF VEHICLE 10 4 1 View of vehicle front left example L01612 10 1 Filler cap 2 Air filter box lid 3 Fuel tap p 17 4 Choke p 18 5 Shift lever p 18 6 Side stand p 19 ...

Page 13: ... 3 Light switch p 15 3 Turn signal switch p 15 4 Speedometer overview 5 Emergency OFF switch p 15 5 Electric starter button p 16 6 Throttle grip p 14 7 Hand brake lever p 14 8 Fork rebound adjustment 9 Shock absorber rebound adjustment 10 Level viewer for brake fluid rear 11 Shock absorber compression adjustment 12 Foot brake lever p 18 13 Kick starter p 18 ...

Page 14: ...l 1 is fixed to the front of the steering head 5 3 Key number TE EU AUS 500125 10 The key number 1 for the steering lock is stamped onto the key connector 5 4 Engine number 401949 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 5 5 Fork part number 401947 10 The fork part number 1 is stamped on the inner side of the fork stub ...

Page 15: ...5 SERIAL NUMBERS 13 5 6 Shock absorber part number 0 0 1 1 401948 10 The shock absorber part number 1 is stamped on the upper part of the shock absorber above the adjusting ring ...

Page 16: ...1 is fitted on the left side of the handlebar Possible states Kill switch in basic position In this position the ignition circuit is closed and the engine can be started Kill switch pressed In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start 6 5 Kill switch TE USA C00547 10 The kill switch 1 is fitted on the left side of the handlebar...

Page 17: ... left of the speedometer Possible states Light off Light switch is pressed in up to the stop In this position the light is switched off Light on Light switch is pulled out to the stop In this position the low beam and tail light are switched on 6 9 Turn signal switch TE EU AUS C00548 10 The turn signal switch 1 is fitted on the left side of the handlebar Possible states Turn signal light off The t...

Page 18: ...lashes green Turn signal light is switched on High beam indicator lamp lights up blue High beam is switched on FI warning lamp MIL lights up flashes orange Inoperative The low fuel warning lamp lights up orange Inoperative 6 14 Overview of indicator lamps TE USA B01648 01 Possible states The high beam indicator light lights up blue Inoperative FI warning lamp MIL lights up flashes orange Inoperati...

Page 19: ...into the ground water the ground or the sewage system L01611 11 Press release button 1 turn the filler cap counterclockwise and lift it free 6 16 Closing the filler cap L01611 10 Replace the filler cap and turn clockwise until release button 1 locks in place Info Run the fuel tank breather hose 2 without kinks 6 17 Fuel tap L01603 10 The fuel tap is found on the left side of the fuel tank Tap hand...

Page 20: ...knob is pulled out all the way Choke function deactivated The choke knob is pushed in all the way 6 19 Shift lever 401950 10 Shift lever 1 is mounted on the left side of the engine 401950 11 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears 6 20 Kick starter L01606 10 The kick starter 1 is fitted on the right side of the engine The ...

Page 21: ...teering head The steering lock is used to lock the steering Steering and therefore riding is no longer possible 6 24 Locking the steering TE EU AUS Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 400732 01 Park the vehicle Turn the handlebar as far as possible to the right Insert the key in the steering lock turn it to the lef...

Page 22: ...cking the steering TE EU AUS 400731 01 Insert the key in the steering lock turn it to the left pull it out and turn it to the right Remove the key You can now steer the bike again Info Never leave the key in the steering lock ...

Page 23: ...peedometer Battery voltage of the speedometer is too low Change the battery Service Service is due Contact an authorized Husqvarna workshop 7 4 Setting the speedometer Condition The motorcycle is stationary 401909 01 Press both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Press one of the buttons to select UNIT for the speed in kilometers KM H or miles M H 401911 01...

Page 24: ...hortening the service interval Press the left button The value decreases Extending the service interval Press the right button The value increases 401914 01 Switching off the service interval display Press and hold the left button off appears on the display 7 5 Setting kilometers or miles Info If you change the unit of measure the ODO value is retained and converted accordingly Condition The motor...

Page 25: ...ft button The value decreases Advancing the time Press the right button The value increases 7 7 Setting the service display Condition The motorcycle is stationary 401913 01 Press both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Wait for the menu of the service display to flash Set the service Guideline Service every 20 h Shortening the service interval Press the le...

Page 26: ...ince the last reset such as between two refueling stops Info If the value of 39999 9 is exceeded DST2 is automatically reset to 0 0 Press the left but ton briefly Next display mode Press the left but ton for 3 5 sec onds DST2 can be preset to a value between 0 0 and 39999 9 by pressing the buttons Press the right but ton briefly Next display mode Press the right but ton for 3 5 sec onds DST2 is re...

Page 27: ...ly The rear brake may fail due to overheating Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info W...

Page 28: ...mance During the first 3 operating hours 70 During the first 5 operating hours 100 Avoid fully opening the throttle 8 3 Preparing the vehicle for difficult riding conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can lead to considerably more rapid wear of components such as the drive train brake system or suspension components For this reas...

Page 29: ... cover for air filter 59006922000 Info Observe the Husky Power fitting instructions Adjust the carburetor jetting and setting Info The recommended carburetor tuning is available from your authorized Husq varna workshop 600868 01 Clean the chain Mount the steel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent radiator fins carefully If used in sand regularly replace the ...

Page 30: ...1100 Info Observe the Husky Power fitting instructions Adjust the carburetor jetting and setting Info The recommended carburetor tuning is available from your authorized Husq varna workshop 600868 01 Mount the steel sprocket Clean the motorcycle p 100 Straighten bent radiator fins carefully 8 7 Preparing for rides at high temperature and slow speed 600872 10 Check the radiator cap Value on radiato...

Page 31: ...Clean the chain Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 87 8 8 Preparing for rides at low temperature and in snow B00437 01 Mount a rain cover on the air filter Rain cover for air filter 77206921100 Info Observe the Husky Power fitting instructions Adjust the carburetor jetting and setting Info The recommended carburetor tuning is available from yo...

Page 32: ...y 9 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Note Engine failure High engine speeds in cold engines have a negative effect on the service life...

Page 33: ...bout 3 4 of its range This barely reduces vehicle speed but lowers fuel consumption considerably Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption To shift down brake and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off...

Page 34: ...of components due to excessive load The side stand is only designed for the weight of the motorcycle Do no sit on the motorcycle when it is resting on the side stand The side stand or the frame may become damaged and the motorcycle may fall over Brake the motorcycle Shift gear to neutral TE EU AUS Press and hold the kill switch while the engine is idling until the engine stops TE USA Press and hol...

Page 35: ...fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water t...

Page 36: ...and hand lever chain and check for smooth operation x Check rectify the fluid level of the hydraulic clutch p 63 Check the front brake fluid level p 67 Check the free travel of the hand brake lever p 66 Check the play of the steering head bearing p 48 Change the spark plug and spark plug connector x Check the intake diaphragm x Check the exhaust control to ensure it is functioning properly and ope...

Page 37: ...raulic clutch fluid x p 64 Grease the steering head bearing x p 49 Check set the carburetor components x Perform a fork service x Service the shock absorber x Check the starter drive x TE 250 300 Change the piston and check the cylinder x TE 125 Change the piston and check the cylinder x TE 250 300 Change the connecting rod conrod bearing and crank pin x Check the transmission and shift mechanism ...

Page 38: ...w speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed The high speed setting has an effect on the landing after a jump for example the rear wheel suspension compresses more quickly The low speed setting has an effect when riding over long ground swells for example the rear wheel suspension compresses more slowly These two ranges can be adjusted separately...

Page 39: ...eed setting can be seen during the fast compression of the shock absorber L01620 11 Turn adjusting screw 1 all the way clockwise with a socket wrench Info Do not loosen nut 2 Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed TE 125 Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Compression damping high speed TE 250 30...

Page 40: ... Measure the distance as vertical as possible between the rear axle and a fixed point for example a mark on the side cover Note down the value as dimension A Finishing work Remove the motorcycle from the lift stand p 43 11 7 Checking the static sag of the shock absorber 0 0 A A 0 B B 400989 10 Measure distance A of the unloaded rear wheel p 38 Hold the motorcycle upright with the aid of an assista...

Page 41: ...essurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized Husqvarna work shop will be glad to help Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Preparatory work Raise the motorcycle with the lift stand p 43 Remove the right side cover p 55 Remo...

Page 42: ...0 Weight of rider 65 75 kg 143 165 lb 51 N mm 291 lb in Weight of rider 75 85 kg 165 187 lb 54 N mm 308 lb in Weight of rider 85 95 kg 187 209 lb 57 N mm 325 lb in Info The spring rate is shown on the outside of the spring Finishing work Install the shock absorber x p 51 Install the main silencer p 54 Install the right side cover p 55 Remove the motorcycle from the lift stand p 43 Check the static...

Page 43: ...licks Standard 13 clicks Sport 11 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 11 13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior L01616 10 Turn the red adjusting screw 1 all the way clockwise Info Adjusting screw 1 is located at the upper end of the right fork leg The compression dam...

Page 44: ...00375 10 Remove screws 1 Remove the handlebar clamp Remove the handlebar and lay it to one side Info Protect the motorcycle and its attachments against damage by covering them Do not bend the cables and lines Remove screws 2 Remove the handlebar support Place the handlebar support in the required position Mount and tighten screws 2 Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 24...

Page 45: ...d 1 to the ground with your foot and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with the rubber band 12 3 Bleeding the fork legs Preparatory work Raise the motorcycle with the lift stand p 43 L01621 10 Main work Release bleeder screws 1 Any excess pressure escapes from the interior of the fork Mount and tighten the bleeder screws Finishing work ...

Page 46: ... right fork leg Push the fork protection downwards 12 6 Positioning the fork protection C00564 11 Position the fork protection on the left fork leg Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and clamp Mount and tighten screws 2 Position the fork protection on the right fork leg Mount and tighten the screws Guideline Remaining screws ch...

Page 47: ...t L01667 11 Tighten screws 2 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft C00578 10 Position the brake caliper Mount and tighten screws 4 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount cable binder 5 Position the brake line wiring harness and clamp Mount and tighten screws 6 Finishing wor...

Page 48: ...t wheel x p 75 Install the headlight mask with the headlight p 83 Check the headlight setting p 84 12 11 Removing the lower triple clamp x Preparatory work Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 82 Raise the motorcycle with the lift stand p 43 Remove the front wheel x p 75 Remove the fork legs x p 44 Remove the front fender p 49 L016...

Page 49: ...ing Mount screw 4 but do not tighten yet Mount the clutch line with cable guide 5 L01628 10 Position the fork legs Info The rebound damping is located in the right fork leg red adjusting screw The compression damping is located in the left fork leg white adjusting screw Grooves are milled into the side of the upper end of the fork legs The sec ond milled groove from the top must be flush with the ...

Page 50: ... motorcycle from the lift stand p 43 12 13 Checking the play of the steering head bearing Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play Adjust the steering head bearing play without delay Your authorized Husqvarna workshop will be glad to help Info If the bike is ridden with play in the steering head bearing the bearing and the bearing seats in the...

Page 51: ...r triple clamp to avoid strains Tighten screws 1 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw 2 Guideline Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Finishing work Check the play of the steering head bearing p 48 Remove the motorcycle from the lift stand p 43 12 15 Greasing the steering head bearing x 800010 10 Remove the lower triple clamp x p 46 Ins...

Page 52: ...Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Connect plug in connectors 3 of the turn signals Finishing work Install the headlight mask with the headlight p 83 Check the headlight setting p 84 12 18 Removing the shock absorber x Preparatory work Raise the motorcycle with the lift stand p 43 Remove the right side cover p 55 Remove the main silencer p 54 L01669 1...

Page 53: ...n screw 3 Guideline Screw bottom shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Finishing work Install the main silencer p 54 Install the right side cover p 55 Remove the motorcycle from the lift stand p 43 12 20 Removing the seat B01819 10 Remove screws 1 in the recessed grips on the left and right Lift up the seat at the rear pull it back and then lift it off 12 21 Mounting the seat L01630 01...

Page 54: ...ilter since dust and dirt can get into the engine and result in increased wear Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Preparatory work Remove the air filter box lid p 52 L01632 10 Main work Push air filter holder 1 toward the air filter at position A ...

Page 55: ...e disposed of as stipulated in applicable regulations Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the air filter box lid p 52 Remove the air filter x p 52 L00944 10 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Info Only press the air filter to dry it never wring it out Oil...

Page 56: ...he main silencer with rubber sleeve 1 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the right side cover p 55 12 30 Changing the glass fiber yarn filling of the main silencer x Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components Info Over time...

Page 57: ... cover L01635 10 Remove screw 1 Pull off the side cover in area A sideways and remove it toward the rear 12 32 Installing the right side cover L01635 10 Position the side cover and engage in area A Mount and tighten screw 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 33 Removing the fuel tank x Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or b...

Page 58: ...2 with the rubber bushing Remove the tube from the fuel tank vent line B01810 01 Pull both spoilers sideways off of the radiator bracket and take off the fuel tank toward the top 12 34 Installing the fuel tank x Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especial...

Page 59: ...ews chassis M6 10 Nm 7 4 lbf ft Connect the fuel hose Finishing work Mount the seat p 51 12 35 Checking the chain for dirt 400678 01 Check the chain for heavy soiling If the chain is very dirty Clean the chain p 57 12 36 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Re...

Page 60: ...rd at the end of the chain sliding piece and determine chain tension A Info The lower chain section 1 must be taut Because chain wear is not always even repeat this measurement at different chain positions Chain tension 55 58 mm 2 17 2 28 in If the chain tension does not meet specifications Adjust the chain tension p 58 Finishing work Remove the motorcycle from the lift stand p 43 12 38 Adjusting ...

Page 61: ... lift stand p 43 12 39 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle with the lift stand p 43 400227 01 Main work Shift gear to neutral Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Change the drivetrain kit x Info The engine sprocket rear sprocket and chain should always be changed toge...

Page 62: ...in line with or below the chain sliding piece Change the chain sliding piece x Check the chain sliding piece for tightness If the chain sliding piece is loose Tighten the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 400985 01 Check the chain guide for wear Info Wear can be seen on the front of the chain guide If the light part of the chain guide is worn Change the c...

Page 63: ...ingarm for damage cracking and deformation If the swingarm shows signs of damage cracking or deformation Change the swingarm x Info A damaged swingarm must always be changed Repair of the swingarm is not authorized by Husqvarna 12 42 Checking the throttle cable routing Preparatory work Remove the seat p 51 Remove the fuel tank x p 55 L01700 10 Main work TE 125 Check the throttle cable routing The ...

Page 64: ...andlebar for damage wear and looseness If a rubber grip is damaged worn or loose Change and secure the rubber grip Rubber grip adhesive 00062030051 p 121 12 44 Additionally securing the rubber grip Preparatory work Check the rubber grip p 62 401198 01 Main work Secure the rubber grip at two points using the securing wire Securing wire 54812016000 Wire twister forceps U6907854 The twisted wire ends...

Page 65: ...t apply any force Do not make any adjustments while riding 12 46 Checking rectifying the fluid level of the hydraulic clutch Info The fluid level rises with increased wear of the clutch facing discs L01702 10 TE 125 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Check the fluid level Fluid level below container rim 4...

Page 66: ...ding syringe 4 L01703 10 Inject the liquid into the system until it escapes from hole 6 of the master cylin der without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount and tighten the bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position the cover with t...

Page 67: ...on the cover with the membrane Mount and tighten the screws 12 48 Removing the engine guard L01704 10 TE 125 Turn quick release 1 counterclockwise until it disengages Remove the engine guard L01644 10 TE 250 300 Turn quick release 1 counterclockwise until it disengages Remove the engine guard 12 49 Installing the engine guard L01704 10 TE 125 Attach the engine guard on the frame at the rear and sw...

Page 68: ...ee travel of the hand brake lever p 66 Adjust the free travel of the hand brake lever with adjusting screw 1 Info Turn the adjusting screw clockwise to reduce free travel The pressure point moves away from the handlebar Turn the adjusting screw counterclockwise to increase free travel The pres sure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by han...

Page 69: ...ke linings are completely worn down Check the brake system and do not continue riding Your autho rized Husqvarna workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized Husqvarna workshop will be glad to help L01647 10 Move the brake fluid reservo...

Page 70: ... the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Add brake fluid to level A Guideline Dimension A brake fluid level below top edge of container 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 119 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 13...

Page 71: ...cient of the brake linings and thus their brake power may vary greatly from that of original Husq varna bake linings If brake linings that differ from the original equipment are used it cannot be guaranteed that these are in keeping with the original homologation In this case the vehicle will not correspond to its condition at delivery and the war ranty shall be void Warning Environmental hazard H...

Page 72: ...the foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to overheating Adjust the free travel on foot brake lever according to specifications L01648 10 Disconnect spring 1 Move the foot brake lever backwards and forwards between the end stop and the foot brake c...

Page 73: ...ly worn down Check the brake system and do not continue riding Your autho rized Husqvarna workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized Husqvarna workshop will be glad to help L01650 10 Stand the vehicle upright Check the brake fluid lev...

Page 74: ...ks paint Use only clean brake fluid from a sealed container B01794 10 Stand the vehicle upright Remove screw cap 1 with membrane 2 and the O ring Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 119 Mount the screw cap with the membrane and the O ring Info Clean up overflowed or spilt brake fluid immediately with water 13 13 Checking the rear brake linings Warning Danger of accidents Reduced...

Page 75: ...e in Husqvarna vehicles The structure and fiction coefficient of the brake linings and thus their brake power may vary greatly from that of original Husq varna bake linings If brake linings that differ from the original equipment are used it cannot be guaranteed that these are in keeping with the original homologation In this case the vehicle will not correspond to its condition at delivery and th...

Page 76: ... the pin and mount the cotter pin Info Always change the brake linings in pairs Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point B01794 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 119 Mount screw cap 1 with membrane 2 and O ring Info Clean up overflowed or spilt brake fluid immediately with water ...

Page 77: ...the front wheel withdraw the wheel spindle Take the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not damaged L00214 10 Remove spacers 3 14 2 Installing the front wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the bra...

Page 78: ...he motorcycle with the lift stand p 43 B01790 10 Main work Press the brake caliper onto the brake disc by hand in order to push back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut 1 Remove chain adjuster 2 Withdraw wheel spindle 3 only enough to allow the rear wheel to be pushed forward Push the rear wheel fo...

Page 79: ...n adjusting screws 5 Check the chain tension p 58 Tighten nut 4 Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters 3 can be turned by 180 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there i...

Page 80: ...lder than five years Change the tire 14 6 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the dust cap Check the tire air pressure when the tires are cold Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Tire air pre...

Page 81: ...ne frequencies from different spokes of equal length and diameter this is an indication of different spoke tensions You should hear a high note If the spoke tension varies Correct the spoke tension x Check the spoke torque Guideline Spoke nipple front wheel M4 5 5 6 Nm 3 7 4 4 lbf ft Spoke nipple rear wheel M4 5 5 6 Nm 3 7 4 4 lbf ft Torque wrench with various accessories in set 58429094000 ...

Page 82: ... 1 and disconnect the negative cable from the battery Pull back the positive terminal cover 2 and disconnect the positive cable from the battery Detach rubber band 3 at the bottom Lift the battery up and out 15 2 Installing the battery x B01789 10 Main work Insert the battery with the terminals facing forward into the battery compartment Battery YTX5L BS Attach rubber band 1 Info Contact disk A mu...

Page 83: ...ng with a high charging current shortens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will ...

Page 84: ...y main fuse 2 Info A defective fuse can be identified by the burned out fuse wire A A reserve fuse 3 is located in the starter relay Install a new main fuse Fuse 58011109110 Check that the electrical equipment is functioning properly Tip Insert the spare fuse so that it is available if needed Mount the protection caps Mount the starter relay onto the holder and lay the cable Finishing work Install...

Page 85: ...n the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 82 L00269 10 Main work Turn protection cap 1 with the bulb socket beneath it all the way counterclockwise and lift it off Pull bulb socket 2 of the parking light out of the reflector 100463 10 Press headlight bulb 3 lightly i...

Page 86: ...urn signal R10W socket BA15s p 110 Mount the orange cap Position the turn signal glass Insert the screw and first turn it counterclockwise until it engages in the thread with a slight jerk Tighten the screw slightly Finishing work Check that the turn signal system is functioning properly 15 9 Checking the headlight setting 400726 10 Position the vehicle upright on a horizontal surface in front of ...

Page 87: ... work Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 82 B01786 10 Main work Remove screws 1 Pull the speedometer upward out of the holder B01644 11 Using a coin turn protection cap 2 all the way counterclockwise and remove it Remove speedometer battery 3 Insert the new battery with the label facing outward Speedometer battery CR 2032 Check t...

Page 88: ...ion the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If...

Page 89: ...t does not meet specifications Correct the coolant level Alternative 1 Coolant p 119 Alternative 2 Coolant mixed ready to use p 119 Mount the radiator cap 16 4 Draining the coolant x Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the ...

Page 90: ... that screw 1 is tightened Position the motorcycle upright Fill the radiator completely with coolant Coolant 1 2 l 1 3 qt Coolant p 119 Coolant mixed ready to use p 119 L01707 10 Loosen screw 2 until coolant that does not contain any bubbles escapes Replace and retighten screw 2 Guideline Bleeder screw cylinder head M6 10 Nm 7 4 lbf ft L01654 10 TE 250 300 Make sure that screw 1 is tightened Posit...

Page 91: ...16 COOLING SYSTEM 89 Place the vehicle back on a level surface L01708 10 Fill the radiator completely with coolant Mount radiator cap 2 Run the engine until it is warm Check the coolant level p 87 ...

Page 92: ...ction system Start the engine and let it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable x p 90 17 2 Adjusting the play in the throttle cable x Preparatory work Remove the seat p 51 Remove the fuel tank x p 55 Check the throttle cable routing p 61 L01656 10 Main work Move the handle...

Page 93: ...ation with the throttle slide partially open This range is influenced by the jet needle form and position The idle setting influences the engine tuning in the lower range and the main jet influences the engine tuning in the upper range If when accelerating with the throttle slide partially opened the engine only stutters while running the jet needle needs to be lowered by one level If the engine k...

Page 94: ...nning Following extreme air temperature or altitude changes adjust the idle speed again 17 5 Emptying the carburetor float chamber x Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fu...

Page 95: ...tch the ignition timing map from Performance to Soft Disconnect plug in connection 1 Figure L01900 10 p 93 Soft Better rideability Switch the ignition timing map from Soft to Performance Connect plug in connection 1 Figure L01900 10 p 93 Performance Higher performance 17 8 Checking the basic position of the shift lever 0 0 0 A A 400692 10 Sit on the vehicle in the riding position and determine dis...

Page 96: ...g with green marking Auxiliary spring contained in the separate enclosure for softer performance Auxiliary spring with red marking Auxiliary spring contained in the separate enclo sure for more aggressive performance The engine characteristic can be influenced by different spring strengths of auxiliary spring 1 17 11 Engine characteristic setting the auxiliary spring x TE 250 300 Warning Danger of...

Page 97: ...ng 54637072300 Auxiliary spring with green marking 54837072100 Auxiliary spring with red marking 54837072000 The cut out of spring insert 5 engages in the angle lever Info Screw 6 must not be turned as this would worsen the engine characteristic Check the O ring in the cap Position the cap Mount and tighten the screws Guideline Screw exhaust control cover M5 6 Nm 4 4 lbf ft ...

Page 98: ...Add gear oil x p 98 Mount and tighten the screw in the opening used to check the gear oil level Guideline Screw gear oil level check M6 10 Nm 7 4 lbf ft L01660 11 TE 250 300 Remove screw 1 from the opening used to check the gear oil level Check the gear oil level A small quantity of gear oil should flow out of the opening If gear oil does not flow out Add gear oil x p 98 Mount and tighten the scre...

Page 99: ... magnet 1 Remove gear oil drain plug 2 Completely drain the gear oil Clean the gear oil drain plug thoroughly Clean the sealing area on the engine Mount the gear oil drain plug with magnet 1 and the seal ring and tighten Guideline Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Mount gear oil drain plug 2 with the seal ring and tighten Guideline Gear oil drain plug M10x1 15 Nm 11 1 lbf f...

Page 100: ...heck the gear oil level p 96 18 5 Adding gear oil x Info Too little gear oil or poor quality gear oil results in premature wear of the transmission The gear oil must be added while the engine is cold Preparatory work Park the motorcycle on a level surface L01711 10 Main work TE 125 Remove screw 1 from the opening used to check the gear oil level L01660 11 TE 250 300 Remove screw 1 from the opening...

Page 101: ...and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effec tive exhaust extraction system Start the engine and check that it is oil tight ...

Page 102: ... and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust system Empty the carburetor float chamber x p 92 Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake...

Page 103: ...he parts are cooled down and while they are installed After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the brake discs with a wax based corrosion inhibitor Info Corrosion inhibitor is not permitted to come in contact with the brake discs as this would greatly reduce the brakin...

Page 104: ...Check the antifreeze and coolant level p 86 When refueling for the last time before taking the motorcycle out of service add fuel additive Refuel p 33 Empty the carburetor float chamber x p 92 Check the tire air pressure p 78 TE 250 300 Remove the battery x p 80 Recharge the battery x p 81 Guideline Storage temperature of battery with out direct sunlight 0 35 C 32 95 F Store the vehicle in a dry l...

Page 105: ...ition system x Short circuit cable in wiring harness frayed kill switch faulty Check the kill switch x The connector or ignition coil is loose or oxydized Clean the connector and treat with contact spray Water in carburetor or jets blocked Check set the carburetor components Engine has no idle Idling jet blocked Check set the carburetor components Adjusting screws on carburetor dis torted Carburet...

Page 106: ...ing system Check the cooling system for leakage Check the coolant level p 87 Too little air stream Switch off engine when stationary Radiator fins very dirty Clean the radiator fins Foam formation in cooling system Drain the coolant x p 87 Refill with coolant x p 88 Damaged cylinder head or cylinder head gasket Check the cylinder head or cylinder head gas ket Bent radiator hose Change the radiator...

Page 107: ...nition adjustment type Kokusan Ignition point BTDC 1 4 mm 0 055 in Spark plug NGK BR9 ECMVX Spark plug electrode gap 0 60 mm 0 0236 in Starting aid Kick starter 22 1 2 All TE 250 Design 1 cylinder 2 stroke engine water cooled with reed intake and exhaust control Displacement 249 cm 15 19 cu in Stroke 72 mm 2 83 in Bore 66 4 mm 2 614 in Exhaust valve Beginning of adjustment 5 600 rpm Exhaust valve ...

Page 108: ...d of adjustment with yellow auxiliary spring 7 900 rpm Exhaust valve end of adjustment with green auxiliary spring 8 400 rpm Crankshaft bearing 1 grooved ball bearing 1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast Piston rings 2 rectangular rings X upper edge of piston to upper edge of cylinder 0 0 10 mm 0 0 0039 in Z height of control flap 4...

Page 109: ... lbf ft Screw engine case M6 10 Nm 7 4 lbf ft Screw exhaust control M6 10 Nm 7 4 lbf ft Screw gear oil level check M6 10 Nm 7 4 lbf ft Screw intake flange reed valve housing M6 10 Nm 7 4 lbf ft Screw kick starter stop plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 Screw shifting gate M6 10 Nm 7 4 lbf ft Loctite 243 Screw water pump cover M6 10 Nm 7 4 lbf f...

Page 110: ...g M6 10 Nm 7 4 lbf ft Loctite 243 Screw kick starter stop plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 Screw slave cylinder of the clutch M6 10 Nm 7 4 lbf ft Screw starter motor M6 8 Nm 5 9 lbf ft Screw stator M6 8 Nm 5 9 lbf ft Loctite 243 Screw water pump cover M6 10 Nm 7 4 lbf ft Screw cylinder...

Page 111: ... bar 15 psi Secondary ratio TE 125 14 50 13 50 Secondary ratio TE 250 300 EU AUS 14 50 13 50 Secondary ratio TE USA 13 50 Chain 5 8 x 1 4 Rear sprockets available 48 50 52 Steering head angle 63 5 Wheelbase TE 125 1 471 10 mm 57 91 0 39 in Wheelbase TE 250 300 1 482 10 mm 58 35 0 39 in Seat height unloaded 960 mm 37 8 in Ground clearance unloaded 355 mm 13 98 in Homologated weight without fuel app...

Page 112: ...n ENDURO COMPETITION IIIe TE USA 80 100 21 M C 51M TT Dunlop GEOMAX MX51 FA 110 100 18 M C 64M TT Dunlop GEOMAX MX51 Additional information is available in the Service section under www husqvarna motorcycles com 22 7 Fork 22 7 1 TE 125 Fork part number 24 18 7N 61 Fork WP Suspension Up Side Down 4860 4CS Compression damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Rebound damping Comfo...

Page 113: ... 61 Shock absorber WP Suspension 5018 BAVP DCC Compression damping low speed Comfort 20 clicks Standard 18 clicks Sport 16 clicks Compression damping high speed Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 13 mm 0 51 in Spring rate Weight of rider 65 75 kg 143 165 lb 48 N mm 274 lb in Weight of rider 75 85 kg...

Page 114: ...ft Remaining screws chassis M6 10 Nm 7 4 lbf ft Screw ball joint of push rod on foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw chain sliding guard M6 6 Nm 4 4 lbf ft Loctite 243 Screw front brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw rear brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw throttle grip M6 5 Nm 3 7 lbf ft Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Nut rear sproc...

Page 115: ...33 2 lbf ft 22 10 Carburetor 22 10 1 TE 125 Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK125 Needle position 4th position from top Jet needle N84I NOZE NOZF NOZG Main jet 100 168 170 172 Idling jet 38X38 45 Starting jet 50 85 Idle air adjusting screw Open 2 75 turns Throttle slide 7 with cut out Slide stop 22 10 2 TE 250 EU Carburetor type KEIHIN PWK 36S AG Carburetor ident...

Page 116: ...TE 300 EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK029 Needle position 2nd position from top Jet needle N84K N4DW N4DJ N4DK Main jet 115 165 168 Idling jet 38X38 35 Starting jet 50 85 Idle air adjusting screw Open 1 75 turns Throttle slide 7 with cut out Slide stop Present 22 10 6 TE 300 USA Carburetor type KEIHIN PWK 36S AG Carburetor identification number BC1 Needle p...

Page 117: ...rized for public road traffic in the homolo gous reduced version only In the derestricted version the motorcycle must be used only on closed off property remote from public road traffic 401769 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces ...

Page 118: ...public road traffic in the homolo gous reduced version only In the derestricted version the motorcycle must be used only on closed off property remote from public road traffic 401770 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces ...

Page 119: ...public road traffic in the homolo gous reduced version only In the derestricted version the motorcycle must be used only on closed off property remote from public road traffic 401767 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces ...

Page 120: ...neral carburetor tuning x 0 0 4 4 0 0 3 3 0 0 5 5 0 0 2 2 0 0 1 1 B00075 10 1 5 Needle position from above The five possible needle positions are shown here The carburetor tuning depends on the defined ambient and operating conditions ...

Page 121: ...tection 40 C 40 F engine oil 15W 50 Standard classification JASO T903 MA p 122 SAE p 122 15W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the correspond ing properties Engine oil 2 stroke Standard classification JASO FC p 122 Guideline Only use high grade 2 stroke engine oil of a reputable brand Fully synthetic Fork...

Page 122: ...ion DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 Super unleaded 95 octane mixed with 2 stroke engine oil 1 60 Standard classification DIN EN 228 JAS...

Page 123: ...24 AUXILIARY SUBSTANCES 121 High viscosity grease Recommended supplier SKF LGHB 2 Rubber grip adhesive 00062030051 Recommended supplier KTM Sportmotorcycle AG GRIP GLUE ...

Page 124: ... In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis cosity The viscosity describes only one property of oil and says nothing about quality JASO FC JASO FC is a cla...

Page 125: ...ecking 59 Chain tension adjusting 58 checking 58 Chassis number 12 Choke 18 Cleaning care 100 101 Clutch fluid level checking rectifying 63 fluid changing 64 Clutch lever 14 basic position adjusting 62 Combination instrument overview 21 Compression damping fork adjusting 41 Compression damping high speed shock absorber adjusting 37 Compression damping low speed shock absorber adjusting 36 Coolant ...

Page 126: ... bulb changing 83 Headlight mask with headlight installing 83 removing 82 Horn button 15 I Ignition timing map changing 93 plug in connection 93 Intended use 6 K Key number 12 Kick starter 18 Kill switch 14 L Light switch 15 Lower triple clamp installing 47 removing 46 M Main fuse changing 82 Main silencer glass fiber yarn filling changing 54 installing 54 removing 54 Motorcycle cleaning 100 raisi...

Page 127: ...9 unlocking 20 Steering head bearing greasing 49 Steering head bearing play adjusting 49 checking 48 Storage 102 Swingarm checking 61 T Technical data capacities 108 carburetor 113 carburetor tuning 115 chassis 109 chassis tightening torques 112 electrical system 110 engine 105 engine tightening torques 107 fork 110 shock absorber 111 tires 110 Throttle cable play adjusting 90 Throttle cable routi...

Page 128: ... 3402005en 3402005en 10 2013 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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