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Husqvarna SMR 449 2011 I.E., Workshop Manual

The 2011 Husqvarna SMR 449 I.E. brings thrilling performance and unmatched versatility to every ride. For easy maintenance and repairs, ensure you have the Workshop Manual that provides essential instructions. Download your free manual from manualshive.com to maintain the peak performance of your SMR 449 effortlessly.

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F1.64

TC 449 2011/2012 I.E.

TE 449 - 511 2011/2012 I.E.

TXC 449 - 511 2011/2012 I.E.

SMR 449 2011 I.E.

SMR 511 2011/2012 I.E.

H01940

H01775

H01775

ENGINE DISASSEMBLY/REASSEMBLY

Workshop Manual  Ed. 03-2012

OIL INTAKE PUMP REPLACEMENT (CRANKCASE COVER REMOVED)

Preliminary operations

Clutch housing axial bearing disassembly

Clutch thrust washer disassembly

Oil pump idler gear disassembly

Oil pump control gear disassembly

Oil intake pump disassembly

•  Disassemble the following parts:

-  Screws (1)

-  Cover (2)

-  Inner rotor (3)

-  Outer rotor (4)

-  Needle roller (5)

Fit oil intake pump

•  Lubricate needle roller (5), outer rotor (4), and inner rotor (3).

Consumables

Molykote D Paste

Clear solid lubricant for metal 

part assembling and settling

•  Assemble the following parts:

-  Needle roller (5)

-  Outer rotor (4), and inner rotor (3) with reference mark pointing out

-  Cover (2)

•  Fit screws (1).

  Tightening torque figures

Pump cover on crankcase

M5 x 12, Microincapsulated 

screw replacement

6 Nm

Summary of Contents for SMR 449 2011 I.E.

Page 1: ...TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E Workshop Manual Ed 03 2012 Rev 02 ...

Page 2: ...22 06 2012 M 2 Updated index cause correction applied on page M 56 01 22 06 2012 M 3 Updated index cause corrections applied on pages M 58 M 59 01 22 06 2012 M 56 M 57 M 58 M 59 Digital dashboard warning lights TE SMR Inserted different instructions for models and Model year Digital dashboard drawings Applied correction Instructions for the instrument setting Inserted new note 02 18 07 2012 D 12 E...

Page 3: ...2 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E MY12 TC 449 ZKHA600AABV050001 TC 449 USA ZKHTC443 BV000001 TE 449 ZKHA600AABV000001 TE 511 ZKHA601AABV000001 TE 449 USA ZKHKEEFM BV000001 TE 511 USA ZKHKEEGM BV000001 TXC 449 USA ZKHTX440 BV000001 TXC 511 USA ZKHTX510 BV000001 SMR 511 ZKHA601ABBV000001 SMR 511 USA ZKHLEEGM BV000001 Workshop Manual Ed 03 2012 FOREWORD TABLE OF C...

Page 4: ... recommendations before repair evaluate the customer s description 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 bef...

Page 5: ... models Table of Contents Title Section Foreword table of contents a Important notices b General information A Maintenance B Troubleshooting C Settings and adjustments D General procedures E Adjustments engine F Engine disassembly reassembly F1 Front suspension I Rear suspension J Brakes L Electrical system M Engine cooling N Hydraulically controlled clutch P Fuel injection system S Tightening tor...

Page 6: ......

Page 7: ...b 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E b Workshop Manual Ed 03 2012 IMPORTANT NOTICES Section ...

Page 8: ...full throttle may result in severe engine damage ALWAYS remember that these motorcycles are specifically designed for racing i e for usage conditions significantly different from those experienced in regular road use In order to maintain the vehicle s Guarantee of Functionality the client must follow the maintenance programme indicated in Section B by having the required maintenance inspections ca...

Page 9: ...A 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E A Workshop Manual Ed 03 2012 GENERAL INFORMATION Section ...

Page 10: ...mario Engine A 3 Timing system A 3 Fuel system A 3 Lubrication A 3 Cooling A 3 Ignition system A 3 Starting A 3 Transmission A 3 Chassis A 4 Suspension A 4 Brakes A 5 Wheels A 5 Tyres A 5 Electrical components location TC A 6 Electrical components location TXC A 6 Electrical components location TE SMR A 6 Supplies reserve included A 7 Overall dimensions Weight A 8 ...

Page 11: ... 30 mm TC INTAKE 0 008 0 01 in 0 20 0 25 mm EXHAUST 0 012 0 014 in 0 30 0 35 mm Fuel system Type Electronic injection feed Air filtering through lubricated filter Lubrication Type wet sump with two lobe pumps and cartridge filter Cooling Liquid with double radiator and electric fan Ignition system Electronic capacitive discharge with adjustable advance digital control Spark plug type NGK CR 9EKB S...

Page 12: ...gear 9 639 Total transmission ratios TE TXC 1st gear 20 348 2nd gear 16 689 3rd gear 13 645 4th gear 11 126 5th gear 9 283 6th gear 8 162 Total transmission ratios SMR 1st gear 17 116 2nd gear 14 038 3rd gear 11 477 4th gear 9 358 5th gear 7 808 6th gear 6 865 Chassis Twin beam and twin cradle steel chassis with round and elliptic cross section rear chassis in aluminium alloy Suspension Front TC T...

Page 13: ... 76 sq cm x 2 Separate hydraulic circuit pedal and master cylinder on right side of vehicle Wheels Rims Front TC TE TXC in light alloy 1 6x21 Front SMR in light alloy 3 5x17 Rear TC in light alloy 2 15x19 Rear TE TXC in light alloy 2 15x18 Rear SMR in light alloy 4 25x17 Tyres TC Front 80 100x21 Rear 110 90x19 TXC Front 80 100x21 Rear 110 100x18 TE Front 90 90x21 Rear 140 80x18 SMR Front 120 70x17...

Page 14: ...hrottle body Voltage regulator located at the back of the steering tube The electrical system includes the following elements 12V 6Ah battery under the saddle A 30A fuse positioned on the starter contactor Fuel pump relay positioned on the front left side under the air box Electric fan relay on chassis right hand side Electric fan Coolant temperature sensor Fuel pump inside the tank Condenser Elec...

Page 15: ...fork oil CASTROL SYNTHETIC FORK OIL 5W TC TXC 33 93 cu in 556 cu cm Cartridge 11 35 cu in 186 cu cm Fork sleeve 22 58 cu in 370 cu cm TE 40 28 cu in 660 cu cm SMR 45 16 cu in 740 cu cm Rear shock absorber oil CASTROL SYNTHETIC FORK OIL 5W Cooling system fluid CASTROL MOTORCYCLE COOLANT 0 24 gal 0 9 litres Front brake fluid CASTROL RESPONSE SUPER DOT 4 Rear brake fluid CASTROL RESPONSE SUPER DOT 4 ...

Page 16: ...I E SMR 511 2011 2012 I E GENERAL INFORMATION Workshop Manual Ed 03 2012 Overall dimensions Weight Kerb weight without fuel TC 108 Kg 238 1 lb Kerb weight without fuel TE 113 Kg 249 12 lb Kerb weight without fuel TXC 110 Kg 242 51 lb Kerb weight without fuel SMR 123 5 Kg 272 27 Ib max width ...

Page 17: ...A 9 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E Workshop Manual Ed 03 2012 GENERAL INFORMATION ...

Page 18: ... 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E 820 mm 32 28 inch 1210 mm 47 64 inch 280 mm 11 02 inch 2170 mm 85 43 inch 1460 mm 57 48 inch H06375 SMR GENERAL INFORMATION Workshop Manual Ed 03 2012 ...

Page 19: ...B 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E B Workshop Manual Ed 03 2012 MAINTENANCE Section ...

Page 20: ...B 2 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E MAINTENANCE Workshop Manual Ed 03 2012 INTENTIONALLY WHITE PAGE ...

Page 21: ...B 3 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E Workshop Manual Ed 03 2012 MAINTENANCE TABLES OF PERIODIC MAINTENANCE MY11 ...

Page 22: ...AINERS VALVE COLLETS C X VALVE BUCKETS ROCKER ARM C X CYLINDER HEAD C CAMSHAFT C TIMING CHAIN SLIDER C X TIMING CHAIN S TIMING DRIVEN GEAR C X TIMING DRIVE GEAR C X TIMING CHAIN TENSIONER C X INTAKE COUPLING C X CYLINDER C X CYLINDER HEAD GASKET S SPARK PLUG P S PISTON S CRANKSHAFT S CRANKCASE BEARINGS S OIL PUMP C PRIMARY TORQUE LIMITER C X GEARBOX C X CLUTCH HUB C X CLUTCH PLATES C X CLUTCH PRES...

Page 23: ...VE COLLETS C X VALVE BUCKETS ROCKER ARM C X CYLINDER HEAD C CAMSHAFT C TIMING CHAIN SLIDER C X TIMING CHAIN S TIMING DRIVEN GEAR C X TIMING DRIVE GEAR C X TIMING CHAIN TENSIONER C X INTAKE COUPLING C X CYLINDER C X CYLINDER HEAD GASKET S SPARK PLUG P S PISTON S CRANKSHAFT S CRANKCASE BEARINGS S OIL PUMP C PRIMARY TORQUE LIMITER C X GEARBOX C X CLUTCH HUB C X CLUTCH PLATES C X CLUTCH PRESSURE PLATE...

Page 24: ... S S VALVES C C S VALVE SPRINGS C X VALVE SPRING RETAINERS VALVE COLLETS C X VALVE BUCKETS ROCKER ARM C X CYLINDER HEAD C CAMSHAFT C TIMING CHAIN SLIDER C X TIMING CHAIN S TIMING DRIVEN GEAR C X TIMING DRIVE GEAR C X TIMING CHAIN TENSIONER C X INTAKE COUPLING C X CYLINDER C X CYLINDER HEAD GASKET S SPARK PLUG S PISTON S CRANKSHAFT S CRANKCASE BEARINGS S OIL PUMP C PRIMARY TORQUE LIMITER C X GEARBO...

Page 25: ... SIDE STAND TE TXC C CHAIN GUIDE ROLLER BEARINGS C STEERING HEAD STEERING CROWN WITH PIN L C LIGHTS INDICATIONS HORN TE C C BATTERY C WHEEL SPOKES TENSION C C HANDLEBAR HOLDERS AND FASTENINGS SET C C C SECOND DRIVE CHAIN C L S REAR CHAINGUIDE REAR CHAIN GUARD C X CHAIN SLIDER C X GEARB OUTPUT SPROCKET REAR SPROCKET C C X BEARINGS FOR SWINGING ARM PIVOT ON CHASSIS L REAR SUSPENSION KINEMATIC MECHAN...

Page 26: ...SMR R LIGHTS INDICATIONS HORN TE C C BATTERY C WHEEL SPOKES TENSION C C HANDLEBAR HOLDERS AND FASTENINGS SET C C SECOND DRIVE CHAIN L C L C X REAR CHAINGUIDE REAR CHAIN GUARD C X CHAIN SLIDER C X GEARB OUTPUT SPROCKET REAR SPROCKET C C X BEARINGS FOR SWINGING ARM PIVOT ON CHASSIS L REAR SUSPENSION KINEMATIC MECHANISMS BEARINGS SHOCK ABSORBER L REAR SHOCK ABSORBER SMR C X THROTTLE CONTROL ASSY C L ...

Page 27: ...B 9 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E Workshop Manual Ed 03 2012 MAINTENANCE TABLES OF PERIODIC MAINTENANCE MY12 ...

Page 28: ...TAINERS VALVE COLLETS C X VALVE BUCKETS ROCKER ARM C X CYLINDER HEAD C CAMSHAFT C TIMING CHAIN SLIDER C X TIMING CHAIN S TIMING DRIVEN GEAR C X TIMING DRIVE GEAR C X TIMING CHAIN TENSIONER C X INTAKE COUPLING C X CYLINDER C X CYLINDER HEAD GASKET S SPARK PLUG P S PISTON S CRANKSHAFT S CRANKCASE BEARINGS S OIL PUMP C PRIMARY TORQUE LIMITER C X GEARBOX C X CLUTCH HUB C X CLUTCH PLATES C X CLUTCH PRE...

Page 29: ...LVE COLLETS C X VALVE BUCKETS ROCKER ARM C X CYLINDER HEAD C CAMSHAFT C TIMING CHAIN SLIDER C X TIMING CHAIN S TIMING DRIVEN GEAR C X TIMING DRIVE GEAR C X TIMING CHAIN TENSIONER C X INTAKE COUPLING C X CYLINDER C X CYLINDER HEAD GASKET S SPARK PLUG P S PISTON S CRANKSHAFT S CRANKCASE BEARINGS S OIL PUMP C PRIMARY TORQUE LIMITER C X GEARBOX C X CLUTCH HUB C X CLUTCH PLATES C X CLUTCH PRESSURE PLAT...

Page 30: ... S S VALVES C C S VALVE SPRINGS C X VALVE SPRING RETAINERS VALVE COLLETS C X VALVE BUCKETS ROCKER ARM C X CYLINDER HEAD C CAMSHAFT C TIMING CHAIN SLIDER C X TIMING CHAIN S TIMING DRIVEN GEAR C X TIMING DRIVE GEAR C X TIMING CHAIN TENSIONER C X INTAKE COUPLING C X CYLINDER C X CYLINDER HEAD GASKET S SPARK PLUG S PISTON S CRANKSHAFT S CRANKCASE BEARINGS S OIL PUMP C PRIMARY TORQUE LIMITER C X GEARBO...

Page 31: ...E TXC C CHAIN GUIDE ROLLER BEARINGS C STEERING HEAD STEERING CROWN WITH PIN L C LIGHTS INDICATIONS HORN TE C C BATTERY C WHEEL SPOKES TENSION C C HANDLEBAR HOLDERS AND FASTENINGS SET C C C SECOND DRIVE CHAIN C L S REAR CHAINGUIDE REAR CHAIN GUARD C X CHAIN SLIDER C X GEARB OUTPUT SPROCKET REAR SPROCKET C C X BEARINGS FOR SWINGING ARM PIVOT ON CHASSIS L REAR SUSPENSION KINEMATIC MECHANISMS BEARINGS...

Page 32: ...SMR R LIGHTS INDICATIONS HORN TE C C BATTERY C WHEEL SPOKES TENSION C C HANDLEBAR HOLDERS AND FASTENINGS SET C C SECOND DRIVE CHAIN L C L C X REAR CHAINGUIDE REAR CHAIN GUARD C X CHAIN SLIDER C X GEARB OUTPUT SPROCKET REAR SPROCKET C C X BEARINGS FOR SWINGING ARM PIVOT ON CHASSIS L REAR SUSPENSION KINEMATIC MECHANISMS BEARINGS SHOCK ABSORBER L REAR SHOCK ABSORBER SMR C X THROTTLE CONTROL ASSY C L ...

Page 33: ...C 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E C Workshop Manual Ed 03 2012 TROUBLESHOOTING Section ...

Page 34: ...nsion cables open circuit or shorted Check 6 Electronic control unit faulty Replace 7 Right hand switch faulty Replace The throttle body is not receiving fuel 1 Faulty fuel pump relay Change 2 Faulty fuel pump Check change 3 Clogged fuel inlet hose Clean Engine stalls 1 Fouled spark plug Clean easily 2 Electronic control unit faulty Replace 3 Dirty injector Clean 4 Low idle Adjust Engine is noisy ...

Page 35: ...Replace 3 Damaged shifter fork shafts Replace Gear shift pedal 1 Weak or broken selector return spring Replace does not return to 2 Worn shifter forks Replace original position 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 ...

Page 36: ...te 4 Improperly set rear shock absorber Adjust Damping is 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 Tight...

Page 37: ...rk plug Generator does 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 Starter motor 1 Battery is flat Charge d...

Page 38: ......

Page 39: ...D 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E D Workshop Manual Ed 03 2012 SETTINGS AND ADJUSTMENTS Section ...

Page 40: ...ent and mesh filters filter cartridge cleaning or replacement D 13 Coolant level check D 14 Coolant replacement D 15 Air filter check D 16 Air filter cleaning D 16 Chain adjustment D 17 Chain lubrication D 18 Disassembling and cleaning D 18 Washing chain without O rings TC D 18 Washing chain with O rings TE TXC SMR D 18 Lubricating chain without O rings TC D 18 Lubricating chain with O rings TE TX...

Page 41: ...C 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E H006104 TC H006105 TE H006106 TXC H06374 SMR Workshop Manual Ed 03 2012 SETTINGS AND ADJUSTMENTS ...

Page 42: ... H006109 1 H006111 1 SETTINGS AND ADJUSTMENTS Workshop Manual Ed 03 2012 Saddle removal Turn pin 1 counter clockwise and remove saddle 2 from central retaining screw Side panel removal Remove the saddle as described in the relevant paragraph Left hand side panel Loosen the four screws 1 using an 8 mm wrench and remove the side panel 2 ...

Page 43: ...2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E H006114 4 6 5 H006113 3 3 Workshop Manual Ed 03 2012 SETTINGS AND ADJUSTMENTS Right hand side panel Loosen the five screws 3 using an 8 mm wrench release side panel 4 from scoop 5 by disengaging retaining tabs 6 ...

Page 44: ...rkshop Manual Ed 03 2012 Scoop removal Remove the saddle and side panels as described in the relevant para graphs Left hand side scoop Loosen the three screws 1 using an 8 mm wrench and remove the scoop 2 Right hand side scoop Loosen the two screws 3 using an 8 mm wrench and remove horn 4 and scoop 5 Engine guard removal Loosen the screws 1 using an 8 mm wrench and remove the engine guard 2 ...

Page 45: ...ake sure that there is a clearance of approx 2 mm 0 08 in should this not be the case loosen check nuts 4 and 5 turn and keep twistgrip 3 in the fully closed position loosen upper return cable 6 using adjuster screw 7 keeping twistgrip 3 fully closed reset cable 6 clearance by turning ad juster screw 7 tighten check nut 4 turn adjuster screw 8 until reaching an opening clearance of approx 2 mm 0 0...

Page 46: ... 1 clockwise until fully closed position then turn anticlockwise through 33 clicks until obtaining an idle speed of 1 850 1 950 rpm which can be read using the suitable diagnosis instrument Idle adjustment TE TXC SMR Adjust the carburettor with warm engine and with the throttle control in closed position Proceed as follows Turn adjuster screw 1 with a screwdriver until reaching an idle speed of 1 ...

Page 47: ...e Chart if hose C is worn or cracked its replacement is advised Front brake lever adjustment and fluid level check TC TE TXC The adjuster 1 located on the control lever allows adjusting of the free play a Free play a shall be of at least 3 mm 0 12 in The level of the fluid in master cylinder reservoir must never be below the mini mum value 2 which can be checked from the inspection window on the r...

Page 48: ...ansparent tank 4 A decrease of the fluid level 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...

Page 49: ...dal 3 accord ing to the instructions provided under paragraph Rear brake pedal free play adjustment Rear brake pedal free play adjustment Before staring the braking action rear brake pedal shall have a free play B of 5 mm 0 2 in Should this not happen operate as follows Loosen the nut 3 Operate the master cylinder linkage 4 to increase or decrease free play Tighten the nut 3 at the end of the oper...

Page 50: ...perature The higher the temperature the higher the oil level inside oil sump Should oil level be checked with the engine cold or after short runs wrong readings may be taken with consequent wrong topping up Start vehicle as described in the relevant section let it run for approx 3 to 5 minutes so as to warm engine up Turn engine off With the vehicle in a flat ground and in vertical position check ...

Page 51: ... Drain the oil with WARM ENGINE proceed as follows Remove the engine guard as described under the relevant paragraph Remove the oil filler cap 1 put a drip pan under engine remove oil drainage plug 2 evacuate the exhausted oil and clean magnet on plug 2 on reassembly tighten plug 2 to a torque of 15 Nm 1 5 Kgm 11 6 ft lb loosen the two caps 3 and remove the two mesh filters 4 and 5 on reassembly t...

Page 52: ...ur the recom mended quantity of oil Start the engine to allow the oil to reach all the points of the engine and check the level as described in the relevant paragraph Coolant level check Check level 1 inside left radiator with the engine cold and the vehicle in vertical position The coolant should be approximately 10 mm 0 4 in above the cells The radiator cap 2 features two locking positions the f...

Page 53: ... on the right side to drain the coolant easily in the vessel Reassemble the screw 1 To fill in the system set motorcycle on a central stand or in any case keep the bike in a vertical position not on the side stand Pour the necessary quantity of coolant in the radiator then warm up the en gine in order to eliminate any possible air bubbles Allow the coolant to cool down then remove cap 2 and check ...

Page 54: ... cleaning or replacing refit all the disassembled parts in reverse order making sure to position filter sponge 5 with the TOP wording facing up Refit filter 2 inside guides push it all the way down and lock it using the clip on fasteners 1 Air filter cleaning Wash the filter with a specific detergent CASTROL FOAM AIR FILTER CLEAN ER or similar then dry it fully wash filter with gasoline only in ca...

Page 55: ... chain has a max 5 mm 0 04 in gap A Incorrect chain tension involves excessive and early wear of the chain slider lower part periodically check for wear and replace it if worn out If it is not proceed as follows on the right side with a 27 mm Allen wrench loosen the locking nut 2 of the wheel axle loosen the check nuts 3 on both chain tensioners with a 12 mm wrench and work on the screws 4 with a ...

Page 56: ...aphtha or paraffin oil Never use fuel trichloroethylene or solvents as the O rings may get damaged Use instead special sprays for chains with O rings Lubricating chain without O rings TC 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 As an alternative you can use suitable spray lubricants Lubr...

Page 57: ...ound harder Shock absorber harder compression and especially harder 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 ...

Page 58: ... wheel on the ground shall be 40 45 mm 1 57 1 77 in SMR MY11 MY12 The difference between dimension A with the wheel raised off the ground and dimension A with the wheel on the ground shall be 20 25 mm 0 79 0 98 in 3 Have bike resting on the ground with rider sitting on it Measure dimension A TC TE TXC MY11 MY12 The difference between dimension A with the wheel raised off the ground and dimension A...

Page 59: ...o suit your weight or riding style and tighten the lock ring nut firmly tightening torque 10 Nm 1 Kgm 7 38 ft lb 6 Refit the right hand side panel and the saddle Be careful not to touch hot exhaust pipe while adjusting the shock absorber TE TC TXC MY11 A Spring standard length when preloaded 251 0 5 mm 9 88 0 02 in B Free length 451 5 mm 17 78 in Maximum length 453 mm 17 83 in Minimum length 323 m...

Page 60: ...ribed in the relevant paragraph 2 Clean lock ring nut 1 and adjuster ring nut 2 of the spring 3 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 10 Nm 1 Kgm 7 38 ft lb 6 Refit the right hand side panel and the saddle Be caref...

Page 61: ... adjuster 2 MY12 2 High damping speed TC TE TXC 1 1 2 turns SMR 18 click 2 click adjuster 2 To reset the standard setting turn upper adjusters 1 and 2 clockwise until reach ing fully closed position Then turn them back to the above mentioned positions In order to obtain a smooth braking action turn the adjusters counter clockwise Vice versa to obtain a harder braking action MY11 B REBOUND Standard...

Page 62: ...er clockwise Vice versa to obtain a harder braking action REBOUND Fig b TC TXC LOWER ADJUSTER TE TOP ADJUSTER MY11 TC TXC 10 clicks TE 14 clicks MY12 TC TXC 14 clicks TE 14 clicks To reset standard calibration 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 ver...

Page 63: ...he oil level Work as follows remove the damper rod caps remove springs from the legs letting the oil drain into the legs bring fork to stroke end TE check that level is at the distance A of 118 mm 4 65 in from rod upper limit MY11 OIL QUANTITY IN EACH FORK LEG TC TXC 556 cu cm 34 54 cu in Cartridge 186 cu cm 11 35 cu in Fork sleeve 370 cu cm 22 58 cu in TE 660 cu cm 40 27 cu in MY12 OIL QUANTITY I...

Page 64: ...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 stand release the fork fully extended and loosen the air vent valve D Once this operation is over tighten the valve Never force the adjusting screws beyond the ma...

Page 65: ...nd hold the lower ends of the fork legs Push and pull in a front to rear motion to feel for play If any play is detected adjust as follows Remove the saddle Loosen the steering head tube nut 1 Loosen the two bolts 3 that secure the fork legs to the steering head turn ring nut 2 on steering tube clockwise using the suitable special wrench until obtaining correct clearance tighten the steering head ...

Page 66: ...change it as follows Remove the saddle and left hand side panel as described in the relevant paragraphs Release the control unit 1 off its mounts and remove it from its housing Using a Phillips screwdriver loosen the clamp 2 connecting the tube 3 to throttle body 4 Remove the front tank tank with pump as described in the corresponding paragraph Slide the tank 5 with tube 3 connected off the bike U...

Page 67: ...visual inspection of the exhaust system first in order to identify pos sible gas leaks from the sealing elements gaskets and to ensure that the Silent Blocks are not damaged Subsequently inspect the single components by disassembling the exhaust system Also check that the flange nuts 1 the screws 2 that fix the silencer to the supports and the screw 3 TE TXC SMR that fixes the manifold to the sile...

Page 68: ......

Page 69: ...E 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E E Workshop Manual Ed 03 2012 GENERAL PROCEDURES Section ...

Page 70: ...Y11 E 8 Rear mudguard removal TE TXC TC MY12 E 9 Battery removal E 10 Tank removal E 10 Fuel pump removal E 14 Cock removal E 14 Throttle body removal E 15 Exhaust system removal SMR E 18 Exhaust system removal TE TXC E 19 Exhaust system removal TC E 22 Rear chassis removal E 24 Rear tank removal E 26 Solenoid starter removal E 26 CDI electronic control unit removal E 27 Voltage regulator removal ...

Page 71: ...6110 2 H006109 1 H006111 1 Workshop Manual Ed 03 2012 GENERAL PROCEDURES Saddle removal Turn pin 1 counter clockwise and remove saddle 2 from chassis fastening Side panel removal Remove the saddle as described in the relevant paragraph Left hand side panel Loosen the four screws 1 using an 8 mm wrench and remove the side panel 2 ...

Page 72: ...ght hand side panel Loosen the five screws 3 using an 8 mm wrench release side panel 4 from scoop 5 by disengaging retaining tabs 6 Tail section removal TC TE TXC MY12 Remove the side panels as described in the relevant paragraph Loosen the four self tapping screws 1 Loosen the screws 2 using a suitable tool Pull the plastic parts apart slightly and slide the tail section 3 off towards the rear of...

Page 73: ...GENERAL PROCEDURES Rear turning indicator removal Disconnect the connectors 1 Loosen the screws 2 and remove the turning indicators 3 When reassembling check that the water drainage hole 4 is placed underneath Front turn indicator removal Disconnect the connectors 1 Loosen the screws 2 and remove the turning indicators 3 When reassembling check that the water drainage hole 4 is placed underneath ...

Page 74: ...3 2012 Number plate holder removal TE MY12 Remove the tail section and the rear turning indicators as described in the relevant paragraphs Loosen the two screws 1 Disconnect the number plate light cable 2 Slide the number plate holder 3 down and remove it When reassembling check that the longest bushings 4 are placed on the mudguard and the shortest ones 5 are placed on the number plate holder ...

Page 75: ...he two screws 1 securing headlamp fairing number plate holder and mudguard Loosen the four screws 2 with a 8 mm wrench and remove front mudguard 3 Number plate holder removal TE MY11 SMR MY11 MY12 Remove rear turning indicators as described in the relevant section Using a 8 mm wrench loosen the two screws 1 disconnect number plate bulb 3 and remove number plate holder 2 On reassembly check the cor...

Page 76: ...12 Rear mudguard removal SMR MY11 MY 12 TE TXC TC MY11 Remove the saddle the two side panels and the number plate holder TE SMR as described in the relevant paragraphs Using a 8 mm wrench loosen the two screws 1 positioned under rear mudguard disconnect connector 2 TE SMR and remove tail light Using a 8 mm wrench loosen the two front retaining screws 3 and remove the complete mudguard 4 ...

Page 77: ...2 GENERAL PROCEDURES Rear mudguard removal TE TXC TC MY12 Remove the saddle the side panels the tail section and the number plate holder TE and the turning indicators TE as described in the relevant paragraphs TE Loosen the two screws 1 disconnect the connector 2 and remove the light 3 TE Remove the wiring harness 4 from the mudguard 5 Loosen the two screws 6 and remove the mudguard 5 ...

Page 78: ...in the relevant paragraph First remove the BLACK negative cable 1 then the RED positive cable 2 when reassembling first connect the RED positive cable then the BLACK negative cable release retaining elastic strap 3 and remove battery 4 from its compartment Tank Removal Close both fuel cocks 1 Remove the saddle and the two side panels as described in the relevant paragraphs Release the electronic c...

Page 79: ...49 2011 I E SMR 511 2011 2012 I E H06516 3 H02416 4 H02417 5 6 Workshop Manual Ed 03 2012 GENERAL PROCEDURES Undo the upper clamp 3 connecting fuel pump to throttle body Disconnect pump supply connector 4 Slacken clamp 5 with long nose pliers and disconnect breather hose 6 from tank ...

Page 80: ...and disconnect hose 8 between the two tanks Loosen upper screw 8 using a 14 mm wrench undo and remove lower bolt 9 with two 14 mm wrenches then remove engine left connecting rod 10 As for TC model remove exhaust manifold as described in the relevant paragraph to undo bolt 9 On reassembly position connecting rod 10 with the written side facing the inner part of the bike to a tightening torque of 50...

Page 81: ...2 H02424 11 Workshop Manual Ed 03 2012 GENERAL PROCEDURES With a 8 mm socket wrench undo screw 11 and remove the screw with rubbers and spacers On reassembly tighten screw 11 to 10 Nm 1 0 Kgm 7 38 ft lb Remove tank 12 and drain any residual fuel through cock For upper tank removal refer to the rear chassis removal para graph ...

Page 82: ...en the five screws 1 securing pump 2 to tank To replace throttle body supply hose 3 open metal clamp 4 and then after hose replacement close clamp again using the special pliers On reassembly tighten screws 1 to a torque of 7 Nm 0 7 Kgm 5 16 ft lb checking that the O ring 8 is correctly positioned in its seat and it is not damaged Cock Removal Remove lower fuel tank as described in the relevant pa...

Page 83: ...ove the air filter as described in the relevant paragraph Use a 4 mm Allen wrench to loosen the screw 1 and remove the cover 2 of the throttle body Using a 10 mm Allen wrench loosen nuts 3 and 4 and remove cables 5 and 6 On reassembly cable 6 with the RED ring shall be fitted onto throt tle body lower side Loosen clamp 7 of intake coupling 8 squeeze hose coupling on the inner side filter box side ...

Page 84: ...E SMR 511 2011 2012 I E H02435 9 H02436 H02437 10 H02438 11 13 12 GENERAL PROCEDURES Workshop Manual Ed 03 2012 Disconnect injector connector 9 Detach the pressure sensor 10 From the right side TE TXC SMR remove second throttle connector 11 second throttle TPS connector 12 and TPS connector 13 ...

Page 85: ...I E SMR 511 2011 2012 I E H02439 14 H02440 16 15 H02441 Workshop Manual Ed 03 2012 GENERAL PROCEDURES TC disconnect TPS connector 14 Loosen intake manifold 16 upper screw 15 Working on bike right side slightly lift throttle body and turn it clockwise by 90 then remove it from bike left side ...

Page 86: ...11 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E SMR H06518 1 2 3 4 5 6 GENERAL PROCEDURES Workshop Manual Ed 03 2012 Exhaust System Removal SMR Key SMR Silencer 1 Clamp 2 Seal 3 Lambda sensor 4 Manifold 5 Seal 6 ...

Page 87: ...1 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E TE TXC H06517 1a 1 2 3 4 5 6 Workshop Manual Ed 03 2012 GENERAL PROCEDURES Exhaust System Removal TE TXC Key TE TXC 1 Silencer Lanfranconi 1a Silencer Krapovic 2 Clamp 3 Seal 4 Lambda sensor 5 Manifold 6 Seal ...

Page 88: ... H06372 1 H02444 2 H02445 5 H02448 3 4 GENERAL PROCEDURES Workshop Manual Ed 03 2012 Working on the right side loosen upper screw 1 using a 12 mm T wrench Working on the left side loosen screw 2 using a 12 mm T wrench Loosen clamp 4 screw 3 with a 13 mm wrench and move it onto the exhaust manifold Remove silencer 5 ...

Page 89: ... I E SMR 449 2011 I E SMR 511 2011 2012 I E H02446 6 H02447 8 7 H02449 9 Workshop Manual Ed 03 2012 GENERAL PROCEDURES Cut Lambda sensor cable clamps and remove connector 6 Loosen the two screws 7 using a 12 mmAllen wrench then remove manifold 8 On reassembly replace seal 9 ...

Page 90: ...12 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E TC H02450 4 6 5 7 3 2 1 8 GENERAL PROCEDURES Workshop Manual Ed 03 2012 Exhaust system removal TC Key Silencer 1 Spring 2 Manifold 3 Spring 4 Flange 5 Bushing 6 Seal 7 Nut 8 ...

Page 91: ... SMR 511 2011 2012 I E H02444 2 1 H02518 3 H02519 4 H02520 Workshop Manual Ed 03 2012 GENERAL PROCEDURES Working on the right side loosen support clamp upper screw 1 using a 12 mm T wrench Working on the left side loosen screw 2 using a 12 mm T wrench Release spring 3 Remove silencer 4 4 H02520 ...

Page 92: ...e manifold 6 Using a 12 mm Allen wrench loosen the two nuts 7 then remove flange 8 bushing 9 and gasket 10 On reassembly screw nuts 7 to a torque of 26 Nm 2 65 Kgm 19 18 ft lb Rear chassis removal Remove saddle side panels number plate holder rear mudguard exhaust silencer and battery as described in the relevant paragraphs Disconnect control unit 1 and solenoid starter 2 from their mounts Detach ...

Page 93: ... 2012 I E 5 H02453 H02454 7 6 H06519 8 H02456 9 10 Workshop Manual Ed 03 2012 GENERAL PROCEDURES Cut clamps 5 of the rear wiring harness Make sure that fuel tank cocks are closed then disconnect hose 6 from rear tank cock 7 Using a 10 mm wrench loosen the four screws 8 and remove the chassis 9 with tank 10 ...

Page 94: ...the relevant paragraph Loosen the two screws 1 securing tank 2 to rear chassis 3 and remove tank On reassembly check the correct positioning of the bushings Solenoid starter removal Remove the saddle as described in the relevant paragraph Disconnect the negative and positive cables of the battery Disconnect the starter motor positive cable 1 from the solenoid starter 2 Disconnect the connector 3 a...

Page 95: ...tronic control unit removal Remove the saddle as described in the relevant paragraph Remove the connector 1 from the CDI electronic control unit 2 and take the control unit together with its anti vibration mount out of the chassis Voltage regulator removal Remove the saddle as described in the relevant paragraph Loosen the screws 1 using a 8 mm wrench Disconnect the connector 2 and remove voltage ...

Page 96: ...ore removing the spark plug It is very useful to examine the state of the spark plug just after it has been removed from the engine since the scale deposits on the plug and the colour of the insulator provide useful indications Correct heat rating The tip of the insulator should be dry and the colour should be light brown or grey High heat rating In this case the insulator tip is dry and covered w...

Page 97: ...park plug Carefully change the spark plug if necessary using one having the same rating Before refitting the plug thoroughly clean the electrodes and the insulator using a metal brush Apply graphitised grease on spark plug thread screw it by hand all the way down then tighten it to the torque of 10 12 Nm 7 38 8 85 ft Ib Loosen spark plug and tighten it again to 10 12 Nm 7 38 8 85 ft Ib Spark plugs...

Page 98: ...kshop Manual Ed 03 2012 Clutch hose removal Loosen screw 1 with a 8 mm wrench and move number plate holder or headlamp fairing Loosen screw 2 with a 8 mm wrench and remove the cover 3 Loosen screw 4 with a 8 mm wrench and disconnect clamp 5 from engine Loosen clutch hose 7 union 6 and drain all oil out of hose On reassembly bleed the clutch system as described in Section P ...

Page 99: ...2 2 2 3 Workshop Manual Ed 03 2012 GENERAL PROCEDURES Horn removal TE SMR Loosen the two screws 1 using a 8 mm wrench Disconnect connector 2 and remove horn 3 Electric cooling fan removal TE TXC SMR Remove saddle first and then the left side panel Disconnect the connector 1 Loosen the four screws 2 with a 7 mm wrench and remove electric fan 3 ...

Page 100: ...RAL PROCEDURES Workshop Manual Ed 03 2012 Air filter box removal Remove saddle left and right side panels filter and voltage regulator as indicated in the relevant paragraphs Loosen screw 1 with a 8 mm wrench securing left scoop Loosen intake coupling 3 clamp 2 and slide coupling out from the front side Disconnect air temperature sensor connector 4 ...

Page 101: ...511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E H02475 5 H02476 7 6 H02478 6 Workshop Manual Ed 03 2012 GENERAL PROCEDURES Disconnect Blow by hose 5 Loosen the three screws 6 with a 8 mm wrench Lower filter box 7 and remove it from the bike right side ...

Page 102: ...l Ed 03 2012 Engine guard removal Using a 8 mm socket wrench loosen the three screws 1 and remove engine guard 2 Gear shift pedal removal Remove chain and engine guard as indicated in the relevant paragraph Engage the 2nd gear with the gear shift pedal 1 Using a 8 mm socket wrench loosen screw 2 and remove gear shift pedal 1 On reassembly tighten screw 2 to 10 Nm 1 02 Kgm 7 38 ft lb ...

Page 103: ... Ed 03 2012 GENERAL PROCEDURES Chain slider removal Remove chain and gear shift pedal as indicated in the relevant para graphs Loosen screw 2 and remove chain guard 1 Fit a support under the engine so that the rear wheel is raised off the ground Loosen lower screw 3 using two 14 mm wrenches Loosen the three screws 4 with a 8 mm wrench securing chain slider 5 to swinging arm 6 ...

Page 104: ...2486 9 8 H02487 10 11 H02488 12 H02485 7 GENERAL PROCEDURES Workshop Manual Ed 03 2012 Loosen screw 7 with a Phillips screwdriver Loosen screw 9 with a 8 mm wrench and remove chain roller 8 Loosen screws 11 with a 8 mm wrench and remove sprocket guard 10 Raise rear wheel 12 and keep it raised off the ground with a belt ...

Page 105: ...12 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E H02489 5 A H02490 5 B Workshop Manual Ed 03 2012 GENERAL PROCEDURES Slide out the chain slider 5 as shown in figures A and B ...

Page 106: ...aust system as described in the relevant paragraphs Loosen screw 1 positioned onto pump body and drain off cooling sys tem Loosen clamps 2 and remove engine cooling hoses 3 4 and 5 Loosen screw 6 with an 8 mm wrench and detach ground cable 8 To loosen the nut 7 retaining the Motor positive cable 9 it is necessary to use two 8 mm wrenches one to hold the lock nut 7a and the other to loose the nut 7...

Page 107: ...13 12 Workshop Manual Ed 03 2012 GENERAL PROCEDURES Loosen screw 10 with a 8 mm wrench and remove cover 11 Loosen screw 12 with a 8 mm wrench and disconnect clamp 13 from engine Loosen the three screws 14 with a 8 mm wrench and disconnect clutch actuator 14a Disconnect spark plug cap coil 16 connector 15 loosen screw 18 with a 8 mm wrench and disconnect ground cable 19 ...

Page 108: ...2 H02502 24 25 GENERAL PROCEDURES Workshop Manual Ed 03 2012 Turn coil 16 by 90 so that connector is pointing to bike rear end then remove it Disconnect Blow by hose 20 Loosen screw 21 and screw 22 with a 14 mm wrench and remove right connecting rod 23 Disconnect all engine wiring harnesses Loosen screw 24 and remove neutral sensor wiring harness 25 ...

Page 109: ...H02506 30 H02505 29 Workshop Manual Ed 03 2012 GENERAL PROCEDURES Remove rear brake pedal 26 by loosening screw 27 with a 6 mm Allen wrench and releasing spring 28 Loosen rear engine mounting bolt 29 with two 14 mm wrenches and the two front screws 30 with a 12 mm wrench engine will rest on chassis cradle Remove engine from chassis right side ...

Page 110: ...11 2012 I E H02509 2 1 H02510 1 2 2 H02508 1 2 H02507 1 GENERAL PROCEDURES Workshop Manual Ed 03 2012 Radiator Removal Remove saddle side panels scoops and radiator grids as described in the relevant paragraphs Drain off all coolant as indicated in the relevant paragraph Loosen clamps 1 and remove hoses 2 ...

Page 111: ...02511 3 H02512 4 H02513 5 H02514 5 H02515 6 H02516 7 Workshop Manual Ed 03 2012 GENERAL PROCEDURES Disconnect temperature sensor connector 3 Disconnect electric fan connector 4 TE TXC SMR Loosen the four screws 5 with a 8 mm wrench and remove left hand ra diator 6 complete with fan TE TXC SMR and right hand radiator 7 ...

Page 112: ......

Page 113: ...F 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E F Workshop Manual Ed 03 2012 ADJUSTMENTS ENGINE Section ...

Page 114: ... 03 2012 Sommario Valve clearance check F 3 Set valve clearance cylinder head cover removed F 4 Engine positioning at ignition TDC F 4 Securing crankshaft at TDC F 4 Valve clearance adjustment F 5 Bearing mount disassembly F 5 Camshaft disassembly F 5 Camshaft assembly F 5 Bearing mount assembly F 6 Bearing mount securing F 6 Valve clearance check F 7 ...

Page 115: ...ce with cold engine Max 35 C 0 71 15 65 in 0 05 0 10 mm TE TXC SMR Intake valve clearance with cold engine Max 35 C 2 84 3 56 in 0 20 0 25 mm TC Exhaust valve clearan ce with cold engine Max 35 C 3 56 4 27 in 0 25 0 30 mm TE TXC SMR Exhaust valve clearan ce with cold engine Max 35 C 4 27 4 98 in 0 30 0 35 mm TC Result Valve clearance outside tolerance values Action When assembling use adjuster pla...

Page 116: ...13 8000H5009 ADJUSTMENTS ENGINE Workshop Manual Ed 03 2012 Set valve clearance cylinder head cover removed Engine positioning at ignition TDC Turn engine until reaching TDC Reference marks arrows parallel with cylinder head Securing crankshaft at TDC Remove screw 1 with sealing ring Lock crankshaft at TDC using special tool 8000H5009 ...

Page 117: ...ming chain 4 at first from intake shaft 2 sprocket then from exhaust shaft 3 and lay it in a safe position to prevent it from falling to the ground Remove intake camshaft 2 Remove exhaust camshaft 3 Mark bucket type tappet Take out bucket type tappets overturn rocker arms Before fitting shims and new half balls measure the thickness using a mi crometer calliper Replace shims and half balls making ...

Page 118: ... ten sioned Fit camshaft 2 and 3 stop washers 1 Bearing mount assembly Assemble guide sleeves 4 Lubricate mount 3 at camshaft sliding surfaces then assemble it Consumables Molykote D Paste Consumables Clear solid lubricant for metal part assembling and settling Fit long 1 and short 2 screws tightening them by hand Bearing mount securing Tighten screws according to the indicated sequence Tightening...

Page 119: ...71 15 65 in 0 05 0 10 mm TE TXC SMR Intake valve clearance with cold engine Max 35 C 2 84 3 56 in 0 20 0 25 mm TC Exhaust valve clea rance with cold engine Max 35 C 3 56 4 27 in 0 25 0 30 mm TE TXC SMR Exhaust valve clea rance with cold engine Max 35 C 4 27 4 98 in 0 30 0 35 mm TC Result Valve clearance outside tolerance values Action Valve clearance adjustment Crankshaft disconnection Remove spec...

Page 120: ......

Page 121: ...F1 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E F1 Workshop Manual Ed 03 2012 ENGINE DISASSEMBLY REASSEMBLY Section ...

Page 122: ... ignition TDC F1 15 Securing crankshaft at TDCF F1 15 Camshaft removal F1 16 Bearing mount disassembly F1 16 Camshaft check F1 16 Camshaft assembly F1 16 Bearing mount assembly F1 17 Bearing mount securing F1 17 Subsequent actions F1 17 Engine left crankcase F1 18 Engine left crankcase cover disassembly F1 18 Engine left crankcase cover assembly F1 18 Alternator replacement F1 19 Preliminary opera...

Page 123: ...mbly F1 36 Clutch housing axial bearing assembly F1 36 Coolant pump disassembly and assembly F1 37 Coolant pump cover disassembly F1 37 Coolant pump rotor disassembly F1 37 Coolant pump rotor assembly F1 38 Coolant pump cover assembly F1 38 Coolant pump inside crankcase oil seal replacement crankcase cover removed F1 39 Coolant pump control rear oil seal disassembly F1 39 Coolant pump control shaf...

Page 124: ...ylinder assembly F1 57 Subsequent actions F1 58 Timing chain disassembly and reassembly or replacement F1 59 Preliminary operations F1 59 Timing chain disassembly F1 59 Timing chain assembly F1 60 Subsequent actions F1 60 Chain chain sprocket check F1 60 Timing chain check F1 60 Replacing oil pump gears crankcase cover removed F1 61 Preliminary operations F1 61 Oil pump idler gear disassembly F1 6...

Page 125: ...4 Preliminary operations F1 74 Crankcase left half disassembly F1 74 Control gear disassembly F1 75 Remove crankshaft and countershaft F1 75 Crankshaft right bearing bushing disassembly F1 76 Crankshaft for countershaft gear disassembly F1 76 Crankshaft left bearing bushing disassembly F1 77 Crankshaft axial clearance adjustment F1 77 Crankshaft wear check F1 78 Connecting rod wear check F1 78 Cra...

Page 126: ...ing assembly F1 94 Gearbox output shaft right bearing assembly F1 94 Gearbox shaft right bearing assembly F1 94 Gearbox input shaft left bearing assembly F1 95 Gearbox input shaft right bearing assembly F1 95 Clutch check inside primary drive unit F1 95 Idler gear disassembly F1 97 Idler gear assembly F1 97 Gearbox shaft replacement crankcase cover removed F1 98 Complete selector shaft disassembly...

Page 127: ... 2012 ENGINE DISASSEMBLY REASSEMBLY Oil filter disassembly Remove plug 1 with O Ring 2 Disassemble oil filter 3 Oil filter assembly Assemble oil filter 3 Assemble screw 1 with the O Ring 2 slightly greased Tightening torque figures Oil filter cover on crankcase M45 x 1 5 with O Ring Grease thread 15 Nm 1 5 Kgm 11 06 ft lb Oil filter replacement ...

Page 128: ...11 2012 I E H01722 H01723 ENGINE DISASSEMBLY REASSEMBLY Workshop Manual Ed 03 2012 Disassemble front oil mesh filter Disassemble the following parts screw 1 Filter 3 O Rings 2 4 5 Disassemble rear oil mesh filter Disassemble the following parts screw 1 Filter 3 O Rings 2 4 5 Engine oil filter disassembly ...

Page 129: ... the following parts O Rings 5 4 2 Filter 3 Fit screw 1 Tightening torque figures Oil mesh filter screw plug on crankcase M20 x 1 5 with O Ring Grease thread 10 Nm 1 Kgm 7 38 ft lb Assemble front oil mesh filter Assemble the following parts O Rings 5 4 2 Filter 3 Fit screw 1 Tightening torque figures Oil mesh filter screw plug on crankcase M20 x 1 5 with O Ring Grease thread 10 Nm 1 Kgm 7 38 ft lb...

Page 130: ...Y Workshop Manual Ed 03 2012 Spark plug recess ignition coil disassembly Disassemble the following parts Screw 1 Spark plug recess ignition coil 2 Spark plug recess ignition coil assembly Fit spark plug recess ignition coil 2 Fit screw 1 Tightening torque figures Ignition coil inside engine M5 x 16 10 9 6 Nm 0 6 Kgm 4 43 ft lb Spark plug recess ignition coil ...

Page 131: ...511 2011 2012 I E H01728 H01868 Workshop Manual Ed 03 2012 ENGINE DISASSEMBLY REASSEMBLY Spark plug recess disassembly Remove seal 1 and spark plug recess 2 Spark plug recess assembly Check lower O Ring inside cylinder head recess for damages Assemble spark plug recess 2 and seal 1 Spark plug recess ...

Page 132: ...29 ENGINE DISASSEMBLY REASSEMBLY Workshop Manual Ed 03 2012 Spark plug disassembly Disassemble spark plug using a wrench suitable tool Spark plug assembly Fit spark plug 1 using the 16 mm spark plug bushing Tightening torque figures Spark plug inside cylinder head M10 Lubrication Copper paste 12 Nm 1 2 Kgm 8 85 ft lb Spark plug ...

Page 133: ...ble the following parts screw 1 Seal 2 Spring 3 Adjuster piston 1 Oil pressure adjustment valve assembly Grease adjuster piston and spring Consumables Castrol GPS SAE 10W 40 Engine oil Assemble the following parts Adjuster piston 4 Spring 3 Seal 2 Fit screw 1 Tightening torque figures Oil adjustment valve screw plug onto crankcase M14 x 1 with sealing ring Grease thread 15 Nm 1 5 Kgm 11 06 ft lb O...

Page 134: ...ws with seal 1 and washers Remove cylinder head cover 2 with gasket 3 Fitting cylinder head cover Clean gasket 3 and cylinder head and cylinder head cover 2 sealing sur face Apply sealant onto gasket Consumables 3 Bond 1209 Surface sealer Assemble cylinder head cover 2 with gasket 3 Fit screws with seal 1 Tightening torque figures Cylinder head cover on cylinder head M6 Grease thread 7 Nm 0 7 Kgm ...

Page 135: ... H01727 H01712 H01713 8000H5009 Workshop Manual Ed 03 2012 ENGINE DISASSEMBLY REASSEMBLY Engine positioning at ignition TDC Turn engine until reaching TDC Reference marks arrows parallel with cylinder head Securing crankshaft at TDC Remove screw 1 with sealing ring Lock crankshaft at TDC using special tool 8000H5009 ...

Page 136: ... a safe position to prevent it from falling to the ground Remove intake camshaft 2 Remove exhaust camshaft 3 Camshaft check Check Check camshafts and bearings for wear and damages Result Camshaft with worn or damaged bearing Action Replace camshaft Camshaft removal Camshaft assembly Make sure that crankshaft is well secured at TDC Lubricate all bearing surfaces Consumables Molykote D Paste Clear s...

Page 137: ... Paste Clear solid lubricant for metal part assembling and settling Fit long 1 and short 2 screws tightening them by hand Bearing mount securing Tighten screws according to the indicated sequence Tightening torque figures Camshaft mount on cylinder head M8 x 30 Grease thread Pre tightening torque 10 Nm 1 Kgm 7 38 ft lb Final tightening torque 20 Nm 2 Kgm 14 75 ft lb M8 x 40 Grease thread Pre tight...

Page 138: ...6 Oil spraying nozzle 7 Engine left crankcase cover assembly Clean sealing surface Assemble the following parts Oil spraying nozzle 7 Guide sleeves 6 Gasket 5 Cover 4 Fit screws 2 with new washers 3 Tightening torque figures Engine and crankcase fairing screw connections M6 x 25 11 Nm 1 1 Kgm 8 11 ft lb Fit screws 1 with new sealing rings 3 Tightening torque figures Engine and crankcase fairing sc...

Page 139: ...2 ENGINE DISASSEMBLY REASSEMBLY Alternator replacement Preliminary operations Engine oil drainage Engine positioning at ignition TDC Securing crankshaft at TDC Engine left crankcase cover disassembly Flywheel disassembly Remove nut 1 Heat flywheel 1 Technical specifications Release connection temperature 80 C Remove flywheel 1 using puller N 8000H5011 and presser N 8000H5013 ...

Page 140: ...owing parts Screws 1 and 2 Cable retaining plate 3 Rubber sheath 4 Stator 5 Freewheel disassembly Disassemble the following parts Screws 1 Flywheel 2 Freewheel 3 Freewheel assembly Clean freewheel 3 threaded holes Position flywheel 2 onto freewheel 3 Fit screws 1 Tightening torque figures Freewheel body onto flywheel M6 x 12 10 9 Cross head microincapsulated screw replacement Pre tightening torque...

Page 141: ...rubber sheath 2 sealing surfaces Consumables 3 Bond 1209 Surface sealer Position retaining plate 4 and pulse transducer 3 Insert rubber sleeve 2 Tighten screws 1 Tightening torque figures Pulse transducer onto engine left crankcase cover M5 x 12 10 9 Microincapsulated screw replacement 6 Nm Flywheel assembly Clean flywheel and crankshaft cone as well as thread Apply a thin layer of sealant onto fl...

Page 142: ...the following new parts Crankcase cover 1 Centring ring 2 Bearing 3 Washer 4 Lay crankcase cover 1 onto a suitable base and protect it against scratch es Insert washer 4 inside crankcase cover 1 Heat crankcase cover 1 at the bearing 3 Technical specifications Release connection temperature 80 C Fit bearing 3 and centring ring 2 all the way down using a suitable tool Crankcase left cover replacemen...

Page 143: ...INE DISASSEMBLY REASSEMBLY Apply a layer of sealant onto rubber sheath 2 sealing surfaces Consumables 3 Bond 1209 Surface sealer Position retaining plate 4 and pulse transducer 3 Insert rubber sleeve 2 Tighten screws 1 Tightening torque figures Pulse transducer onto engine left crankcase cover M5 x 12 10 9 Microincapsulated screw replacement 6 Nm ...

Page 144: ...2 Crankshaft sensor replacement Preliminary operations Engine oil drainage Engine left crankcase cover disassembly Crankshaft sensor disassembly Remove screws 1 Remove crankcase sensor 2 Crankshaft sensor assembly Assemble crankcase sensor 2 Fit new screws 1 Tightening torque figures Pulse transducer onto engine left crankcase cover M5 x 12 10 9 Microincapsulated screw replacement 6 Nm ...

Page 145: ...assemble the following parts Screws 1 Guide 2 Gear 3 Needle roller bearing 4 Freewheel gear replacement Freewheel gear assembly Lubricate needle roller bearing 4 and gear 3 then fit them Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Fit guide 2 with screws 1 Tightening torque figures Starter motor freewheel retainer onto crankcase M5 Microincapsulated sc...

Page 146: ...Manual Ed 03 2012 Clutch disassembly and reassembly or replacement Preliminary operations Engine oil drainage Securing crankshaft at TDC Brake pedal release Clutch actuator disassembly Clutch cover disassembly Remove screws 1 Remove clutch cover 2 with gasket 3 Removing clutch pressure plate Disassemble the following parts Presser 1 O Ring 2 Bearing 3 Screws 4 Pressure plate 5 ...

Page 147: ...36 Workshop Manual Ed 03 2012 ENGINE DISASSEMBLY REASSEMBLY Removing clutch plates Remove clutch plates pack 1 Technical specifications Clutch plates number 6 steel plates 6 lined plates Clutch hub disassembly Remove nut 1 Remove hub 2 Clutch housing disassembly Disassemble the following parts Thrust washer 1 Clutch housing 2 Bearing 3 ...

Page 148: ...housing in the direction of the arrow Result Perceptible clearance Action Replace clutch housing seat crankcase cover removed Clutch housing clearance reading Fit needle roller bearing cage 1 clutch housing 2 thrust washer 3 and hub 4 Fit nut 5 Tightening torque figures Clutch hub on crankshaft Collar nut M20 x 1 5 10 9 Replace microincapsulated screw nut 120 Nm Check using a feeler gauge 2 read t...

Page 149: ...E DISASSEMBLY REASSEMBLY Action Replace clutch thrust washer If needed repeat the procedure Technical specifications Space washers thickness for clutch cage distance adjustment 2 200 mm 2 250 mm 2 300 mm 2 350 mm 2 400 mm 2 450 mm 2 500 mm 2 550 mm 2 600 mm Disassemble the following parts Hub 4 Thrust washer 3 Clutch housing 2 Needle roller bearing cage 1 ...

Page 150: ...ubricant for metal part assembling and settling Assemble clutch housing 2 Fit thrust washer 1 Clutch hub assembly Lubricate hub 2 inner toothing and fit it Consumables MP 3 paste High performance lubricating grease Clean crankshaft thread and nut 1 Fit nut 1 Tightening torque figures Clutch hub on crankshaft Collar nut M20 x 1 5 10 9 Replace microincapsulated screw nut 120 Nm Fit clutch plates Tak...

Page 151: ...umber 6 steel plates 6 lined plates Consumables Castrol GPS SAE 10W 40 Engine oil Pressure plate assembly Fit pressure plate 5 Fit screws 4 working crossways Tightening torque figures Pressure plate on clutch case M5 x 12 10 9 Microincapsulated screw replacement 6 Nm Fit bearing 3 Fit presser 1 with O Ring 2 Clutch cover assembly Clean gasket groove and bearing surface check gasket and if needed r...

Page 152: ...lutch cover disassembly Mushroom type disengagement element disassembly Clutch disengagement bearing disassembly Remove disengagement bearing 1 Clutch disengagement bearing assembly Lubricate disengagement bearing 1 and assemble it Consumables Castrol GPS SAE 10W 40 Engine oil Checking the clutch pack thickness Clutch plates pack thickness must be L 31 0 4 0 if this size is reduced due to wear and...

Page 153: ...te Removing clutch plates Clutch hub disassembly Clutch housing disassembly Coolant pump cover disassembly Coolant pump rotor disassembly Engine right crankcase cover disassembly Disassemble the following parts Screws 1 2 3 Washer 4 Engine right crankcase Disassemble the following parts Cover 1 with idler gear 2 Guide sleeves 3 Gasket 4 Engine right crankcase assembly Clean sealing surface Assembl...

Page 154: ...torque figures Engine and crankcase fairing screw connections M6 x 30 11 Nm Fit screws 1 working crossways Tightening torque figures Engine and crankcase fairing screw connections M6 x 25 11 Nm Fit a new screw 3 with washer 4 but do not tighten them Tightening torque figures Cooling channel gasket inside right engine fairing on crankcase M6 x 16 Replace screw with microincapsulated sealing washer ...

Page 155: ... E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E H01742 H01869 Workshop Manual Ed 03 2012 ENGINE DISASSEMBLY REASSEMBLY Clutch thrust washer disassembly Remove washer 1 Clutch thrust washer Clutch thrust washer assembly Fit washer 1 ...

Page 156: ...01720 H01854 ENGINE DISASSEMBLY REASSEMBLY Workshop Manual Ed 03 2012 Clutch housing axial bearing disassembly Remove bearing 1 Clutch housing axial bearing Clutch housing axial bearing assembly Lubricate bearing 1 and assemble it Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling ...

Page 157: ...11 2011 2012 I E H01941 H01740 H01741 Workshop Manual Ed 03 2012 ENGINE DISASSEMBLY REASSEMBLY Coolant pump disassembly and assembly Coolant pump cover disassembly Disassemble the following parts Screws 1 2 3 Cover 5 Seal 6 Coolant pump rotor disassembly Disassemble the following parts screw 1 Rotor 2 ...

Page 158: ... shaft M5 x 10 10 9 Microincapsulated screw replacement 6 Nm Coolant pump cover assembly Clean seal groove and bearing surface check seal 6 and if needed re place it Fit pump cover 5 with seal 6 Fit screw 3 Tightening torque figures Engine and crankcase fairing screw connections M6 x 45 11 Nm Fit screw 2 Tightening torque figures Engine and crankcase fairing screw connections M6 x 25 11 Nm Fit scr...

Page 159: ...BLY REASSEMBLY Coolant pump inside crankcase oil seal replacement cran kcase cover removed Coolant pump control rear oil seal disassembly Remove oil seal 1 Coolant pump control shaft check Check Result Damaged or worn shaft Action Replace coolant pump drive crankcase cover removed Coolant pump control rear oil seal assembly Clean oil seal seat Fit oil seal 1 using a suitable tool ...

Page 160: ...12 Coolant pump drive replacement crankcase cover remo ved Slider loosening in the lower area Remove screw with O Ring 1 Coolant pump shaft disassembly Disassemble the following parts Oil seal 1 Stop ring 2 Take special care not to let timing chain touch coolant pump gear Remove shaft 3 and front bearing 5 using a suitable sliding hammer pull er Remove stop ring 4 and bearing 5 from shaft 3 ...

Page 161: ...ing 5 and shaft 3 Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Assemble bearing 5 and stop ring 4 onto shaft 3 When fitting the shaft take special care to the timing chain Fit shaft 3 with front bearing 5 Assemble the following parts Stop ring 2 Oil seal 1 Slider assembly in the lower area Fit screw with O Ring 1 Tightening torque figures Front slider a...

Page 162: ...E DISASSEMBLY REASSEMBLY Workshop Manual Ed 03 2012 Chain sprocket removal Remove screws 1 and stop washer 2 Remove chain sprocket 3 Chain sprocket Sprocket assembly Assemble chain sprocket 3 Fit stop washer 2 and new screws 1 Tightening torque figures Sprocket on gearbox output shaft M5 x 8 10 9 Microincapsulated screw replacement 6 Nm ...

Page 163: ...E DISASSEMBLY REASSEMBLY Chain tensioner disassembly Disassemble the following parts screw 1 Chain tensioner 2 O Rings 3 4 Chain tensioner assembly Assemble the following parts O Rings 4 3 Chain tensioner 2 Fit screw 1 Tightening torque figures Chain tensioner screw cap M24 x 1 5 with O Ring Grease thread 20 Nm Chain tensioner disassembly and reassembly or replace ment ...

Page 164: ... Screws 2 Nuts 3 Cylinder head 4 Cylinder head gasket 5 Guide sleeves 6 Cylinder head disassembly and reassembly head gasket re placement Cylinder head assembly Clean sealing surfaces Apply reference pins 6 and a new head gasket 5 Pull timing chain through the recess Fit nuts 3 1 and cylinder head screws 2 without tightening them Secure nuts 3 working crossways then secure nuts 1 Tightening torque...

Page 165: ...pe tappets 1 and remove them with a suitable tool Check tappet 1 for wear Replace it if necessary Remove valve bearing plate and lay it onto the relevant bucket type tappet 1 Caution Half balls can fall inside cylinder head oil ducts Plug ducts with a cloth Overturn rocker arms 2 and disassemble half balls 3 Note half balls 3 position Screw flat insert N 8000H5042 onto bearing plate N 8000H5015 Cy...

Page 166: ...pindle with handle N 8000H5016 connector N 8000H5018 and compression plate N 8000H5019 Precharge springs using the compression plate N 8000H5019 Remove valve collets 1 Remove supporting bracket N 8000H5017 spindle with handle N 8000H5016 connector N 80005018 and compression plate N 80005019 Remove support plate N 80005015 Take out valves downward Removing valve spring Take upper retainer 1 and val...

Page 167: ...14 H01915 H06520 1 2 Workshop Manual Ed 03 2012 ENGINE DISASSEMBLY REASSEMBLY Rocker arm disassembly Remove stop rings 1 and rocker arms 2 Rocker arm shaft disassembly Remove the screw 1 with the O ring 2 Remove left rocker arm shaft 1 with a suitable tool 2 Remove right rocker arm shaft 1 using a suitable sliding hammer puller ...

Page 168: ...place valve seat Valve guide clearance check Check Apply a dial gauge at right angles with valve stem preferably close to cylinder head bearing point Measure valve clearance by moving it Repeat this procedure by moving dial gauge by 90 A B Technical specifications Intake valve clearance inside corresponding guide New with 15 mm valve lift 0 01 mm Wear limit with 15 mm valve lift Max 0 25 mm Exhaus...

Page 169: ...ker arms shaft assembly Lubricate rocker arm shafts Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Assemble right rocker arm shaft 1 with a suitable tool 2 Assemble left rocker arm shaft 1 with a suitable tool Fit screw 1 and screw with the O Ring 2 Tightening torque figures Rocker arm shafts onto cylinder head M6 Microincapsulated screw replacement 11 Nm...

Page 170: ...shafts Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Fit tappet roller 2 Caution Rocker arm correct operation will be impaired if clips are reused Always change safety clips Fit safety fasteners 1 Fitting valve stem seal Install valve Fit spring 2 lower retainer Install valve stem seal 1 Valve spring assembly Fit valve spring 2 with the thicker side poin...

Page 171: ...ompression plate N 8000H5019 Precharge springs using the compression plate N 8000H5019 Lubricate and assemble valve collets 1 Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Removesupportingplate N 8000H5015 supportingbracket N 8000H5017 spindle with handle N 8000H5016 connector N 8000H5018 and com pression plate N 8000H5019 Caution Half balls can fall ins...

Page 172: ... Ed 03 2012 Chain tensioning slider disassembly Remove screw 1 Remove chain tensioning slider 2 Slider disassembly Disassemble the following parts screw 1 Washer 2 Screw with O Ring 3 Slider 4 Chain slider Chain sliding and tensioning sliders check Check Check chain tensioning 1 and sliding 2 sliders sliding surfaces Result Sliding surfaces are damaged or worn Action Change sliders ...

Page 173: ...sembly Assemble the following parts Slider 4 Washer 2 Fit screw 1 Tightening torque figures Slider onto cylinder head Calibrated screw M8 15 Nm Fit screw with O Ring 3 Tightening torque figures Front slider at crankcase lower part M8 15 Nm Chain tensioner assembly Fit chain tensioner 2 Fit screw 1 Tightening torque figures Chain tensioner on crankcase M8 Microincapsulated screw replacement 15 Nm ...

Page 174: ...y operations Spark plug recess ignition coil disassembly Spark plug disassembly Removing cylinder head cover Spark plug recess disassembly Bearing mount disassembly Camshaft removal Slider disassembly Cylinder head disassembly Cylinder disassembly Remove cylinder 1 taking special care not to let screws fall down Remove gasket 2 and centring pins 3 Cylinder disassembly and reassembly or replacement...

Page 175: ...d right stop rings 1 Piston pin 2 Piston 3 Cylinder check Check Check cylinder liner and sealing surface for damages Measure bore using an inside micrometer gauge in three points A B C Technical specifications Cylinder bore diameter Tolerance group 1 New 40 mm from upper edge 450 cc 98 000 0 012 mm 0 480 cc 101 000 0 012 mm 0 Cylinder bore diameter Tolerance group 2 New 40 mm from upper edge 450 c...

Page 176: ...0 100 925 0 005 mm Piston diameter Tolerance group 2 New transverse to piston pin axis above piston lower edge by 4 mm 450 97 935 0 005 mm 0 005 480 100 935 0 005 mm Result Piston diameter is outside tolerance values Action Replace piston Piston stroke clearance definition Check Piston diameter B less cylinder diameter A piston clearance Technical specifications Piston installation clearance 0 06 ...

Page 177: ...r for piston rings Lower scraper ring spring 3 Lower scraper ring 2 with the EK wording pointing up Upper piston ring 1 with the TOP wording pointing up Piston with cylinder assembly Position piston ring and scraper ring inside annular grooves offset by 180 Warning Offset garter spring port by approx 180 compared to scraper ring port The TOP wording shall be pointing up Technical specifications Pi...

Page 178: ... pins 3 and a new gasket 2 Insert timing chain inside recess fit cylinders 1 with piston until connecting rod small end Keep cylinder 1 with piston 2 at the height of connecting rod small end Lubricate piston pin 3 and assemble it Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Fit the new stop rings 4 Make sure to respect correct assembly position Fit the...

Page 179: ...er head cover Spark plug recess disassembly Engine positioning at ignition TDC Securing crankshaft at TDC Chain tensioner disassembly Bearing mount disassembly Camshaft removal Clutch disassembly Coolant pump disassembly Engine right crankcase cover disassembly Chain tensioning slider disassembly Slider disassembly Coolant pump shaft disassembly Timing chain disassembly Slide timing chain 1 out of...

Page 180: ...t check Check Check timing chain for damages and wear Result Worn or damaged timing chain Action Replace timing chain Check Check gear and chain sprocket for damages and wear Result Figure 1 no distortion or min teeth distortion Action Wheel chain and sprocket are in good conditions Result Figure 2 teeth distortion Action Change chain and gear Result Figure 3 heavily worn teeth Action Change chain...

Page 181: ...SSEMBLY Preliminary operations Idler gear disassembly Clutch housing axial bearing disassembly Clutch thrust washer disassembly Oil pump idler gear disassembly Disassemble the following parts Stop ring 1 Washer 2 Gear 3 Bearing 4 Oil pump control gear disassembly Disassemble the following parts Stop ring 1 Washer 2 Gear 3 Needle roller 4 Replacing oil pump gears crankcase cover removed ...

Page 182: ...sser N 8000H5014 onto crankshaft Remove gear using puller N 8000H5011 and jaws N 8000H5012 Assembly of crankshaft gear pointing oil pump idler gear Heat gear 1 Technical specifications Release connection temperature 180 C Fit gear 1 with the dowel protruding towards crankcase Oil pump control gear assembly Lubricate needle roller 4 and gear 3 Consumables Molykote D Paste Clear solid lubricant for ...

Page 183: ... 511 2011 2012 I E H01724 Workshop Manual Ed 03 2012 ENGINE DISASSEMBLY REASSEMBLY Oil pump idler gear assembly Lubricate bearing 4 and gear 3 Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Assemble the following parts Bearing 4 Gear 3 Washer 2 Stop ring 1 ...

Page 184: ... disassembly Oil pump control gear disassembly Oil intake pump disassembly Disassemble the following parts Screws 1 Cover 2 Inner rotor 3 Outer rotor 4 Needle roller 5 Fit oil intake pump Lubricate needle roller 5 outer rotor 4 and inner rotor 3 Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Assemble the following parts Needle roller 5 Outer rotor 4 and i...

Page 185: ...isassembly Engine left crankcase cover disassembly Oil force pump disassembly Disassemble the following parts Stop ring 1 Cover 3 with seal 2 Inner rotor 4 Outer rotor 5 Needle roller 6 Oil force pump assembly Lubricate needle roller 6 outer rotor 5 and inner rotor 4 Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Assemble the following parts Needle roller...

Page 186: ...REASSEMBLY Workshop Manual Ed 03 2012 Oil pumps shaft disassembly Remove shaft 1 from crankcase Oil pumps shaft assembly Lubricate shaft 1 and assemble it inside crankcase Shaft side with two holes shall be positioned on engine right side Consumables Molykote D Paste Clear solid lubricant for metal parts assembling and settling Oil pumps shaft ...

Page 187: ...H01997 Workshop Manual Ed 03 2012 ENGINE DISASSEMBLY REASSEMBLY Replace gearbox control shaft radial sealing ring Preliminary operations Gear lever disassembly Removing oil seal from gearbox shaft Using a suitable tool remove oil seal 1 with the utmost care Fitting gearbox shaft oil seal Fit oil seal 1 using a suitable tool ...

Page 188: ...SSEMBLY Workshop Manual Ed 03 2012 Replacing output shaft oil seal Gearbox output shaft left oil seal disassembly Remove oil seal 1 Gearbox output shaft right oil seal disassembly Remove oil seal 1 Gearbox output shaft right oil seal assembly Fit the new oil seal 1 using a suitable tool Gearbox output shaft left oil seal assembly Fit oil seal 1 using a suitable tool ...

Page 189: ... 2 Remove starter motor 3 Starter motor assembly Check sealing ring 1 for damages Replace it if necessary Lubricate contact surface arrow Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Fit starter motor taking special care to sealing ring 3 Fit screws 2 with the ground cable pointing up Tightening torque figures Starter motor onto crankcase M6 x 25 Grease...

Page 190: ...cement Preliminary operations Engine oil drainage Gear lever disassembly Engine left crankcase cover disassembly Securing crankshaft at TDC Starter motor idle gear disengagement Flywheel disassembly Gear disassembly with starter motor protected against overload Remove gear 1 with shaft 2 Starter motor idle gear disassembly Disassemble the following parts Nut 1 Washer 2 Gear 3 Needle roller bearing...

Page 191: ...sassembly Disassemble the following parts Screws 1 Guide 2 Gear 3 Needle roller bearing 4 Freewheel gear assembly Lubricate needle roller bearing 4 and gear 3 then fit them Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Fit guide 2 with screws 1 Tightening torque figures Starter motor freewheel retainer onto crankcase M5 Microincapsulated screw replacemen...

Page 192: ...les Molykote D Paste Clear solid lubricant for metal part assembling and settling Lubricate gear 3 and assemble it with the dowel pointing towards counter shaft Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Fit washer 2 with nut 1 but do not tighten them Gear assembly with starter motor protected against overload Lubricate shaft 2 with gear 1 and assembl...

Page 193: ...721 Workshop Manual Ed 03 2012 ENGINE DISASSEMBLY REASSEMBLY Starter motor idle gear disengagement Loosen nut 1 Starter motor idle gear fitting Tighten nut 1 all the way down Tightening torque figures Engine and crankcase fairing screw connections M12 x 1 Replace microincapsulated screw nut 50 Nm Starter motor idle gear ...

Page 194: ... axial clearance adjustment with engine removed Crankshaft axial clearance check Crankshaft countershaft and relevant bearings Preliminary operations Engine oil drainage Head disassembly Gear lever disassembly Engine left crankcase cover disassembly Securing crankshaft at TDC Starter motor idle gear disengagement Flywheel disassembly Crankcase left half disassembly Remove screws 1 2 3 Disassemble ...

Page 195: ... 03 2012 ENGINE DISASSEMBLY REASSEMBLY Control gear disassembly Lock control gear 1 using tool N 8000H5010 to prevent it from moving Remove screw Caution LH thread 2 Remove control gear 1 Remove crankshaft and countershaft Move crankshaft 1 and countershaft 2 reference marks arrows so as to make them match Remove countershaft and countershaft at the same time ...

Page 196: ...ntact with hot heated parts Should you have to touch hot parts wear protective gloves Remove bushing 1 using a suitable pre heated puller Technical specifications Pre heating tempera ture of puller for main bearing inner rings 300 C Apply puller around the bushing 1 After a reduced heating phase remove bushing Crankshaft for countershaft gear disassembly Remove space washer 1 if any Mark assembly ...

Page 197: ...ive gloves Remove bushing 1 using a suitable pre heated puller Technical specifications Pre heating temperature of puller for main bearing inner rings 300 C Apply puller around the bushing 1 After a reduced heating phase remove bushing Crankshaft axial clearance adjustment Measure crankshaft at the bearing seats arrows and divide the read value A by 2 A1 Technical specifications Crankshaft referen...

Page 198: ...with connecting rod Connecting rod wear check Check connecting rod for damages and wear Measure connecting rod bearing clearance Lock crankshaft in vertical posi tion and using a dial gauge read the max possible bearing clearance A Technical specifications Connecting rod axial clearance 0 80 0 90 mm Result Damaged connecting rod or bearing clearance outside tolerance val ues Action Replace cranksh...

Page 199: ...value If needed adjust axial clear ance using a thrust washer Technical specifications Crankcase gasket thickness 0 5 mm Crankshaft space washer thickness 0 1 mm 0 15 mm 0 2 mm 0 25 mm 0 3 mm Crankshaft axial clearance adjustment right side Measure right bearing D seat depth using a depth gauge Add to this value half of crankcase gasket value The value measured on right crankshaft A1 B is deducted...

Page 200: ...n temperature 180 C Remove bearing 1 Crankshaft right bearing disassembly Caution Temperature differences as well as casing overheating may lead to struc ture changes and to cracks due to internal stresses Evenly heat casing making sure not to exceed the recommended value Heat crankcase Technical specifications Release connection temperature 180 C Remove bearing 1 Remove ring 2 Crankshaft left bea...

Page 201: ...ble tool and ring 2 Countershaft right bearing disassembly Remove oil seal 1 Caution Temperature differences as well as casing overheating may lead to struc ture changes and to cracks due to internal stresses Evenly heat casing making sure not to exceed the recommended value Heat crankcase Technical specifications Release connection temperature 180 C Remove bearing 2 Countershaft left bearing disa...

Page 202: ...ase Technical specifications Release connection temperature 180 C Fit bearing 3 using a suitable tool Fit stop striker 2 with new screws 1 Tightening torque figures Countershaft retainer onto crankcase M5 x 12 Microincapsulated screw replacement 6 Nm Countershaft right bearing assembly Caution Temperature differences as well as casing overheating may lead to struc ture changes and to cracks due to...

Page 203: ...you have to touch hot parts wear protective gloves Heat bearing bushing 1 Technical specifications Pre heating temperature of puller for main bearing inner rings 300 C Spray crankshaft with cooling fluid Fit bearing bushing 1 using a suitable tool Oil pump gear assembly onto crankshaft Fit reference pins 3 Heat gear 2 Technical specifications Release connection temperature 80 C For installation re...

Page 204: ... puller for main bearing inner rings 300 C Spray crankshaft with cooling fluid Fit bearing bushing 2 using a suitable tool Fit roller cage 1 Control gear assembly Fit control gear 1 holding it in place with a tool N 8000H5010 to prevent it from turning Fit screw 2 Tightening torque figures Engine and crankcase fairing screw connections Left hand thread M16 x1 Microincapsulated screw repla cement 1...

Page 205: ...isassembly Clutch unit disassembly Crankcase left half disassembly Remove screws 1 2 3 Disassemble crankcase left half 4 Warning Due to sealant high adhesion some engine parts could prove hard to disassemble Disengage these parts by gently tapping them with a rub ber hammer taking care not to damage cooling fins or other crankcase parts Remove gasket 5 and guide sleeves 6 Gearbox disassembly Disas...

Page 206: ...Action Replace gear Check Check if teeth sides 4 show pitting or wear signs Result Teeth sides worn or pitted Action Replace gear Disassembly Reassembly of the gearbox 5 Speed TC Caution During operation gear wheel sets slide one towards the other If just one coupling gear is replaced the load bearing capacity on gears may be come significantly worse Replace gear wheels together with the coupled w...

Page 207: ...2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E TC 1st 4th 3rd 5th 2nd H06429 Z 30 Z 24 Z 32 Z 29 Z 23 1st 4th 3rd 5th 2nd H06428 TC Z 14 Z 23 Z 15 Z 23 Z 16 Workshop Manual Ed 03 2012 ENGINE DISASSEMBLY REASSEMBLY Input shaft 6 speed TC Output shaft 6 speed TC ...

Page 208: ...the other If just one coupling gear is replaced the load bearing capacity on gears may be come significantly worse Replace gear wheels together with the coupled wheels only Caution Reinstall the input shaft and output shaft as indicated in the figure paying attention not to damage the roller cages the washers and snap rings Upon reassembly always use new snap rings Lubricate bearing shaft and gear...

Page 209: ...11 I E SMR 511 2011 2012 I E TE TXC SMR 1st 5th 3rd 6th 2nd 4th H06430 Z 14 Z 23 Z 15 20 Z 24 Z 16 6th 2nd 1st 5th 3rd 4th H06431 Z 30 Z 22 Z 32 Z 24 Z 23 Z 25 TE TXC SMR Workshop Manual Ed 03 2012 ENGINE DISASSEMBLY REASSEMBLY Input shaft 6 speed TE TXC SMS Output shaft 6 speed TE TXC SMS ...

Page 210: ...overheating may lead to struc ture changes and to cracks due to internal stresses Evenly heat casing making sure not to exceed the recommended value Heat crankcase Technical specifications Release connection temperature 180 C Remove bearing 1 Gearbox input shaft left bearing disassembly Caution Temperature differences as well as casing overheating may lead to struc ture changes and to cracks due t...

Page 211: ...to cracks due to internal stresses Evenly heat casing making sure not to exceed the recommended value Heat crankcase Technical specifications Release connection temperature 180 C Remove bearing 2 Gearbox output shaft left bearing disassembly Remove oil seal 1 Caution Temperature differences as well as casing overheating may lead to struc ture changes and to cracks due to internal stresses Evenly h...

Page 212: ... Remove bearing 1 Gearbox shaft left bearing disassembly Remove oil seal 1 Caution Temperature differences as well as casing overheating may lead to struc ture changes and to cracks due to internal stresses Evenly heat casing making sure not to exceed the recommended value Heat crankcase Technical specifications Release connection temperature 180 C Remove bearing 2 Gearbox input shaft idler gear b...

Page 213: ...es Evenly heat casing making sure not to exceed the recommended value Heat crankcase Technical specifications Release connection temperature 180 C Fit bearing 1 using a suitable tool Gearbox shaft left bearing assembly Caution Temperature differences as well as casing overheating may lead to struc ture changes and to cracks due to internal stresses Evenly heat casing making sure not to exceed the ...

Page 214: ...ft bearing assembly Caution Temperature differences as well as casing overheating may lead to struc ture changes and to cracks due to internal stresses Evenly heat casing making sure not to exceed the recommended value Heat crankcase Technical specifications Release connection temperature 180 C Fit bearing 2 using a suitable tool Fit the new oil seal 1 using a suitable tool Gearbox output shaft ri...

Page 215: ...e Heat crankcase Technical specifications Release connection temperature 180 C Fit bearing 1 open side facing the crankcase with a suitable tool Gearbox input shaft right bearing assembly Caution Temperature differences as well as casing overheating may lead to struc ture changes and to cracks due to internal stresses Evenly heat casing making sure not to exceed the recommended value Heat crankcas...

Page 216: ...t Bearings do not move properly or they have increased clearance Action Replace bearings Check Check bearing points 2 Result Damaged or widened bearing points Action Replace crankcase cover Replace crankcase Insert idler gear 1 inside locking tool N 8000H5020 Apply an insert for socket wrench N 8000H5767 onto clutch Check Check starting torque Technical specifications Clutch check torque inside pr...

Page 217: ...ue to internal stresses Evenly heat casing making sure not to exceed the recommended value Heat gear 1 and remove it using a suitable tool Technical specifications Release connection temperature 80 C Idler gear assembly Caution Temperature differences as well as casing overheating may lead to struc ture changes and to cracks due to internal stresses Evenly heat casing making sure not to exceed the...

Page 218: ...Gearbox shaft replacement crankcase cover removed Complete selector shaft disassembly Remove gearbox shaft 1 with spring 2 and washer 3 Gearbox shaft check Check Check gearbox shaft for damages Result Damaged gearbox shaft Action Replace gearbox shaft crankcase cover removed Gearbox shaft complete assembly Fit gearbox shaft 1 with spring 2 and washer 3 Take special care to correct spring 2 positio...

Page 219: ...SEMBLY Selector cylinder replacement Selector drum disassembly Remove gearbox guides 1 Turn forks 2 from selector cylinder 3 Remove selector drum 3 Selector drum check Check Check drum grooves for wear at curved sections in particular arrow Result Worn grooves Action Replace selector drum Selector drum assembly Fit selector drum 3 Turn forks 2 inside selector drum 3 Fit gearbox guides 1 ...

Page 220: ...heck Check forks A bearing surfaces for wear Technical specifications Gear selector fork rib width on contact surfaces New 4 9 0 05 mm 0 05 Wear limit Min 4 6 Nm Result Dimension A outside tolerance values Action Replace forks Check Measure clearance between fork and engagement gear using a feeler gauge Technical specifications Gear selector fork axial clearance inside engagement gear groove Wear ...

Page 221: ...rum 3 Gearbox control shaft 4 with fork 5 32 tooth 1st gear 6 Space washer 7 Gearbox output shaft guide 8 Gearbox input shaft guide 9 Clean sealing surfaces and apply a new gasket 5 Fit guide sleeves 6 Fit crankcase left half 4 Fit screws 1 2 3 but do not tighten them Fit screws 1 Tightening torque figures Engine and crankcase fairing screw connections M6 x 70 11 Nm Fit screw 2 Tightening torque f...

Page 222: ...tch plates Clutch hub disassembly Clutch housing disassembly Coolant pump cover disassembly Coolant pump rotor disassembly Engine right crankcase cover disassembly Gear selector lock disassembly Disassemble the following parts screw 1 Bushing 2 Stop element 3 Washer 4 Spring 5 Gear selector lock assembly Assemble the following parts Spring 5 Washer 4 Stop element 3 Bushing 2 Fit new screw 1 Tighte...

Page 223: ...nt pump cover disassembly Coolant pump rotor disassembly Engine right crankcase cover disassembly Gear selector disassembly Remove gear selector lock and secure it using a suitable auxiliary tool Remove screw 1 Remove gear selector 2 with reference pin 3 Remove gear selector lock retainer Gear selector assembly Remove gear selector lock and secure it using a suitable auxiliary tool Fit gear select...

Page 224: ......

Page 225: ...I 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E I Workshop Manual Ed 03 2012 FRONT SUSPENSION Section ...

Page 226: ...f the fork I 29 General rules for a proper overhauling I 30 Instructions for clamping in the vice I 31 Problems Possible causes Solutions I 32 Cleaning the dust seal I 33 Bleeding the air I 33 Draining the oil I 34 Braking down the pumping element and the bottom valve I 35 Braking down the fork leg slider and removing the oil seals I 37 Overhauling and modifying the cartridge and bottom valve sett...

Page 227: ...9 1 H006207 A Workshop Manual Ed 03 2012 FRONT SUSPENSION Front fork removal Measure height A it will need to be restored to original value on assembly Set a block 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 ...

Page 228: ...Manual Ed 03 2012 FRONT SUSPENSION 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 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 ...

Page 229: ... air from the outer tube and drain screws to drain cartridge oil INNER TUBES Special high strength steel chrome 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...

Page 230: ...511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E Workshop Manual Ed 03 2012 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 231: ... each outer tube Note it is good practice to moderately 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 n...

Page 232: ...uter tube Do not remove the nut at the bottom end of the 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 233: ...er tube are still assembled together place the fork leg 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 234: ...d for distortion or damage Replace as required Check the 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...

Page 235: ...ng Note 2 Before sliding the sealing ring over the inner 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 Insta...

Page 236: ...he dust seal to the outer tube Make sure that there is not 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 237: ...and install the bottom valve assembly With the bottom valve 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 figur...

Page 238: ...ul not to distort or damage the piston rod or any other 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 cart...

Page 239: ...ol shown in the figure between wheel axle carrier and cartridge 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 240: ...I E SMR 511 2011 2012 I E Workshop Manual Ed 03 2012 FRONT 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 241: ...12 I E SMR 449 2011 I E SMR 511 2011 2012 I E Workshop Manual Ed 03 2012 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 travelis 300 mm Front suspension Mod TE 2010 ...

Page 242: ...rk disassembly TE Loosen the cap nut at the top of each outer tube Note 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 243: ...012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E Workshop Manual Ed 03 2012 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 244: ... TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E Workshop Manual Ed 03 2012 FRONT SUSPENSION Take the cartridge out of the outer tube Remove the dust seal using a flat head screwdriver ...

Page 245: ...quickly but carefully pump the tubes back and forth until 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 an...

Page 246: ...f the tube shows surface defects sand the surface If repair 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 edg...

Page 247: ...ing 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 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 out...

Page 248: ...2 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E Workshop Manual Ed 03 2012 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 249: ...nto the piston rod Make sure that at least an 18 mm 0 71 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 t...

Page 250: ...th inner and outer tube Now slowly pump the piston rod up 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 r...

Page 251: ... the compression and extension adjustment On both fork s legs upper cap you can find a screw for the slider inner air bleed Stanchion tubes Made of special chromed high resistance steel with a special hardening surface treatment TIN Sliders Made of CNC aluminium alloy anodised and polished inside Sliding bushings With Teflon facing free from static friction Seals Computer designed seal rings guara...

Page 252: ...2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E SMR Workshop Manual Ed 03 2012 FRONT SUSPENSION Front suspension SMR Front suspension is handled by a MARZOCCHI U S D upside down telescopic hydraulic fork with advanced axle and 50 mm legs Wheel travelis 258 mm ...

Page 253: ...n adjustment screw 21 Spri ng 24 Spri ng gui de 25 Pre load tube 28 Foot buffer 30 Cartridge body 31 Inner rod 32 Pumping element rod 33 Washers recall spring 34 Rebound piston washer 36 Pumping element piston 37 Rebound damping piston washers stack 39 Upper sliding bushing 41 Bottom valve 43 Compression valve washer 45 Bottom valve piston 46 Compression damping piston washers stack 48 Cap 70 Whee...

Page 254: ...e the seals lips before reassembling Use only metric spanners not imperial spanners which may have similar sizes but can damage the bolts and make it impossible to unscrew them Use the correct size and sort of screwdriver to unscrew slotted or crosshead screws Whenusingascrewdrivertoassembleordisassemblemetalstoprings o rings sliding bushings or seal segments avoid scratching or cutting the compon...

Page 255: ...arable damage to the fork Scrupulously follow the instructions below Limit the use of the vice to those operations where the use of the same is absolutely necessary Use a vice with padded jaws Avoid over tightening the vice Avoid clamping parts of the fork where even slight ovalization could damage the part The figure shows the zones recommended for fixing the fork in the vice A Wheel axle clamp B...

Page 256: ...ivity 1 Worn sliding bushings 1 Replace the sliding bushings 2 Old oil 2 Change the oil Fork legs not sliding properly 1 Fork legs not aligned correctly 1 Loosen the wheel axle and align the fork correctly see Par 4 2 The fork does not react to adjustment variations 1 The pin inside the rod is stuck 1 Clean or replace rod 2 The adjustment screw is stuck 2 Take off and clean adjustment screw 3 Impu...

Page 257: ...fork legs slightly and remove any traces of dirt from the stanchion tubes Lubricate the dust seal and the visible surface of the oil seal with silicon grease Re assembly Re assemble the dust seal 12 in its seat pressing it home with your hands Bleeding the air This operation must be carried out with the fork assembled on the motorcycle and with the fork s legs fully extended front wheel off the gr...

Page 258: ...each the locknut 23 with the 19 mm spanner Holding the locknut 23 with A 19 mm spanner use another 19 mm spanner to unscrew the fork cap 48 completely Remove the fork cap 48 the guide spring cap 20 the spring 21 and the preload tube 25 Remove from the rod s edge 32 the adjustment return inner rod 31 Free the fork leg 5 from the vice and tip it into a container of a suitable size to drain the oil p...

Page 259: ... inside the fork leg in a way that you can block the body rotation to do so the slot obtained at the tooling lower edge must be perfectly inserted into the body hexagon In the tooling upper part there are two opposite holes where you can insert an axle to make the blocking easier However the tooling must not be rotated in any case but only used to hold the fork leg inner parts Using the 21 mm tube...

Page 260: ... with a 17 mm hexagonal spanner Remove the upper nut 26 and the foot buffer 28 Using a small screwdriver prize the stop ring 27 off the rod Remove the stop ring 27 and the push rod 29 off the rod Push the rod 32 towards the inside area of the body 30 to be able to slide the complete pumping element out starting from the bottom The pumping element can be completely overhauled and adjusted Paragraph...

Page 261: ... out of the slider 13 to separate these two elements you will have to pull hard With this operation the oil seal 10 the spring cup 9 and the bottom guide bushing 8 will be removed from the slider Remove the top guide bushing 39 by hand If this operation is difficult by hand use a flat tip screwdriver in the bushing groove Remove the bottom guide bushing 8 the spring cup 9 the oil seal 10 the stop ...

Page 262: ...shers stack regulating the rebound 37 the piston 36 complete with the segment 35 the washer 34 and the spring 33 following this order Assembling Thewashers 37 andthepiston 36 aretheonescausingtherebound braking It is possible if needed to modify the fork s behaviour dur ing the rebound phase by replacing the washers 37 and the piston 36 with other components having different characteristics Only u...

Page 263: ... 38 manually Clamp in the vice the damping rod 32 milled area Using a proper spanner 12 or 13 mm according to the installed nut tighten the nut 38 up to the required torque see Table 1 Tightening torques Bottom valve overhauling compression braking Dismantling Clamp in the vice the bottom screw through the spanner seizing 47 Using a 13 mm spanner unscrew the nut 42 Remove the nut 42 the spring 33 ...

Page 264: ...sion 46 the piston 45 complete with the o ring 44 the washer 43 and the spring 33 following this order The piston must be oriented in a way that the holes having smaller diameter are placed towards the setting washers 46 Tighten the nut 42 by hand Lock the bottom screw in the vice through the spanner seizing 47 Using a 13 mm spanner tighten the nut 42 up to the required torque see Table 1 Tighteni...

Page 265: ... spring cup 9 Remove the adhesive tape from the end of the stanchion tube cleaning any traces of adhesive left on the fork Insert the top guide bushing 39 by hand If this operation is difficult by hand use a flat tip screwdriver in the bushing groove Delicately introduce the stanchion tube into the slider being very careful not to damage the top guide bushing Guide the bottom guide bushing until i...

Page 266: ... scratch the stanchion tube Re assemble the dust seal 12 in its seat pressing it home with your hands Re assembling the pumping element unit and the bottom valve Insert the pumping element rod 32 into the body 30 In both pumping elements there is a sealing segment before the assembling make sure that it is not worn or damaged Replace if necessary Take great care and if necessary use a small flat t...

Page 267: ...e metal ring 27 into the proper seat F Bring the push rod 29 into contact with the stop ring Insert the foot buffer 28 this must be inserted keeping the oil flow slots towards the push rod Insert the upper nut 26 and tighten it on the push rod 29 Hold the nut 26 with a 18 mm spanner and tighten the push rod 29 up to the required torque see Table 1 Tightening Torques using a 17 mm span ner Insert t...

Page 268: ...e R5081AA tooling inside the fork leg in a way that you can block the body rotation to do so the slot obtained at the tooling bottom edge must be perfectly inserted into the body hexagon In the tooling upper part there are two opposite holes where you can insert an axle to make blocking easier However the tooling must not be rotated in any case but only used to hold the fork leg inner parts Using ...

Page 269: ...it a few minutes and check the air volume see Table 2 Oil and quantity and if necessary refill to the right level A lower or higher volume of air or a type of oil other than the recommended type can change the behaviour of the fork in every phase Lift the slider 13 on the stanchion tube 5 Insert the adjustment return inner rod 31 Insert the preload tube 21 the spring 25 and the guide spring cup 20...

Page 270: ......

Page 271: ...J 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E J Workshop Manual Ed 03 2012 REAR SUSPENSION Section ...

Page 272: ...E Workshop Manual Ed 03 2012 REAR SUSPENSION Rear shock absorber J 3 Tightening torque J 3 Lubrication points grease J 3 Rear suspension J 4 Rear shock absorber removal J 5 Disassembling and servicing the swinging arm J 6 Linkage disassembly J 8 Chain roller chain guide chain slider J 9 Chain sprocket removal J 9 ...

Page 273: ... E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E 1 H006175 2 H006176 H006244 H006178 Workshop Manual Ed 03 2012 REAR SUSPENSION Rear shock absorber Tightening torque figures 1 2 50 Nm 5 0 Kgm 36 88 ft lb Lubrication points grease ...

Page 274: ...2012 REAR SUSPENSION Rear suspension The rising rate rear 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: ...d off the ground Remove the saddle the side panels and control unit as described in the cor responding chapters Remove wiring from the top mounting point Loosen lower screw 1 using two 14 mm wrenches Loosen upper screw 2 using two 14 mm wrenches Shift the rear cover 3 and take out the rear shock absorber 4 from the rear right hand side of the bike Upon reassembly remove rear brake hose support 5 t...

Page 276: ...6185 3 4 Workshop Manual Ed 03 2012 REAR SUSPENSION Disassembling and servicing the swinging arm Remove the chain and rear wheel as described in the relevant chapters Remove the two side protections A from the chassis Disconnect the rear stop connector 1 Loosen the two screws 2 and remove the brake master cylinder 3 complete with tube and calliper 4 ...

Page 277: ...06187 8 H006186 5 6 H006189 9 10 H006190 10 Workshop Manual Ed 03 2012 REAR SUSPENSION Loosen the two screws 5 using an 8 mm wrench and remove rear brake hose support 6 to slide out the pin 7 Using a 17 mm wrench loosen nut 8 and remove pin 7 on the other side Using a 10 mm Allen wrench loosen pins 9 and remove swinging arm 10 ...

Page 278: ...Grease the inner race of the bearings before refitting them Linkage disassembly To remove drag link 1 and drop link 2 proceed as follows Using a 14 mm wrench remove the screw 3 retaining shock absorber drop link 2 Using a 17 mm wrench remove nut 4 and remove pin 5 on the other side Using a 14 mm wrench remove nut 6 and screw 7 on the other side Ensure that needle roller bearings 8 and bushes 9 are...

Page 279: ...sprocket 1 Chain roller 2 Chain guide 3 Chain slider a Master link clip Chain sprocket removal Fit a support under the engine so that the rear wheel is raised off the ground Remove chain chassis side protections rear shock absorber lower screw as indicated in the relevant paragraphs chapters Using a 10 mm Allen wrench loosen pins 1 fastening swinging arm to chassis Shift swinging arm 2 toward the ...

Page 280: ......

Page 281: ...L 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E L Workshop Manual Ed 03 2012 BRAKES Section ...

Page 282: ... Ed 03 2012 BRAKES Sommario Braking system L 3 Brake disc L 5 Checking brake pads for wear replacing the pads TC TE TXC L 6 Checking brake pads for wear replacing the pads SMR L 7 Bleeding the front braking system TC TE TXC L 8 Bleeding the front braking system SMR L 9 Bleeding the rear braking system L 10 Changing the fluid L 11 ...

Page 283: ...94 4 5 3 Workshop Manual Ed 03 2012 BRAKES Braking system The braking system uses two independent circuits Each system is equipped with a brake calliper connected to a master cylinder with a fluid reservoir 1 Front brake lever 2 Front brake master cylinder with fluid reservoir 2a Brake master cylinder 2b Brake fluid reservoir 3 Front brake line 4 Front brake calliper 5 Front brake disc ...

Page 284: ... 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E H006214 11 10 6 7 8 9 Workshop Manual Ed 03 2012 BRAKES 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 285: ...260 mm 10 24 in TC TE TXC 320 mm 12 6 in SMR Front brake disc thickness when new 3 0 mm 0 12 in TC TE TXC 5 0 mm 0 2 in SMR Wear limit 2 5 mm 0 1 in TC TE TXC 4 5 mm 0 18 in SMR Rear brake disc diameter 240 mm 9 45 in Rear brake disc thickness when new 4 0 mm 0 16 in Wear limit 3 5 mm 0 14 in Disc warpage must not exceed 0 15 mm 0 015 in check disc mounted on the rim with a dial gauge To remove th...

Page 286: ...any oil gets on brake pads or discs Clean off with alcohol any fluid or oil that inadvertently gets on the pads or disc Replace the pads with new ones if 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 abo...

Page 287: ...n brake pads or discs Clean off with alcohol any fluid or oil that inadvertently gets on the pads or disc Replace the pads with new ones if they cannot be cleaned satisfactorily PADS REMOVAL REAR Remove clips 1 Slide out pin 2 Remove pads FRONT Press on clips 3 Slide out pins 4 Remove clips 3 Remove pads Do not work the brake lever or pedal while removing the pads PADS INSTALLATION REAR Install ne...

Page 288: ...m remains under pressure loosen the valve 1 tighten the valve 1 always with the lever pulled then release the lever Top up the fluid level wait a few seconds then repeat a few times the proce dure described in the line above until the liquid comes out of the transparent hose without bubbles Tighten the bleed valve to the indicated torque restore the fluid level A and refit the rubber gaiter and co...

Page 289: ...luid Pull the lever 3 of the brake and keep it pulled so that the system remains under pressure loosen the valve 1 tighten the valve 1 always with the lever pulled then release the lever Top up the fluid level A wait a few seconds then repeat a few times the procedure described in the line above until the liquid comes out of the trans parent hose without bubbles Lock the bleed valves to the specif...

Page 290: ...t of the small tube initially only air will come out then close the valve 1 always keeping the pedal lowered then release the pedal Top up the fluid level wait a few seconds then repeat a few times the proce dure described in the line above until the liquid comes out of the transparent hose without bubbles Tighten the bleed valve to the specified torque and check fluid level B in the reservoir bef...

Page 291: ...from a sealed container DOT 4 Never reuse brake fluid Avoid the ingress of contaminants 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 ...

Page 292: ...ressure Loosen the valve 1 or 1A and wait for the oil to come out then tighten the valve 1 or 1A and release the lever or the pedal Repeat this operation a few times until the oil is completely drained Fill the reservoir 2 or 2A with the new fluid Pull and hold the lever 3 or press and hold the pedal 3A so that the system is under pressure loosen the valve 1 or 1A tighten the valve 1 or 1A always ...

Page 293: ...XC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E H06407 C TC TE TXC H006230 D SMR H06408 C Workshop Manual Ed 03 2012 BRAKES Periodicallychecktheconnectinghoses C and D seeScheduledMaintenance Chart Section B replace worn or cracked hoses ...

Page 294: ......

Page 295: ...M 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E M Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Section ...

Page 296: ...38 Charging system inspections M 39 Battery M 39 Regulated voltage M 39 Voltage regulator rectifier inspection M 39 Voltage regulator rectifier wiring diagram M 39 Electric starting system M 40 Starting system inspection M 41 Starter motor inspection M 41 Starter motor M 41 No load test M 41 Solenoid starter inspection M 41 Solenoid starter wiring diagram M 41 Coil windings resistance inspection M...

Page 297: ...orkshop Manual Ed 03 2012 ELECTRICAL SYSTEM Dashboard replacement TE SMR M 58 Instructions for the instrument setting M 59 Troubleshooting M 59 Charging system M 59 Starting system M 59 Electronic ignition system M 59 Connector position TE SMR M 60 Connector position TC M 65 Connector position TXC M 67 Important M 71 ...

Page 298: ...TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E TC 2 5 1 10 7 6 3 9 8 4 11 13 14 15 12 17 18 19 16 21 20 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Engine wiring diagram TC MY11 MY12 ...

Page 299: ... Map change starting connector 18 Solenoid starter 19 Engine ground 20 Condenser 21 Diode connector Colour coding key blge Blue Yellow blgn Blue Green blrt Blue Red blsw Blue Black br Brown brbl Brown Blue brge Brown Yellow brgr Brown Grey brsw Brown Black brvi Brown Violet brws Brown White gebl Yellow Blue gebr Yellow Brown gegn Yellow Green gert Yellow Red gnbl Green Blue gnge Green Yellow gngew...

Page 300: ...012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E TE TXC SMR 2 5 1 10 7 6 3 9 8 4 11 12 14 15 13 17 18 19 16 21 22 20 24 23 25 26 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Engine wiring diagram TE TXC SMR MY11 SMR MY12 ...

Page 301: ...uel pump relay 19 Fuel pump 20 Map change connector 21 Solenoid starter 22 Engine ground 23 Condenser 24 Diode connector 25 Fan relay 26 Fan Colour coding key blge Blue Yellow blgn Blue Green blrt Blue Red blsw Blue Black br Brown brbl Brown Blue brge Brown Yellow brgr Brown Grey brsw Brown Black brvi Brown Violet brws Brown White gebl Yellow Blue gebr Yellow Brown gegn Yellow Green gert Yellow Re...

Page 302: ...Y E L L O W G I A L L O G R A Y G R I G I O B L U E B L U B R O W N M A R R O N E B L A C K N E R O R E D R O S S O P I N K R O S A G R E E N V E R D E V I O L E T V I O L A B k R P G r V W I R E C O L O R W O Y G y B B r 1 2 3 4 5 6 7 8 9 10 11 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 27 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Engine wiring diagram TE TXC MY12 ...

Page 303: ...pump 7 Fuel pump relay 8 HT coil 9 Electric fan relay 10 Cooling fan 11 Condenser 12 Interface 13 MAP change push button 14 Engine ground 15 Battery 16 Solenoid starter 17 Starter motor 18 Voltage regulator 19 Alternator 20 Air temperature sensor 21 Throttle position sensor 1 22 Throttle position sensor 2 23 Pressure sensor 24 Power relay 25 Injector 26 Neutral sensor 27 Spark plug Colour coding k...

Page 304: ...12 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E TE 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Vehicle wiring diagram TE MY12 ...

Page 305: ...nsor 4 Fuses 5 DC relay 6 Interface 7 Rear R H turning indicator 8 Tail light 9 Rear L H turning indicator 10 Front stop light switch 11 Rear stop light switch 12 Turning indicators flasher 13 Horn 14 R H switch 15 Speed sensor 16 Front L H turning indicator 17 Headlamp 18 Front R H turning indicator Colour coding key B Blue Bk Black Br Brown Gr Green Gy Grey O Orange P Pink R Red Sb Sky blue V Vi...

Page 306: ...M 12 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E TCX 1 2 3 4 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Adapter TXC ...

Page 307: ...2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Key to wiring diagram 1 Adapter to engine wiring connector 2 Clutch connector 3 RH switch connector 4 Speed sensor connector ...

Page 308: ...MY12 MY11 H11180 2 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Electrical components location TC The ignition system includes the following elements Generator 1 on the inner side of L H crankcase half cover Electronic ignition coil 2 with integrated spark plug cap positioned on cylinder head Spark plug on cylinder head Electronic control unit 3 under the saddle ...

Page 309: ...511 2011 2012 I E 4 H06274 H06285 5 H06443 6 7 H06276 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Voltage regulator 4 located at the back of the steering tube Starter motor 5 in front of engine cylinder Solenoid starter 6 positioned under saddle on rear chassis MAP SENSOR 7 sensor on throttle body ...

Page 310: ...shop Manual Ed 03 2012 ELECTRICAL SYSTEM The electrical system includes the following elements Fuel pump 8 positioned inside the tank 9 12V 4Ah Battery 10 under the saddle A 30A fuse 11 positioned on the solenoid starter MY11 Fuel pump relay 12 positioned on the front left side under the air box Main starting relay 13 positioned on the front left side under the air box ...

Page 311: ...E H06279 14 H06280 15 H11255 12a MY12 13a Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM MY12 Fuel pump relay 12a positioned on the front right side under the air box Main starting relay 13a positioned on the front right side under the air box Coolant temperature sensor 14 Condenser 15 positioned on engine rear side ...

Page 312: ...12 MY11 H11180 2 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Electrical components location TE SMR The ignition system includes the following elements Generator 1 on the inner side of L H crankcase half cover Electronic ignition coil 2 with integrated spark plug cap positioned on cylinder head Spark plug on cylinder head Electronic control unit 3 under the saddle ...

Page 313: ... H06281 7 8 4 H06274 H06285 5 H06443 6 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Voltage regulator 4 located at the back of the steering tube Starter motor 5 in front of engine cylinder Solenoid starter 6 positioned under saddle on rear chassis Potentiometers 7 and 8 on throttle body 7 2nd throttle 8 1st throttle ...

Page 314: ...184 10 11 MY11 H11185 10 11 MY12 12 H11186 13 MY11 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM The electrical system includes the following elements 12V 6Ah Battery 9 under the saddle Turning indicator flasher 10 at the front end below the headlamp fairing Light relay 11 MY11 Fuel pump relay 12 and main relay 13 positioned on the front left side under the air box ...

Page 315: ...11 2011 2012 I E H11188 14 MY11 14 H11189 MY12 H06293 15 13a H11256 12a MY12 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM MY12 Fuel pump relay 12a and main relay 13a positioned on the front right side under the air box Electric fan relay 14 on the rigt side under the under the air box Electric fan 15 ...

Page 316: ...E SMR 511 2011 2012 I E 16 H11190 MY11 Condensatore 14 posizionato sulla parte posteri H11191 MY12 16 H11192 17 MY11 H11193 MY12 17 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM A 10A lights fuse 16 positioned below the headlamp fairing and a 30A main fuse 17 positioned on the solenoid starter ...

Page 317: ...4 18 19 H06295 20 22 22 H06296 21 22 22 H06291 24 23 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Coolant temperature sensor 18 Lambda sensor 19 Headlamp 20 with 12V 35W twin halogen bulb and 12V 5W parking light bulb LED tail light 21 with stop light bulb Turning indicators 22 12V 6W bulbs Fuel pump 23 inside the tank 24 ...

Page 318: ...511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E H06292 26 H11195 25 MY11 SMR MY12 H11196 25 TE MY12 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Odometer 25 Condenser 26 positioned on engine rear side ...

Page 319: ...Y12 MY11 H11180 2 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Electrical components location TXC The ignition system includes the following elements Generator 1 on the inner side of L H crankcase half cover Electronic ignition coil 2 with integrated spark plug cap positioned on cylinder head Spark plug on cylinder head Electronic control unit 3 under the saddle ...

Page 320: ...06450 7 7A 4 H06274 H06285 5 H06443 6 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Voltage regulator 4 located at the back of the steering tube Starter motor 5 in front of engine cylinder Solenoid starter 6 positioned under saddle on rear chassis Potentiometers 7 and 7A on throttle body 7 2nd throttle 7A 1st throttle ...

Page 321: ...MR 511 2011 2012 I E H06271 9 8 10 H06277 H11197 11 MY11 H11198 MY12 11 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM The electrical system includes the following elements Fuel pump 8 positioned inside the tank 9 12V 6Ah Battery 10 under the saddle A 30A fuse 11 positioned on the solenoid starter ...

Page 322: ...anual Ed 03 2012 ELECTRICAL SYSTEM MY11 Fuel pump relay 12 positioned on the front left side under the air box Main starting relay 13 positioned on the front left side under the air box MY12 Fuel pump relay 12a positioned on the front right side under the air box Main starting relay 13a positioned on the front right side under the air box Electric fan relay 14 on the chassis right side Lambda sens...

Page 323: ...11 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E H06377 16 H06378 17 H06300 18 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Coolant temperature sensor 16 Electric fan 17 Condenser 18 positioned on engine rear side ...

Page 324: ...isconnect the stator coil connector from the wiring and measure resistance with a meter 1 Check that across the terminals of the connector 2 the value is about 0 8 If resistance is outside the specified limits replace the complete generator Generator no load performance MAX 13A at 14V RPM A D C typical 1900 11A AT EACH ENGINE OVERHAUL CLEAN FLYWHEEL ROTOR TO REMOVE ANY DEBRIS SUSPENDED IN SWIRLING...

Page 325: ...Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Condenser inspection The condenser 1 keeps the bike running in case of accidental disconnection of battery loosening of cable fastening device Disconnect the condenser and check that its capacitance is 2 200 Micro farad In case the reading is different it is necessary to replace it ...

Page 326: ...M 32 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E TC 2 5 1 6 3 4 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Ignition system TC MY11 ...

Page 327: ...ankshaft position pick up sensor 2 an ECU 1 an ignition coil 3 and an intake manifold pressure sensor 5 The ignition coil is fed by the battery through a power relay 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 4 and pressure 5 sensors and from the coolan...

Page 328: ... 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E TE TXC SMR 2 5 1 6 3 4 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Ignition system TE TXC SMR MY11 SMR MY12 ...

Page 329: ...of a crankshaft position pick up sensor 2 an ECU 1 an ignition coil 3 and an intake manifold pressure sensor 5 The ignition coil is fed by the battery through a power relay and is controlled by the ECU Ignition timing is accurately determined based on engine RPM and accelerator position In ad dition to these key parameters inputs from the intake air temperature 4 and pressure 5 sensors and from th...

Page 330: ... N C O O R A N G E A R A N C I O Y E L L O W G I A L L O G R A Y G R I G I O B L U E B L U B R O W N M A R R O N E B L A C K N E R O R E D R O S S O P I N K R O S A G R E E N V E R D E V I O L E T V I O L A B k R P G r V W I R E C O L O R W O Y G y B B r 6 1 3 5 4 2 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Ignition system TE TXC MY12 ...

Page 331: ...f a crankshaft position pick up sensor 2 an ECU 1 an ignition coil 3 and an intake manifold pressure sensor 5 The ignition coil is fed by the battery through a power relay 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 4 and pressure 5 sensors and from the ...

Page 332: ...of Alternator 1 Voltage regulator rectifier 2 Solenoid starter 3 Battery 4 Starter motor 5 The alternated 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...

Page 333: ...With the engine warmed up and running at slightly above 3000 rpm measure 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 14 0 14 5 V range check generator and voltage regulator rectifier as described in the relevant paragraph Voltage regulator rectifier inspection With the ignition on and t...

Page 334: ... OFF 1 2 RH SWITCH Red Brown Red White blue Red blue STARTER MOTOR OFF RUN Clutch switch START Red white Red Brown TC TXC MY11 TE TC TXC MY12 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Electric starting system the starting system is composed of Battery 1 Solenoid starter 2 Starter motor 3 R H switch 4 Clutch microswitch 5 TC TXC Ignition switch 6 TE SMR For a description of wires and components ...

Page 335: ... Rated voltage 12V Current draw 450 W No load test Voltage 11 25 V Current 30 A Speed 12 000 rpm Solenoid starter inspection 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 Apply 12 Volts to relay terminals 1 and 2 and check ...

Page 336: ...tance with a meter Primary winding resistance 0 6 0 7 15 at 20 C Secondary winding resistance Open circuit If resistance is outside the specified limits replace the coil Terminal cap resistance 4 5 5 5 K 5 at 20 C If resistance is outside the specified limits replace the cap Electronic control unit ECU Remove the saddle see Section E to gain access to the electronic control unit 1 It is composed o...

Page 337: ...battery it is advisable to carry out a standard slow charging cycle 12V 6Ah battery 0 6A for 8 hours Quick charging is advised only in situations of extreme necessity since the life of lead elements is drastically reduced by such cycle 12V 6Ah battery 6A for 0 5 hours Battery charger To gain access to the battery 1 remove the saddle as outlined in the relevant paragraph first remove the BLACK nega...

Page 338: ...ws Place the motorcycle 10 metres 32 8 ft away from a vertical wall The motorcycle must be on level ground and the optical axis of the headlamp must be perpendicular to the wall The motorcycle must be upright Measure the height from the ground to the centre of the lamp and draw a cross 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 10...

Page 339: ... 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E 2 H06313 2 H06314 3 H06315 4 H06316 5 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM loosen the two lower screws 2 using a Phillips screwdriver move headlight unit 3 aside release connector 4 slide off the rubber gaiter 5 ...

Page 340: ...CTRICAL SYSTEM release the bulb holder clips 6 and take out bulb 7 Note Headlamp bulb 7 is of the halogen type be careful when replacing it since the glass part shall not be touched with bare hands 12V 35 35 W bulb HS1 To replace the parking light bulb 8 extract it from the inside cover Once the bulb has been replaced reverse the above procedure to reassem ble 12V 6W bulb ...

Page 341: ... H06320 1 H06321 2 3 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Turning indicator bulb replacement TE SMR Loosen screw 1 using a Phillips screwdriver remove lens 2 and replace bulb 3 pushing it inside and turning it to remove it Once the bulb has been replaced reverse the above procedure to reassem ble 12V 6W bulb ...

Page 342: ... Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Tail light replacement TE SMR Remove the tail light as follows Loosen the two screws 1 under the rear mudguard Extract the tail light 2 and disconnect the connector 3 Once the bulb has been replaced reverse the above procedure to reassem ble Make sure you do not overtighten the screws and refit the bu shings correctly if present ...

Page 343: ...n screw 1 and remove the number plate bulb 2 from the mud guard Extract the bulb holder 3 with the bulb 4 from the housing Pull the bulb 4 to detach it from bulb holder Once the bulb has been replaced reverse the above procedure to reassem ble 12V 5W bulb Handlebar switches Measure continuity on the different switches using a meter Replace any part found to be faulty Left hand switch TC 1 Engine s...

Page 344: ... 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 Grey Y Yellow R Red Sb Sky blue W W...

Page 345: ... 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E H06453 B Bk B Br G Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Right hand switch TE TXC SMR 1 Engine start button 2 Engine start stop switch Colour coding key B Blue Br Brown G Green Br Bk Brown Black ...

Page 346: ...SMR 449 2011 I E SMR 511 2011 2012 I E H06453 R Bk Bk G B B Bk Bk G Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Right hand switch TC 1 Engine start button 2 Double map push button Colour coding key Bk Black R Red B Blue G Green Br Bk Brown Black Bk G Black Green B Bk Blue Black ...

Page 347: ... the saddle on the solenoid starter Protection TC Injector coil fuel pump TE SMR TXC Injector lambda sensor heater coil fuel pump electric fan Auxiliary fuse 2 10A TE SMR Positioned in the bike front side below the headlamp fairing and close to the dashboard Protection TE SMR Lights horn dashboard power supply turning indicators In order to avoid short circuits on models TE SMR before working on f...

Page 348: ...2 I E 2 H11213 1 MY11 2 H11214 1 MY12 3 H11215 3 MY11 H11216 4 MY11 H11217 4 MY12 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM Relay test Gain access to the relays as indicated in the relevant paragraph then remove them 1 Main starting relay 2 Fuel pump relay 3 Electric fan relay TE TXC SMR 4 Light relay TE SMR ...

Page 349: ...Manual Ed 03 2012 ELECTRICAL SYSTEM 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 350: ...st 2 seconds after the check routine the dashboard shows the last planned function A few seconds after the engine has been turned off the dashboard is deac tivated To select the instrument functions and to set to zero the functions use the SCROLL knob A The functions which can be selected in this sequence are as follows 1 SPEED ODO 2 SPEED CLOCK 3 SPEED TRIP 4 SPEED LAP TIMER 5 SPEED 1 SPEED ODO I...

Page 351: ... mph CLOCK clock reading from 0 00 to 23 59 59 To reset the clock push the SCROLL button A and hold for more than 3 sec onds in order to increase the hour value release button and after 3 seconds the minutes can be increased 3 SPEED TRIP SPEED speed maximum value 299 Km h or 299 mph TRP distance maximum value 999 9 km or 621 31 mi data will be lost after disconnecting the battery To reset TRIP pus...

Page 352: ...splay also provides a fuel injection system Malfunction indication the latter takes priority over any other indication FAIL a FUEL INJECTION SYSTEM MALFUNCTION indicated by the word FAIL appearing in the right hand portion of the dashboard display Dashboard replacement TE SMR Removetheheadlampfairingasexplainedunder Headlampbulbreplacement Remove the two retaining screws 1 securing the dashboard t...

Page 353: ... symptom of 1 current draw see paragraph Battery 2 incorrect voltage see paragraph Regulated voltage 3 no continuity in generator see paragraph Checking generator stator wind ings resistance 4 defective generator 5 voltage regulator malfunction see paragraph Voltage regulator rectifier inspection a battery overload indicates 1 faulty voltage regulator see paragraph Voltage regulator inspection 2 d...

Page 354: ...position TE SMR The following connectors are positioned on the front side below the headlamp fairing 1 Headlamp connector 2 Turning indicator flasher connector 3 Light relay connector 4 Dashboard connector 5 Wiring harnesses connector MY11 6 Front brake stop switch connector 7 Speed sensor connector 8 Ignition switch connector TE SMR MY11 SMR MY12 9 Left hand dip switch connector 10 Right hand swi...

Page 355: ... parte p H11228 MY12 13 13a 13b Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM The following connectors are positioned on the bike right side 12 Temperature sensor connector 13 Electric fan relay connector 13a Main starter relay connector MY12 13b Fuel pump relay connector MY12 14 Lambda sensor connector 15 Condenser connector 16 2nd throttle connector 17 1st throttle connector 18 Sensor connector ...

Page 356: ...49 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E H06456 19 20 H06342 H06344 21 H06345 22 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM 19 Current generator connector 20 Voltage regulator connector 21 Injector connector 22 Pressure sensor connector ...

Page 357: ...tor The following connectors are positioned on the bike rear side 24 Tail light connector 25 Rear turning indicator connector 26 Number plate light connector The following connectors are positioned on the bike left side 27 Main starting relay connector MY11 28 Fuel pump relay connector MY11 29 Air temperature sensor connector 30 Electric fan connector 31 Coil connector The following connectors are...

Page 358: ... 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E H11230 33 34 MY11 H11231 33 34 MY12 H11232 35 MY11 H11233 35 MY12 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM 33 Electronic control unit connector 34 Solenoid starter connector 35 Diagnostics connector ...

Page 359: ... Connector position TC The following connectors are positioned on the front side below the number holder 1 RH switch connector 2 Clutch sensor connector 3 Engine stop connector The following connectors are positioned on the bike right side 4 Temperature sensor connector 5 TPS connector 6 Generator connector 7 Fuel pump connector 8 Injection connector 9 Pressure sensor connector 10 Voltage regulato...

Page 360: ...nnectors are positioned on the bike left side 11 Main starting relay connector MY11 11a Main starting relay connector MY12 on the right hand side of the engi ne 12 Fuel pump relay connector MY11 12a Fuel pump relay connector MY12 on the right hand side of the engi ne 13 Air temperature sensor connector 14 Coil connector 15 Condenser connector The following connectors are positioned under the saddl...

Page 361: ...Ed 03 2012 ELECTRICAL SYSTEM 18 Diagnostics connector Connector position TXC The following connectors are positioned under the number holder 1 Speed sensor connector 2 Clutch connector 3 RH switch connector 4 Wiring harnesses connector The following connectors are positioned on the bike right side 5 Temperature sensor connector 6 Lambda sensor connector 7 Electric fan relay connector MY11 ...

Page 362: ...49 2011 I E SMR 511 2011 2012 I E 9 H06457 8 10 H06362 13 12 H06361 H06527 11 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM 8 2nd throttle connector 9 2nd throttle TPS connector 10 TPS connector 11 Current generator connector 12 Voltage regulator connector 13 Pressure sensor connector ...

Page 363: ...llowing connectors are positioned on the bike left side 14 Main starting relay connector MY11 14a Main starting relay connector MY12 15 Fuel pump relay connector MY11 15a Fuel pump relay connector MY12 15b Electric fan relay connector 16 Air temperature sensor connector 17 Electric fan connector 18 Coil connector The following connectors are positioned under the saddle 19 Fuel pump connector 20 El...

Page 364: ... 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E H11242 22 MY11 H11243 22 MY12 Workshop Manual Ed 03 2012 ELECTRICAL SYSTEM 22 Diagnostics connector ...

Page 365: ...t is necessary to duly protect the following parts from water a Rear opening 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 FUEL INJECTION SYSTEM and especially the el...

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Page 367: ...N 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E N Workshop Manual Ed 03 2012 ENGINE COOLING Section ...

Page 368: ...I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E Workshop Manual Ed 03 2012 ENGINE COOLING Sommario Coolant level check N 3 Cooling circuit N 4 Engine cooling system overhaul N 5 ...

Page 369: ...g medium water no heat exchange occurs between cylinder head and radiator The cylinder and piston assembly will overheat and seize and in the 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 pres...

Page 370: ...2012 ENGINE COOLING Cooling circuit The forced circulation cooling system uses a 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 Water temperature sensor 5 Water pump 6 Breather hose 7 Cylinder head radiator connection pipe 8 Water pump radiator lower pipe 9 Cooling fan TE TXC SMR ...

Page 371: ... air flow and must be removed carefully to avoid damage to radiator Straighten 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 en...

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Page 373: ...P 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E P Workshop Manual Ed 03 2012 HYDRAULICALLY CONTROLLED CLUTCH Section ...

Page 374: ...XC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E Workshop Manual Ed 03 2012 HYDRAULICALLY CONTROLLED CLUTCH Sommario Hydraulic clutch system P 3 Draining clutch fluid P 4 Clutch master cylinder servicing P 5 Bleeding the clutch system P 6 ...

Page 375: ...composed of a master cylinder with its reservoir located on the left side of the handlebar and a piston installed on the right crankcase half Clutch is disengaged through piston 1 that works on clutch pushrod 1 Clutch master cylinder 2 Clutch lever 3 Master cylinder to piston hose 4 Piston assembly 5 Bleed fitting The fluid used in the hydraulic circuit will damage painted parts if spilt on them H...

Page 376: ... 511 2011 2012 I E H006205 Workshop Manual Ed 03 2012 HYDRAULICALLY 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 377: ...ICALLY CONTROLLED CLUTCH Clutch master cylinder servicing 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 378: ...in the lubricant table see Sec tion A Pull the lever 4 and keep it pulled so that the system remains under pres sure loosen the valve 2 tighten the valve 2 always with the lever pulled then release the lever Top up the fluid level wait a few seconds then repeat a few times the proce dure described in the line above until the liquid comes out of the transparent hose without bubbles Lock the valve 1...

Page 379: ...S 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E S Workshop Manual Ed 03 2012 FUEL INJECTION SYSTEM Section ...

Page 380: ...TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E Workshop Manual Ed 03 2012 FUEL INJECTION SYSTEM Sommario Fuel injection system S 3 Instructions for using HUSQVARNA SERVICE TOOL for a fuel injection system S 4 Fuel pump inspection S 6 ...

Page 381: ...5 located under the saddle signals the injector to open and a fan shaped spray of fuel is injected into the combustion chamber The parameters that play a role in determining proper fuel delivery under all operating conditions are as follows Air temperature in the intake manifold Engine coolant temperature Atmospheric pressure in the intake manifold in current location and at cur rent altitude Thro...

Page 382: ...o the instructions provided in the User Guide proceed as follows remove the saddle slip off the cap B of the ECU interface connector C connect the kit cable 3 to the connector C Connect the USB cable 4 to the PC start the Diagnostic Tool software you have installed and perform the required tests at the end of the analysis remove the cable 3 from the connector C If the cable remains connected the c...

Page 383: ...Workshop Manual Ed 03 2012 FUEL INJECTION SYSTEM In addition to identifying any current malfunction the software stores past malfunctions that have been resolved store malfunc tions can be deleted following the instructions provided in the Operation Manual For fuel pump and relay inspections see relevant paragraphs ...

Page 384: ...12 FUEL INJECTION SYSTEM Fuel pump inspection Remove the pump as described in Section E Connect the power supply unit positive pole 12V to the red lead pin in the pump connector Connect the power supply unit negative pole to the negative lead pin in the pump connector Never keep the pump connected to the power supply unit for more than 3 seconds in a row ...

Page 385: ...a nut or a screw might become damaged or work itself loose 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 accord ance with thread diameter pitch and specifi...

Page 386: ...10 00 1 00 7 38 ENGINE LOWER FASTENING 50 00 5 00 36 88 THROTTLE BODY CLAMP FASTENING 0 30 0 03 0 22 THROTTLE BODY COVER FASTENING 3 00 0 30 2 21 SHOCK ABSORBER TO DROP LINK FASTENING 50 00 5 00 36 88 SHOCK ABSORBER TO CHASSIS FASTENING 50 00 5 00 36 88 REAR BRAKE MASTER CYLINDER FASTENING 10 00 1 00 7 38 STARTER MOTOR FASTENING 10 00 1 00 7 38 POSITIVE CABLE TO STARTER MOTOR FASTENING 8 00 0 80 5...

Page 387: ... LEFT FORK LEG FASTENING 28 00 2 80 20 65 REAR SHOCK ABSORBER PROTECTION FASTENING 5 00 0 50 3 69 CLUTCH ACTUATOR COVER TO ENGINE FASTENING 5 00 0 50 3 69 REAR WHEEL AXLE FASTENING 142 00 14 20 104 73 CHASSIS PROTECTION TO CHAIN ROLLER FASTENING 10 00 1 00 7 38 HORN FASTENING 5 00 0 50 3 69 RIGHT SCOOP FASTENING 5 00 0 50 3 69 LEFT SCOOP FASTENING 5 00 0 50 3 69 LEFT SIDE PANEL FASTENING 5 00 0 50...

Page 388: ...NG US TANK 9 00 0 90 6 64 SOLENOID STARTER MOUNT PLATE FASTENING 4 00 0 40 2 95 COCK FASTENING 1 50 0 15 1 11 COCK FASTENING US TANK 9 00 0 90 6 64 TANK FASTENING 2 00 0 20 1 48 REAR CHASSIS TO TANK PAD FASTENING 8 00 0 80 5 90 RIGHT REAR CHASSIS TO SIDE PANEL PAD FASTENING 8 00 0 80 5 90 LEFT REAR CHASSIS TO SIDE PANEL PAD FASTENING 8 00 0 80 5 90 NUMBER PLATE LIGHT FASTENING 3 00 0 30 2 21 SADDL...

Page 389: ... ft lb Steel screws on plastic with metal spacers M5 4 Nm 0 4 Kgm 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 ...

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Page 391: ...Y 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E Y Workshop Manual Ed 03 2012 CHASSIS AND WHEELS Section ...

Page 392: ...t wheel TC TE TXC Y 5 Front wheel SMR Y 6 Removing the front wheel Y 7 Reassembling the front wheel Y 8 Rear wheel TC TE TXC Y 11 Rear wheel SMR Y 12 Removing the rear wheel Y 13 Wheel servicing Y 14 Wheel axle warpage Y 14 Axle runout over 100 mm Y 14 Wheel spokes Y 15 Wheel rim warpage Y 15 Rear chain sprocket secondary drive sprocket and chain Y 16 Tightening torque Y 16 Checking pinion and spr...

Page 393: ...11 I E SMR 511 2011 2012 I E Workshop Manual Ed 03 2012 CHASSIS AND WHEELS Chassis The single frame branches off at the exhaust and is made of steel tubes with circular rectangular and ellipsoidal section the rear chassis is made from light alloy A badly damaged chassis must be replaced ...

Page 394: ...1 1 H006231 Workshop Manual Ed 03 2012 CHASSIS AND WHEELS Lubrication 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 RETAINING PINS SCREWS B ENGINE MOUNTING LINKS C REAR CHASSIS MOUNTING BOLTS D CHAIN GUIDE ROLLER BEARING E FOOTPEGS PINS SPRINGS ...

Page 395: ...Workshop Manual Ed 03 2012 CHASSIS AND WHEELS Front wheel TC TE TXC Legend 1 Tyre 2 Inner tube 3 Rim 4 Spoke 5 Nipple 6 Wheel axle 7 Seal 8 Bearings 9 Hub 10 Spacer 11 Brake Disc 12 Brake disc retaining screw 13 Circlip 14 Outer spacer 15 Pin retaining screw For technical characteristics regarding the front wheel see section A Gen eral Information of this manual ...

Page 396: ...15 Workshop Manual Ed 03 2012 CHASSIS AND WHEELS Front wheel SMR Legend 1 Tyre 2 Inner tube 3 Rim 4 Spoke 5 Nipple 6 Wheel axle 7 Seal 8 Bearings 9 Hub 10 Spacer 11 Brake Disc 12 Brake disc retaining screw 13 Circlip 14 Outer spacer 15 Pin retaining screw For technical characteristics regarding the front wheel see section A Gen eral Information of this manual ...

Page 397: ...R 511 2011 2012 I E H006234 2 H06409 TC TE TXC 1 H06411 SMR 2 Workshop Manual Ed 03 2012 CHASSIS AND WHEELS Removing the front wheel Set a stand or a block under the engine and see that the front wheel is lifted from the ground Loosen the bolts 1 holding the wheel axle 2 to the front fork mounts ...

Page 398: ... 03 2012 CHASSIS AND WHEELS Hold the head of the wheel axle in place and unscrew the bolt 3 on the op posite side draw the wheel axle out Do not operate the front brake lever when the wheel has been removed this causes the calliper pistons to move outwards After removal lay down the wheel with brake disc on top Reassembling the front wheel Fit the L H spacer on the wheel hub ...

Page 399: ...sc into the calliper Fit the wheel axle 2 from the R H side after greasing it and push it fully home against the L 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 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 f...

Page 400: ...TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E TE TXC SMR H06389 Workshop Manual Ed 03 2012 CHASSIS AND WHEELS TE TXC SMR Check the gap B between magnet 6 on brake disc and sensor 7 on brake calliper Set height A back to original value ...

Page 401: ... Manual Ed 03 2012 CHASSIS AND WHEELS Rear wheel TC TE TXC Key 1 Tyre 2 Inner tube 3 Rim 4 Spoke 5 Nipple 6 Wheel axle 7 Spacer 8 Brake Disc 9 Seal 10 Circlip 11 Bearings 12 Inner spacer 13 Hub 14 Sprocket 15 Sprocket retaining screw 16 Wheel axle locking nut 17 Sealing ring For technical characteristics regarding the rear wheel see section A General Information of this manual ...

Page 402: ...hop Manual Ed 03 2012 CHASSIS AND WHEELS Rear wheel SMR Key 1 Tyre 2 Inner tube 3 Rim 4 Spoke 5 Nipple 6 Wheel axle 7 Spacer 8 Brake Disc 9 Seal 10 Circlip 11 Bearings 12 Inner spacer 13 Hub 14 Sprocket 15 Sprocket retaining screw 16 Wheel axle locking nut 17 Sealing ring For technical characteristics regarding the rear wheel see section A Gen eral Information of this manual ...

Page 403: ...ut 1 of the wheel axle 3 and extract it It is not necessary to loosen the 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 ...

Page 404: ...er and use the same procedure for the other bearing Discard 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...

Page 405: ...ck simply tap the spokes with the tip of a metal tool such 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...

Page 406: ...cket secondary drive sprocket and chain The figure at the side 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 407: ...ion 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 significantly increases c...

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Page 409: ...Z 1 TC 449 2011 2012 I E TE 449 511 2011 2012 I E TXC 449 511 2011 2012 I E SMR 449 2011 I E SMR 511 2011 2012 I E Z Workshop Manual Ed 03 2012 NOTES FOR USA CDN Section ...

Page 410: ...12 I E H06433 Workshop Manual Ed 03 2012 NOTES FOR USA CDN Spark arrester te txc smr The models are equipped with a U S Forest Service approved spark arrester for maximum efficienty and performance SPARK ARRESTER MAINTENANCE AND CLEANOUT INSTRUCTIONS Proceed as follows Disassembly and cleanout every 5000miles ...

Page 411: ...ap then pull out the screen Inspect the screen and a Cleanout the screen blowing air on the outside surface in order to remove any carbon particles b Shake the muffler handling it vertically with S A chamber toward the bottom in order to remove any carbon particles from the chamber if the screen is broken Replace the spark arrester unit as a whole screen end cap It is not allowed to replace the sc...

Page 412: ...6434 H06438 H06439 H06440 Workshop Manual Ed 03 2012 NOTES FOR USA CDN Assembly Mount the screen matching the 3 holes Tighten the screw and washer with a torque of 3Nm For all screws check the proper torque every 500Km and tighten if necessary Final assembly Muffler side view SA Homologation stamp on the opposite face ...

Page 413: ... SERBATOIO FUEL TANK RESERVOIR TANK DEPOSITO MOTORE ENGINE MOTEUR MOTOR MOTOR ARIA AIR AIR LUFT AIRE 6 5 11 9 2 3 4 12 7 8 1 10 9 H06441 Workshop Manual Ed 03 2012 NOTES FOR USA CDN KIT Canister TE TXC SMR 1 Canister 2 Support 3 Clamp 4 Adhesive gum 5 Fitting 6 Seal washer 7 Clamp 8 Clamp 9 Clamp 10 Tube 11 Tube 12 Tube ...

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