Husqvarna TC 125 Owner'S Manual Download Page 82

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11 SERVICE WORK ON THE CHASSIS

Guideline

Nut, rear wheel spin-
dle

M25x1.5

80 Nm (59 lbf ft)

Info

The wide adjustment range of the chain adjusters
(32 mm (1.26 in)) enables different secondary ratios
with the same chain length.
Chain adjusters

can be turned by 180°.

Finishing work

–

Remove the motorcycle from the lift stand. (

p. 53)

11.39

Checking the chain, rear sprocket, engine sprocket and chain guide

Preparatory work

–

Raise the motorcycle with a lift stand. (

p. 53)

400227-01

Main work

–

Shift the transmission to idle.

–

Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket or engine sprocket is worn:

–

Change the drivetrain kit.

Info

The engine sprocket, rear sprocket and chain
should always be replaced together.

400987-10

–

Pull at the top part of the chain with the specified weight

Guideline

Weight, chain wear mea-
surement

10 … 15 kg (22 … 33 lb.)

–

Measure distance

of 18 chain rollers in the lower chain

section.

Info

Chain wear is not always even, so you should repeat
this measurement at different chain positions.

Maximum distance

the longest chain section

272 mm (10.71 in)

» If distance

is greater than the specified measurement:

–

Change the drivetrain kit.

Info

When a new chain is mounted, the rear
sprocket and engine sprocket should also be
changed.
New chains wear out faster on an old, worn
rear sprocket or engine sprocket.

Summary of Contents for TC 125

Page 1: ...OWNER S MANUAL 2018 TC 250 TX 300 Art no 3402165en ...

Page 2: ......

Page 3: ...ials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice Husqvarna Motorcycles accepts no liability for delivery options devi ations from illustrations and descriptions as well as misprints and other errors The models portrayed partly contain special equipment ...

Page 4: ...lever 22 6 15 Plug in stand TC 250 22 6 16 Side stand TX 300 22 6 17 Service hour counter 23 7 PREPARING FOR USE 24 7 1 Advice on first use 24 7 2 Running in the engine 25 7 3 Preparing the vehicle for difficult riding conditions 26 7 4 Preparing vehicle for rides on dry sand 26 7 5 Preparing vehicle for rides on wet sand 28 7 6 Preparing vehicle for rides on wet and muddy circuits 29 7 7 Preparin...

Page 5: ...he air filter box 71 11 28 Removing the main silencer 72 11 29 Installing the main silencer 72 11 30 Changing the glass fiber yarn filling in the main silencer 72 11 31 Removing the right side cover 73 11 32 Installing the right side cover 74 11 33 Removing the fuel tank 75 11 34 Installing the fuel tank 76 11 35 Checking the chain for dirt 77 11 36 Cleaning the chain 78 11 37 Checking the chain t...

Page 6: ...tic setting the auxiliary spring 127 17 SERVICE WORK ON THE ENGINE 130 17 1 Checking the gear oil level 130 17 2 Changing the gear oil 130 17 3 Adding gear oil 131 18 CLEANING CARE 133 18 1 Cleaning the motorcycle 133 19 STORAGE 135 19 1 Storage 135 19 2 Preparing for use after storage 136 20 TROUBLESHOOTING 137 21 TECHNICAL DATA 139 21 1 Engine 139 21 1 1 TC 250 139 21 1 2 TX 300 139 21 2 Engine ...

Page 7: ...l be optimally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Indicates the end of an activity including potential rework 1 2 Formats used The typographical formats used in this document are explained below ...

Page 8: ...le is designed for use in offroad endurance competition and not primarily for use in motocross 2 2 Misuse The vehicle must only be used as intended Dangers can arise for people property and the environment through use not as intended Any use of the vehicle beyond the intended and defined use constitutes misuse Misuse also includes the use of operating and auxiliary fluids which do not meet the req...

Page 9: ...f noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below 1 Removal or puncturing of the main silencer baffles header pipes or any other components which conduct exha...

Page 10: ...e clothing 2 8 Work rules Special tools are necessary for certain tasks The tools are not a component of the vehicle but can be ordered using the number in parentheses Example bearing puller 15112017000 During assembly use new parts to replace parts which cannot be reused e g self locking screws and nuts seals sealing rings O rings pins and lock washers In the case of certain screws a thread locke...

Page 11: ...l you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as needed If you would like to know more about the vehicle or have questions on the material you read please contact an authorized Husqvarna Motorcycles dealer The Owner s Manual is an important component of th...

Page 12: ...re specified in parentheses in the descrip tions Your authorized Husqvarna Motorcycles dealer will be glad to advise you The current Husqvarna Motorcycles accessories for your vehicle are available from your authorized Husqvarna Motorcycles dealer and on the Husqvarna Motorcycles website International Husqvarna Motorcycles website www husqvarna motorcycles com 3 4 Service A prerequisite for perfec...

Page 13: ...dealer will be happy to answer any questions you may have regarding your vehicle and Husqvarna Motorcycles A list of authorized Husqvarna Motorcycles dealers can be found on the Husqvarna Motorcycles website International Husqvarna Motorcycles website www husqvarna motorcycles com ...

Page 14: ...4 VIEW OF VEHICLE 12 4 1 View of vehicle front left example H02378 10 1 Filler cap 2 Air filter box cover 3 Plug in stand p 22 TC 250 4 Shift lever p 21 5 Engine number p 14 6 Choke p 20 7 Fuel tap ...

Page 15: ... 17 2 Clutch lever p 16 3 Fork air pressure adjustment 4 Fork compression adjustment 5 Throttle grip p 16 6 Hand brake lever p 16 7 Kick starter p 21 8 Foot brake lever p 22 9 Shock absorber compression adjustment bk Shock absorber rebound adjustment bl Level viewer for brake fluid rear ...

Page 16: ...r ing head 5 2 Type label 401946 10 The type label 1 is fixed to the front of the steering head 5 3 Engine number H01047 10 The engine number 1 is embossed on the left side of the engine above the engine sprocket 5 4 Fork part number 401947 10 The fork part number 1 is stamped on the inner side of the fork stub ...

Page 17: ...5 SERIAL NUMBERS 15 5 5 Shock absorber article number 0 0 1 1 401948 10 The shock absorber article number 1 is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 18: ...ati cally 6 2 Hand brake lever F00225 11 Option Brembo The hand brake lever 1 is fitted on the right side of the han dlebar K00881 10 Option Magura The hand brake lever 1 is fitted on the right side of the han dlebar The front brake is engaged using the hand brake lever 6 3 Throttle grip K00881 11 Throttle grip 1 is fitted on the right side of the handlebar ...

Page 19: ...switch in position II The ignition timing map Soft is active in this position 6 6 Electric starter button TX 300 K00883 10 The electric starter button 1 is fitted on the right side of the handlebar Possible states Electric starter button in basic position Electric starter button pressed In this position the elec tric starter is actuated 6 7 Opening the filler cap Danger Fire hazard Fuel is highly ...

Page 20: ... of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system K00902 10 TC 250 Turn filler cap 1 counterclockwise and lift it off F00228 10 TX 300 Press release button 1 turn the filler cap counterclock...

Page 21: ... Fuel tap TC 250 F00230 10 The fuel tap is on the left side of the fuel tank Open or close the supply of fuel to the carburetor using tap han dle 1 on the fuel tap Possible states Fuel supply closed OFF Fuel cannot flow from the fuel tank to the carburetor Open fuel supply ON Fuel can flow from the fuel tank to the carburetor The fuel tank empties completely ...

Page 22: ...n flow from the fuel tank to the carburetor The fuel tank empties completely 6 11 Choke F00233 10 TC 250 Choke 1 is fitted on the left side of the carburetor F00234 10 TX 300 Choke 1 is fitted on the left side of the carburetor Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel This results in a richer fuel air mixture which is needed fo...

Page 23: ... is between the first and second gears 401950 13 TC 250 The gear positions can be seen in the figure The neutral or idle position is between the first and second gears 6 13 Kick starter 0 0 1 1 401954 10 Kick starter 1 is fitted on the right side of the engine The top part of the kick starter pivots Info Before riding swing the top part of the kick starter inward toward the engine ...

Page 24: ... 402001 10 Support for plug in stand 1 is the left side of the wheel spindle The plug in stand is used to park the motorcycle Info Remove the plug in stand before riding 6 16 Side stand TX 300 401943 10 The side stand 1 is on the left side of the vehicle 401944 10 The side stand is used to park the motorcycle Info When you are riding side stand 1 must be folded up and secured with rubber band 2 ...

Page 25: ...fitted in front of the handlebar It shows the total number of service hours of the engine The service hour counter begins counting when the engine is started and stops when the engine is switched off Info The value indicated by the service hour counter cannot be cleared or adjusted ...

Page 26: ...idents An unadapted riding style impairs the handling characteristic Adapt your riding speed to the road conditions and your riding ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents The brake system fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously ...

Page 27: ...ch other Try also to ride as slowly as possible and in a standing position to get a better feeling for the motorcycle Do not make any off road trips that exceed your ability and experience Hold the handlebar firmly with both hands and keep your feet on the footrests when riding Do not take luggage along Do not exceed the maximum permissible weight and the maximum permissible axle loads Guideline M...

Page 28: ...necessary Difficult riding conditions are Rides on dry sand p 26 Rides on wet sand p 28 Rides on wet and muddy circuits p 29 Rides at high temperatures or slow riding p 30 Riding at low temperatures and in snow p 30 7 4 Preparing vehicle for rides on dry sand M01129 01 Check the radiator cap Value on the radiator cap 1 8 bar 26 psi If the indicated value does not correspond to the setpoint value W...

Page 29: ...9006922000 Info Observe the fitting instructions for Husqvarna Motor cycles accessories M01107 01 Adjust the carburetor jetting and setting Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop 600868 01 Clean the chain Fit the steel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent radiator fins carefully Condition Regul...

Page 30: ...system are at operating temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Change the radiator cap M01274 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 79006921000 Info Observe ...

Page 31: ...ides on wet and muddy circuits M01274 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 79006921000 Info Observe the fitting instructions for Husqvarna Motor cycles accessories M01107 01 Adjust the carburetor jetting and setting Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop 600868 01 Fit the steel sprocket ...

Page 32: ...own before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Change the radiator cap 600868 01 Adjust the secondary drive to the road conditions Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively high sec ondary ration Clean the chain Clea...

Page 33: ...7 PREPARING FOR USE 31 M01107 01 Adjust the carburetor jetting and setting Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop ...

Page 34: ...ondition p 108 Check the tire air pressure p 108 Check the spoke tension p 109 Info The spoke tension must be checked regularly as incorrect spoke tension will strongly impair riding safety Clean the dust boots of the fork legs p 54 Bleed the fork legs p 54 Check the air filter Check the settings of all controls and ensure that they can be operated smoothly Check all screws nuts and hose clamps re...

Page 35: ...e choke lever out as far as possible Press the kick starter robustly through its full range Info Do not open the throttle TX 300 Turn the tap handle of the fuel tap to the ON position Fuel can flow from the fuel tank to the carburetor Remove the motorcycle from the side stand Shift gear to neutral Condition The engine is cold Pull the choke lever out as far as possible Press the electric starter b...

Page 36: ...e throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and either open the throttle or shift again Switch off the engine if running at idle or standing for a long time Guideline 2 min Avoid frequent and longer slipping of the clutch As a result the engine oil engine and cooling system heat up Ride at a low engine speed instead of at a high eng...

Page 37: ...ge The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand Note Fire hazard Hot vehicle components pose a fire ...

Page 38: ...ngine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact ri...

Page 39: ...mm 1 38 in Total fuel tank capacity approx TC 250 7 l 1 8 US gal Super unleaded 95 octane mixed with 2 stroke engine oil 1 60 p 154 Total fuel tank capacity approx TX 300 10 l 2 6 US gal Super unleaded 95 octane mixed with 2 stroke engine oil 1 60 p 154 Engine oil 2 stroke p 153 Close the filler cap p 18 ...

Page 40: ... lever p 94 Check the frame p 82 Check the swingarm p 82 Check the swingarm bearing for play Check the heim joint for play Check the shock absorber linkage Check the tire condition p 108 Check the tire air pressure p 108 Check the wheel bearing for play Check the wheel hubs Check the rim run out Check the spoke tension p 109 Check the chain rear sprocket engine sprocket and chain guide p 80 Check ...

Page 41: ...ake a test ride Make the service entry in the Husqvarna Motorcycles Dealer net and in the Service and Warranty Booklet One time interval Periodic interval 9 3 Recommended work Every 40 operating hours when used for motorsports Annually Every 80 operating hours Every 40 operating hours Once after 20 operating hours Every 20 operating hours Once after 10 operating hours Every 10 operating hours Chan...

Page 42: ...check the cylin der and Z dimension Check the exhaust control for functioning and smooth oper ation TC 250 Perform major engine service including removing and installing the engine Change the connecting rod conrod bearing and crank pin Check the transmission and shift mechanism Change all engine bearings TC 250 Perform minor engine service Check the exhaust control for functioning and smooth opera...

Page 43: ...spension WP Performance Systems AER 48 is used in the fork In this system suspension is located in the left fork leg and damping in the right fork leg As fork springs are no longer required a significant weight advantage is achieved when compared to conventional forks The response on slightly uneven surfaces is significantly improved In normal driving mode suspension is provided exclusively by an ...

Page 44: ... the transition between high speed and low speed is gradual Thus changes in the high speed range affect the compression damping in the low speed range and vice versa 10 4 Adjusting the low speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor rectly The shock absorber is filled with highly compres...

Page 45: ...usqvarna Motorcycles workshop will be glad to help Info The effect of the high speed setting can be seen in fast compression of the shock absorber H01521 10 Using an open end wrench turn adjusting screw 1 clock wise all the way Info Do not loosen fitting 2 Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed TC 250 Comfort 2...

Page 46: ...hop will be glad to help H01522 10 Turn adjusting screw 1 clockwise up to the last perceptible click Turn counterclockwise by the number of clicks correspond ing to the shock absorber type Guideline Rebound damping TC 250 Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping TX 300 Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping turn coun...

Page 47: ...ck absorber 402416 10 Measure dimension A of rear wheel unloaded p 44 Hold the motorcycle upright with the aid of an assistant Again measure the distance between the rear axle and mark ing SAG on the rear fender using the sag gauge Note down the value as dimension B Info The static sag is the difference between measure ments A and B Check the static sag Static sag TC 250 35 mm 1 38 in Static sag T...

Page 48: ...ck the riding sag Guideline Riding sag TC 250 105 mm 4 13 in Riding sag TX 300 105 mm 4 13 in If the riding sag differs from the specified measurement Adjust the riding sag p 47 10 10 Adjusting the spring pretension of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor rectly The shock absorber is filled with highly compre...

Page 49: ...d TX 300 8 mm 0 31 in Info Depending on the static sag and or the riding sag it may be necessary to increase or decrease the spring pretension Tighten screw 1 Guideline Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Finishing work Install the shock absorber p 64 Remove the motorcycle from the lift stand p 53 10 11 Adjusting the riding sag Preparatory work Raise the motorcycle with a lift s...

Page 50: ...p 64 Remove the motorcycle from the lift stand p 53 Check the static sag of the shock absorber p 45 Check the riding sag of the shock absorber p 46 Adjust the rebound damping of the shock absorber p 44 10 12 Checking the basic setting of the fork Info For various reasons no exact riding sag can be determined for the fork 401000 01 Smaller differences in the rider s weight can be compensated for by...

Page 51: ...n the right fork leg Preparatory work Raise the motorcycle with a lift stand p 53 K00475 10 Main work Remove protection cap 1 Push fork pump 2 together fully Fork pump 79412966000 Info The fork pump is included as part of the motorcycle s separate enclosure Connect the fork pump to the left fork leg The fork pump indicator switches on automatically A little air escapes from the fork leg when conne...

Page 52: ...ng determines the fork suspension behavior H01178 13 Turn adjusting screw 1 clockwise all the way Info Adjusting screw 1 is located at the upper end of the right fork leg Turn counterclockwise by the number of clicks correspond ing to the fork type Guideline Compression damping TC 250 Comfort 17 clicks Standard 12 clicks Sport 7 clicks Compression damping TX 300 Comfort 17 clicks Standard 12 click...

Page 53: ...nter clockwise to reduce damping Mount protection cap 1 10 16 Handlebar position H01188 10 The holes on the handlebar supports are placed at a distance of A from the center Hole distance A 3 5 mm 0 138 in The handlebar can be mounted in 2 different positions In this way the handlebar can be mounted in the most comfortable position for the rider 10 17 Adjusting the handlebar position Warning Danger...

Page 54: ...andlebar supports are longer and higher on one side Position the left and right handlebar supports evenly Mount and tighten screws 2 Guideline Screw handle bar support M10 40 Nm 29 5 lbf ft Loctite 243 Position the handlebar Info Make sure the cables and wiring are positioned cor rectly Position the handlebar clamp Mount screws 1 but do not tighten yet First bolt the handlebar clamp with screws 1 ...

Page 55: ...lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand 0 0 1 1 402001 10 TC 25...

Page 56: ... of both fork legs downward Info The dust boots remove dust and coarse dirt parti cles from the inside fork tubes Over time dirt can accumulate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with b...

Page 57: ...ew screws 4 Take out the right fork leg 11 6 Installing the fork legs H01182 10 Main work Position the fork legs Air release screw 1 of the right fork leg is positioned to the front Valve A of the left fork leg faces the front Info Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the upper triple clamp The a...

Page 58: ...the right fork leg Take off the right fork protector 11 8 Installing the fork protector F00047 11 Position the fork protector on the left fork leg Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and clamp Mount and tighten screws 2 Position the fork protector on the right fork leg Mount and tighten screws 3 Guideline Remaining screws chassi...

Page 59: ...s H01528 10 Remove O ring 4 Remove protective ring 5 Take off the lower triple clamp with the steering stem Remove the upper steering head bearing 11 10 Installing the lower triple clamp 102146 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 155 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing Check w...

Page 60: ...de of the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the upper triple clamp The air suspension is located in the left fork leg The pressure and rebound damping is located in the right fork leg V00889 10 Tighten screws 6 Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft V00890 10 Tighten screw 4 Guideline Screw top steering head M20x1 5...

Page 61: ...that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the play of the steering head bearing p 59 Remove the motorcycle from the lift stand p 53 Mount the handlebar cushion 11 11 Checking the play of the steering head bearing Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages co...

Page 62: ... steering head bearing and change if neces sary Finishing work Remove the motorcycle from the lift stand p 53 11 12 Adjusting the steering head bearing play Preparatory work Raise the motorcycle with a lift stand p 53 Remove the handlebar cushion H01532 10 Main work Loosen screws 1 Remove screw 2 Loosen and retighten screw 3 Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plasti...

Page 63: ... 11 14 Removing the start number plate H01533 10 Remove screw 1 Remove screw 2 and take off the brake line guide and start number plate 11 15 Installing the start number plate S01297 10 Position the brake line and brake line guide on the start num ber plate Mount and tighten screw 1 Position the start number plate The holding lugs engage in the fender Mount and tighten screw 2 11 16 Removing front...

Page 64: ...k Remove screws 1 and 2 Remove front fender 11 17 Installing front fender H01535 10 Main work Position front fender Mount and tighten screws 1 and 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the start number plate p 61 ...

Page 65: ...rs Remove the frame protectors on the left and right H01537 10 Remove screw 3 Remove fitting 4 Info Raise the wheel slightly to be able to remove the screws more easily H01538 10 Press angle lever 5 toward the rear Press linkage lever 6 downward H01539 10 Option Brembo Remove screws 7 Pull off foot brake cylinder from the push rod A00063 10 Option Magura Remove screws 7 Pull off foot brake cylinde...

Page 66: ...ove screw 9 Remove the shock absorber carefully at the bottom 11 19 Installing the shock absorber H01543 10 Main work Carefully position the shock absorber into the vehicle from the bottom Mount and tighten screw 1 Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 H01544 10 Position the swingarm and mount the swingarm pivot Info Pay attention to flat area A Mount and tighten nu...

Page 67: ...M6 10 Nm 7 4 lbf ft A00064 10 Option Magura Position the foot brake cylinder Push rod 3 engages in the foot brake cylinder The dust boot is correctly positioned Mount and tighten screws 4 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft H01546 10 Position the angle lever and linkage lever Mount and tighten fitting 5 Guideline Nut linkage lever to angle lever M14x1 5 80 Nm 59 lbf ft Info Pay ...

Page 68: ...unt and tighten screws 8 with the washers Guideline Screw frame pro tector M5 3 Nm 2 2 lbf ft Mount the cable tie s Check the free travel of the foot brake lever p 94 Finishing work Remove the motorcycle from the lift stand p 53 11 20 Removing the seat Preparatory work Remove the air filter box cover p 68 F00237 10 Main work TC 250 Remove screw 1 Pull seat back and lift it off ...

Page 69: ...f 11 21 Mounting the seat F00238 10 Main work TC 250 Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket Push the seat forward Make sure that the seat is correctly locked in Mount and tighten screw 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 70: ...ctly locked in Mount and tighten screw 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the air filter box cover p 69 11 22 Removing the air filter box cover K00901 10 TC 250 Pull off the air filter box cover sideways in areas A B and C and remove toward the front K00908 10 TX 300 Pull off the air filter box cover sideways in areas A B and C and remove toward the fro...

Page 71: ... in areas A B and C K00907 10 TX 300 Position air filter box cover on collar bushings 1 and 2 and push toward the rear Engage the air filter box cover in areas A B and C 11 24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine Dust and dirt will enter the engine without an air filter Never start to use the vehicle without an air...

Page 72: ...ose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the air filter box cover p 68 Remove the air filter p 69 K00518 01 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry pr...

Page 73: ...n bushing B The air filter is correctly positioned Secure the bottom retaining pin with holding tab 2 Info If the air filter is not mounted correctly dust and dirt may enter the engine and result in damage Finishing work Install the air filter box cover p 69 11 27 Sealing the air filter box Preparatory work Remove the air filter box cover p 68 F00248 01 Main work Seal the air filter box cover in m...

Page 74: ...ition the main silencer with rubber sleeve 1 Mount and tighten screws 2 with the washers Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the right side cover p 74 11 30 Changing the glass fiber yarn filling in the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing an...

Page 75: ...tube 4 over the inner tube with the new glass fiber yarn filling Mount and tighten all screws 1 Guideline Screws on the main silencer M5 7 Nm 5 2 lbf ft Finishing work Install the main silencer p 72 Install the right side cover p 74 11 31 Removing the right side cover K00904 10 TC 250 Remove screw 1 Pull off the side cover sideways in areas A and B and remove toward the front K00906 10 TX 300 Remo...

Page 76: ...h toward the rear Engage the side cover in areas A and B Mount and tighten screw 3 Guideline Remaining screws chassis M5 5 Nm 3 7 lbf ft K00905 10 TX 300 Position the side cover on collar bushings 1 and 2 and push toward the rear Engage the side cover in areas A and B Mount and tighten screw 3 Guideline Remaining screws chassis M5 5 Nm 3 7 lbf ft ...

Page 77: ...octor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Preparatory work TC 250 Turn the tap handle of the fue...

Page 78: ...rly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoro...

Page 79: ...t and tighten screw 1 with the rubber bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft H01413 11 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Connect the fuel hose Finishing work Install the right side cover p 74 Mount the seat p 67 Install the air filter box cover p 69 11 35 Checking the chain for dirt 400678 01 Check the chain for heavy soiling ...

Page 80: ...aintenance Preparatory work Raise the motorcycle with a lift stand p 53 400725 01 Main work Rinse off loose dirt with a soft jet of water Clean chain and apply chain spray Offroad chain spray p 155 Finishing work Remove the motorcycle from the lift stand p 53 11 37 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents If the chai...

Page 81: ...r wheel bearings wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand p 53 Check the chain te...

Page 82: ...e rear sprocket or engine sprocket is worn Change the drivetrain kit Info The engine sprocket rear sprocket and chain should always be replaced together 400987 10 Pull at the top part of the chain with the specified weight A Guideline Weight chain wear mea surement 10 15 kg 22 33 lb Measure distance B of 18 chain rollers in the lower chain section Info Chain wear is not always even so you should r...

Page 83: ...ding guard M6 6 Nm 4 4 lbf ft Loctite 243 H01556 10 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the screw on the chain sliding piece Guideline Screw chain slid ing piece M8 15 Nm 11 1 lbf ft 40...

Page 84: ... a frame that has been damaged due to a mechanical impact Repair of the frame is not authorized by Husqvarna Motorcycles 11 41 Checking the swingarm 401520 01 Check the swingarm for damage cracking and deformation If the swingarm shows signs of damage cracking or deformation Change the swingarm Info Always change a damaged swingarm Repair of the swingarm is not authorized by Husq varna Motorcycles...

Page 85: ...ll the right side cover p 74 Mount the seat p 67 Install the air filter box cover p 69 11 43 Checking the rubber grip 401197 01 Check the rubber grips on the handlebar for damage wear and looseness Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right The left sleeve is clamped onto the handlebar The rubber grip can only be replac...

Page 86: ...a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Info The fluid level rises with increasing wear of the clutch facing discs Never use D...

Page 87: ...fluid spills on to your clothing change the clothing Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Av...

Page 88: ...n extract fluid from the master cylinder reservoir to prevent overflow Remove the bleeding syringe Tighten the bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water ...

Page 89: ...ver to your hand size by turning adjusting screw 1 Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar The range of adjustment is limited Only turn the adjusting screw by hand and do not use force Do not make any adjustments w...

Page 90: ...ge cracking and deformation If the brake disc exhibits damage cracking or deforma tion Change the front brake disc Change the rear brake disc 12 4 Checking the front brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the b...

Page 91: ...ized Husqvarna Motorcycles workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of wa...

Page 92: ... 2 with membrane 3 Add brake fluid to level A Guideline Level A brake fluid level below reservoir rim 5 mm 0 2 in Brake fluid DOT 4 p 153 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immedi ately with water A00067 10 Option Magura Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Rem...

Page 93: ... p 91 12 7 Changing the front brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail Ensure that service work and repairs are performed professionally Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothi...

Page 94: ... and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container K00533 10 Option Brembo Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 F00064 10 Manually press the brake caliper toward the brake disc to push back the brake pistons Ensure that brake fluid does not flow out of the brake f...

Page 95: ...Info Clean up overflowed or spilled brake fluid immedi ately with water A00069 10 Option Magura Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 H02363 10 Manually press the brake caliper toward the brake disc to push back the brake pistons Ensure that brake fluid does not flow out of the brake fluid reservoir if necess...

Page 96: ...nd there is a pressure point A00067 10 Add brake fluid up to level A Guideline Level A brake fluid level below reservoir rim 5 mm 0 2 in Brake fluid DOT 4 p 153 Position cover 2 with membrane 3 Mount and tighten screws 1 Info Clean up overflowed or spilled brake fluid immedi ately with water 12 8 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the...

Page 97: ... in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification K00534 10 Option Brembo Detach spring 1 Loosen nut 4 and with push rod 5 turn it back until you have maximum free travel To adjust the basic position of the foot brake lever to indi vidual requirements loosen nut 2 and turn screw 3 accordingly Info The range of adjustment is limi...

Page 98: ...ne Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Attach spring 1 12 10 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding...

Page 99: ... Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes tho...

Page 100: ...screw cap with the membrane and O ring Info Clean up overflowed or spilled brake fluid immedi ately with water K00951 10 Option Magura Stand the vehicle upright Remove the cable ties on the frame protector Remove screw cap 1 with membrane 2 and the shim Add brake fluid to marking A Brake fluid DOT 4 p 153 Mount and tighten screw cap with the membrane and the shim Info Clean up overflowed or spille...

Page 101: ... Motorcycles workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the eve...

Page 102: ...embo Stand the vehicle upright Remove screw cap 1 with membrane 2 and the O ring M01328 10 Manually press the brake caliper to the brake disc to push back the brake piston Ensure that brake fluid does not flow out of the brake fluid reservoir extracting it by suc tion if it does Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove cott...

Page 103: ... ring Info Clean up overflowed or spilled brake fluid immedi ately with water K00951 10 Option Magura Stand the vehicle upright Remove the cable ties on the frame protector Remove screw cap 1 with membrane 2 and the shim H02368 11 Manually press the brake caliper to the brake disc to push back the brake piston Ensure that brake fluid does not flow out of the brake fluid reservoir extracting it by ...

Page 104: ...nings in pairs Make sure that decoupling plate 7 is mounted on the piston side brake lining Mount cotter pins 3 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point K00951 10 Add brake fluid to level A Brake fluid DOT 4 p 153 Mount and tighten screw cap 1 with membrane 2 and the shim Info Clean up overflowed or spilled bra...

Page 105: ...by hand in order to push back the brake pistons Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons H02371 10 Loosen screw 1 by several rotations Loosen screws 2 Press on screw 1 to push the wheel spindle out of the axle clamp Remove screw 1 H02372 10 Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the w...

Page 106: ...ontact surface A of the spacers Long life grease p 155 Insert the spacers Clean and grease the wheel spindle Long life grease p 155 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned H02371 11 Mount and tighten screw 2 Guideline Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Operate the hand brake lever several times until the brake linings are se...

Page 107: ...Remove chain adjuster 2 Pull out wheel spindle 3 far enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Info Cover the components to protect them against damage Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Ho...

Page 108: ... rear sprocket Info Cover the components to protect them against damage Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the rear wheel withdraw the wheel spindle Take the rear wheel out of the swingarm Info Do not operate the foot brake lever when the rear wheel is removed H00936 10 Remove ...

Page 109: ...ed Mount the chain H02376 10 Position chain adjuster 3 Mount nut 4 but do not tighten it yet Make sure that chain adjusters 3 are fitted correctly on adjusting screws 5 Check the chain tension p 78 Tighten nut 4 Guideline Nut rear wheel spin dle M25x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length ...

Page 110: ...ck the tread depth Info Adhere to the legally required minimum tread depth Minimum tread depth 2 mm 0 08 in If the tread depth is less than the minimum tread depth Change the tires H01144 01 Check the tire age Info The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT number The first two digits indicate the week of manufacture and ...

Page 111: ...ral and radial run out will form in the wheel Other spokes will become looser as a result Check spoke tension regularly and in particular on a new vehicle Your authorized Husqvarna Motorcycles workshop will be glad to help 400694 01 Strike each spoke briefly using a screwdriver blade Info The frequency of the sound depends on the spoke length and spoke diameter If you hear different tone frequenci...

Page 112: ...ies if charge is already below the minimum voltage Minimum voltage before the start of the charge 9 V Dispose of batteries with less than the minimum voltage correctly Preparatory work Press and hold the kill switch while the engine is idling until the engine stops Remove the air filter box cover p 68 Remove the seat p 66 H01190 10 Main work Pull back the negative terminal cover 1 and disconnect n...

Page 113: ...ver the negative terminal Finishing work Mount the seat p 67 Install the air filter box cover p 69 14 3 Recharging the battery TX 300 Warning Risk of injury Batteries contain harmful substances Keep batteries out of the reach of children Keep sparks and open flames away from the batteries Only charge batteries in well ventilated rooms Maintain a minimum clearance from inflammable materials when ch...

Page 114: ...e over discharged and sul fated destroying the battery The battery is maintenance free Preparatory work Press and hold the kill switch while the engine is idling until the engine stops Remove the air filter box cover p 68 Remove the seat p 66 Remove the battery p 110 F00114 10 Main work Check the battery voltage Battery voltage 9 V Do not charge the battery Replace the battery and dispose of the o...

Page 115: ...l system Only use fuses with the required ampere value Do not bypass or repair fuses Info The main fuse protects all power consumers of the vehicle It is located in the starter relay housing under the seat Preparatory work Press and hold the kill switch while the engine is idling until the engine stops Remove the air filter box cover p 68 Remove the seat p 66 E00308 10 Main work Pull starter relay...

Page 116: ...fuse 4 is located in the starter relay Install a new main fuse Fuse 58011109110 p 148 Check that the electrical equipment is functioning properly Tip Insert a spare fuse so that it is available if needed Mount the protection caps Mount the starter relay onto the holder and route the cable Finishing work Mount the seat p 67 Install the air filter box cover p 69 ...

Page 117: ...e cooling effect Dirty cooling fins also reduce the cooling effect 15 2 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and the engine...

Page 118: ...ine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediatel...

Page 119: ...lant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold Position the...

Page 120: ...ake sure that screw 1 is tightened Position the motorcycle upright Completely fill the radiator with coolant Coolant p 153 S01289 10 Loosen screw 2 until coolant escapes without bubbles Mount and tighten screw 2 Guideline Bleeder screw cylinder head M6 10 Nm 7 4 lbf ft Completely fill the radiator with coolant Coolant p 153 K00893 10 Mount radiator cap 3 Danger Danger of poisoning Exhaust gases ar...

Page 121: ... Nm 7 4 lbf ft Completely fill the radiator with coolant Coolant p 153 S01287 10 Mount radiator cap 3 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventila tion when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Allow the engin...

Page 122: ...xhaust extraction system when starting or running the engine in an enclosed space Start the engine and let it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 120 16 2 Adjusting the play in the throttle cable Preparatory work TC 250 Turn the tap handle of the fuel tap to the OFF po...

Page 123: ...throttle cable p 120 16 3 Carburetor setting Effects of the carburetor setting H01400 01 The different carburetor components must be tuned both to one another and for the use intended Main jet MJ The main jet MJ has the greatest influence with the throttle slide open full throttle If the insulator of a new spark plug is very light or white after a brief ride at full throttle or if the engine knock...

Page 124: ... 2 3 4 0 1 K00495 01 The idling jet has the greatest influence when the throttle slide is closed The first cylindrical part of the needle and the clip position have only minimal influence When the throttle slide is 1 8 open the first cylindrical part of the needle the idling jet and the clip position have the greatest influence 1 4 1 8 1 2 3 4 0 1 1 4 1 8 1 2 3 4 0 1 K00496 01 When the throttle sl...

Page 125: ...e carburetor and the bottom left jet needle F1 corresponds to the leanest The optimal carburetor tuning is shown under the respective model 0 0 4 4 0 0 3 3 0 0 5 5 0 0 2 2 0 0 1 1 B00075 10 Clip position 1 5 Clip position from above The five possible clip positions are shown here The carburetor tuning depends on the defined ambient and oper ating conditions 16 4 Carburetor idle 402799 10 The idle ...

Page 126: ... time 5 min Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Adjust the idle speed with adjusting screw 2 Guideline Choke function deactivated The choke lever is pushe...

Page 127: ...l is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of wate...

Page 128: ... lever must not touch the rider s boot when in the basic position When the shift lever keeps touching the boot the transmission will be subject to an excessive load 400692 10 Sit on the vehicle in the riding position and determine distance A between the upper edge of your boot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not mee...

Page 129: ... spring mounted at the factory with medium tuning standard for good rideability Auxiliary spring with green color coding Auxiliary spring for even softer performance Auxiliary spring with red color coding Auxiliary spring for aggressive performance The engine characteristic can be influenced by different spring strengths of auxiliary spring 1 16 10 Engine characteristic setting the auxiliary sprin...

Page 130: ... position them together in the clutch cover Auxiliary spring with yellow marking 54637072300 Auxiliary spring with green marking 54837072100 Auxiliary spring with red marking 54837072000 The recess in spring insert 5 engages in the angle lever Info Screw 6 must not be turned as this would worsen the engine characteristic Check the O ring in the cap Position the cap Mount and tighten the screws Gui...

Page 131: ...tion them together in the clutch cover Auxiliary spring with yellow marking 54637072300 Auxiliary spring with green marking 54837072100 Auxiliary spring with red marking 54837072000 The recess in spring insert 5 engages in the angle lever Info Screw 6 must not be turned as this would worsen the engine characteristic Check the O ring in the cap Position the cap Mount and tighten the screws Guidelin...

Page 132: ... 7 4 lbf ft Screw gear oil level check TX 300 M6 10 Nm 7 4 lbf ft 17 2 Changing the gear oil Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Dispose...

Page 133: ...l 0 8 l 0 8 qt Engine oil SAE 10W 40 p 153 Mount and tighten filler plug 2 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and check that it is oil t...

Page 134: ...ine Screw gear oil level check TC 250 M6 10 Nm 7 4 lbf ft Screw gear oil level check TX 300 M6 10 Nm 7 4 lbf ft Mount and tighten filler plug 2 Finishing work Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or...

Page 135: ...Avoid direct sunshine when cleaning the motorcycle 401061 01 Close off the exhaust system to keep water from entering Remove coarse dirt particles with a gentle spray of water Spray dirty parts with a normal commercial engine cleaner and then brush off with a soft brush Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always...

Page 136: ...t bare metal except for brake discs and the exhaust sys tem with a corrosion inhibitor Preserving materials for paints metal and rubber p 155 Treat all plastic parts and powder coated parts with a mild cleaning and care product ...

Page 137: ...eriod less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Refuel p 36 Clean the motorcycle p 133 Change the gear oil p 130 Check the antifreeze and coolant level p 115 Empty the carburetor float chamber p 125 Check the tire air pressure p ...

Page 138: ...19 STORAGE 136 19 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 53 Perform checks and maintenance measures when preparing for use p 32 Make a test ride ...

Page 139: ... change it if necessary Electrode distance plug gap of spark plug too wide Adjust the plug gap Guideline TC 250 Spark plug electrode gap 0 60 mm 0 0236 in TX 300 Spark plug electrode gap 0 60 mm 0 0236 in Fault in ignition system Check the ignition system Kill switch cable in wiring har ness frayed kill switch defec tive Check the kill switch The connector or ignition coil is loose or oxidized Cle...

Page 140: ...X 300 Turn the tap handle of the fuel tap to the RES position Refuel p 36 Engine takes in bad air Check the intake flange and carbure tor for tightness The connector or ignition coil is loose or oxidized Clean the connector and treat it with contact spray Engine overheats Too little coolant in cooling system Check the cooling system for leakage Check the coolant level p 116 Too little air stream S...

Page 141: ...ically activated Transmission 5 gear claw shifted Transmission ratio First gear 14 28 Second gear 16 26 Third gear 18 24 Fourth gear 21 24 Fifth gear 22 21 Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment type Kokusan Spark plug NGK BR 8 ECM Spark plug electrode gap 0 60 mm 0 0236 in Starting aid Kick starter 21 1 2 TX 300 Design 1 cylinder 2 stroke...

Page 142: ... plate EJOTDELTA PT 30x12 1 Nm 0 7 lbf ft Screw outer membrane sheets EJOTDELTA PT 30x6 1 Nm 0 7 lbf ft Screw angle lever exhaust con trol M5 6 Nm 4 4 lbf ft Loctite 243 Screw bearing retainer M5 7 Nm 5 2 lbf ft Loctite 243 Screw clutch spring retainer M5 6 Nm 4 4 lbf ft Screw crankshaft position sensor M5 6 Nm 4 4 lbf ft Loctite 243 Screw exhaust control bearing support M5 6 Nm 4 4 lbf ft Loctite...

Page 143: ...w kick starter M8 25 Nm 18 4 lbf ft Loctite 2701 Nut cylinder base M10 35 Nm 25 8 lbf ft Screw drive chain engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701 Nut rotor M12x1 60 Nm 44 3 lbf ft Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Spark plug M14x1 25 25 Nm 18 4 lbf ft Nut inner clutch hub M18x1 5 100 Nm 73 8 lbf ft Loctite 648 Nut primary gear M18LHx1 5 150 Nm 110 6 lbf ft Locti...

Page 144: ...n M6 10 Nm 7 4 lbf ft Loctite 243 Screw kick starter stop plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw outer clutch cover M6 8 Nm 5 9 lbf ft Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 Screw starter motor M6 10 Nm 7 4 lbf ft Screw starter motor bearing bush M6 10 Nm 7 4 lbf ft Loctite 243 Screw starter motor protection cap M6 8 Nm 5 9...

Page 145: ...21 TECHNICAL DATA 143 Nut primary gear M18LHx1 5 150 Nm 110 6 lbf ft Loctite 648 ...

Page 146: ...BFY44 73 Main jet 440 430 450 460 Idling jet 42 5 37 5 40 45 47 5 Starting jet 80 Needle jet S 1 Idle air adjusting screw Open 1 5 turns 21 3 2 Carburetor basic setting for sandy surfaces TC 250 Idle air adjusting screw Open 1 5 turns Idling jet 45 Jet needle 6BFY44 73 Needle position 3rd position from top Main jet 470 Info If the engine is not running smoothly use a smaller main jet ...

Page 147: ...TA 145 21 3 3 Carburetor tuning TC 250 402893 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from top MJ Main jet Info Do not use on sandy terrain ...

Page 148: ...8 80 Needle position 2nd position from top Jet needle 6BFY43 75 6BFY42 75 Main jet 450 430 440 460 Idling jet 25 22 5 27 5 Starting jet 80 Needle jet S 4 Idle air adjusting screw Open 1 5 turns 21 3 5 Carburetor tuning TX 300 402896 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open ...

Page 149: ...x TX 300 10 l 2 6 US gal Super unleaded 95 octane mixed with 2 stroke engine oil 1 60 p 154 Fuel reserve approx TX 300 1 5 l 1 6 qt 21 5 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Performance Systems Upside down AER 48 Suspension travel front 310 mm 12 2 in rear 300 mm 11 81 in Fork offset 22 mm 0 87 in Shock absorber WP Performance Systems 5018 DCC Link Brake ...

Page 150: ... overall weight 335 kg 739 lb 21 6 Electrical system 21 6 1 TX 300 Battery HJTZ5S FP Lithium ion battery Battery voltage 12 V Nominal capacity 2 0 Ah Maintenance free Fuse 58011109110 10 A 21 7 Tires Validity Front tire Rear tire TC 250 80 100 21 51M TT Dunlop GEOMAX MX3S 110 90 19 62M TT Dunlop GEOMAX MX3S TX 300 90 90 21 54M TT Dunlop GEOMAX AT81F 110 100 18 64M TT Dunlop GEOMAX AT81 The tires s...

Page 151: ...ping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Air pressure 9 4 bar 136 psi Fork length 950 mm 37 4 in Oil capacity external mechanism left 200 40 20 ml 6 76 1 35 0 68 fl oz Fork oil SAE 4 48601166S1 p 154 Oil capacity external mechanism right 200 40 20 ml 6 76 1 35 0 68 fl oz Fork oil SAE 4 48601166S1 p 154 Grease capac...

Page 152: ... 21 9 2 TX 300 Shock absorber article number 18 18 7R 73 Shock absorber WP Performance Systems 5018 DCC Link Compression damping low speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping high speed Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 8 mm 0 31 in Spring rate Weight of rider 6...

Page 153: ...ng guard M6 6 Nm 4 4 lbf ft Loctite 243 Screw front brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw rear brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw throttle grip M6 5 Nm 3 7 lbf ft Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Nut rear sprocket screw M8 35 Nm 25 8 lbf ft Loctite 2701 Nut rim lock M8 12 Nm 8 9 lbf ft Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 ...

Page 154: ... lbf ft Loctite 243 Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Nut frame on linkage lever M14x1 5 80 Nm 59 lbf ft Nut linkage lever on swingarm M14x1 5 80 Nm 59 lbf ft Nut linkage lever to angle lever M14x1 5 80 Nm 59 lbf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Screw in no...

Page 155: ...er and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility compatibility with other coolants Recommended...

Page 156: ...ainer and that exhibit the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 ...

Page 157: ...rproof Grease Multi purpose grease 00062010051 Recommended supplier Klüber Lubrication CENTOPLEX 2 EP Offroad chain spray Guideline Recommended supplier Bel Ray Blue Tac Chain Lube Oil for foam air filter Recommended supplier Bel Ray Foam Filter Oil Preserving materials for paints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil spray Recommended suppl...

Page 158: ...st motorcycle engines the transmission and clutch are lubricated with the same oil The JASO MA standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity The viscosity describes only one property of oil and says nothing about quality JASO FD JASO FD is a classification fo...

Page 159: ...25 LIST OF ABBREVIATIONS 157 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 160: ...retor float chamber emptying 125 idle 123 idle speed adjusting 124 Carburetor setting 121 Chain checking 80 cleaning 78 Chain guide checking 80 Chain tension adjusting 79 checking 78 Chassis number 14 Choke 20 Clutch fluid level checking correcting 84 fluid changing 85 Clutch lever 16 basic position adjusting 84 Compression damping fork adjusting 50 Compression damping high speed shock absorber ad...

Page 161: ...sition adjusting 87 free travel checking 87 Handlebar position 51 adjusting 51 I Implied warranty 10 Intended use 6 K Kick starter 21 Kill switch 17 L Lower triple clamp installing 57 removing 56 Low speed compression damping shock absorber adjusting 42 M Main fuse changing 113 Main silencer glass fiber yarn filling changing 72 installing 72 removing 72 Map switch 17 Misuse 6 Motorcycle cleaning 1...

Page 162: ...ension checking 109 Start number plate installing 61 removing 61 Starting 32 Steering head bearing lubricating 61 Steering head bearing play adjusting 60 checking 59 Storage 135 Swingarm checking 82 T Technical data capacities 147 carburetor 144 chassis 147 chassis tightening torques 151 electrical system 148 engine 139 engine tightening torques 140 fork 148 shock absorber 149 tires 148 Throttle c...

Page 163: ... 3402165en 3402165en 06 2017 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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Summary of Contents for TC 125

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Husqvarna TC 125, Owner'S Manual, Page: 82 / 163

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Summary of Contents for TC 125

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