Husqvarna TC 250 2011 Workshop Manual Download Page 264

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M.2

ELECTRICAL SYSTEM

Ed. 07-2010

Wiring diagram (TC) .................................................................................... M.5

Key to wiring diagram .................................................................................. M.5

Colour coding key ........................................................................................ M.5

Wiring diagram (TE) .................................................................................... M.6

Key to wiring diagram .................................................................................. M.6

Colour coding key ........................................................................................ M.6

Wiring diagram (TXCi) ................................................................................. M.7

Key to wiring diagram .................................................................................. M.7

Colour coding key ........................................................................................ M.7

Electrical components location (TC) ............................................................ M.8

Condensatore (TC) ...................................................................................... M.8

Electrical components location (TE) ............................................................ M.9

Electrical components location (TXCi)....................................................... M.13

Checking generator stator windings resistance ......................................... M.16

Generator no-load performance ................................................................ M.17

Key to wiring diagram ................................................................................ M.18

Ignition system (TC) .................................................................................. M.18

Ignition system (TE - TXCi) ....................................................................... M.19

Key ............................................................................................................ M.19

Key to wiring diagram ................................................................................ M.20

CHARGING SYSTEM (TE - TXCi) ............................................................ M.21

CHARGING SYSTEM WIRING DIAGRAM .............................................. M.21

CHARGING SYSTEM INSPECTIONS ...................................................... M.22

Current loss at the battery (TE - TXCi) ...................................................... M.22

Regulated voltage (TE - TXCi) .................................................................. M.22

Voltage regulator/rectifier inspection (TE - TXCi)

...................................... M.22

Voltage regulator ....................................................................................... M.22

VOLTAGE REGULATOR/RECTIFIER WIRING DIAGRAM ....................... M.22

WIRING DIAGRAM ................................................................................... M.22

ELECTRICAL STARTING SYSTEM (TE - TXCi) ....................................... M.23

STARTING SYSTEM INSPECTION .......................................................... M.24

Starter motor inspection (TE - TXCi) ......................................................... M.24

Starter motor test curves (TE - TXCi) ........................................................ M.24

Solenoid starter inspection (TE - TXCi) ..................................................... M.24

Checking coil windings resistance ............................................................ M.25

Electronic control unit (ECU) ..................................................................... M.26

Spark plug ................................................................................................ M.26

Gear position sensor inspection (GPS: Gear Position Sensor) ................. M.27

BATTERY (TE - TXCi) ............................................................................... M.28

Battery charger .......................................................................................... M.28

HEADLAMP, TAIL LIGHT (TE)................................................................... M.29

Headlamp adjustment ............................................................................... M.29

Headlamp bulbs replacement .................................................................... M.29

Tail light replacement ................................................................................. M.30

Number plate bulb replacement ................................................................ M.30

Handlebar switches ................................................................................... M.31

Left-hand switch (TC) ................................................................................ M.31

Left-hand switch (TE) ................................................................................ M.31

Colour coding key ...................................................................................... M.31

Right-hand switch (TE - TXCi) ................................................................... M.32

Colour coding key ...................................................................................... M.32

FUSES....................................................................................................... M.33

SEMICONDUCTOR PARTS ...................................................................... M.33

Relay test (TE - TXCi) ............................................................................... M.34

DIGITAL DASHBOARD, WARNING LIGHTS (TE) .................................... M.35

Warning lights panel (TXCi) ....................................................................... M.37

Dashboard replacement (TE) .................................................................... M.38

TROUBLESHOOTING .............................................................................. M.38

CHARGING SYSTEM (TE - TXCi) ............................................................ M.38

Summary of Contents for TC 250 2011

Page 1: ...Workshop Manual TE 250 310 2011 I E TEi 250 2011 I E USA TC 250 2011 TC 250i 2011 I E USA TXCi 250 2011 I E USA Ed 07 2010 ...

Page 2: ... any errors or omissions in this manual and reserves the right to make changes to reflect on going product development Illustrations in the ma nual may differ from actual components No reproduction in full or in part without written authorisation 1st edition 07 2010 ...

Page 3: ...1024 Varese Italy tel 39 0332 75 61 11 tel 39 0332 756 558 www husqvarna motorcycles com Workshop Manual 1 Chassis serial number TE 250 310 2011 I E TEi 250 2011 I E USA TC 250 2011 TC 250i 2011 I E USA TXCi 250 2011 I E USA TE 250 ZKHA300AABV000001 TE 250 USA ZKHKCECF BV000001 TE 310 ZKHA301AABV000001 TE 310 USA ZKHKCEDG BV000001 TC 250 ZKHA300AABV050001 TC 250 USA ZKHTC253 BV000001 TXCi 250 USA ...

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

Page 5: ...ngs and Adjustments D General Procedures E Engine Disassembly F Engine Overhaul G Engine Reassembly H Front Suspension I Rear Suspension J Brakes L Electrical System M Engine Cooling N Hydraulically Controlled Clutch P Fuel Injection System S Special Tools W Tightening Torque Figures X Chassis and Wheels Y NOTES Unless otherwise specified data and specifications apply to all models ...

Page 6: ......

Page 7: ...b 1 b IMPORTANT NOTICES Ed 07 2010 Section ...

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

Page 9: ...A 1 A GENERAL INFORMATION Ed 07 2010 Section ...

Page 10: ...atio TE TXCi A 3 Transmission ratio TC A 4 SECONDARY DRIVE A 4 FINAL RATIOS TE TXCi A 4 FINAL RATIOS TC A 4 FRAME A 4 FRONT SUSPENSION A 4 REAR SUSPENSION A 4 FRONT BRAKE A 4 REAR BRAKE A 4 RIMS A 4 TIRES A 5 Cold tire pressure A 5 Electrical components location TC A 5 Electrical components location TXCi A 5 Electrical components location TE A 5 Overall dimensions A 6 Weight A 7 Capacities A 7 ...

Page 11: ...ven by a combined chain gears system Valve clearance with engine cold Intake 0 15 mm 0 006 in Exhaust 0 20 mm 0 008 in LUBRICATION Type wet crankcase lobe pump and cartridge and mesh filters IGNITION Type Electronic inductive discharge with adjustable advance digital control Spark plug type NGK CR9EB Spark plug gap 0 7 0 8 mm 0 027 0 031 in FUEL SYSTEM Type Electronic injection feed PRIMARY DRIVE ...

Page 12: ... 994 5th gear 12 726 FRAME Type Steel single tube cradle roud rectangular ellipsoidal tubes light alloy rear frame FRONT SUSPENSION Type Upside down telescopic hydraulic front fork with advanced axle adjustable in compression and rebound stroke stanchions tubes Ø 1 89 in ø 48 mm Legs axis stroke 300 mm 11 8 in REAR SUSPENSION Type progressive with hydraulic single shock absorber Wheel stroke 296 m...

Page 13: ...l under the fuel tank Electronic control unit under the fuel tank Voltage regulator under the fuel tank Spark plug on cylinder head 12V 450W starter motor behind the engine cylinder Solenoid starter on the left of rear chassis M A Q S sensor pressure throttle position air temperature on throttle body The electrical system includes the following elements 12V 6Ah battery under the saddle Electric fa...

Page 14: ...A fuse on right side of rear chassis Coolant temperature sensor Lambda sensor Headlamp with 12V 35W twin halogen bulb and 12V 3W parking light bulb LED tail light with stop light bulb 12V 10W turning indicator bulbs Fuel pump inside the fuel tank Odometer Overall dimensions Wheelbase A TE TXCi mm 1460 57 47 in TC mm 1470 57 87 in Overall length B TC mm 2215 87 20 in TE mm 2260 88 97 in TXCi mm 217...

Page 15: ...lacement 850 cc oil change Front fork oil KAYABA KHL15 11 SAE 7 5 SAE 5 for extremely cold weather TC 325 cu cm TXC 325 cu cm TE 100 mm Rear shock absorber oil CASTROL SYNTHETIC FORK OIL 5W Coolant CASTROL MOTORCYCLE COOLANT 0 9 litres Front brake fluid CASTROL RESPONSE SUPER DOT 4 Rear brake fluid CASTROL RESPONSE SUPER DOT 4 Clutch fluid CASTROL RESPONSE SUPER DOT 4 Drive chain lubrication CASTR...

Page 16: ......

Page 17: ...B 1 B MAINTENANCE Ed 07 2010 Section ...

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

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

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

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

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

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

Page 24: ......

Page 25: ...C 1 C TROUBLESHOOTING Ed 07 2010 Section ...

Page 26: ...nit faulty Replace 3 Carburettor jets clogged Clean 4 Low idle Adjust Engine is noisy Noise seems to come from piston 1 Too much piston to cylinder clearance Replace 2 Worn piston rings or piston grooves Replace 3 Too much carbon build up in combustion chamber or on piston crown Clean 4 Valve clearances too large Adjust 5 Weak or seized valve springs Replace 6 Worn timing chain Replace 7 Incorrect...

Page 27: ...rooves Replace 3 Worn dog slots in gears Replace 4 Worn selector shaft splines Replace 5 Damaged shifter fork shafts Replace Engine has low power 1 Dirty air filter Clean 2 Poor fuel quality Replace 3 Intake coupling loose Tighten 4 Spark plug electrode gap too wide Adjust 5 Insufficient compression Identify cause 6 Incorrect valve clearances Adjust 7 Valve seats or guides faulty Replace 8 Weak or...

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

Page 29: ...improperly connected or Connect correctly or is not providing enough charge shorted replace 2 Voltage regulator faulty Replace 3 Generator coil faulty Replace Generator overcharges battery 1 Voltage regulator faulty Replace Battery does not hold charge 1 Battery terminals dirty Clean TE TXCi Starter motor 1 Battery is flat Charge does not start or slips 2 Control on R H switch faulty Replace TE TX...

Page 30: ......

Page 31: ...D 1 D SETTINGS AND ADJUSTMENTS Ed 07 2010 Section ...

Page 32: ... check D 16 Coolant replacement D 16 Air filter check TC D 17 Air filter check TE TXCi D 18 Air filter cleaning D 18 Assembly D 19 Secondary drive chain adjustment D 20 Chain lubrication D 21 Disassembling and cleaning D 21 Washing a chain without O rings D 21 Lubricating a chain without O rings D 21 Lubricating an O ring chain D 21 Suspension setup according to track condition D 22 Shock absorber...

Page 33: ...D 3 H02176 TC H02177 TE H02178 TXCi SETTINGS AND ADJUSTMENTS Ed 07 2010 ...

Page 34: ... removal Turn the rear fixing 1 counter clockwise remove it and extract the saddle Tank removal Remove the screws 1 and the side panels Remove the tank retaining screw 2 TE TXCi Close the two taps 3 and 4 and connect the hose 5 Disconnect connector 6 of the reserve sensor ...

Page 35: ... ADJUSTMENTS Ed 07 2010 Lift the tank and disconnect the fuel pump connector 7 from the main wiring harness Disconnect the supply hose 8 from the outlet fitting 9 on the fuel pump located in the rear bottom section of the tank Remove the tank 10 together with the scoops ...

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

Page 37: ...placing the cables 4 and 5 Refit the cover 1 and tighten the screw Operation with damaged throttle cable could result in an unsafe riding condition Exhaust gas contains poisonous carbon monoxide Never run the engine indoors To replace the cables you will need to remove the fuel tank as described in the relevant paragraph Enrichener lever play adjustment The lever 1 holder features an adjuster scre...

Page 38: ... engine and with the throttle control in closed position Proceed as follows Turn the idle speed adjuster screw 3 located on the throttle body on the right hand side of the vehicle until setting idle speed to 1 600 RPM turn clockwise to increase the speed and counter clockwise to reduce it ...

Page 39: ... the motorcycle leaning to the left there is no need to drain engine oil Remove the brake pedal 1 Remove the six retaining screws 2 and the clutch cover 3 Using an 8 mm wrench unscrew the six screws 4 securing the clutch springs Remove springs pressure plate 5 with bearing 6 and clutch actuator plate 7 ...

Page 40: ...0 1 in The lever position can be adjusted to suit the rider hand size To decrease the lever distance from the handgrip rotate the adjuster B CLOCKWISE To increase the lever distance from the handgrip rotate the adjuster B COUN TER CLOCKWISE Fluid level is checked as follows Remove screws 1 cover 2 and rubber diaphragm from the control Keep the control cylinder 3 in a horizontal position and make s...

Page 41: ...et air into the system hence an extension of the lever stroke If the brake lever feels mushy when pulled there may be air in the brake line or the brake may be defective CHECK THE BRAKING SYSTEM see Section L Too much brake lever free play may reduce braking action CHECK BRAKE PAD THICKNESS see Section L Do not spill brake fluid onto any painted surface or lens for example lights lens Do not mix t...

Page 42: ...d according to individual needs For adjusting proceed as follows Loosen the screw 1 Turn the cam 2 in order to raise or lower the brake pedal within the range available A When finished tighten the screw 1 Once this adjustment is completed adjust the free play of the pedal following the instructions provided in paragraph Rear brake pedal free play adjustment ...

Page 43: ...er linkage 4 to increase or decrease free play Tighten the nut 3 at the end of the operation When the free play requirement is not met the brake pads will be subjected to an early wear that may lead to TOTAL BRAKE INEFFECTIVENESS If the brake pedal feels mushy when pulled there may be air in the brake line or the brake may be defective CHECK THE BRAKING SYSTEM see Section L Rear brake fluid level ...

Page 44: ...g the motorcycle level and upright check the oil level through the inspec tion window 1 on the right crankcase Make sure level is up to window midline 1 To top up remove the filler cap 2 Have this operation made with warmed up engine Be careful not to touch hot engine oil ...

Page 45: ...fit it into its seat TE 310 loosen tie 3a without disconnecting tube 3b unscrew hose tail 3c remove mesh filter 4 and drain the used oil Unscrew the screws 5 and remove cover 6 together with filter 7 Change the filter 7 and refit the assembly making sure to fit the Belleville washer 8 in the correct position TE TEi TC TXCi 250 Refit the drain plug 3 25 Nm 2 5 Kgm 33 89 ft lb and the oil sump guard...

Page 46: ...in eliminating coolant from painted surfaces If this occurs wash off with water Coolant replacement Place a vessel on the L H side of the cylinder under the hose 1 Loosen the clamp 2 on the hose 1 and detach the hose from the engine SLOWLY open the cap 3 of the right hand radiator and lean the motorcycle to the left to let the coolant drain into the vessel When finished refit the hose 1 and secure...

Page 47: ...2010 Air filter check TC Turn the rear fixing 1 counter clockwise remove it and extract the saddle re leasing it from the front retaining screw Remove the screw 3 remove the complete air filter 4 and separate filter 5 from rear chassis 6 ...

Page 48: ...5 from intake silencer 6 Air filter cleaning Wash the filter with a specific detergent see Capacities table in Section A then dry it fully wash filter with gasoline only in case of need Plunge the filter in special oil for filters see Capacities table in Section A then wring it to drain superfluous oil Do not use fuel or a low flash point solvent to clean the filtering element A fire or explosion ...

Page 49: ... sealing When refitting the filter into its housing make sure to position it with the tab A pointing upwards and edge B at the left bottom corner of the filter housing Refit any parts you have removed An improperly positioned filter might let dirt or dust into the engine leading to early wear of piston rings and cylinder A Upper side B Left hand side ...

Page 50: ...ree turns In this condition the chain should be neither taut nor slack Fig A Quick adjustment Fig B Insert a 35 mm socket a or a shim of the same size at the position shown in the figure and check that the lower section C of the chain is slightly taut If it is not proceed as follows Loosen the wheel axle nut 1 on the right hand side using a 27 mm socket wrench Loosen the check nuts 2 on both chain...

Page 51: ...especially trichloroethylene dry and lubricate the chain to avoid oxidisation Lubricating a chain without O rings After drying dip the chain in Molybdenum Disulphide chain lubricant if possible or in warm high viscosity engine oil if warmed up oil will be more fluid Lubricating an O ring chain Lubricate all metallic and rubber O ring elements using a brush and engine oil with SAE 80 90 viscosity i...

Page 52: ...d settings Work on the spring preload to lower the motorcycle riding height rear end MUDDY GROUND Front fork set compression harder or replace the standard spring with a harder spring Shock absorber harder compression and rebound settings or replace the standard spring with a harder spring Work on the spring preload to lift the motorcycle riding height rear end Changing the springs front and rear ...

Page 53: ...asure distance A 2 Sit on the motorcycle in normal riding position with full riding gear on 3 Have someone else measure distance A again 4 The difference between these two measurements is the distance the rear end settles when the rider sits on the motorcycle RIDER SAG Recommended rider sag is 100 mm with a cold shock absorber and 95 mm with a warm shock absorber 5 To achieve correct rider sag for...

Page 54: ...the retaining screws 2 and remove the right hand side panel 3 2 Clean lock ring nut 4 and adjuster ring nut 5 of the spring 6 3 Either with a hook wrench or an aluminium punch loosen the lock ring nut 4 Turn the adjuster ring nut as required 5 Adjust preload to suit your weight or riding style and tighten the lock ring nut firmly tightening torque 50 Nm 5 Kgm 67 8 ft lb 6 Reassemble the R H side p...

Page 55: ...tion Then turn them back the number of clicks speci fied above In order to obtain a smooth braking efficiency turn the adjusters counter clock wise Vice versa to obtain a harder braking action B REBOUND Standard setting 18 clicks 2 clicks To reset the standard setting turn lower adjuster 2 clockwise until reaching fully closed position Then turn it back by the mentioned clicks In order to obtain a...

Page 56: ...raking action REBOUND Fig b TC TXCi LOWER ADJUSTER TE TOP ADJUSTER KAYABA 9 clicks TC TXCi KAYABA 10 clicks TE To reset standard setting turn adjuster C clockwise to reach the fully closed position then turn it back by the mentioned clicks In order to obtain a smooth braking action turn the adjuster counter clockwise Vice versa to obtain a harder braking action BLEEDING Fig a b to carry out after ...

Page 57: ...D 27 H02190 TC TXCi H02191 TE SETTINGS AND ADJUSTMENTS Ed 07 2010 KAYABA front fork springs STANDARD TC TXCi K 4 4 N mm spring part no 8000 H2669 TE K 4 2 N mm spring part no 8000 H2690 ...

Page 58: ...ar motion to feel for play If any play is detected adjust as follows Loosen the steering head tube nut 1 Loosen the four bolts 3 that secure the fork legs to the steering head Turn the steering head tube ring nut 2 clockwise using the special key until achieving correct play adjustment Tighten the steering head tube nut 1 to 8 9 Kgm 78 4 88 3 Nm Tighten the four bolts 3 on the steering head to 22 ...

Page 59: ...bolts 3 and 4 and then remove the handlebar upper 1 and lower 2 clamps a Changing handlebar position Rotate the lower clamp by 180 to move handlebar position forward or back ward 10 mm 0 04 in b Changing handlebar height Remove the lower spacer A and replace the screw 4 with a 65 mm long screw When finished tighten the bolts 3 to 2 75 3 05 kgm 27 30 Nm 19 9 22 lb ft and the bolts 4 to 2 0 2 2 kgm ...

Page 60: ...y hose check Remove saddle and side panels as described in Section E Remove the tank 1 retaining screw 2 Lift the tank 2 and check the hose 3 running from the pump 4 to the throttle body 5 To replace the hose squeeze the two retainer tabs 6 at one end of the hose and detach hose Repeat at the other end of the hose ...

Page 61: ...2196 1 2 3 SETTINGS AND ADJUSTMENTS Ed 07 2010 Exhaust system check Remove exhaust system components as described in Section E Check pipes 1 and 2 silencer 3 for cracks or damage replace if cracked or damaged ...

Page 62: ......

Page 63: ...E 1 E GENERAL PROCEDURES Ed 07 2010 Section ...

Page 64: ...m removal E 8 Fuel tank scoops and spoiler removal E 10 Fuel pump removal TC E 14 Rimozione pompa benzina TE TXCi E 15 Solenoid starter removal TE TXCi E 16 Battery Less TC E 16 CDI electronic control unit removal E 17 Voltage regulator removal E 17 Ignition coil removal E 18 Clutch hose removal E 19 Horn removal TE E 19 Electric cooling fan removal TE TXCi E 20 Secondary drive chain removal E 21 ...

Page 65: ...s section describes the operations preliminary to engine removal Please note that in order to gain access to certain motorcycle components rear shock absorber electrical parts wiring etc it may be necessary to partially remove some parts RIGHT HAND SIDE LEFT HAND SIDE ...

Page 66: ...n the relevant paragraph Loosen the retaining screws 1 and remove the side panels 2 and 3 Battery removal TE TCXi Remove the saddle as described in the relevant paragraph First remove the BLACK negative cable 8 mm Allen wrench then the RED positive cable when reassembling first connect the RED positive cable then the BLACK negative cable remove the battery 1 from its housing ...

Page 67: ...dy Cut tie 4 and remove the condenser 5 from the chassis support Remove the upper fixing 6 and lower fixings 7 on both sides of the rear chassis using a 10 mm ring wrench Pull the rear chassis 8 rearwards together with mudguard and air box and detach it from the main chassis Removing the rear chassis complete with mudguard and air box TE TXCi Remove the following parts in the order given saddle si...

Page 68: ...621 8 7 GENERAL PROCEDURES Ed 07 2010 Disconnect the connector 4 of the tail light unit TE Detach relays 5 and fuses 6 on the right hand side of the motorcycle Detach the breather hose 7 from the air filter 8 ...

Page 69: ...rew the clamp 9 connecting air filter 8 to throttle body 10 Remove the four screws 11 of the rear chassis 12 using a 10 mm ring wrench Pull the rear chassis 12 rearwards together with mudguard and air box and detach it from the main chassis ...

Page 70: ...E 8 H02338 TE TXCi H02205 TC GENERAL PROCEDURES Ed 07 2010 Exhaust system removal ...

Page 71: ...left hand side panel as described in the relevant paragraph Using an 8 mm T wrench on the outside and a 10 mm T wrench on the inside remove the silencer 4 retaining screw 1 Remove the spring 2 TC and the screw 3 using an 8 mm T wrench slide out the silencer 4 Disconnect the Lambda sensor connector 7 and shear the wiring clips TE TXCi ...

Page 72: ... 7 7 6 TC H02211 TC Husqvarna 3 4 3 1 2 6 12 10 11 3 4 3 5 6 GENERAL PROCEDURES Ed 07 2010 TE TXCi Loosen the two bolts 5 and remove the exhaust pipe 6 TC Detach springs 7 and remove exhaust pipe 6 Fuel tank scoops and spoiler removal ...

Page 73: ...4 10 11 5 6 3 H02210 TE TXCi GENERAL PROCEDURES Ed 07 2010 Remove the saddle as described in the relevant paragraph Remove the side panels as described in the relevant paragraph Remove the breather hose 1 Loosen the fuel tank retaining screw 2 ...

Page 74: ...02212 4 3 3 GENERAL PROCEDURES Ed 07 2010 Remove the screws 3 retaining the scoops to the fuel tank Remove the scoops 4 and the screws 5 retaining the spoilers 6 to the radiators and then remove the spoilers ...

Page 75: ...tank and disconnect the hose 8 from the fuel pump outlet fitting 9 in the bottom section of the tank TE TXCi Close the two taps 7 and 8 and connect the hose 9 Disconnect connector 6 of the reserve sensor Lift the tank and disconnect the hose 10 from the fuel pump outlet fitting 11 in the bottom section of the tank Disconnect the fuel pump connector 12 from the main wiring harness Slide out the tan...

Page 76: ... described in the relevant paragraph Remove the tank filler cap and pour the fuel contained in the tank into a ves sel of adequate capacity Use an Allen wrench to loosen the 6 screws 1 and remove the pump 2 WARNING On assembly make sure that the pump O ring 3 is correctly po sitioned in its seat ...

Page 77: ...ke use of a 10 mm wrench to slacken the 4 screws 1 of the pump flange 2 and the four screws 3 of the fitting flange 4 Slide the fitting flange 4 out of the tank then remove the delivery and return hoses by releasing the quick fittings 5 and 6 Disconnect the pump supply connector 7 Slide the pump 2 with relevant small hoses out of the tank NOTE To refit the pump follow the removal reverse procedure...

Page 78: ... Disconnect the negative and positive cables of the battery Disconnect the starter motor positive cable 1 from the solenoid starter Disconnect the connector 2 and remove the solenoid starter 3 from its mount Battery Less TC Remove the left body panel as described in the relevant paragraph Disconnect the connector 1 Remove the condenser 2 with the relevant rubber support ...

Page 79: ...s described in the relevant paragraphs Detach the connector 1 from the CDI electronic control unit 2 and take the control unit together with its vibration mount out of the chassis TC Slacken the two screws 3 disconnect connector 4 and remove control unit 5 Voltage regulator removal Remove the electronic control unit as described in the relevant paragraph Disconnect the connector 1 ...

Page 80: ... GENERAL PROCEDURES Ed 07 2010 Loosen the two retaining screws 2 and remove the regulator 3 Ignition coil removal Remove saddle and fuel tank as described in the relevant paragraphs Remove the spark plug cap 1 Remove the retaining screws 2 and then the coil 3 ...

Page 81: ...Drain any oil left in the hose On assembly bleed the clutch system as de scribed in Section P Horn removal TE Remove saddle and fuel tank in this order as outlined in the relevant para graphs Loosen the screw 1 securing the spoiler to the right hand radiator Disconnect the two connectors 2 and remove the horn 3 with its bracket ...

Page 82: ...EDURES Ed 07 2010 Electric cooling fan removal TE TXCi Remove saddle fuel tank and scoops in this order as outlined in the relevant paragraphs Disconnect the connector 1 Loosen the screw 2 and remove the electric fan 3 ...

Page 83: ...hains without O rings Remove screws 1 sprocket guard 2 clip 3 master link 4 and chain 5 Engine removal Remove the saddle as described in the relevant paragraph Remove the side panels as described in the relevant paragraph Remove the fuel tank as described in the relevant paragraph Remove the exhaust system as described in the relevant paragraph ...

Page 84: ...ector 3 from the throttle body 4 Loosen the clamps 5 and 6 Push the intake coupling 7 towards the rear end of the motorcycle to re lease the throttle body 4 and then extract it from the right hand side of the motorcycle Place a vessel on the left hand side of the cylinder under the engine Slacken the radiator cap 8 ...

Page 85: ...n the clamp 11 and disconnect the hose 12 connecting the radiators to the engine Drain all fluid Slacken the clamp 13 and disconnect the hose 14 connecting the radiator to the water pump Drain engine oil as described in the relevant paragraph ...

Page 86: ...RES Ed 07 2010 Remove the spark plug cap 17 Remove the clamp 18 and disconnect the hose 19 from the cylinder head cover Remove the chain as described in the relevant paragraph Remove the chain guide plate 20 unscrewing the screw 21 with an 8 mm wrench ...

Page 87: ...oosen the three screws 22 and remove the clutch actuator 23 Remove the clip 24 that holds clutch hose and wiring harness together Disconnect connectors 25 and 26 that connect generator and gear sensor connector 27 Remove the water temperature sensor connector 27 Remove the ground cables 28 TE TXCi ...

Page 88: ... Ed 07 2010 Remove the positive power supply cable 29 of the starter motor TE TXCi To remove the brake lever 32 use an 8 mm wrench to loosen the master cylinder linkage 33 and a 6 mm Allen wrench to loosen the central screw 34 Remove the lever ...

Page 89: ... H02348 37 38 GENERAL PROCEDURES Ed 07 2010 Loosen the upper retaining screw 35 of the shock absorber 36 with a 14 mm wrench Remove the guards 37 on both sides shearing the clips 38 TE TXCi Loosen clamp 39 and disconnect the Blow by tube 40 ...

Page 90: ... on the right hand side Loosen the swinging arm axle nut 42 using a 22 mm wrench pull out the axle 43 from the right hand side of the engine and pull the swinging arm rearwards to facilitate engine removal Lift the engine tilt it to the left and remove it from the motorcycle Place the engine on a rotating stand to perform the procedures described in Sections F G H ...

Page 91: ...fan TE TXCi as described in the relevant paragraph Place a pan under the hose 1 to collect coolant then loosen the clamp 2 detach the hose 1 and drain all coolant Loosen the clamp 3 and disconnect the hose 4 from the left hand radiator 5 Loosen the clamp 6 and disconnect the hose 7 from the right hand radiator 8 Remove the plastic grids 9 from the radiators Remove the clamp 10 and disconnect the r...

Page 92: ...ft hand radiator 5 Loosen the screws 13 and remove the right hand radiator 8 Thermostat removal TE TXCi Remove the fuel tank and the left hand spoiler as outlined in the relevant paragraph Loosen the three clamps 1 securing the thermostat 2 Disconnect the hoses 3 and remove the thermostat 2 ...

Page 93: ...F 1 F ENGINE DISASSEMBLY Ed 07 2010 Section ...

Page 94: ...F 15 Kick start pedal removal F 16 Sprocket removal F 16 Oil filter removal F 18 Clutch cover removal F 19 Clutch disassembly F 20 Slider removal F 23 Kick start disassembly F 23 Starter motor removal TE TXCi F 25 Starter motor disassembly TE TXCi F 27 Starter drive disassembly TE TXCi F 27 Oil pump disassembly F 30 Gear shift pedal and selector assembly removal F 31 Primary drive gear removal F 3...

Page 95: ...SSEMBLY Ed 07 2010 Layout of engine components 1 Throttle body 2 Cylinder head cover 3 Cylinder head 4 Chain tensioner 5 Cylinder 6 Starter motor TE TXCi 7 Head lubrication pipe 8 Oil filter 9 Clutch cover 10 Kick start lever 11 Water pump 12 Alternator cover 13 Sprocket ...

Page 96: ...r head cover removal Remove the two retaining screws 1 10 mm wrench and remove the head cover 2 with its gasket Camshaft removal Remove the six retaining screws 1 of the alternator cover 2 4 mm Allen wrench and remove the cover with its gasket ...

Page 97: ...F 5 H02244 3 4 TE TXCi ENGINE DISASSEMBLY Ed 07 2010 To remove the gear sensor 3 loosen the two screws 4 8 mm wrench and its pushrod and spring ...

Page 98: ... a 17 mm wrench bring the piston to T D C at the end of the compres sion stroke in this condition the two holes 5 and the two marks 6 on the gears must be positioned as shown in the figure Cover parting line A is visible through the holes 4 INTAKE EXHAUST ...

Page 99: ...g 7 16 mm wrench and the head lubrication pipe 8 unscrewing the drilled screw 9 12 mm wrench Remove the screws 10 4 mm wrench and the screws 11 5 mm wrench from both clamps 12 and 13 and remove them Remove the intake camshaft 14 and the exhaust camshaft 15 ...

Page 100: ... 2010 Water pump body removal Remove the four screws 1 securing pump body 2 to head 4 mm Allen wrench and remove pump body Water pump disassembly Loosen the screw 1 to disassemble the pump Loosen the nut 2 to remove the impeller 3 ...

Page 101: ...d 07 2010 Remove the oil seal 4 and slide off the gear 5 together with the bearing 6 Remove the circlip 7 and remove the bearing 6 from the gear 5 On assembly make sure the centring pins 8 are correctly located in their seats ...

Page 102: ...move the camshafts as described in the relevant paragraph Remove the chain tensioner 1 as follows Loosen the screw 2 with an 8 mm wrench Turn the screw 3 fully clockwise with a flat head screwdriver until locking it so as to release the spring Loosen the two screws 4 using an 8 mm wrench and remove the chain tensioner 1 ...

Page 103: ...5 using a screwdriver Loosen the two screws 6 using a Phillips screwdriver and remove the timing drive shaft 7 while holding the gear 8 with your hand Support the gear 8 using a screwdriver or a punch unwrap the chain 9 and remove the gear Let the chain drop into the engine ...

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

Page 105: ...or they will weaken Mark all parts to ensure that they are refitted in their original positions on assembly If the valve collets have caused burrs on the valve stems remove them before removing the valves Remove the seals A from the valve guides Remember that seals must be replaced on assembly Compress the springs using the valve spring compressor 1 Remove valve collets 2 spring retainer 3 springs...

Page 106: ...2010 Cylinder removal Remove the front slider 1 of the timing chain pulling it upwards Remove the cylinder 2 with its gasket 3 Piston removal Remove the piston pin retaining rings 1 slide out the piston pin 2 and remove the piston 3 ...

Page 107: ...F 15 1 2 H02350 H02243 2 3A ENGINE DISASSEMBLY Ed 07 2010 Flywheel removal Loosen the rotor 2 nut 1 17 mm wrench Remove the rotor 2 using the puller 3A part no 8000 H2146 ...

Page 108: ...SEMBLY Ed 07 2010 Remove the key 4 from the crankshaft Kick start pedal removal Remove the pedal retaining bolt 1 12 mm wrench the washer and the pedal 2 Sprocket removal Lift the tab of the lock washer 1 using a chisel ...

Page 109: ...F 17 ENGINE DISASSEMBLY Ed 07 2010 Loosen the nut 2 using a 22 mm wrench and remove sprocket 3 and spacer 4 ...

Page 110: ... Ed 07 2010 Oil filter removal Loosen the drilled nut 1 and disconnect the hose 2 from the oil pump cover 3 Loosen the three screws 4 using an 8 mm wrench Remove the cover 3 together with its filter 5 and Belleville washer 6 ...

Page 111: ...F 19 ENGINE DISASSEMBLY Ed 07 2010 Clutch cover removal Remove the nine screws 1 and the screw 2 securing the cover 3 8 mm wrench and remove the cover 3 Remove the gasket 4 and the bushings 5 ...

Page 112: ... 2010 Clutch disassembly Remove the six retaining screws 2 and the clutch cover 3 Using an 8 mm wrench unscrew the six screws 4 securing the clutch springs Remove springs pressure plate 5 with bearing 6 and clutch actuator plate 7 ...

Page 113: ... 07 2010 Remove the plates 8 lubricate the new plates with engine oil and install them always start with a friction plate Remove the clutch pushrod 9 from the opposite side of the engine Straighten the tab of the lock washer 10 ...

Page 114: ...22 ENGINE DISASSEMBLY Ed 07 2010 Remove the nut 11 22 mm wrench using the clutch removal tool A part no 8000 79015 Remove the washer 10 Remove hub 12 washer 13 and clutch housing 14 Remove the bushing 15 ...

Page 115: ...removal Use a 5 mm Allen wrench to loosen the screw 1 and remove the slider 2 Kick start disassembly Release the spring 1 from the casing 2 and remove the complete shaft assembly 3 Be careful not to lose the washer 11 located on the crank case ...

Page 116: ...MBLY Ed 07 2010 Remove the snap ring 4 the washer 5 and the timing drive gear 6 Disassemble the shaft as shown in the diagram On assembly make sure that the dot 7 on shaft end 8 and the dot 9 on the ratchet 10 are aligned ...

Page 117: ...LY Ed 07 2010 Starter motor removal TE TXCi Remove the exhaust pipe as described in the relevant paragraph Disconnect the positive power supply cable 1 loosening the hexagonal head screw 8 mm wrench Unscrew the four screws 2 using a 4 mm Allen wrench ...

Page 118: ...de the starter motor 3 towards the rear end of the motorcycle to remove it WARNING Upon assembly check the gasket 4 for damage and replace it if needed Make sure to position it correctly with the gasket hole 5 matching the hole 6 in the starter motor flange ...

Page 119: ...F 27 ENGINE DISASSEMBLY Ed 07 2010 Starter motor disassembly TE TXCi Separate the starter motor 1 from the starter drive 2 Starter drive disassembly TE TXCi ...

Page 120: ...ove flywheel and starter motor as outlined in the relevant paragraph Disassemble the starter motor as outlined in the relevant paragraph Remove the cap 1 using a 10 mm Allen wrench Remove the circlip 2 and the bearing 3 with the bevel gear ...

Page 121: ...SSEMBLY Ed 07 2010 Place the wormshaft 4 assembly in a vice with aluminium jaws loosen the nut 5 using a 10 mm T wrench and slide out the wormshaft 4 Remove the freewheel 6 Remove the needle roller bearing 7 and the thrust ring 8 ...

Page 122: ...using a 4 mm Allen wrench and remove pump body 2 and gasket Remove the pump rotors 3 and 4 and extract the drive pin 5 to release the gear 6 Remove drive gear 7 and oil suction stub 8 Make sure to align the rotor dots 9 on assembly Gear shift pedal and selector assembly removal ...

Page 123: ...t Remove the retaining screw 2 of the gear shift pedal 1 8 mm wrench and slide the pedal from the selector shaft Remove the selector shaft 3 from the right hand side Remove the two screws 4 4 mm Allen wrench and 8 mm wrench secur ing the selector retaining plate 5 and remove retaining plate and ratchet mechanism 6 ...

Page 124: ...ENGINE DISASSEMBLY Ed 07 2010 Remove the bolt 7 of the selector drum 8 12 mm wrench Release the ratchet 10 spring 9 and remove retaining ring 11 washer 12 and ratchet 10 Be careful not to lose the roller 13 ...

Page 125: ...F 33 ENGINE DISASSEMBLY Ed 07 2010 Primary drive gear removal Loosen the central nut 1 using a 22 mm wrench Remove primary gear 2 and water pump drive gear 3 ...

Page 126: ...case disassembly Remove the nine screws 1 from the left crankcase 2 8 mm wrench Important the screws 1 are not all the same length Refer to figure A on assembly to ensure correct installation FIG A a1 6x60 mm a2 6x55 mm a3 6x70 mm a4 6x90 mm ...

Page 127: ...ankcase half 4 Tap the output shaft 5 with a rubber hammer at intervals during removal to keep the crankcase half from getting stuck Gearbox disassembly Remove the shaft 1 of the output shaft shifter forks Release the shifter forks 2 and 3 from the drum 4 and remove the forks making sure to collect the drive bushings 5 Remove the drum 4 ...

Page 128: ...6 ENGINE DISASSEMBLY Ed 07 2010 Remove the retaining ring 5 and then the shaft 6 of the input shaft shifter fork 7 Remove the input shaft 8 and output shaft 9 being careful not to lose any shims if fitted ...

Page 129: ... part no 8000 A7015 over the right end of the crank shaft Secure the puller to the crankcase half and remove the crankshaft 2 from the opposite side In case crankshaft and or connecting rod are worn it is necessary to replace the whole crankshaft assembly and the connecting rod ...

Page 130: ......

Page 131: ...G 1 G ENGINE OVERHAUL Ed 07 2010 Section ...

Page 132: ...in and gears G 10 Timing chain tensioners G 10 Cylinder G 11 Piston G 11 Cylinder to piston clearance G 12 Piston pin G 12 Piston rings G 13 Piston ring to cylinder clearance G 13 Piston ring to groove clearance G 14 Big end axial clearance G 14 Crankshaft G 15 Crankshaft straightness G 15 Crankshaft G 15 Clutch G 16 Friction plate to clutch housing clearance G 17 Clutch spring G 17 Oil pump G 19 ...

Page 133: ... be within the specified tolerance A tight fit will lead to seizure as moving parts heat up whereas a loose fit will cause annoying vibration resulting in early wear of moving parts Cylinder head Remove fouling deposits from the combustion chamber using a rounded scraper Do not use sharp tools or you might damage valve seats and spark plug thread Check the machined surface of the cylinder head for...

Page 134: ... similar tool Remove the valve and measure the width X of the seating face If width is greater than 1 2 mm 0 0472 in the seat needs to be refaced The standard width measured as shown of the seating face of the valve is x 0 6 0 7 mm 0 0236 0 0275 in for INTAKE valves x 0 7 0 8 mm 0 0275 0 0314 in for EXHAUST valves Valves cannot be ground and must be replaced if damaged INTAKE EXHAUST ...

Page 135: ...o each other using a suitably positioned dial gauge Intake valve normal clearance 0 008 0 035 mm Service limit 0 05 mm 0 0019 in Exhaust valve normal clearance 0 018 0 045 mm Service limit 0 08 mm 0 0031 in Valve guide replacement Make sure that the cylinder head is not damaged Heat up the head in a furnace at 170 C for 30 minutes Remove the valve guide from the cylinder head using a suitable punc...

Page 136: ...e guide with oil before installation Ream the valve guide using a suitable reamer and lubricate with cutting fluid Rotate the reamer when extracting it to avoid scoring the valve guide When a valve guide is changed the valve seat must be refaced Check clearance again as outlined above Refit the sealing rings 1 ...

Page 137: ...t 0 05 mm Valve head out of round place valve on a V block and check with a dial gauge at right angles to the head while turning the valve Service limit 0 03 mm Valve spring Check free length L Replace springs if they exceed the service limit Intake Spring 1 L1 25 4 mm Service limit 23 9 mm Spring 2 L2 21 4 mm Service limit 19 9 mm Exhaust Spring 1 L2 22 6 mm Service limit 21 1 mm Spring 2 L2 19 6...

Page 138: ...slides freely in their seats If not so replace them Valve installation Smear valve guides and stems with oil before installation Install spring seat 1 and springs 2 place spring a at head end and finally the spring retainer 3 Use tool no 8000 A7317 to compress the valve springs and install the valve collets 4 Do not compress the springs too much and avoid damage to the cylinder head ...

Page 139: ...ightly with a plastic hammer and an aluminium punch to help the valve collets become seated Tap the valve stem tip to avoid pushing the valve off centre Valve leak check Check the valves for proper sealing before assembling the cylinder head to the engine ...

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

Page 141: ...out of round Max taper wear limit 0 05 mm Max out of round wear limit 0 05 mm If cylinder is worn beyond these limits replace both cylinder and piston The liner undergoes a special hardening treatment and cannot be ground Piston Clean off any carbon deposits from piston crown and grooves Perform a careful visual inspection of the piston and check its dimensions There should be no signs of forcing ...

Page 142: ...r diameter Measure inside diameter Dc with an internal bore micrometer 25 mm 0 9842 in below the edge distance A Piston diameter Measure piston diameter Dp 7 mm 0 2755 in above skirt edge distance B Clearance is calculated as follows Dc Dp Piston pin The piston pin 1 must be perfectly smooth with no signs of scoring dents or bluing due to overheating ...

Page 143: ...n Piston ring to cylinder clearance Insert the piston ring at the bottom of the bore where minimum wear occurs taking care to position it squarely and measure end gap Piston ring to cylinder clearance PISTON RING MOUNTING CLEARANCE H SERVICE LIMIT A 0 15 0 30 mm 0 00591 0 01182 in 0 45 mm 0 01773 in B 0 2 0 7 mm 0 00788 0 02758 in 0 85 mm 0 03349 in ...

Page 144: ...end clearance A 0 019 0 01 mm SERVICE LIMIT 0 050 mm Big end side clearance B 0 018 0 030 mm SERVICE LIMIT 0 070 mm Big end axial clearance Measure axial clearance A between crankshaft 1 and connecting rod 2 using a feeler gauge Compare measured clearance with the table below PISTON RING MOUNTING CLEARANCE H SERVICE LIMIT A 0 02 0 06 mm 0 00078 0 02362 in 0 09 mm 0 00354 in B 0 01 0 18 mm 0 00039 ...

Page 145: ...od condition Crankshaft straightness Place the crankshaft 1 on a stand 2 with two dial gauges 3 positioned on the journals Turn the crankshaft and measure runout STANDARD SERVICE LIMIT than 0 02 mm 0 00078 in than 0 04 mm 0 0015 in If measured runout exceeds 0 04 mm 0 0016 in the crankshaft must be straightened or replaced Crankshaft ...

Page 146: ...ow no signs of bluing scoring or distortion Measure the thickness of friction plates Plate thickness when new 3 0 mm 0 1181 in Service limit 2 9 mm 0 1141 in Clutch pack thickness 29 4 mm 1 1574 in Place each friction and steel plate on a surface plate and check for distortion using a feeler gauge Use a feeler gauge Service limit 0 2 mm ...

Page 147: ...nce exceeds the service limit replace clutch plates or housing and repeat measurement If measurement is still outside the service limit replace the complete clutch assembly Clutch spring Measure the free length L of each spring with a calliper New spring L 37 3 mm 1 4685 in Service limit 35 mm 1 3779 in Change any spring that is outside the service limit STANDARD SERVICE LIMIT 0 30 0 50 mm 0 012 0...

Page 148: ...art 5 Clutch hub Check the steel plate slots for signs of wear or failure If any are found replace the part 6 Clutch housing Check the friction plate slots for signs of wear or failure Check the needle roller bearing seats for signs of wear If any are found replace the part 7 Primary drive gear pair Check gear teeth for signs of wear or failure If any are found replace the part ...

Page 149: ... Allen wrench and remove pump body 2 and gasket Remove the pump rotors 3 and 4 and extract the drive pin 5 to release the gear 6 Check gear 6 and rotors 4 for wear Replace if worn Smear the rotors with oil and make sure to align the rotor dots 9 on assembly Use a new gasket ...

Page 150: ...hree gears is outside the service limit measure the width of gear groove and fork thickness to determine which component needs to be replaced Shifter fork to groove clearance new fork and gear 0 22 0 37 mm 0 008661 0 014566 in Service limit 0 5 mm 0 019685 in Selector drum Check the grooves A for wear or dents and make sure the selector drum is not bent worn or damaged Drive bushing roundness Chec...

Page 151: ...H 1 H ENGINE REASSEMBLY Ed 07 2010 Section ...

Page 152: ...SPEED H 17 Output shaft 5 SPEED H 18 Input shaft 6 SPEED H 20 Output shaft 6 SPEED H 21 Crankcase assembly H 22 Gear shift control assembly H 27 Kick start assembly H 31 Timing chain and primary drive assembly H 32 Clutch assembly H 35 Sprocket installation H 37 Flywheel and starter motor installation H 38 Assemble the starter motor 7 H 39 Piston ring installation H 40 Piston and cylinder installa...

Page 153: ...ated for a certain life We recommend replacing the bearings especially those exposed to heavy loading also considering that checking them for wear is not an easy procedure These recommendations are in addition to the dimensional checks of individual components specified in the relevant section see Section G ENGINE OVERHAUL Cleaning all components thoroughly is critical to reliability bearings and ...

Page 154: ...H 4 ENGINE REASSEMBLY Ed 07 2010 Assembly and lubrication instructions CRANK ALTERNATOR LUBRICATION LEFT CRANKCASE HALF ...

Page 155: ... TE TXCi M5 L35 6 Nm 0 6 Kgm 4 43 ft lb 3B TC M5 L25 6 Nm 0 6 Kgm 4 43 ft lb 3B TE TXCi M5 L35 6 Nm 0 6 Kgm 4 43 ft lb 19 M5x0 8 L12 Loctite 270 or 272 8 Nm 0 8 Kgm 5 9 ft lb 49 M5 L8 6 Nm 0 6 Kgm 4 43 ft lb LUBRICATION POINTS NOTES LUBRICANT INSTALLATION INSTRUCTIONS A Degrease B Apply engine oil on installation E Line up stator mark with cover mark G WATER RESISTANT grease O Engine oil ...

Page 156: ...H 6 ENGINE REASSEMBLY Ed 07 2010 Assembly and lubrication instructions GEARBOX GEAR SHIFT CONTROL ...

Page 157: ... L13 LOCTITE 243 8 Nm 0 8 Kgm 5 9 ft lb 23B M6 L14 LOCTITE 243 8 Nm 0 8 Kgm 5 9 ft lb 24 M5x0 8 L12 6 Nm 0 6 Kgm 4 43 ft lb 48 M6 L20 8 Nm 0 8 Kgm 5 9 ft lb LUBRICATION POINTS NOTES LUBRICANT INSTALLATION INSTRUCTIONS D Install with open end pointing to engine centre O Engine oil O G Engine oil or WATER RESISTANT grease ...

Page 158: ...H 8 ENGINE REASSEMBLY Ed 07 2010 Assembly and lubrication instructions GEARBOX GEAR SHIFT CONTROL ...

Page 159: ... L13 LOCTITE 243 8 Nm 0 8 Kgm 5 9 ft lb 23B M6 L14 LOCTITE 243 8 Nm 0 8 Kgm 5 9 ft lb 24 M5x0 8 L12 6 Nm 0 6 Kgm 4 43 ft lb 48 M6 L20 8 Nm 0 8 Kgm 5 9 ft lb LUBRICATION POINTS NOTES LUBRICANT INSTALLATION INSTRUCTIONS D Install with open end pointing to engine centre O Engine oil O G Engine oil or WATER RESISTANT grease ...

Page 160: ...H 10 ENGINE REASSEMBLY Ed 07 2010 Assembly and lubrication instructions CLUTCH KICK START LUBRICATION RIGHT CRANKCASE HALF ...

Page 161: ...octite 5205 19 M5 L12 LOCTITE 270 or 272 6 Nm 0 6 Kgm 4 43 ft lb 26 M8 X 1 25 Al 8 Nm 0 8 Kgm 5 9 ft lb 27 M5 L16 8 Nm 0 8 Kgm 5 9 ft lb 28 M5 x 0 8 L20 6 Nm 0 6 Kgm 4 43 ft lb 29 M6 x 1 LOCTITE 243 8 Nm 0 8 Kgm 5 9 ft lb 30 M8 x 1 25 LOCTITE Alt 272 25 Nm 2 55 Kgm 18 44 ft lb 31 M6 L14 LOCTITE Alt 272 8 Nm 0 8 Kgm 5 9 ft lb 32 M6 L10 LOCTITE Alt 243 8 Nm 0 8 Kgm 5 9 ft lb 40 M6 L20 8 Nm 0 8 Kgm 5...

Page 162: ...H 12 ENGINE REASSEMBLY Ed 07 2010 Assembly and lubrication instructions RIGHT CRANKCASE COVER ...

Page 163: ...es LUBRICATION POINTS NOTES LUBRICANT INSTALLATION INSTRUCTIONS O Engine oil O G Engine oil or WATER RESISTANT grease 27 M5 L16 6 Nm 0 6 Kgm 4 43 ft lb 33 M6 L22 8 Nm 0 8 Kgm 5 9 ft lb 34 M6 x 1 L50 8 Nm 0 8 Kgm 5 9 ft lb 35 M6 x 1 L20 8 Nm 0 8 Kgm 5 9 ft lb ...

Page 164: ...H 14 ENGINE REASSEMBLY Ed 07 2010 Assembly and lubrication instructions HEAD CYLINDER PISTON TIMING SYSTEM WATER PUMP SPARK PLUG ...

Page 165: ... 5 9 ft lb 37 Special flanged screw L 31 3 8 Nm 0 8 Kgm 5 9 ft lb 38 M5 x 0 8 L8 LOCTITE 243 6 Nm 0 6 Kgm 4 43 ft lb 39 M10 x 1 25 5 Nm 0 5 Kgm 3 69 ft lb 40 M10 L104 5 40 Nm 4 Kgm 29 5 ft lb 41 M10 L104 5 40 Nm 4 Kgm 29 5 ft lb 42 M6 L20 8 Nm 0 8 Kgm 5 9 ft lb 43 M4 L10 3 Nm 0 3 Kgm 2 21 ft lb 44 M5 L25 6 Nm 0 6 Kgm 4 43 ft lb 45 M4 L12 LOCTITE 243 3 Nm 0 3 Kgm 2 21 ft lb 46 M5 LOCTITE 270 or 272...

Page 166: ...H 16 ENGINE REASSEMBLY Ed 07 2010 Input shaft Output shaft ...

Page 167: ...then install the washer 3 and the retaining ring 4 The washer must be placed between gear and retaining ring Fit 3rd gear 5 retaining ring 6 and washer 7 Fit the roller cage 8 Fit 4th gear 9 Fit 2nd gear 10 Fit the circlip 11 B with 5th gear engaged C with 4th gear engaged D lubricate with MOLYKOTE G n plus ...

Page 168: ...r 5 and retaining ring 6 Fit the washer 7 Fit roller cage 8 and 3rd gear 9 Fit washer 10 and retaining ring 11 Apply MOLYKOTE G n plus on the 3rd gear 9 Fit 5th gear 13 and washer 14 Fit roller cage 15 1st gear 16 and washer 12 A with 1st gear engaged B with 3rd gear engaged C with 2nd gear engaged D lubricate with MOLYKOTE G n plus ...

Page 169: ...H 19 ENGINE REASSEMBLY Ed 07 2010 Input shaft Output shaft ...

Page 170: ... and then install the washer 3 and the retaining ring 4 The washer must be placed between gear and retaining ring Fit 3rd 4th gear 5 retaining ring 6 and washer 7 Fit the roller cage 8 Fit 6th gear 9 Fit 2nd gear 10 Fit the circlip 11 B with 5th gear engaged and 5th gear in contact with 1st gear C with 4th gear in contact with 6th gear ...

Page 171: ...ining ring 13 Apply MOLYKOTE G n plus on the 4th gear 11 Fit 5th gear 14 and washer 15 Fit roller cage 16 1st gear 17 and washer 18 A Control dimension with 1st gear engaged and 1st gear butted up on the shaft B Control dimension with 4th gear engaged and 4th gear butted up against shaft washer and circlip C Control dimension with 3rd gear engaged and 1st and 3rd gears and their washers and circli...

Page 172: ...8A00 90662 Heat up to around 125 C and drive the ball bearings into each crankcase half using a suitable driver tool Fit the retaining plates 1 and 2 to the crankcase bearings 5 Nm 0 5 Kgm 3 6 ft lb Loctite 272 for crankshaft bearing retaining plate 1 11 Nm 1 1 Kgm 7 9 ft lb Loctite 272 for right hand bearing retaining plate 2 ...

Page 173: ...010 Install the input and output shaft assembly making sure the output shaft 3 shim is in place Lubricate the three shifter forks 4 with engine oil and install them Make sure the bushings 5 are correctly in place grease the bushings ...

Page 174: ...drum 6 into its seat Install the fork shafts 7 and 8 and make sure the forks move freely Make sure the fork bushings 5 are correctly located in the drum grooves 6 Insert the circlip 9 of the input shaft fork shaft Rotate the selector drum to test operation ...

Page 175: ...up the crankshaft bearing 10 and install the crankshaft 11 Make sure both crankcase locating bushings 12 are in place Apply a layer of LOCTITE 5205 on the right crankcase mating surface 13 making sure not to obstruct the oil passage hole 14 ...

Page 176: ...c hammer Tighten the screws 15 using an 8 mm wrench 10 Nm 1Kgm 7 25 ft lb Make sure to fit the screws in the correct positions according the specified pattern see Section F paragraph Crankcase disassembly Cover the upper section of the engine with a cloth a sponge or the like to prevent screws or other parts from accidentally falling into the engine ...

Page 177: ...rench apply Loctite 243 and tighten to 20 Nm 2 0 Kgm 14 5 ft lb Install ratchet 2 spring 3 washer 4 and circlip 5 Install the selector drum 6 making sure the tab 7 locates in the recess 8 and secure drum with its screw 9 Apply Loctite 243 tighten to 20 Nm 2 0 Kgm 14 5 ft lb use 12 mm wrench Engage the spring 3 ...

Page 178: ...ogether with the plate making sure ratchets and springs are in the correct positions Tighten the upper screw 11 using a 4 mm Allen wrench Loctite 243 10 Nm 1 0 Kgm 7 2 ft lb Tighten the lower screw 12 using an 8 mm wrench Loctite 243 10 Nm 1 0 Kgm 7 2 ft lb Turn the engine over and install the gear shift lever oil seal 13 and its circlip 14 ...

Page 179: ... shaft is positioned correctly Check the gear shift lever shaft 16 and the slot of the gear selector mechanism for signs of wear Lubricate the shaft with engine oil and insert the shaft 16 into the crankcase so that the fork 17 slides over the ratchet detent and the spring 18 locates to its abutment pin ...

Page 180: ...H 30 ENGINE REASSEMBLY Ed 07 2010 Install the gear shift lever 19 and operate the gearbox manually 8 mm wrench 8 Nm 0 8 Kgm 5 8 ft lb ...

Page 181: ...ate 1 use a 4 mm wrench 8 Nm 0 8 Kgm 5 8 ft lb Loctite 243 Fit the complete shaft assembly 2 to its seat B in the crankcase making sure the ratchet is correctly positioned on the shaft marks lined up and insert the spring end 3 into the hole D Fit transmission gear 4 washer 5 and snap ring 6 ...

Page 182: ...lider 1 tighten the screw 2 using a 5 mm wrench 10 Nm 0 1 Kgm 7 3 ft lb Loctite 243 and make sure the slider moves freely Fit the oil pump drive gear 3 making sure the side with the dot is facing out side Fit the primary drive double gear 4 making sure to line up the timing dot A with the shaft dot B ...

Page 183: ...H 33 ENGINE REASSEMBLY Ed 07 2010 Install the timing chain 5 Refit the bushing 6 Refit the clutch housing 7 ...

Page 184: ...GINE REASSEMBLY Ed 07 2010 Place a dummy gear 8 or an aluminium shim between clutch housing 7 gear and double gear 4 and then tighten the primary drive shaft nut 9 use a 22 mm wrench 100 Nm 10 Kgm 72 50 ft lb ...

Page 185: ...H 35 ENGINE REASSEMBLY Ed 07 2010 Clutch assembly Install washer 1 hub 2 lock washer 3 and nut 4 Use the suitable tool 5 to prevent rotation and tighten to 60 Nm 6 Kgm 43 5 ft lb use a 22 mm wrench ...

Page 186: ... keep alternating between friction and steel plates the last to go in should be a steel plate Fit actuator plate 7 thrust bearing 8 thrust washer 9 pressure plate 10 and springs 11 Tighten the spring screws 12 gradually in a cross pattern 5 Nm 0 5 Kgm 3 6 ft lb Turn the engine over Install the clutch pushrod 13 ...

Page 187: ...screws 2 use an 8 mm wrench 5 5 Nm 0 55 Kgm 4 ft lb Fit the spacer 3 with the grooved side facing inwards Install sprocket 4 lock washer 5 and nut 6 Hold the sprocket 4 with the suitable tool 7 to prevent rotation and tighten the nut 6 use a 22 mm wrench 100 Nm 10 Kgm 72 5 ft lb Bend the tabs of the lock washer ...

Page 188: ... rotor to remove any debris suspended in swirling oil and captured by the magnets Fit the tab 1 to the crankshaft TE TXCi Lubricate needle roller bearing 2 and thrust ring 3 with engine oil and install them making sure the thrust ring slots are pointing outwards TE TXCi Lubricate the freewheel 4 with engine oil and refit it ...

Page 189: ... installing the starter motor 7 check for free clockwise rotation of the freewheel 4 while holding the rotor 5 steady Assemble the starter motor 7 WARNING On assembly check the gasket 8 for damage and re place it if needed Make sure to position it correctly with the gasket hole 9 matching the hole 10 in the starter motor flange Fit the starter motor 7 into place Tighten the bevel drive screws 11 u...

Page 190: ...oil rail end gap position C1 Oil rail spacer end gap position C1 Bottom oil rail end gap position Piston and cylinder installation Remove the rubber protection 1 Install a new cylinder foot gasket 2 Assemble piston 3 to connecting rod 4 lubricate with engine oil and fit the piston pin retaining rings 5 Make sure the arrow mark on the piston is pointing to the front end Make sure that the locating ...

Page 191: ...H 41 ENGINE REASSEMBLY Ed 07 2010 Lubricate the cylinder liner 7 with engine oil and slide it over the piston rings Make sure to collect the timing chain 8 Position the slider 9 ...

Page 192: ...low Remove spacers and screws 10 and fit the appropriate head gasket Cylinder head gasket selection table Bring piston to T D C at the end of the compression stroke measure distance A between piston crown and head gasket mating face and select the appropriate gasket according to the table below CONDITION see diagram A Gasket thickness Gasket part no 1 piston lower than cylinder mating face 0 1 0 0...

Page 193: ...d gasket selection table Install the head 1 while supporting the timing chain 2 with a screwdriver Tighten the head bolts 3 gradually in a cross pattern to 40 Nm 4 Kgm 29 ft lb use a 12 mm wrench WARNING Refit each of the bolts 3 and 3a in its original position Bolt 3 119 5 mm long Bolt 3a 104 5 mm long Refit the water temperature sensor 4A use a 17 mm ring wrench 5 Nm 0 5 Kgm 3 69 ft lb ...

Page 194: ...val Check the bearings of the timing drive upper gear 7 and replace them if needed The gear 7 requires no timing Refit the gear 7 with its shaft 8 and gasket 9 Tighten the screws 10 with a Phillips screwdriver 4 Nm 0 4Kgm 2 9 ft lb Loctite 243 Push the gear until exposing the groove and fit the retaining ring 11 ...

Page 195: ... mm On assembly position the screw 13a at the uppermost position and fit the ground rings 14 before tightening IMPORTANT Do not confuse the screws and do not tighten the screw 13a unless you have fitted the ground rings RISK OF CYLINDER FAILURE Release the chain tensioner 12 using a screwdriver turn counter clockwise Water pump installation Refit the water pump 1 with its gasket Avoid using excess...

Page 196: ...k plug hole Turn the crankshaft manually until bringing the piston to Top Dead Centre Refit intake camshaft 2 and exhaust camshaft 3 with the gears positioned as shown in the figure Cover parting line A is visible through the holes 4 Make sure that the bushings 5 are in place in the covers ...

Page 197: ...e 8 to check clearance between valve buckets and cam lobes Correct values are as follows intake 15 hundredths exhaust 20 hundredths If the value is outside the limit remove the covers and replace the shims under the valve buckets with shims of the appropriate size so as to achieve correct clearance Replacement shims are available in a 1 60 mm to 2 60 mm thickness range in 0 05 mm increments Thickn...

Page 198: ...g screws 2 use a 4 mm Allen wrench 6 Nm 0 6 Kgm 4 3 ft lb Loctite 272 Insert the cable guide 3 into its seat in the cover and tighten the two retaining screws 4 of the pick up sensor 5 with its plate 6 Nm 0 6 Kgm 4 3 ft lb Loctite 272 Install the flywheel cover 7 with its gasket and tighten the six screws 8 to 6 Nm 0 6 Kgm 4 3 ft lb Make sure the two centring bushings 6 are in place ...

Page 199: ...E REASSEMBLY Ed 07 2010 Neutral sensor installation Refit pin 1 and spring 2 Check the O ring 3 of the sensor 4 Refit the sensor 4 and tighten the screws 5 using an 8 mm wrench 5 5 Nm 0 55 Kgm 4 ft lb Loctite 243 ...

Page 200: ...ighten the screws 2 with the wire clip 3 placed on the upper screw Cylinder head cover spark plug oil feed hose installation Position the central seal 1 Fit the head cover 3 with its gasket to the head 2 Tighten the screws 4 and 4a 8 Nm 0 8 Kgm 5 9 ft lb Screw 4 L 23 4 mm Screw 4a L 31 3 mm Install the spark plug 10 12 Nm 1 1 23 Kgm 7 2 8 9 ft lb ...

Page 201: ...ts shaft 2 Check the O rings of the oil suction stub 3 and replace them if needed Refit the oil suction stub 3 Refit the centring bushings 4 Refit the gasket 5 Manually check for correct installation and operation of the pump 6 and make sure the crankshaft sealing ring 7 is in the correct position ...

Page 202: ... sure pump gear and drive gear engage correctly Check the O ring 10 for damage and replace it if needed Refit the spring 11 of the oil filter 12 Refit the oil filter into its housing and tighten the screws 13 using an 8 mm wrench 5 5 Nm 0 55 Kgm 3 98 ft lb WARNING When assembling filter to cover make sure to fit the filter oil seal A first onto the cover 6 ...

Page 203: ... 2 into place with its gasket using a 12 mm wrench 25 Nm 2 5 Kgm 18 44 ft lb Blow by tube fitting filter 310 Insert the oil filter 1 screw the hose fitting 2 insert hose 3 and screw clamp 4 Oil feed hose installation Refit the hose 1 and tighten the drilled screws 2 with their seals using a 12 mm wrench 8 Nm 0 8 Kgm 5 9 ft lb ...

Page 204: ...all the gear shift pedal 1 and tighten the screw 2 using an 8 mm wrench 8 Nm 0 8 Kgm 5 8 ft lb Check the pedal 1 for damage Refit the kick start pedal 3 and tighten the screw 4 using a 12 mm wrench 25 Nm 2 5 Kgm 18 44 ft lb Loctite 272 Make sure that the pedal does not foul the cover ...

Page 205: ... Kgm 10 8 ft lb Refit the coolant hoses with their clamps Refit the rear brake pedal with its bolt 41 6 Nm 4 2 Kgm 30 7 ft lb Loctite 243 Refit the side guards of the chassis Refit the carburettor Refittheexhaustsystem piperetainingscrews 10 4Nm 1Kgm 7 7ft lb exhaust pipe retaining screws use an 8 mm wrench 8 4 Nm 0 8 Kgm 5 8 ft lb Refit the fuel tank together with the scoops Refit the fuel tank f...

Page 206: ......

Page 207: ...I 1 I FRONT SUSPENSION Ed 07 2010 Section ...

Page 208: ...I 2 FRONT SUSPENSION Ed 07 2010 Front fork removal I 4 Service instructions for Ø48USD Kayaba fork TC TXCi I 6 Front suspension TC TXCi I 7 Front fork disassembly TC TXCi I 8 Front suspension TE I 18 ...

Page 209: ...I 3 H02176 TC H02177 TE H02178 TXCi FRONT SUSPENSION Ed 07 2010 ...

Page 210: ...r the engine and see that the front wheel is lifted from the ground and then proceed as follows remove the screws 1 and the brake line clamp on the left hand side remove the six screws 2 and the fork leg guards remove the brake calliper from the L H fork leg loosening the two retaining screws 3 remove the front wheel as described in Section Y ...

Page 211: ...USPENSION Ed 07 2010 loosen the bolts 4 that secure the fork legs to steering head and bottom yoke remove the fork legs Refit fork legs and front wheel as described in Section Y Set height A back to original value ...

Page 212: ...TIN coated OUTER TUBES CNC machined aluminium alloy anodised and polished in side SLIDING BUSHES Teflon coated stiction free SEALS Computer designed sealing rings ensure maximum sealing on compression and minimal friction on rebound SPRINGS Steel springs different spring rates K available See Table for more detailed information OIL Special KAYABA formulation prevents foaming and retains same visco...

Page 213: ...7 H02255 TC TXCi FRONT SUSPENSION Ed 07 2010 Front suspension TC TXCi 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 214: ...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 not to hurt your fingers ...

Page 215: ...t 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 216: ...her 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 217: ... 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 surface If repair ...

Page 218: ...g 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 Install the retaining ring Make sure tha...

Page 219: ...ke 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 220: ...mbly 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 figure Pump the piston rod up and down...

Page 221: ...iston 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 cartridge Insert the cartridge into t...

Page 222: ... 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 223: ... FRONT SUSPENSION Ed 07 2010 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 224: ...FRONT SUSPENSION Ed 07 2010 Front suspension TE Front suspension is handled by a KAYABA upside down telescopic hydraulic fork with advanced axle and 48 mm legs Wheel travel is 300 mm Front suspension Mod TE ...

Page 225: ... 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 226: ...I 20 FRONT SUSPENSION Ed 07 2010 Remove nut spring guide O ring and collar bushing Hold the cartridge top end steady Loosen and remove the bottom valve assembly ...

Page 227: ...I 21 FRONT SUSPENSION Ed 07 2010 Take the cartridge out of the outer tube Remove the dust seal using a flat head screwdriver ...

Page 228: ...ating them Remove the sealing rings and the metal rings mounted on the inner tube Do not reuse any metal parts after removal Replace them with new components Replace damaged sealing rings Washer and retaining ring may be reused if they are not damaged Check the rebound adjuster rod for distortion or damage Replace as required Loosen and remove the bottom valve assembly Replace damaged O rings Repl...

Page 229: ...ot possible replace the tube Never reuse an inner tube if scored or showing bulges on the outer surface Check the outer tube Replace the tube is any distortion is detected or if the sliding surface is dam aged Mount sealing rings and metal parts on the inner tube See the figure below for the installation sequence Note 1 Grease the edge of the sealing ring Note 2 Before sliding the sealing ring ove...

Page 230: ...and push it home using an appropriate in staller Make sure that the retaining ring groove inside the outer tube is fully visible Install the retaining ring Make sure that the retaining ring is fully seated in the groove inside the outer tube Fit the dust seal to the outer tube Make sure that there is not play between dust seal and outer tube ...

Page 231: ...I 25 FRONT SUSPENSION Ed 07 2010 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 232: ...ion of the rebound adjuster rod protrudes from the piston rod Oil filling Fill with the specified quantity of oil Fill the damper unit with the specified quantity of oil Slowly pump the piston rod up and down to help oil reach all points of the car tridge Note if you haven t drained all oil from the damper unit on disassembly follow the procedure outlined below Filling oil to specified level ...

Page 233: ...wn to help oil reach all points of the cartridge Note add oil if level in the damper unit is too low Finally top up to the upper edge of the outer tube Allow the fork leg to rest until no more air bubbles can be seen then top up oil to specified level Insert the rebound adjuster rod into the piston rod Insert spring and spring guide retainer and tighten the cap nut Tighten fork cap nut and nut to ...

Page 234: ......

Page 235: ...J 1 J REAR SUSPENSION Ed 07 2010 Section ...

Page 236: ...eservoir cap with its valve removal J 7 Piston assembly inspections J 9 Seal replacement J 9 Checking the setting J 10 Reservoir replacement J 11 Floating piston removal J 12 Shock absorber assembly J 12 Driving the cap onto the body J 14 Shock absorber damping adjustment J 15 Disassembling and servicing the swinging arm J 16 Servicing the swinging arm shaft J 17 Servicing the rear suspension drop...

Page 237: ...J 3 REAR SUSPENSION Ed 07 2010 Rear shock absorber TIGHTENING TORQUE FIGURES 1 2 52 4 Nm 5 35 Kgm 38 6 ft lb Lubrication points grease ...

Page 238: ...nsion 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 239: ... side panels silencer and rear chassis see Section E General Procedures Loosen the front clamp 1 of the intake coupling Remove the front bolt 2 securing the suspension linkage to the chassis the bottom 3 and top 4 shock absorber mounting bolts and remove the shock absorber 5 IMPORTANT On assembly fit the bottom locking nut 3 of the shock absorber on the LEFT SIDE ...

Page 240: ...oval clamp the shock absorber in a vice taking care to avoid distorting it Slacken lock ring nut and ring nut spring retainer and spring Measure spring free length SERVICE LIMIT 245 1 5 mm SMR 255 1 5 mm TE TXCi 250 Change the spring if length is outside the service limit Shock absorber inspection Visually inspect the shock absorber and look for oil leaks or other issues Replace the shock absorber...

Page 241: ...se out the retaining ring using two small screwdrivers Take care not to dam age the inner surface To remove the retaining ring first prise one end of the ring out of its groove Then slide out the other end slip the tip of a screwdriver between ring and reservoir and prise off with the other screwdriver Take out the retaining ring Check the grooves in reservoir body for burrs If any burrs are detec...

Page 242: ...lace the shock absorber on a bench Unscrew or knock out the cover depend ing on the model Once the tank cap is removed push the rod guide down into the body so as to expose the circlip groove and remove the circlip with a screwdriver ...

Page 243: ...he reservoir floating piston Pour the oil into a clean pan and leave it to settle Piston assembly inspections 1 Check the seal for wear or damage replace if worn or damaged 2 Check the O ring on the rod guide Replace if scored 3 Check the surface of the chrome plated rod for dents or scoring If any dam age is found seal and DU bush will be damaged as well and you will need to replace the rod guide...

Page 244: ...ension is not operating properly and you need to adjust compression damping loosen the knob dowel heat with an air gun before loosening Proceed as follows loosen the ring nut with the suitable key slide off all parts noting their positions to ensure correct assembly ...

Page 245: ... the cap to 30 Nm 3 kgm 29 2 ft lb It is strictly forbidden to change the compression washers This could cause the shock absorber to explode while in service Reservoir replacement In the event the reservoir needs to be replaced heat the area near the threaded end with an air gun and loosen using suitable equipment Replace the reservoir O ring Grease the O ring being careful not to smear the thread...

Page 246: ...Shock absorber assembly Wash the shock absorber body thoroughly with a degreasing product Make sure it is fully dry Blow with compressed air if needed Clamp the shock absorber eye in a vice with aluminium or bronze jaws or use a shop rag to protect the eye Fill 70 80 cu cm 4 3 4 9 cu in of oil into the shock absorber body Insert the complete piston rod into the shock absorber body taking care not ...

Page 247: ...m 0 8 in below shock body edge Pump the rod up and down through 5 6 cm 2 2 4 in strokes four or five times to expel any air trapped under the piston Pump slowly or the floating piston might become displaced due to cavita tion or compression Top up with oil up to the circlip groove while slowly setting the rod so the bumper is level with the groove Hold the rod steady and slide the rod guide into t...

Page 248: ...k for oil or air leaks Drive the cap onto the body Refitting bumper and washer If you have replaced the bumper clamp the rod in a vice with bronze or aluminium jaws apply Loctite to the mount and tighten to about 50 Nm Refit the spring and set to initial preload using ring nut and lock ring nut All liability is disclaimed for any damage resulting from procedures other than those described in this ...

Page 249: ...ckwise until reaching fully closed position Then turn them back the number of clicks specified above In order to obtain a smooth braking action turn the adjuster screws counter clockwise Vice versa to obtain a harder braking action B REBOUND Standard setting 18 clicks 2 clicks To reset the standard setting turn lower adjuster screw 2 clockwise until reach ing fully closed position Then turn it bac...

Page 250: ...ere is no need to loosen the chain tensioners 6 on the swinging arm in this way the chain tension will re main unchanged after reassembly Extract the complete wheel C keeping the spacers located at the hub sides Remove the shock absorber 7 as described at page J 3 Remove the swinging arm shaft nut 8 and then the swinging arm Check swinging arm straightness and manually check the roller cages D and...

Page 251: ... drop link 1 and drag link 2 still in place connected to swinging arm and chassis respectively rock them both back and forth in all directions to check for radial and axial clearance Some axial clearance in the drop drag link is required for the swinging arm to achieve the ideal position for proper operation If any radial clearance is detected remove the part from swinging arm or chassis and check...

Page 252: ...r Check the wear of the above mentioned elements and replace them when necessary Check the chain guide alignment and remember that a bent element can cause chain early wear In this case chain might unwrap from the sprocket 1 Chain roller 2 Chain guide 3 Chain slider a Master link clip ...

Page 253: ...L 1 L BRAKES Ed 07 2010 Section ...

Page 254: ...2 BRAKES Ed 07 2010 Braking system L 3 Brake disc L 4 Checking brake pads for wear replacing the pads L 5 Bleeding the front braking system L 6 Bleeding the rear braking system L 7 Changing the fluid L 8 ...

Page 255: ...calliper connected to a master cylinder with a fluid reservoir 1 Front brake lever 2 Front brake master cylinder with fluid reservoir 3 Front brake line 4 Front brake calliper 5 Front brake disc 6 Rear brake fluid reservoir 7 Rear brake line 8 Rear brake calliper 9 Rear brake disc 10 Rear brake master cylinder 11 Rear brake control pedal ...

Page 256: ... Front brake disc thickness when new 3 0 mm Wear limit 2 5 mm Rear brake disc diameter 240 mm Rear brake disc thickness when new 4 0 mm Wear limit 3 5 mm Disc warpage must not exceed 0 15 mm check disc mounted on the rim with a dial gauge To remove the disc from the wheel rim you need to loosen the four retaining screws Onassembly cleanallmatingsurfacesthoroughlyandtightenthescrews to the specifie...

Page 257: ...nnot be cleaned satisfactorily PADS REMOVAL Remove clips 1 Slide out pins 2 Remove pads Do not work the brake lever or pedal while removing the pads PADS INSTALLATION Install new brake pads Reassemble the two pins 2 and the clips 1 The above procedure eliminates the need to bleed the braking system after replacing the pads Simply operate the control lever several times until bringing the pistons b...

Page 258: ... the bleed valve Top up fluid level A and refit rubber gaiter and reservoir cover 2 Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure Brake fluid is corrosive In the event of contact with eyes rinse with abundant water Motorcycle handlebar must be turned to the left during the bleeding procedure This will keep the master cylinder reservoir high...

Page 259: ...at first then slightly close the valve Release the pedal and wait a few seconds Repeat the process until you see only fluid coming out of the hose Tighten the bleed valve to the specified torque and check fluid level B in the reservoir before refitting the cap A If the bleeding procedure was performed correctly the pedal will no longer have that mushy feel If not so repeat the procedure Fluid leve...

Page 260: ...minants such as dirt water etc into the reservoir Do not keep the reservoir open without its cover longer than neces sary this would increase the risk of contamination Handle the fluid with care to avoid damage to painted parts Do not mix two brands of fluid This would reduce boil over point leading to loss of braking efficiency or degrading of rubber parts Replacement procedure is as follows Take...

Page 261: ...d fill the reservoir with fresh fluid Loosen the bleed valve operate lever or pedal tighten the valve keeping lever or pedal pressed and then release quickly Repeat the process until the circuit is full and you can see clear fluid coming out of the plastic hose now tighten the bleed valve Top up with fluid up to level A or B and refit rubber gaiter and reservoir cover After changing the fluid you ...

Page 262: ...L 10 BRAKES Ed 07 2010 Periodicallychecktheconnectinghoses C and D seeScheduledMaintenance Chart Section B replace worn or cracked hoses ...

Page 263: ...M 1 M ELECTRICAL SYSTEM Ed 07 2010 Section ...

Page 264: ...E TXCi M 22 Voltage regulator M 22 VOLTAGE REGULATOR RECTIFIER WIRING DIAGRAM M 22 WIRING DIAGRAM M 22 ELECTRICAL STARTING SYSTEM TE TXCi M 23 STARTING SYSTEM INSPECTION M 24 Starter motor inspection TE TXCi M 24 Starter motor test curves TE TXCi M 24 Solenoid starter inspection TE TXCi M 24 Checking coil windings resistance M 25 Electronic control unit ECU M 26 Spark plug M 26 Gear position senso...

Page 265: ... 8 TE TXCi M 45 Battery negative cable routing TE TXCi M 45 Securing the voltage regulator ground cable 9 TE TXCi M 46 Securing the engine ground chassis ground cables 10 M 46 Electrical system ground M 46 Wiring connection to voltage regulator TE TXCi M 46 Connection of relays and fuses TE TXCi M 47 Electric fan connection TE TXCi M 47 Injector connection TE TXCi M 47 Ignition coil connection TE ...

Page 266: ...M 4 ELECTRICAL SYSTEM Ed 07 2010 Securing the wiring harness M 53 Securing the wiring harness M 53 Securing the wiring harness M 53 IMPORTANT M 54 ...

Page 267: ...et W White W Bk White Black W G White Green W R White Red W V White Violet W Y White Yellow Y Yellow Y Bk Yellow Black Y Br Yellow Brown Y G Yellow Green Y Sb Yellow Sky blue Y R Yellow Red Key to wiring diagram 1 Electronic control unit 2 Gear sensor 3 R H switch 4 Control unit interface 5 Coolant temperature sensor 6 HT coil 7 Fuel pump 8 Condenser 9 Injector 10 Voltage regulator 11 Alternator 1...

Page 268: ...top light switch 28 Rear stop light switch 29 Horn 30 Turning indicators flasher 31 Rear R H turning indicator 32 Tail light 33 Rear L H turning indicator 34 Front R H turning indicator 35 Headlamp 36 Front L H turning indicator 37 Spark plug 38 Pressure sensor 22 39 Throttle position sensor 22 40 Air temperature sensor 22 Colour coding key B Blue B Bk Blue Black Bk Black Br Brown Br Bk Brown Blac...

Page 269: ...er 13 Starter motor 14 Voltage regulator 15 Alternator 16 Gear sensor 17 M A Q S 22 23 24 18 Power relay 19 Fuses 20 Injector 21 R H switch 22 Pressure sensor 17 23 Throttle position sensor 17 24 Air temperature sensor 17 25 Spark plug Colour coding key B Blue Bk Black Br Brown Br Bk Brown Black Br W Brown White G Green G Gr Green Grey G R Green Red Gr Grey Gr B Grey Blue Gr Bk Grey Black O Orange...

Page 270: ...nts Generator 1 on the inner side of L H crankcase half cover Electronic ignition coil 2 under the fuel tank Electronic control unit 3 under the fuel tank Voltage regulator 4 on the electronic control unit Spark plug 4 on cylinder head MAQS sensor 6 on throttle body Fuel pump 7 Coolant temperature sensor 8 Condenser TC Condenser 9 located on the rear chassis left side ...

Page 271: ... ignition system includes the following elements Generator 1 on the inner side of L H crankcase half cover Electronic ignition coil 2 under the fuel tank Electronic control unit 3 under the fuel tank Spark plug 4 on cylinder head Voltage regulator 5 under the fuel tank over the electronic control unit 3 ...

Page 272: ...der Solenoid starter 7 on left side of rear chassis M A Q S sensor air temperature pressure throttle position 8 on throttle body The electrical system includes the following elements 12V 6Ah battery 9 under the saddle Turning indicators flasher 10 on left side of rear chassis ...

Page 273: ... rear chassis DC Relay 13 light system turning indicators horn on right side of rear chassis Fuses 14 15 16 on rear mudguard right side Fuse 14 15A coil injection system fuel pump Fuse 15 15A dashboard parking lights control unit Fuse 16 20A electric fan light system turning indicators horn Electric fan 17 Coolant temperature sensor 18 Lambda sensor 19 ...

Page 274: ...2 23 H02304 ELECTRICAL SYSTEM Ed 07 2010 Headlamp 20 with 12V 35 35W twin halogen bulb and 12V 5W parking light bulb LED tail light 21 Turning indicators 22 12V 10W bulbs Fuel pump 23 inside the fuel tank ...

Page 275: ...ition system includes the following elements Generator 1 on the inner side of L H crankcase half cover Electronic ignition coil 2 under the fuel tank Electronic control unit 3 under the fuel tank Spark plug 4 on cylinder head Voltage regulator 5 under the fuel tank over the electronic control unit 3 ...

Page 276: ... 14 ELECTRICAL SYSTEM Ed 07 2010 12V 350W starter motor 6 behind the cylinder Solenoid starter 7 on left side of rear chassis M A Q S sensor air temperature pressure throttle position 8 on throttle body ...

Page 277: ...tery 9 under the saddle Relay 10 coil injection system fuel pump on right side of rear chassis Relay 11 solenoid valve on right side of rear chassis Fuses 12 13 14 on rear mudguard right side Fuse 12 15A coil injection system fuel pump Fuse 13 15A control unit Fuse 14 20A electric fan Electric fan 15 ...

Page 278: ... SYSTEM Ed 07 2010 Coolant temperature sensor 16 Lambda sensor 17 Fuel pump 18 inside the fuel tank Checking generator stator windings resistance Disconnect the stator coil connector from the wiring and measure resistance with a meter ...

Page 279: ...alue is about 0 6 If resistance is outside the specified limits replace the complete generator Generator no load performance RPM A D C typical 1200 8 6 2000 13 8 3000 15 5 5000 16 4 6000 16 6 AT EACH ENGINE OVERHAUL CLEAN FLYWHEEL ROTOR TO REMOVE ANY DEBRIS SUSPENDED IN SWIRLING OIL AND CAPTURED BY THE MAGNETS ...

Page 280: ...on 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 and pressure sensor and from the coolant sensor are also used to control ignition timing 7 Fuel pump 8 Condenser 9 Injector 10 Voltage regulator 11 Alternator...

Page 281: ...nd is controlled by the ECU Ignition timing is accurately determined based on engine RPM and accelerator position In addition to these key parameters inputs from the intake air temperature and pressure sensor and from the coolant sensor are also used to control ignition timing Key 1 Electronic control unit 2 Control unit interface 3 Coolant temperature sensor 4 HT coil 6 Fuel pump 7 Solenoid valve...

Page 282: ...terface 3 Coolant temperature sensor 4 HT coil 6 Fuel pump 7 Electric fan relay 8 Lambda sensor 9 Cooling fan 11 Battery 12 Solenoid starter 13 Starter motor 14 Voltage regulator 15 Alternator 16 Gear sensor 17 M A Q S 22 23 24 18 Power relay 19 Fuses 20 Injector 21 R H switch 22 Pressure sensor 17 23 Throttle position sensor 17 24 Air temperature sensor 17 25 Spark plug ...

Page 283: ...ed current generated by the alternator is converted into direct cur rent by the voltage regulator rectifier The voltage regulator rectifier serves a dual purpose it provides overvoltage protection for the battery and converts alternated current into direct current All components listed above help keep voltage constant and protect the battery against overloading CHARGING SYSTEM WIRING DIAGRAM ...

Page 284: ...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 12 5 14 5 V range check generator and voltage regulator rectifier as described in the relevant paragraph Voltage regulator rectifier inspection TE TXCi With the ignition on and the battery charged 12 5 13 V start the engine if...

Page 285: ... Ed 07 2010 ELECTRICAL STARTING SYSTEM TE TXCi The starting system is composed of Battery 16 Solenoid starter 17 Starter motor 18 R H switch 25 Clutch microswitch 27 TE Ignition switch 26 TE Fuses 37 For a description of wires and components please see the key to the wiring diagram ...

Page 286: ...gm 2 5 ft lb Starter motor test curves TE TXCi 1 Output power W 2 Torque TQ 3 RPM N rpm x 1000 4 Light voltage V 5 Charging current A Solenoid starter inspection TE TXCi 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 1...

Page 287: ...ive coil Primary winding resistance 4 5 15 at 20 C Secondary winding resistance 19 5 K 20 at 20 C without spark plug cap cable If resistance is outside the specified limits replace the coil Also check the resistance of the terminal cap contacting the spark plug Terminal cap resistance 4 5 5 5 K 5 at 20 C If resistance is outside the specified limits replace the cap NOTE Theareawherethecoilissecure...

Page 288: ...rload the coil A gap that is too narrow may cause difficulties when accelerating when idling or poor performance at low speed Clean off any dirt around spark plug base before removing the spark plug It is good practice to closely inspect the spark plug after removal as any deposits on it and the colour of the insulator provide useful indications on spark plug heat rating carburetion ignition and t...

Page 289: ...the connector hole for the WHITE BLACK gear sensor wire 2 The lever 3 is placed on the left hand side of the engine After each gear shift it automatically returns to the horizontal position First gear is engaged by pushing the lever downwards for other gears push it upwards Check the read ings provided in the relevant table TC A NEUTRAL open circuit B 1st 556 568 C 2nd 817 833 D 3rd 1 48 1 51 K E ...

Page 290: ...egative cable remove the battery 1 from its housing Check using a voltmeter that battery voltage is not less than 12 5 V If it is not so the battery needs to be charged Using a battery charger with a constant voltage first connect the RED positive cable to the battery positive terminal then the BLACK negative cable to the battery negative terminal At a constant voltage level of 14 4 V apply x Amps...

Page 291: ...wall at the same height When the low beam is on the upper edge between dark and lit zone should be at 9 10th of the height of headlamp centre from ground Beam height can be raised or lowered turning the screw 1 Headlamp bulbs replacement Proceed as follows to reach the headlamp bulbs remove the upper retaining screw securing headlamp fairing to dashboard bracket A slide the headlamp fairing B forw...

Page 292: ...the tail light has been replaced reverse the above procedure to reas semble Be careful not to overtighten the screws Number plate bulb replacement Loosen screw 1 and remove the number plate bulb 2 from the mudguard Extract the bulb holder 3 with the bulb 4 from the housing Pull the bulb 4 to detach it from bulb holder Once the tail light has been replaced reverse the above procedure to reas semble...

Page 293: ...t hand switch TE 1 High beam flasher self cancelling 2 High beam switch Low beam switch 3 Left hand turning indicators self cancelling Right hand turning indicators self cancelling To deactivate the turning indicators press the control lever after it is returned to the centre 4 Horn Colour coding key B Blue Bk Black B Bk Blue Black B W Blue White G Green G Bk Green Black G W Green White Gr Grey Y ...

Page 294: ...H01040 H01041 B Bk Br Y Sb Br ELECTRICAL SYSTEM Ed 07 2010 Right hand switch TE TXCi 1 Engine start button 2 Engine start stop switch Colour coding key B Blue Br Brown Br Bk Brown Black Y Sb Yellow Sky blue ...

Page 295: ...fuse with a different rating Never use a wire or other makeshift repair techniques instead of installing a new fuse SEMICONDUCTOR PARTS Be careful to never drop parts that incorporate a semiconductor such as the ECU or the voltage regulator rectifier Closely follow the relevant instructions when inspecting these parts An improper procedure may lead to severe damage ...

Page 296: ...ocated on the R H side of the chassis A Set the meter to the Impedance scale and check the energiser coil for proper operation Reading should be 80 Ohm 10 at 20 C B Set the meter to Continuity mode and check the circuit is open C Feed the coil from a power supply unit with stable 12V output and make sure that the circuit closes ...

Page 297: ...tions and reset functions use the SCROLL button A The functions available in the sequence are as follows 1 SPEED ODO 2 SPEED CLOCK 3 SPEED TRIP 4 SPEED LAP TIMER 5 SPEED RPM engine r p m numerical value 1 SPEED ODO IMPORTANT In the event of a FUEL INJECTION SYSTEM MALFUNCTION the word FAIL appears on the right side of the dashboard display see page 14 When this is the case contact your HUSQVARNA d...

Page 298: ... mph TRIP 1 distance maximum value 999 9 km or 621 31 mi data will be lost after disconnecting the battery To reset TRIP push the SCROLL button A and hold for more than 3 sec onds 4 SPEED LAP TIMER STP figure 4 SPEED speed maximum value 299 Km h or 299 mph STP 1 miles kilometres covered time Reading from 0 00 to 99 59 59 data will be lost after disconnecting the bat tery To activate the function S...

Page 299: ...el injection Fail indication the latter takes prior ity 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 Warning lights panel TXCi The motorcycle is fitted with a small warning lights panel with two warning lights 1 Red warning light POWER 2 Yellow warning light FUEL RESERVE ...

Page 300: ...ect no load performance of generator see paragraph Generator no load performance 5 voltage regulator malfunction see paragraph Voltage regulator rectifier inspection a battery overload indicates 1 faulty voltage regulator see paragraph Voltage regulator rectifier inspec tion 2 faulty battery see paragraph Current loss at the battery STARTING SYSTEM TE TXCi If the starter motor does not start this ...

Page 301: ...M 39 H02334 1 2 3 5 4 8 7 6 ELECTRICAL SYSTEM Ed 07 2010 1 Engine stop button 2 Coil 3 Control unit 4 Voltage regulator 5 Main wiring harness 6 MAQS sensor 7 Gear sensor 8 Condenser Wiring TC ...

Page 302: ... instructions TC HT coil position 1 TC Connect the HT coil as shown in the figure Fuel injection control unit position 2 TC Electronic control unit installed with the flat side down Securing engine stop button ground cable to chassis TC The ground cable of the engine stop button is secured to the coil screw 3 ...

Page 303: ...Connect the control unit connector 4 as shown Ignition coil connection TC Connect the ignition coil connectors 5 as shown Gear sensor cable connection TC Connect the gear sensor connector 6 as shown Fuel pump connector position TE TXCi Position the fuel pump connector 21 as shown ...

Page 304: ...as shown in the figure Securing the engine stop button cable TC Secure the engine stop button cable 8 with two clips 9 Securing the wiring TC Secure the ignition and gear sensor wiring loom to the clutch hose Voltage regulator connection TC Connect the connector 10 as shown Condenser connection TC Connect the connector 11 as shown ...

Page 305: ...M 43 TE H00973 H02324 TXCi ELECTRICAL SYSTEM Ed 07 2010 Wiring TE TXCi ...

Page 306: ...L PARTS INSTALLATION INSTRUC TIONS TE TXCi Coil position TE TXCi Connect the HT coil as shown in the figure Relay 1 and fuses 2 position TE TXCi On right side of motorcycle Turning indicators flasher 3 TE and solenoid starter position TE TXCi On left side of motorcycle ...

Page 307: ...gulator with heat grease Securing the starter motor solenoid starter cable TE TXCi Connect the starter motor solenoid starter cable 7 as shown in the figure Securing the engine ground to chassis and engine ground to battery cables 8 TE TXCi The engine ground to chassis and engine ground to battery cables are secured to the timing chain tensioner screw Battery negative cable routing TE TXCi Routing...

Page 308: ... coil Securing the engine ground chassis ground cables 10 Electrical system ground Secure the engine ground chassis ground cable and the wiring harness ground eye terminal to the coil retaining screw Wiring connection to voltage regulator TE TXCi Connect the connector 11 to the regulator Pay attention to the routing of radia tor breather hose and throttle cables ...

Page 309: ...DC to relay 14 TE only fuses Connect the cable marked POW to fuse 15 Connect the cable marked MAN to fuse 16 Connect the cable marked FAN TXCi to fuse 17 Connect the cable marked DC FAN TE to fuse 17 Electric fan connection TE TXCi Connect the electric fan connector 18 Injector connection TE TXCi Connect the connector 19 to the throttle body Ignition coil connection TE TXCi Connect the ignition co...

Page 310: ...1 as shown MAQS connector TE TXCi Connect the connector 22 as shown Engine water temperature connector TE TXCi Connect the engine water temperature connectors 23 to the thermostat Lambda sensor position and connector TE TXCi Tighten the Lambda sensor 24 in the corresponding seat Connect the Lambda sensor connector 25 as shown ...

Page 311: ...ng of rear chassis cables tail light connection flasher contactor Route the rear end of the wiring 28 as shown in the figure Connect the tail light turning indicators connector 29 TE Connect the connector 30 to the flasher TE Connect the connector 31 to the solenoid starter Clip installation on fuse holders Install the suitable clips 33 on the three fuse holders ...

Page 312: ...g of steering head tube wiring Secure the wiring harness with the suitable clip 34 Dashboard bracket connectors TE Secure the dashboard 35 and diagnostic 36 connector using the suitable clips Fit the cap 37 to the diagnostic connector 36 Headlamp front turning indicators STOP connection TE Connect the headlamp unit to the connector 38 Connect the connectors 39 to the turning indicators Connect the...

Page 313: ...d 07 2010 Double map connector TE Connect the connector 40 Speed sensor and ignition switch connectors TE Connect the speed sensor connector Connect the connector 41 of the ignition switch 42 Horn connector TE Connect the connector 43 to the horn ...

Page 314: ...n in the figure Securing the wiring harness to rear chassis left side Secure wiring harness with a clip as shown in the figure Securing the wiring harness to the chassis Strap wiring harness to chassis on right and left side with clips as shown in the figure Securing the wiring harness Position the GPS and Pick Up connectors 27 as shown ...

Page 315: ... 26 Securing the wiring harness Secure the ignition gear sensor and Lambda sensor wiring loom to the clutch hose with two clips Securing the wiring harness Secure the ignition and gear sensor wiring loom to the clutch hose Securing the wiring harness Secure the front wiring loom with two clips as shown ...

Page 316: ...f 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 electronic control unit 1 and the digital dashboard 2 ...

Page 317: ...N 1 N ENGINE COOLING Ed 07 2010 Section ...

Page 318: ...N 2 ENGINE COOLING Ed 07 2010 Coolant level check N 3 Cooling circuit TC N 4 Engine cooling system overhaul TC N 5 Cooling circuit TE TXCi N 6 Engine cooling system overhaul TE TXCi N 7 ...

Page 319: ...scenario crankshaft damage may result If the event of engine overheating check that the radiator is full Level in the radiator must be checked from cold see Section D In the event you need to check level when the engine is hot be sure to discharge pressure gradually The radiator cap 1 has a pressure relief position to depressurize the system safely Failure to follow the above instructions will cre...

Page 320: ...d to the left of the head and two down draft radiators 1 Radiator cap 2 Right hand radiator 3 Left hand radiator 4 Fitting 5 Water pump 6 Breather hose 7 Radiator connecting pipe 8 Radiators to cylinder head pipe 9 Water pump to fitting pipe 10 Fitting to left hand radiator pipe 11 Fitting to right hand radiator pipe ...

Page 321: ...en any bent fins to ensure free flow of air If the cooling mass is clogged or damaged no more than 20 of its surface must be affected If damage exceeds this limit the radiator must be replaced Periodically check the connecting hoses see Section B Scheduled Maintenance Chart this will avoid coolant leakage and consequent engine seizure If hoses show cracks swelling or hardening due to sheaths desic...

Page 322: ... centrifugal pump located to the left of the head and two down draft radiators 1 Radiator cap 2 Right hand radiator 3 Left hand radiator 4 Thermostat 5 Water pump 6 Breather hose 7 Radiator connecting pipe 8 Radiators to cylinder head pipe 9 Water pump to fitting pipe 10 Thermostat to radiators pipe 11 Cooling fan ...

Page 323: ...any bent fins to ensure free flow of air If the cooling mass is clogged or damaged no more than 20 of its surface must be affected If damage exceeds this limit the radiator must be replaced Periodically check the connecting hoses see Section B Scheduled Maintenance Chart this will avoid coolant leakage and consequent engine seizure If hoses show cracks swelling or hardening due to sheaths desiccat...

Page 324: ......

Page 325: ...P 1 P HYDRAULICALLY CONTROLLED CLUTCH Ed 07 2010 Section ...

Page 326: ...P 2 HYDRAULICALLY CONTROLLED CLUTCH Ed 07 2010 Hydraulic clutch system P 3 Draining clutch fluid P 4 Clutch master cylinder servicing P 5 Bleeding the clutch system P 6 ...

Page 327: ...o the gearbox input shaft b via the gear on the clutch housing 8 The clutch housing accommodates friction plates 9 and steel plates 10 that operate the clutch hub 11 secured to the gearbox input shaft 1 Clutch master cylinder 2 Clutch lever 3 Master cylinder to piston hose 4 Pushrod 5 Piston assembly 6 Pressure plate 7 Bleed fitting 8 Clutch housing with clutch ring gear 9 Steel plate 10 Friction ...

Page 328: ...CLUTCH Ed 07 2010 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 329: ... 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 330: ...e lever 4 repeatedly until the fluid flowing out of the hose looks clear and free of air bubbles now tighten the bleed valve Top up fluid level A and refit rubber diaphragm 3 and reservoir cover 2 Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure Hydraulic fluid is corrosive In the event of contact with eyes rinse with abundant water Motorcycle...

Page 331: ...S 1 S FUEL INJECTION SYSTEM Ed 07 2010 Section ...

Page 332: ...DING SYSTEM TE TXCi S 3 INJECTION FUEL FEEDING SYSTEM TC S 4 Operation Manual for HUSQVARNA SERVICE TOOL for injection fuel feeding system TE TXCi S 5 Operation Manual for HUSQVARNA SERVICE TOOL for injection fuel feeding system TC S 7 Fuel pump test TC S 9 ...

Page 333: ...pray 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 Throttle opening Battery voltage Gear shift position Fuel injection pulse widt...

Page 334: ...e 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 Throttle opening Gear shift position Fuel injection pulse width The HUSQVARNASERVICE TOOL provides a tool to c...

Page 335: ...ove the front headlight fairing number holder as described in the relevant section 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 TE Turn the ignition key F to ON TXCi Check that switch G is in RUN position start the Diagnostic Tool software you have installed and perform the required tests In case of throttle body H...

Page 336: ...ollowing the instructions provided in the Operation Manual The ECU stores the number of service hours of the engine toler ance range 1 hour The first equipment ECU also stores the vehicle identification number VIN and engine number engine no of the motorcycle If ECU is replaced the new ECU will only report engine service hours For fuel pump and relay inspections see relevant paragraphs ...

Page 337: ...in the User Guide proceed as follows Remove the saddle and disconnect the fuel pump connector Slip off the cap B of the ECU interface connector C Connect the Kit cable 5 to the connector C Connect the USB cable 4 to the PC Connect the cable 5 to the battery clamps cable 6 Connect the clamps to the battery according to the polarity Start the Diagnostic Tool software you have installed and perform t...

Page 338: ...ove the pump as described in Section E pump operation Connect the RED and BLACK wires on the pump connector to a power supply unit with constant 12V output and make sure that the pump runs Never keep the pump connected to the power supply unit for more than 3 seconds in a row ...

Page 339: ...nsor and then set the meter to the Impedance scale and measure across the BLUE and WHITE wires Cor rect value is as follows 1 3 KOhm 10 at 20 C B pump operation Connect the RED and BLACK wires to a power supply unit with con stant 12V output and make sure that the pump runs Never keep the pump connected to the power supply unit for more than 3 seconds in a row ...

Page 340: ......

Page 341: ...W 1 W SPECIAL TOOLS Ed 07 2010 Section ...

Page 342: ...15 Crankcase puller 2 8000 A1580 T D C timing tool 3 8000 H2146 Flywheel puller 5 8000 A7345 Jig TC 8000 H7345 Jig TE TXCi 7 8000 A7317 Valve installation removal tool 8 8000 A1625 Dial gauge mount 11 8000 79015 Clutch hub tool 13 1519 84701 Spring hook 16 8000 95749 Spark plug tool ...

Page 343: ...ing damage to motorcycle and injury to rider An overtightened nut or screw might become damaged its thread might strip or the nut screw might fail and work itself loose Listed in the table are the tightening torque figures for the most important nuts and screws which have determined in accordance with thread diameter pitch and specific application These figures are obtained after cleaning the thre...

Page 344: ...TEF M6 L20 Chain tensioner 8 Nm 0 8 Kgm Special M6x1 screw Slider use LOCTITE 243 8 Nm 0 8 Kgm Crankcase Screw TSEI M5 L12 Crankshaft bearing plate LOCTITE 270 or LOCTITE 272 6 Nm 0 6 Kgm Screw TEF M5x0 8 CH8 L8 For oil seal retaining plate 6 Nm 0 6 Kgm Screw TSEI M6 L10 Desmo bearing plate use LOCTITE 270 or LOCTITE 243 8 Nm 0 8 Kgm Selector spring pin M8x1 25 Use LOCTITE 270 or LOCTITE 272 25 Nm...

Page 345: ...6 Kgm Short nut M6x1 Gear to starter motor shaft LOCTITE 243 3 9 Nm 0 5 Kgm Screw TCEI M5 L20 Bevel drive body 6 Nm 0 6 Kgm Screw TEF M8 L 15 Kick start lever LOCTITE 272 25 Nm 2 55 Kgm Gearbox Nut M16x1 Sprocket 90 Nm 9 2 Kgm Gear shift control Selector drum rtng screw M8x1 25 Use LOCTITE 270 or LOCTITE 243 25 Nm 2 55 Kgm Screw TSEI M6 L14 Selector rtng plate LOCTITE 243 8 Nm 0 8 Kgm Screw TEF M6...

Page 346: ... CHASSIS 99669 1 Nm 0 73756 ft lb NOTE Unless otherwise specified standard torque values for the different thread sizes are as follows M5x0 8 5 6 6 2 Nm 0 57 0 63 Kgm 4 1 4 5 ft lb M6x1 7 6 8 4 Nm 0 80 0 85 Kgm 5 8 6 1 ft lb M8x1 25 24 26 Nm 2 4 2 6 Kgm 17 3 18 8 ft lb ...

Page 347: ...X 5 TIGHTENING TORQUE FIGURES Ed 07 2010 TIGHTENING TORQUE FIGURES 5 HANDLEBAR AND CONTROLS 99669 TIGHTENING TORQUE FIGURES 5 FRONT SUSPENSION 99669 1 Nm 0 73756 ft lb 1 Nm 0 73756 ft lb ...

Page 348: ...X 6 TIGHTENING TORQUE FIGURES Ed 07 2010 TIGHTENING TORQUE FIGURES 5 REAR SUSPENSION 99669 1 Nm 0 73756 ft lb ...

Page 349: ...X 7 TIGHTENING TORQUE FIGURES Ed 07 2010 TIGHTENING TORQUE FIGURES 5 FAIRINGS AND MUDGUARDS 99669 1 Nm 0 73756 ft lb TIGHTENING TORQUE FIGURES 5 ELECTRICAL SYSTEM 99669 1 Nm 0 73756 ft lb ...

Page 350: ...X 8 TIGHTENING TORQUE FIGURES Ed 07 2010 TIGHTENING TORQUE FIGURES 5 FUEL SYSTEM 99669 1 Nm 0 73756 ft lb TIGHTENING TORQUE FIGURES 5 WHEELS AND BRAKES 99669 1 Nm 0 73756 ft lb ...

Page 351: ...ORQUE FIGURES Ed 07 2010 TIGHTENING TORQUE FIGURES 5 EXHAUST 99669 TIGHTENING TORQUE FIGURES 5 INSTRUMENTS 99669 1 Nm 0 73756 ft lb 1 Nm 0 73756 ft lb TIGHTENING TORQUE FIGURES 5 COOLING SYSTEM 99669 1 Nm 0 73756 ft lb ...

Page 352: ... Steel screws on brass copper aluminium M5 4 Nm 0 4 Kgm 3 ft lb Steel screws on iron steel M5 6 Nm 0 6 Kgm 4 4 ft lb Steel screws on plastic with metal spacers M6 6 5 Nm 0 65 Kgm 4 8 ft lb Steel screws on brass copper aluminium M6 6 5 Nm 0 65 Kgm 4 8 ft lb Steel screws on iron steel M6 10 5 Nm 1 Kgm 7 7 ft lb Steel screws on brass copper aluminium M8 16 Nm 1 6 Kgm 11 8 ft lb Steel screws on iron s...

Page 353: ...Y 1 Y CHASSIS AND WHEELS Ed 07 2010 Section ...

Page 354: ...installation Y 7 Rear wheel Y 8 Rear wheel removal Y 9 Tightening torque figures Y 9 Wheel servicing Y 10 Wheel axle warpage Y 10 Axle runout over 100 mm Y 10 Wheel spokes Y 11 Wheel rim warpage Y 11 Rear chain sprocket secondary drive sprocket and chain Y 12 Tightening torque figures Y 12 Checking chain and sprockets for wear Y 13 ...

Page 355: ... Ed 07 2010 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 356: ...ication points lubricant 1 Steering bearings grease Check the assemblies shown in the figure for cracks or damage If any are found replace the part A ENGINE MOUNTING BOLTS B REAR CHASSIS MOUNTING BOLTS C CHAIN GUIDE ROLLER BEARING D FOOTPEGS PINS SPRINGS ...

Page 357: ... hub and rim with high strength steel spokes Type and size of wheel rims light alloy 1 6x21 TC Size of tyre 80 100 x 21 TE TXCi Size of tyre 90 90 x 21 TE USA 90 90 x 21 Cold tyre pressure TC 0 9 1 0 Kg sq cm TE TXCi racing 0 9 1 0 Kg sq cm TE road use 1 1 Kg sq cm ...

Page 358: ... Loosen the bolts 1 holding the wheel axle 2 to the front fork mounts Hold the head of the wheel axle in place and unscrew the bolt 3 on the opposite side draw the wheel axle out Do not operate the front brake lever when the wheel has been re moved this causes the calliper pistons to move outwards After removal lay down the wheel with brake disc on top ...

Page 359: ...leg during this operation the wheel should be turned Tighten the screw 3 on the fork L H side but DO NOT lock it Now pump for a while pushing the handlebar downwards until you are sure that the fork legs are perfectly aligned Lock the screws 1 on the R H leg 10 4 Nm 1 05 Kgm 7 7 ft lb the screw 3 on the L H side 51 45 Nm 5 25 Kgm 38 ft lb the screws 1 on the L H leg 10 4 Nm 1 05 Kgm 7 7 ft lb Afte...

Page 360: ...gh strength steel spokes TC Type and size of wheel rims light alloy 1 85x19 TE TXCi Type and size of wheel rims light alloy 2 15x18 TE USA Size of tyre 140 80x18 TC Size of tyre 120x90x18 Cold tyre pressure TC 0 8 0 9 Kg sq cm TE TXCi racing 0 8 0 9 Kg sq cm TE road use 1 0 Kg sq cm ...

Page 361: ...tensioners 2 in this way the chain tension will remain un changed after reassembly Extract the complete rear wheel keeping the spacers located at the hub sides To reassemble reverse the above procedure remembering to insert the brake disc into the calliper Do not operate the rear brake pedal when the wheel has been re moved this causes the calliper pistons to move outwards After removal lay down t...

Page 362: ...bearings after removal Never reuse them Before installing the new bearings check to ensure the seat is clean and shows no grooves or scratches Lubricate the seat before installing the bearing Drive the bearing into place using the special installer that only applies pressure to the outer race Fit the spacer and the other bearing Check for perfect alignment as you slide the axle into place Wheels s...

Page 363: ... screwdriver a clear crisp sound indicates proper tightening a dull sound means that the spokes need to be tightened Wheel rim warpage The table below reports the allowed limits for wheel rim warpage Exceeding runout or out of round are generally due to worn bearings When this is the case replace the bearings If this does not solve the problem change the wheel rim or the wheel Standard Max limit S...

Page 364: ... 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 365: ...ck the transmission sprocket for damage or wear When worn down like the sprocket shown in the figure it must be replaced Wheelmisalignmentcausesabnormalwear makingthemotorcycle unsafe to ride Dirt caked on sprockets and chain collected while riding on muddy or wet terrain increases chain tension If you expect to ride on muddy or wet terrain slacken the chain a bit Riding on muddy terrain significa...

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Summary of Contents for TC 250 2011

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Husqvarna TC 250 2011, Workshop Manual, Page: 264 / 366

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Summary of Contents for TC 250 2011

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