Husqvarna TC 50 2023 Owner'S Manual Download

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11 SERVICE WORK ON THE CHASSIS

11.5

Removing the fork protector

A00079-10

–

Remove screws

and take off the clamp.

–

Remove screws

on the left fork leg. Take off the fork pro-

tector.

A00078-10

–

Remove screws

on the right fork leg. Take off the fork

protector.

11.6

Installing the fork protector

A00078-11

–

Position fork protector on the right fork leg. Mount and
tighten screws

Guideline

Remaining screws,

chassis

10 Nm (7.4 lbf ft)

A00079-11

–

Position fork protector on left fork leg. Mount and tighten
screws

Guideline

Remaining screws,

chassis

10 Nm (7.4 lbf ft)

–

Position the brake line and the clamp. Mount and tighten
screws

Guideline

Screw, brake line

holder

EJOT PT

K60x20-Z

2 Nm (1.5 lbf ft)

Summary of Contents for TC 50 2023

Page 1: ...OWNER S MANUAL 2023 TC 50 TC 50 MINI Art no 3402625en ...

Page 2: ......

Page 3: ...olors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice Husqvarna Motorcycles accepts no liability for delivery options deviations from illustrations and descriptions as well as misprints and other errors The models por trayed partly contain s...

Page 4: ...ur counter 19 7 PREPARING FOR USE 20 7 1 Advice on preparing for first use 20 7 2 Running in the engine 22 8 RIDING INSTRUCTIONS 23 8 1 Checks and maintenance measures when preparing for use 23 8 2 Starting the vehicle 23 8 3 Starting off 24 8 4 Riding 24 8 5 Braking 25 8 6 Stopping parking 25 8 7 Transporting 26 8 8 Refueling 26 8 9 Filling up with oil TC 50 MINI 27 9 SERVICE SCHEDULE 28 9 1 Addi...

Page 5: ...ket cover 66 11 37 Installing the engine sprocket cover 66 11 38 Checking the chain for dirt 67 11 39 Cleaning the chain 67 11 40 Checking the chain tension 68 11 41 Adjusting the chain tension 69 11 42 Checking the chain rear sprocket engine sprocket and chain guide 70 11 43 Adjusting the chain guide 74 11 44 Checking the frame 74 11 45 Checking the link fork 74 11 46 Checking the throttle cable ...

Page 6: ...the gear oil 115 17 CARBURETOR 117 17 1 Removing the carburetor TC 50 MINI 117 17 2 Removing the carburetor TC 50 118 17 3 Installing the carburetor TC 50 MINI 120 17 4 Installing the carburetor TC 50 121 18 CLEANING CARE 123 18 1 Cleaning the motorcycle 123 19 STORAGE 125 19 1 Storage 125 19 2 Preparing for use after storage 126 20 TROUBLESHOOTING 127 21 TECHNICAL DATA 130 21 1 Engine 130 21 2 En...

Page 7: ...here to the highest degree by specially trained experts using the special tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Indicates the end of an activity including potential reworking 1 2 Formats used The typographical formats used in this document are explained belo...

Page 8: ... instruction and all further instructions included carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info Various information and warning labels are attached in prominent locations on the product described Do not remove any information or warning labels If they are missing you or others may not recognize dangers and may therefore be injured ...

Page 9: ...on Danger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others Do not operate the vehicle if you are not fit to ride due to alcohol drugs or medication Do not operate the vehicle if you are physically or mentally impaired Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is s...

Page 10: ...tain screws a screw adhesive e g Loctite is required Observe the manufacturer s instruc tions If thread locker e g Precote has already been applied to a new part do not apply any additional thread locker After disassembly clean the parts that are to be reused and check them for damage and wear Change dam aged or worn parts After completing a repair or service work check the operating safety of the...

Page 11: ...r s Manual must be downloaded again by the new owner The Owner s Manual can be downloaded several times using the QR code or the link on the delivery certificate The Owner s Manual is also available for download from your authorized Husqvarna Motorcycles dealer and on the Husqvarna Motorcycles website A printed copy can also be ordered from your authorized Husqvarna Motorcycles dealer Internationa...

Page 12: ...e www husqvarna motorcycles com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual An incorrect suspension setting can lead to damage and breakage of chassis components Use of the vehicle under difficult conditions such as on sand or on wet du...

Page 13: ...EW OF VEHICLE 4 11 4 1 View of vehicle front left example V02844 10 1 Hand brake lever p 15 2 Valve for fork airpump 3 Fuel tap p 17 4 Quick release of seat 5 Shock absorber compression adjustment 6 Choke ...

Page 14: ...le V02845 10 1 Fuel tank filler cap 2 Stop button p 15 3 Fork rebound adjustment 4 Throttle grip p 15 5 Vehicle identification number p 13 6 Kick starter lever p 18 7 Foot brake lever p 18 8 Shock absorber rebound adjuster 9 Level viewer for brake fluid rear ...

Page 15: ...n the right side of the steering head 5 2 Type label 402154 10 TC 50 The type label 1 is located on the front frame tube 401946 10 TC 50 MINI Type label 1 is fixed to the front of the steering head 5 3 Engine number 401949 11 The engine number 1 is located on the left side of the engine under the engine sprocket ...

Page 16: ...utside of the axle clamp 5 5 Shock absorber article number H01186 10 TC 50 The shock absorber article number 1 is stamped on the bottom of the shock absorber toward the right hand side 401948 11 TC 50 MINI The shock absorber article number 1 is stamped on the top of the shock absorber toward the rear ...

Page 17: ...ignition circuit is closed and the engine can be started Stop button pressed In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start 6 4 Opening the fuel tank filler cap Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not fuel the vehicle in the vicinity of open flame...

Page 18: ... spills on them Keep fuels correctly in a suitable canister and out of the reach of children Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system F02222 10 Turn fuel tank filler cap 1 counterclockwise and lift it off 6 5 Closing the fuel tank filler cap F02222 11 Mount the fuel tank filler cap an...

Page 19: ...ting the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel This results in a richer fuel air mixture which is needed for a cold start Info If the engine is warm the choke function must be deacti vated Possible states Choke function activated The choke lever is pulled out to the stop Choke function deactivated The choke lever is pushed in to the stop 6...

Page 20: ...he engine The kick starter lever can be swiveled Info Before riding swing the kick starter lever inwards towards the engine 6 12 Foot brake lever 401956 10 Foot brake lever 1 is located in front of the right footrest The rear brake is engaged with the foot brake lever 6 13 Plug in stand 402581 10 The fixture for plug in stand 1 is located on the frame on the left side of the vehicle The plug in st...

Page 21: ...tail section under the left hand side cover It shows the total number of service hours of the engine The service hour counter begins counting when the engine is started and stops when the engine is switched off Info The value indicated by the service hour counter cannot be cleared or adjusted ...

Page 22: ...n increased safety risk Ensure your child wears appropriate protective clothing such as helmet boots gloves as well as trousers and a jacket with protectors on all rides Alway use protective clothing for your child that is in good condition and meets the legal require ments When you ride a motorcycle set an example for your child and wear suitable protective clothing Warning Danger of crashing Dif...

Page 23: ...c position of the foot brake lever p 86 Before using the vehicle for the first time ensure that the basic settings of the chassis are suitable for the weight of your child Allow your child to become accustomed to the handling of the motorcycle on suitable terrain preferably on a large open meadow Info To give your child a feeling for the brake system you should push your child at first Do not star...

Page 24: ... in the engine During the running in phase do not exceed the specified engine performance Guideline Maximum engine performance During the first 3 operating hours 70 During the first 5 operating hours 100 Avoid fully opening the throttle ...

Page 25: ...ndition p 97 Check tire pressure p 98 Check the spoke tension p 98 Info The spoke tension must be checked regularly as incorrect spoke tension will strongly impair riding safety Clean the dust boots of the fork legs p 43 Bleed the fork legs p 42 Check the air filter Check the settings of all controls and ensure that they can be operated smoothly Check all screws nuts and hose clips regularly for t...

Page 26: ...he kick starter lever pushing it all the way forward Info Do not open the throttle Final steps Remove the motorcycle from the lift stand p 42 8 3 Starting off Info The plug in stand must be removed before riding Open the throttle carefully 8 4 Riding Info If unusual noises occur while riding stop immediately switch off the engine and contact an authorized Husqvarna Motorcycles workshop If the chok...

Page 27: ...e vehicle unattended if the engine is running Protect the vehicle against access by unauthorized persons Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch any parts such as the exhaust system radiator engine shock absorber or brake sys tem before the vehicle parts have cooled down Let the vehicle parts cool down before you perform any work on...

Page 28: ...vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is harmful to health Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not...

Page 29: ... p 138 Close the fuel tank filler cap p 16 8 9 Filling up with oil TC 50 MINI Warning Engine damage The engine will not be lubricated unless there is 2 stroke oil in the oil tank For a full fuel tank fill the oil tank at least up to the MINmark Switch off the engine Open the oil tank cap p 16 A00094 11 Fill the oil tank at least up to the MINmark A Guideline MIN mark Sufficient for a single tank f...

Page 30: ...l p 86 Check the free travel of the foot brake lever p 85 Check the frame p 74 Check the link fork p 74 Check the fork bearing for play Check the shock absorber heim joint for play Check the tire condition p 97 Check tire pressure p 98 Check the wheel bearing for play Check the wheel hubs Check the rim run out Check the spoke tension p 98 Check the chain rear sprocket engine sprocket and chain gui...

Page 31: ...very 48 months every 12 months Every 80 operating hours After 20 operating hours Every 20 operating hours After 10 operating hours Change the front brake fluid Change the rear brake fluid TC 50 Change the rear brake fluid TC 50 MINI Service the fork Perform the shock absorber service Lubricate the steering head bearing p 52 Check adjust the carburetor components Change the coolant p 103 Perform mi...

Page 32: ...ated in the left fork leg and damping in the right fork leg As fork springs are no longer required a significant weight advantage is achieved when compared to conven tional forks The response on slightly uneven surfaces is significantly improved In normal driving mode suspension is provided exclusively by an air cushion A steel spring is located in the left fork leg as an end stop Info If the fork...

Page 33: ...he compression damping in the low speed range and vice versa 10 4 Adjusting the low speed compression damping of the shock absorber TC 50 Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incor rectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized Husqvarna Motorcycles workshop ...

Page 34: ...he side Using an open end wrench turn adjusting screw 1 clock wise all the way Info Do not loosen fitting 2 Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline High speed compression damping Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Info Turn clockwise to increase damping turn counter clockwise to reduce damping Position the splash protector 10 ...

Page 35: ...uce damping when the shock absorber rebounds TC 50 MINI Raise the motorcycle with a lift stand p 42 V00257 10 Remove nut 1 V00258 10 Remove screw 2 Pull the shock absorber out of the support and push the rear wheel upwards V00259 10 Turn adjusting screw 3 clockwise up to the last percep tible click Turn counterclockwise by the number of clicks corre sponding to the shock absorber type Guideline Re...

Page 36: ...h as a marking on the side cover Note the value as dimension A Finishing work Remove the motorcycle from the lift stand p 42 10 8 Checking the static sag of the shock absorber 400989 10 Measure dimension A of rear wheel unloaded p 34 Hold the motorcycle upright with aid of an assistant Measure the distance between rear axle and fixed point again Note the value as dimension B Info The static sag is...

Page 37: ...he specified measurement Adjust the riding sag p 37 10 10 Adjusting the spring preload of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incor rectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized Husqvarna Motorcycles workshop will be glad to help Preparat...

Page 38: ...87 10 TC 50 MINI Measure the full spring length while it is under tension and note down the value Loosen retaining ring 1 Turn adjusting ring 2 until the spring is no longer under tension Hook wrench T304 Hook wrench T1533 Info If the spring cannot be fully released the spring must be removed to accurately measure the spring length Measure the total spring length while the spring is not under tens...

Page 39: ... 25 N mm 143 lb in Weight of rider stan dard 25 35 kg 55 77 lb 30 N mm 171 lb in Weight of rider 35 45 kg 77 99 lb 35 N mm 200 lb in Spring rate TC 50 MINI Weight of rider 15 25 kg 33 55 lb 65 N mm 371 lb in Weight of rider stan dard 25 35 kg 55 77 lb 75 N mm 428 lb in Weight of rider 35 45 kg 77 99 lb 85 N mm 485 lb in Info The spring rate is shown on the outside of the spring Smaller weight diff...

Page 40: ...ing may seriously alter the handling charac teristic Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components Only make adjustments within the recommended range Make sure your child rides slowly to start with after making adjustments in order that he or she can assess the new handling characteristic Info Check or adjus...

Page 41: ... the left fork leg When disconnecting excess pressure will escape from the hose the fork leg itself does not lose any air The fork airpump indicator switches off automatically after 80 seconds Mount the protection cap Info Only mount the protection cap by hand Finishing work Remove the motorcycle from the lift stand p 42 10 14 Adjusting the rebound damping of the fork TC 50 Info The hydraulic rebo...

Page 42: ...ndlebar position Warning Danger of accidents A repaired handlebar poses a safety risk If the handlebar is bent or straightened the material becomes fatigued The handlebar may break as a result Change the handlebar if the handlebar is damaged or bent C00249 10 Remove screws 1 Take off the handlebar clamps Remove the handlebar and lay it to one side Info Cover the components to protect them against ...

Page 43: ... order that he or she can assess the new handling characteristic Preparatory work Raise the motorcycle with a lift stand p 42 A00095 10 Main work Remove nut 1 K00651 10 Hold the rear wheel with the link fork and remove screw 2 Position the shock absorber according to the required seat height Guideline Low seat position standard A High seat position B Position screw 2 A00095 10 Mount nut 1 and tigh...

Page 44: ...orcycle from the lift stand Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 402581 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand 1 into the plug in stand bracket on the left side of the vehicle Info Remove the plug in stand before riding 11 3 Bleeding the fork legs Prep...

Page 45: ... remove dust and coarse dirt parti cles from the inside fork tubes Over time dirt can accumulate behind the dust boots If this dirt is not removed the seals rings behind can start to leak Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Clean and oil the...

Page 46: ... protector 11 6 Installing the fork protector A00078 11 Position fork protector on the right fork leg Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft A00079 11 Position fork protector on left fork leg Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and the clamp Mount and tighten screws 3 Guideline Screw br...

Page 47: ...o hang loosely to the side Info Do not kink the brake line F02897 10 TC 50 Loosen screws 3 Remove the left fork leg Loosen screws 4 Remove the right fork leg F02896 10 TC 50 MINI Loosen screws 3 Remove the left fork leg Loosen screws 4 Remove the right fork leg 11 8 Installing the fork legs F02179 10 Main work TC 50 Position the fork legs Bleeder screws 1 are positioned toward the rear Info The se...

Page 48: ...iple clamp F02896 11 Tighten screws 2 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft F02225 10 Position the brake caliper mount screw 4 and tighten Guideline Screw front brake caliper M8x60 20 Nm 14 8 lbf ft Loctite 243 Mount and tighten screw 5 Guideline Screw front brake caliper M8x40 20 Nm 14 8 lbf ft Loctite 243 P...

Page 49: ...te p 55 Remove front fender p 55 V02085 10 Main work Pull fuel tank breather 1 out of the steering stem Remove nut 2 Release screw 3 take off the upper triple clamp with the handlebar and set aside Info Cover the components to protect them against dam age Do not kink the cables and lines V02086 10 Remove protective ring 4 Remove the lower triple clamp with the steering stem Remove the upper steeri...

Page 50: ...steering stem Mount upper steering head bearing 1 Check whether upper steering head seal 2 is correctly posi tioned Push on protective ring 3 V02097 10 Position the upper triple clamp with the handlebar Mount nut 4 but do not tighten it yet F02179 11 TC 50 Position the fork legs Bleeder screws 5 are positioned toward the rear Info The second milled groove from the top must be flush with the upper ...

Page 51: ...ideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws 9 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft F02192 11 TC 50 MINI Position the fork legs Bleeder screws 5 are positioned toward the rear Info The second milled groove from the top must be flush with the upper edge of the upper triple clamp F02...

Page 52: ...unt screw bk and tighten Guideline Screw front brake caliper M8x60 20 Nm 14 8 lbf ft Loctite 243 Mount and tighten screw bl Guideline Screw front brake caliper M8x40 20 Nm 14 8 lbf ft Loctite 243 Position the brake line and the clamp Mount and tighten screws bm Guideline Screw brake line holder EJOT PT K60x20 Z 2 Nm 1 5 lbf ft Finishing work Install front fender p 56 Install the start number plate...

Page 53: ...uld not be detectable on the steering head bear ing If there is detectable play Adjust the steering head bearing play p 51 Move the handlebar to and fro over the entire steering range It must be possible to move the handlebar easily over the entire steering range There should be no detectable detent positions If detent positions are detected Adjust the steering head bearing play p 51 Check the ste...

Page 54: ... hammer tap lightly on the upper triple clamp to avoid stresses Tighten screw 3 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Tighten screws 2 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Position the fuel tank breather 1 in the steering stem Finishing work Check the steering head bearing play p 51 Remove the motorcycle from the lift stand p 42 11 13 Lubricating the steering head ...

Page 55: ...Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing if fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Preparatory w...

Page 56: ... a doctor if you swallow fuel Do not inhale fuel vapors Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing if fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Main work Check the throttle cab...

Page 57: ... and remove it 11 17 Installing the start number plate F02903 10 Attach the start number plate to the brake line Position the start number plate Holding lugs 1 engage in the fender F02904 10 Mount and tighten screw 2 Guideline Screw start number plate M6 4 Nm 3 lbf ft 11 18 Removing front fender V02096 10 Remove screws 1 Take off the front fender ...

Page 58: ...th drill holes 1 in the holding lugs on the start number plate V02093 10 Position front fender Mount and tighten screws 2 Guideline Screw fender M6 6 Nm 4 4 lbf ft 11 20 Removing the right side cover Preparatory work Remove the seat p 62 S01546 10 Condition Right side cover secured Remove screw 1 ...

Page 59: ...the front 11 21 Installing the right side cover F02231 10 Main work Position the side cover on collar bushings 1 and 2 and push toward the rear Engage the side cover in areas A and B S01546 11 Condition Right side cover secured Mount and tighten screw 3 Guideline Screw side cover EJOT PT K60x20 Z 2 Nm 1 5 lbf ft ...

Page 60: ... Remove the seat p 62 Remove the right side cover p 56 S01545 10 Main work Drill a hole at marking A Guideline Diameter 6 5 mm 0 256 in Finishing work Install the right side cover p 57 Mount the seat p 62 11 23 Removing the left side cover Preparatory work Remove the seat p 62 S01547 10 Condition Left side cover secured Remove screw 1 ...

Page 61: ... the front 11 24 Installing the left side cover F02232 10 Main work Position the side cover on collar bushings 1 and 2 and push toward the rear Engage the side cover in areas A and B S01547 11 Condition Left side cover secured Mount and tighten screw 3 Guideline Screw side cover EJOT PT K60x20 Z 2 Nm 1 5 lbf ft ...

Page 62: ...in Finishing work Install the left side cover p 59 Mount the seat p 62 11 26 Removing the shock absorber Preparatory work TC 50 Raise the motorcycle with a lift stand p 42 TC 50 MINI Raise the motorcycle with a lift stand p 42 Remove the rear wheel p 94 F02233 10 Main work TC 50 Pull brake line 1 out of the holder Remove nut 2 Remove screw 3 and lower the link fork carefully F02234 11 Remove screw...

Page 63: ...e sure your child rides slowly to start with after making adjustments in order that he or she can assess the new handling characteristic F02234 10 Main work TC 50 Push splash protector 1 to the side Position the shock absorber with screw 2 depending on the desired seating height F02233 11 Raise the link fork mount and tighten the shock absorber with screw 3 Guideline Screw bot tom shock absorber M...

Page 64: ...absorber M10 45 Nm 33 2 lbf ft Loctite 243 Mount nut 5 and tighten the fitting Guideline Screw bot tom shock absorber M10 45 Nm 33 2 lbf ft Loctite 243 Install the rear wheel p 96 Finishing work Remove the motorcycle from the lift stand p 42 11 28 Removing the seat K00654 10 Open quick release 1 and raise the rear of the seat Pull back the seat and remove it 11 29 Mounting the seat K00655 10 Hook ...

Page 65: ... brake fluid etc correctly and in compliance with the applicable regulations Preparatory work Remove the seat p 62 K00671 10 Main work Press rear holding lug 1 together slightly and swing the air filter box cover upward Pull out the front holding lug and take off the air filter box cover Take off the air filter 11 31 Installing the air filter K00672 10 Main work Position the clean air filter Posit...

Page 66: ...g liquid and allow it to dry properly Air filter cleaner p 139 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high grade air filter oil Oil for foam air filter p 139 Clean the air filter box Check intake flange for damage and looseness Finishing work Install the air filter p 63 Mount the seat p 62 11 33 Removing the main silencer Warning Danger of burns T...

Page 67: ...before performing any work on the vehicle Info Over time the fibers of the insulating material vanish into the air and the silencer burns out Not only is the noise level higher the performance characteristic changes Preparatory work Remove the seat p 62 Remove the right side cover p 56 Remove the main silencer p 64 700514 01 Main work Remove screws with toothed washers 1 from the silencer cap 2 Re...

Page 68: ... 50 Remove screws 1 Remove screw 2 Take off the engine sprocket cover A00100 10 TC 50 MINI Remove screws 1 Remove screw 2 Take off the engine sprocket cover 11 37 Installing the engine sprocket cover A00080 10 Main work TC 50 Position the engine sprocket cover Mount screws 1 but do not tighten yet Mount and tighten screw 2 Guideline Screw engine sprocket cover M8 15 Nm 11 1 lbf ft Tighten screws 1...

Page 69: ...1 39 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip Remove lubricants from the tires using a suitable cleaning agent Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Note Environmental hazard Hazardous substa...

Page 70: ... As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand p 42 F02235 10 Main work TC 50 Press the chain upward at the end of the chain sliding piece and determine chain tension A Info The top part of chain 1 must be taut Chain wear is not alway...

Page 71: ...sult the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand p 42 Check the chain tension p 68 F02198 10 Main work TC 50 Loosen nut 1 Loosen nuts 2 Adjust the chain tension by turning adjusting screws 3 left and right Guideline Chain tension 5 8 mm 0 2 0 3...

Page 72: ...e chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle with a lift stand p 42 Remove the engine sprocket cover p 66 H01863 10 Main work Check the engine sprocket cover for wear If the engine sprocket cover is worn through in the marked area A Change the engine sprocket cover 400227 01 Check the rear sprocket and the engine sprocket for wear If the rear sprocket...

Page 73: ... that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the screw of the chain sliding guard Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft F02241 10 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated ...

Page 74: ...hain guide is loose Tighten the screws on the chain guide Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft K00677 10 TC 50 MINI Check the chain sliding guard for wear If the ridge is worn down to the level of the main cor pus Change the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the screw of the chain sliding guard Guid...

Page 75: ...in sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 400985 01 Check the chain guide for wear Info Wear can be seen on the front of the chain guide If the light part of the chain guide is worn Change the chain guide H00095 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the screws on the chain guide Guideline Remaining screws chassis M6 10 Nm...

Page 76: ...crew 1 Position the chain guide Tighten the screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 44 Checking the frame S00876 01 Check the frame for damage cracks and deformation If the frame shows signs of damage cracks or deforma tion Change the frame Guideline Repairs on the frame are not permitted 11 45 Checking the link fork F02203 01 Check the link fork for damage cracks and defor...

Page 77: ...rled screw on the fuel tap all the way clockwise Remove the fuel tank p 53 V02081 01 Main work Check the throttle cable routing The throttle cable must be routed to the carburetor behind the handlebars and above the fuel tank bracket If the throttle cable is not routed as specified Correct the throttle cable routing Finishing work Install the fuel tank p 54 Install the left side cover p 59 Install...

Page 78: ...r grip Preparatory work Check the rubber grip p 75 401198 01 Main work Secure the rubber grip at two points using the securing wire Securing wire 54812016000 Wire twister forceps 00029015100 The twisted wire ends face away from the hands and are bent toward the rubber grip ...

Page 79: ... brake lever 3 5 mm 0 12 0 2 in If the play does not meet specifications Adjust the play of the hand brake lever p 77 12 2 Adjusting the play of the hand brake lever V02098 10 Check the play of the handbrake lever p 77 Adjust the play of the hand brake lever using adjusting screw 1 Guideline Play of hand brake lever 3 5 mm 0 12 0 2 in 12 3 Adjusting the basic position of the hand brake lever V0209...

Page 80: ...ake discs are replaced immediately Your authorized Husqvarna Motor cycles workshop will be glad to help 400257 10 Check the front and rear brake disc thickness at multiple points for the dimension A Info Wear reduces the thickness of the brake disc around the contact surface of the brake linings Brake discs wear limits front 2 2 mm 0 087 in rear 2 2 mm 0 087 in If the brake disc thickness is less ...

Page 81: ...f brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized Husqvarna Motorcycles workshop will be glad to help Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils gre...

Page 82: ...Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in ...

Page 83: ...uce the braking effect Ensure that worn out brake linings are replaced immediately Your authorized Husqvarna Motorcy cles workshop will be glad to help A00088 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the brake linings of the front brake p 81 Check the brake linings for damage and cracking If damage or...

Page 84: ...ved for Husqvarna motorcycles The structure and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original brake linings If brake linings are used that differ from the original equipment compliance with the original homolo gation is not guaranteed In this case the vehicle no longer corresponds to its condition at delivery and the manufacturer warran...

Page 85: ...low out of the brake fluid reservoir extract some if necessary V00553 11 Warning Danger of accidents Brake linings which have not been approved alter the braking efficiency Not all brake linings are tested and approved for Husqvarna motorcycles The structure and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original brake linings If brake lining...

Page 86: ... is a pressure point Secure the hand brake lever in the activated position The brake caliper straightens Tighten screw 6 Guideline Screw front brake caliper M8x60 20 Nm 14 8 lbf ft Loctite 243 Tighten screw 7 Guideline Screw front brake caliper M8x40 20 Nm 14 8 lbf ft Loctite 243 Remove the locking piece of the hand brake lever V02100 10 Correct the brake fluid level Guideline Brake fluid level un...

Page 87: ...travel of the hand brake lever p 85 Attach spring 1 12 10 Adjusting the free travel of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification V02857 10 Detach the foo...

Page 88: ...ree travel A Guideline Free travel of foot brake lever 3 5 mm 0 12 0 2 in Hold push rod 2 and tighten nut 1 Attach the foot brake lever spring Check whether the basic position of the foot brake lever is suitable for the rider 12 12 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops bel...

Page 89: ...een swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake ...

Page 90: ...ork Remove the motorcycle from the lift stand p 42 12 14 Checking the brake linings of the rear brake Warning Danger of accidents Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Your authorized Husqvarna Motorcy cles workshop will be glad to help F02204 10 TC 50 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 0...

Page 91: ...y and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Danger of acc...

Page 92: ...k ring 1 Remove screw 2 Remove screw 3 and screw 4 F02207 10 Take off the brake caliper Info Do not kink or damage the brake line Remove the brake linings Clean the brake caliper and the brake caliper bracket Allow the brake caliper and the brake line to hang loosely to the side Check the brake discs p 78 F03004 11 Remove screws 5 Take off cover 6 with washer 7 and membrane 8 Press the brake pisto...

Page 93: ...ve screw 2 Remove screw 3 and screw 4 F02165 10 Take off the brake caliper and pull the brake line out of holder 5 Info Do not kink or damage the brake line Remove the brake linings Clean the brake caliper and the brake caliper bracket Allow the brake caliper and the brake line to hang loosely to the side Check the brake discs p 78 V02855 10 Remove screws 6 Take off cover 7 with washer 8 and membr...

Page 94: ...ine Screw rear brake caliper M6x40 10 Nm 7 4 lbf ft Loctite 243 Mount and tighten screw 2 Guideline Screw brake lin ings M5 8 Nm 5 9 lbf ft Mount lock ring 1 H01654 10 Operate the foot brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point Add brake fluid up to level A Guideline Level A brake fluid level below reservoir rim 10 mm 0 39 in Br...

Page 95: ...down in such a way that the brake disc is not damaged Hold the front wheel and remove the wheel spindle Take the front wheel out of the fork Info Do not actuate the hand brake lever when the front wheel is removed H00934 10 Remove spacers 3 13 2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil...

Page 96: ...wheel spindle V00545 10 Mount and tighten screw 1 Guideline Screw front wheel spindle M10 40 Nm 29 5 lbf ft Loctite 243 Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc Remove the motorcycle from the lift stand p 42 Operate the front brake and compress the fork a few times firmly The fork legs straighten Tighten screws 2 Guideline Screw...

Page 97: ...heel and remove the wheel spindle Take the rear wheel out of the link fork Info Do not operate the foot brake lever when the rear wheel is removed F02175 10 Remove spacers 4 V00281 10 TC 50 MINI Remove nut 1 with washer 2 Info Cover the components to protect them against damage Pull out wheel spindle 3 with washer 4 Remove the chain from the rear sprocket Warning Danger of accidents Damaged brake ...

Page 98: ...e spacers Info Insert the wide spacer on the left in the direction of travel F02210 11 TC 50 Clean and grease wheel spindle 1 Long life grease p 139 Position the rear wheel and insert wheel spindle The brake linings are correctly positioned Mount the chain Position chain adjuster 2 on both sides and push the wheel spindle in all the way F02209 11 Mount nut 3 but do not tighten it yet Make sure tha...

Page 99: ...contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 42 13 5 Checking the tire condition Info Only mount tires approved and or recommended by Husqvarna Motorcycles Other tires could have a negative effect on handling characteristics The type condition and pressure of the tires all have a major impact on the handling characteristic of ...

Page 100: ...es optimal riding comfort and maximum tire service life 400695 01 Remove protection cap Check tire pressure when the tires are cold Offroad tire pressure front 1 0 bar 15 psi rear 1 0 bar 15 psi If the tire pressure does not meet specifications Correct tire pressure Mount the protection cap 13 7 Checking spoke tension Warning Danger of accidents Incorrectly tensioned spokes impair the handling cha...

Page 101: ...h and spoke diameter If you hear different tone frequencies from different spokes of equal length and diameter this is an indica tion of different spoke tensions You should hear a high note If the spoke tension differs Correct the spoke tension Check the spoke torque Guideline Spoke nipple M3 5 3 Nm 2 2 lbf ft Torque wrench kit 58429094000 ...

Page 102: ...r hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is harmful to health Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately wit...

Page 103: ...ght on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level A above the radiator fins 10 mm 0 39 in If the coolant level does not match the specified value Correct the coolant level Coolant p 137 Mount the radiator cap 14 4 Draining the coolant Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not...

Page 104: ... thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing K01162 10 Main work Make sure that screw 1 is tightened Position the motorcycle upright Add coolant to level A Guideline Distance A above the radi ator fins 10 mm 0 39 in Coolant 0 7 l 0 7 qt Coolant p 137 400677 11 Move the vehicle into the position shown and ...

Page 105: ...the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Con...

Page 106: ...ll of the air to be able to escape from the cooling system the vehicle must be raised at the front If the cooling system is poorly de aerated its cooling power will be reduced and the engine may overheat Return the vehicle to the horizontal position Add coolant to level A Mount the radiator cap Finishing work Go for a short test ride Check the cooling system for leaks Check the coolant level p 101...

Page 107: ...running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and let it run at idle speed Move the handle bar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 105 15 2 Adjusting the play in the throttle cable Preparatory work Remove the seat p 6...

Page 108: ...incorrectly set idle speed Info The carburetor and its components are subject to increased wear caused by engine vibration Wear can result in malfunctioning The idle speed is adjusted using the idle speed adjusting screw 1 The idle mixture is adjusted using the idle air adjusting screw 2 15 4 Carburetor idle setting TC 50 MINI A00106 10 The idle setting of the carburetor has a big influence on the...

Page 109: ...ivated The choke lever is pushed in to the stop p 17 Idle speed 1 400 1 500 rpm Turn idle air adjusting screw 2 slowly in a clockwise direc tion until the idle speed begins to fall Note the position and turn the idle air adjusting screw slowly counterclockwise until the idle speed again begins to fall Adjust to the point between these two positions with the highest idle speed Info If there is a bi...

Page 110: ...d The choke lever is pushed down all the way to the stop p 18 Idle speed 1 400 1 500 rpm Turn idle air adjusting screw 2 slowly in a clockwise direc tion until the idle speed begins to fall Note the position and turn the idle air adjusting screw slowly counterclockwise until the idle speed again begins to fall Adjust to the point between these two positions with the highest idle speed Info If ther...

Page 111: ...r running the engine in an enclosed space Start the motorcycle Only ride full throttle to the point where the maximum engine speed is reached Guideline Operation at full throttle 3 s Read the speed Slip speed 8 700 9 300 rpm If the specified value is not reached Adjust the clutch p 110 15 8 Removing the clutch cover Note Environmental hazard Improper handling of fuel is a danger to the environment...

Page 112: ...ockwise to the last detectable click Turn adjusting screws 2 clockwise by 9 clicks to the basic setting Guideline Basic setting of slip speed 8 700 9 300 rpm Info The springs may not be pretensioned by more than 17 clicks from the stop using the adjusting screws Condition If the slip speed is too low Turn adjusting screws 2 clockwise Guideline 1 click increases the slip speed by 250 350 rpm Info T...

Page 113: ...the clutch cover p 111 Check the gear oil level p 113 Check the clutch setting p 109 15 10 Installing the clutch cover K01165 11 Main work Position the clutch cover 1 with the seal ring Mount and tighten screws 2 Guideline Screw clutch cover M6 10 Nm 7 4 lbf ft Finishing work Check the gear oil level p 113 ...

Page 114: ...level in the oil tank For a full fuel tank the oil tank must be filled up to MIN mark A at a minimum If the oil level does not meet specifications Fill up with oil p 27 16 2 Bleeding the oil pump TC 50 MINI Condition The fuel tank has been removed H00080 10 Pull off oil line 1 300652 10 Fill the oil line with a syringe Engine oil 2 stroke p 137 H00080 10 Connect oil line 1 ...

Page 115: ...pump Mount and tighten screws 2 Guideline Screw oil pump M5 6 Nm 4 4 lbf ft 16 3 Checking the gear oil level Condition The engine is cold Preparatory work Stand the motorcycle upright on a horizontal surface K01172 11 Main work TC 50 MINI Remove screw 1 Check the gear oil level A small quantity of gear oil must run out of the drilled hole If no gear oil runs out Add the gear oil p 115 Mount and ti...

Page 116: ...ewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Drain gear oil with engine at operating temperature Preparatory work Stand the motorcycle on the plug in stand on a horizontal surface K01172 10 Main work TC 50 MINI Position an app...

Page 117: ...3 p 138 Info Too little gear oil or poor quality gear oil results in pre mature wear to the transmission Mount and tighten filler plug 2 together with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or runnin...

Page 118: ...Dexron 3 p 138 Mount and tighten gear oil level monitoring screw 1 Guideline Screw gear oil level monitoring M6 6 Nm 4 4 lbf ft Mount and tighten filler plug 2 together with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction ...

Page 119: ...mful to health Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing if fuel spills on them Keep fuels correctly in a sui...

Page 120: ...el the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is harmful to health Avoid skin eye and clothing contact with fuel Immediately consult a doctor if y...

Page 121: ...p 2 Loosen hose clip 3 R04502 10 Push back hose clamp 4 and pull off the vent hose Pull the carburetor out of the intake flange Pull the carburetor forward out of the inlet sleeve R04487 10 Remove throttle slide cover 5 Pull the throttle slide out of the carburetor Drain the remaining fuel R04504 10 Pull back the spring retainer and throttle slide spring Detach throttle cable wire 6 Take off the t...

Page 122: ...40 11 Position the throttle slide and throttle slide cover Mount and tighten screw 3 Guideline Screw throttle slide cover M5 1 3 Nm 0 96 lbf ft R03039 11 Mount the carburetor Position and tighten hose clip 4 Guideline Hose clip carburetor 2 8 Nm 2 07 lbf ft Position and tighten hose clip 5 Guideline Hose clip carburetor 2 8 Nm 2 07 lbf ft R03038 10 Remove the plug Connect the oil line ...

Page 123: ... TC 50 R04504 11 Main work Attach throttle cable wire 1 Position the spring retainer and throttle slide spring T03276 10 Position the throttle slide and throttle slide cover Tighten throttle slide cover 2 hand tight Measure the distance between the carburetor housing and the throttle slide cover Distance A 3 mm 0 12 in If the specified value is not reached Screw on the throttle slide cover correct...

Page 124: ...Mount the inlet sleeve Position and tighten hose clip 4 Guideline Hose clip carburetor 2 8 Nm 2 07 lbf ft Position and tighten hose clip 5 Guideline Hose clip carburetor 2 8 Nm 2 07 lbf ft R04503 11 Mount fuel hose 6 Finishing work Check the play in the throttle cable p 105 Carburetor adjust the idle speed p 107 ...

Page 125: ...ning the motorcycle 401061 01 Close off exhaust system to keep water from entering Remove loose dirt first with a soft jet of water Spray the heavily soiled parts with a normal commercial motorcycle cleaner and clean using a brush Motorcycle cleaner p 139 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehi...

Page 126: ...g parts and pivot points Clean the chain p 67 Treat bare metal except for brake discs and the exhaust sys tem with a corrosion inhibitor Preserving materials for paints metal and rubber p 139 Treat all plastic parts and powder coated parts with a mild cleaning and care product Special cleaner for glossy and matte paint finishes metal and plastic surfaces p 140 ...

Page 127: ...riod less workshop overload This allows you to avoid long waiting periods when the next season starts 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 139 Refuel p 26 Clean the motorcycle p 123 Change the gear oil p 114 Check the antifreeze and coolant level p 100 Empty the carburetor float chamber Check tire pressure p 98 Sto...

Page 128: ...19 STORAGE 126 19 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 42 Perform checks and maintenance measures when preparing for use p 23 Take a test ride ...

Page 129: ...m 0 0236 in Fault in ignition system Check the ignition system Short circuit cable in wiring harness frayed stop button faulty Check the stop button The connector or ignition coil is loose or oxidized Clean the plug in connection and treat it with contact spray Water in carburetor or jets blocked TC 50 Check set the carburetor compo nents TC 50 MINI Check set the carburetor compo nents Engine has ...

Page 130: ...nition system defective Check the ignition coil Check the spark plug connector Diaphragm or reed valve hous ing damaged Check the diaphragm and reed valve housing Noticeable wear Overhaul the engine Clutch engagement speed too low or too high Check the clutch setting p 109 Engine stalls or is popping into the carburetor Lack of fuel Turn the knurled screw on the fuel tap all the way counterclockwi...

Page 131: ...maged cylinder head or cylinder head gasket Check the cylinder head or cylinder head gasket Gear oil exits at the vent hose Too much gear oil added Check the gear oil level p 113 Water in the gear oil Damaged radial shaft seal ring or water pump Check the radial shaft seal ring and the water pump ...

Page 132: ...K LR 8 B Spark plug electrode gap 0 60 mm 0 0236 in Cooling Water cooled Starting aid Kick starter system 21 2 Engine tightening torques Screw bearing retainer M5 5 Nm 3 7 lbf ft Screw kick starter lever M5 6 Nm 4 4 lbf ft Loctite 243 Screw oil pump TC 50 MINI M5 6 Nm 4 4 lbf ft Screw stator bracket M5 6 Nm 4 4 lbf ft Loctite 243 Screw water pump impeller M5 2 Nm 1 5 lbf ft Loctite 243 Bleeder fla...

Page 133: ...Nut primary gear wheel M10x1 25 40 Nm 29 5 lbf ft Loctite 243 Nut rotor M10x1 25 15 Nm 11 1 lbf ft Loctite 243 Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft 21 3 Carburetor with carburetor tuning 21 3 1 TC 50 Carburetor type Dell Orto PHBG 19BS Needle position 2nd position from top Idle air adjusting screw Open 3 turns Jet needle W7 Idling jet 50 Needle jet 262AU Throttle slide 40 Choke noz...

Page 134: ... 50 MINI WP XACT 5035 Shock absorber TC 50 WP XACT 5735 Shock absorber TC 50 MINI WP XACT 5435 Suspension travel TC 50 front 205 mm 8 07 in rear 185 mm 7 28 in Suspension travel TC 50 MINI front 100 mm 3 94 in rear 147 mm 5 79 in Fork offset 22 mm 0 87 in Brake system front Disc brake with 4 piston brake caliper rear Disc brake with 2 piston brake caliper Brake disc diameters front 160 mm 6 3 in r...

Page 135: ...cified represent one of the possible series production tires For alternative manufacturers if any contact an authorized dealer or qualified tire dealership If local road approval regulations apply these and the respective technical specifications must be observed Additional information is available in the Service section under www husqvarna motorcycles com 21 7 Fork 21 7 1 TC 50 Fork article numbe...

Page 136: ...t 18 clicks Standard 15 clicks Sport 12 clicks High speed compression damping Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 3 mm 0 12 in Spring rate Weight of rider 15 25 kg 33 55 lb 25 N mm 143 lb in Weight of rider standard 25 35 kg 55 77 lb 30 N mm 171 lb in Weight of rider 35 45 kg 77 99 lb 35 N mm 200 lb ...

Page 137: ...60x20 Z 2 Nm 1 5 lbf ft Screw stop button M3 0 4 Nm 0 3 lbf ft Spoke nipple M3 5 3 Nm 2 2 lbf ft Remaining nuts chassis M5 5 Nm 3 7 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw brake assembly M5 5 Nm 3 7 lbf ft Screw brake line guide TC 50 MINI M5 2 Nm 1 5 lbf ft Screw brake linings M5 8 Nm 5 9 lbf ft Screw throttle slide cover TC 50 MINI M5 1 3 Nm 0 96 lbf ft Nut push rod ball joint o...

Page 138: ...octite 243 Screw engine sprocket cover M8 15 Nm 11 1 lbf ft Screw front brake caliper M8x60 20 Nm 14 8 lbf ft Loctite 243 Screw front brake caliper M8x40 20 Nm 14 8 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw rear sprocket M8 25 Nm 18 4 lbf ft Loctite 243 Screw steering stem M8 20 Nm 14 8 lbf ft Screw top triple clamp M8 20 Nm 14 8 lbf ft Nut link fork pivot M10 45 Nm 33 2 ...

Page 139: ...irements stated see specifications on the container and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibil...

Page 140: ...pecifications on the container and that exhibit the corresponding properties Super unleaded ROZ 95 Standard classification DIN EN 228 ROZ 95 Guideline Only use super unleaded fuel that matches or is equivalent to the specified standard Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E...

Page 141: ...r High viscosity grease Recommended supplier SKF LGHB 2 Long life grease Recommended supplier MOTOREX Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX Moto Clean Off road chain spray Recommended supplier MOTOREX Chainlube Offroad Oil for foam air filter Recommended supplier MOTOREX Racing Bio Liquid Power Preserving materials for paints metal and rubber Recommended supplier MOTOREX...

Page 142: ... GRIP GLUE Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Special grease 00062010053 Recommended supplier Klüber Lubrication Klüberfood NH1 34 401 Universal oil spray Recommended supplier MOTOREX Joker 440 Synthetic ...

Page 143: ... first rate synthetic esters and specially designed additives superb combustion is achieved even under extreme operating conditions SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity The viscosity describes only one property of oil and says nothing about quality ...

Page 144: ...25 LIST OF ABBREVIATIONS 142 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 145: ... a i n i n g l o c a t i o n n e a r e s t y o u c a l l 8 7 7 2 8 8 7 0 9 3 d i r t b i k e s c h o o l c o m 2 0 1 5 M o t o r c y c l e S a f e t y F o u n d a t i o n I n c 2 J e n n e r S u i t e 1 5 0 I r v i n e C A 9 2 6 1 8 9 4 9 7 2 7 3 2 2 7 m s f u s a o r g ...

Page 146: ...perienced off highway motorcycle riders about appropriate riding locations in your area Although the Motorcycle Safety Foundation will continue to publish responsible viewpoints on this subject it must disclaim specific or general liability for the views expressed herein The Motorcycle Safety Foundation MSF is a national not for profitorganizationpromotingthesafetyofmotorcyclists with programs in ...

Page 147: ...afe and responsible use of an off highway motorcycle We urge you to read this booklet thoroughly Also read other information provided with the motorcycle The owner s manual contains important warnings and features of the motorcycle Deciding if your youngster is ready to ride an off highway motorcycle is an important decision The MSF strongly urges you to carefully determine your youngster s readin...

Page 148: ...2 ...

Page 149: ...res and Practice Protective Gear and Clothing Mounting Dismounting Mastering the Controls Learning Activities PART 3 Operating Procedures and Practice Learning Area Riding Area Getting Used to theVehicle in Motion Let s Start Riding PART 4 Readiness Checklist Visual Perception Motor Development Physical Development Social Emotional Development Reasoning and Decision Making Ability FINAL NOTE To Pa...

Page 150: ...erating Procedures Part 4 Readiness Checklist There is information about protective gear mounting control operation and starting the engine Operating procedures include starting shifting stopping and turning Once your youngster is ready to learn to ride YOU must be familiar with the motorcycle You will be serving as teacher coach and safety supervisor for your youngster You must know the controls ...

Page 151: ...autions as well as operating tips Motorcycle dealers may have other literature and safety information Another booklet Tips and Practice Guide for the Off Highway Motorcyclist gives detailed riding procedures The MSF DirtBike SchoolSM offers training on how to ride off highway motorcycles The course is available to youth as young as six years of age as well as to adults Call toll free 877 288 7093 ...

Page 152: ...e first important decision you will have to make concerning your youngster and off highway motorcycles OHMs is whether your youngster is ready to ride There are several factors that you must consider carefully There is no certain way to predict that your child is able to ride an OHM safely However the following information is a guide to help you determine your youngster s readiness to ride Only pa...

Page 153: ...7 PART 1 7 ...

Page 154: ...r Askyouryoungstertotellyouwhatcausesaccidents and injuries Your youngster needs to be able to tell Additional signs of physical readiness can be observed in your youngster s other play activities In general a youngster should be well coordinated having good balance and agility This coordination can be demonstrated by the abilities to jump rope skate skateboard ride a bicycle etc If a youngster ca...

Page 155: ...r should be able to see objects ninety degrees to the side while looking straight ahead Rider awareness and safety improves with good side vision Being able to judge distance is another visual skill helpful when operating an OHM Is your youngster able to tell how far one object is from another or which of two objects is closer OHM riding requires a person to judge distance and react properly Being...

Page 156: ... your youngster about OHM safety Pay particular attention to the warning labels and stickers on the motorcycle STEP TWO Teach Your Youngster Safe and Proper Riding Techniques Teaching your youngster off highway motorcy cling is a step by step process It begins with safety rules and moves to actual riding techniques Since youngsters learn at different rates it will be up to you to set the pace of y...

Page 157: ...deanoff highwaymotorcycle without a Department of Transportation DOT compliant motorcycle helmet Be sure the fit is correct It should be snug but not tight It must be properly fastened Protective gear is necessary in any weather even when the temperature is warm In cooler weather you should dress your youngster with additional layers of clothing Some riders choose to wear a kidney belt and chest o...

Page 158: ...e the controls Proper straight line riding posture includes Head and eyes up looking well ahead Shoulders relaxed back straight Elbows bent slightly out and away from the body Hands on the handlebars Knees in toward the tank Feet on the footpegs toes pointing straight ahead The hand and foot controls are important to riding safely While riding both hands should be kept on the handlebars and both f...

Page 159: ...ine OFF Mastering The Controls Show your youngster how to use each control as you describe its action Refer to the owner s manual to learn control location and function before instructing your youngster Test yourself by operating the controls Have your youngster dress in the proper protective gear and sit on the machine as you point out each control It is important to have your youngster wear all ...

Page 160: ...They tend to use it like an on off switch With the engine off have your youngster move the throttle to various positions Practice turning the handlebars and using the throttle at the same time ENGINE STOP SWITCH Explain to your youngster how to use the engine stop switch to turn off the engine With the engine off show how the stop switch works Later your youngster can practice using the stop switc...

Page 161: ...ng out the front brake is released The throttle is gradually opened while the clutch is slowly released If the clutch is released too quickly or too much throttle is applied the motorcycle may lunge forward causing loss of control With the engine off have your youngster practice upshifts downshifts and locating neutral SPEED LIMITERS supervisor control feature Some models come equipped with a remo...

Page 162: ...VES OFF ROAD SAFETY Here are some activities that your youngster can usetohelplearnaboutmotorcyclepartsandcontrols CROSSWORD PUZZLE Here is a crossword puzzle for your youngster to complete Across 1 What this booklet is all about 2 A piece of safety equipment for your head that you must never forget to wear 3 Protective gear for the hands 4 Where you should always ride your motorcycle a synonym 5 ...

Page 163: ...he motorcycle part or control on the correct line for the diagrams shown Answer Guide on Page 42 1 Clutch lever 2 Hand brake lever 3 Foot brake lever or pedal 4 Throttle 5 Choke or enrichening device 6 Engine stop switch 7 Gas cap tank vent 8 Starter kick 9 Electric starter if equipped ...

Page 164: ...r if equipped Clutch if equipped 2 Have your youngster show you how the controls work Be sure he or she understands the proper operation of each control Skilled use of these controls should develop with practice Under actual riding conditions the rider will have to watch ahead while operating the controls Your youngster should be able to find the controls quickly without looking for them 3 With yo...

Page 165: ... the vehicle and maintained it according to the owner s manual 5 Is your youngster wearing the proper protective gear Is the mounting procedure correct 6 Has your youngster learned to locate the motor cycle controls without looking at them Does he or she know how to operate them smoothly 7 Does your youngster understand that he or she must always ride off road 8 Have you stressed to your youngster...

Page 166: ... Follow a regular maintenance program See the owner s manual for inspection details Even after young riders have learned the basic riding skills direct supervision by an experienced adult is necessary AT ALL TIMES Make sure that all off highway motorcycle users under your supervision get proper riding instructions Stress that an OHM is not a toy Follow safety precautions strictly to provide a safe...

Page 167: ...21 PART 3 ...

Page 168: ...ow much throttle it takes to start moving in a later exercise Explain that opening the throttle will increase speed and that closing the throttle will decrease speed Releasing the throttle and applying the brakes will slow the motorcycle Ask your youngster to tell you how throttle control and braking affect the motorcycles speed GETTING THE FEEL OF THE CLUTCH if equipped With the engine OFF have y...

Page 169: ...opped and the engine OFF have your youngster practice the proper turning technique 1 For a right turn look to the right and lean the motorcycle to the right 2 For a left turn look to the left and lean the motorcycle to the left Repeat this exercise with the kickstand up as you push the motorcycle Make sure he or she can turn the vehicle in both directions using this technique while you maintain ba...

Page 170: ...he motorcycle for your young ster To remember the proper starting technique use FINE C Double check for neutral Start the engine Have your youngster carefully mount Let your youngster operate the engine stop switch and shut off the motor Re start the engine and repeat Allow the engine to warm up until it runs smoothly with the choke off Put to on position Ignition on Motorcycle in neutral the moto...

Page 171: ...braking STARTING OUT AND STOPPING Before your youngster moves the motorcycle underpower takeafewmomentstopracticesmooth clutch control After shifting to first gear have your youngsterrockthemotorcycleafewinchesbackand forth by moving the clutch in and out of the friction zone The clutch is not fully released while doing this It is important that clutch operation is smooth before riding in the prac...

Page 172: ...ht and lean the motorcycle to the right 2 For a left turn look to the left and lean the motorcycle to the left Have your youngster practice turning in both directions at slow speeds Allow enough room to make a wide turn After your youngster is skilled in making wide turns try tighter turns Keep speed slow Your youngster should master these skills at low speedsbeforegoingfaster Next practicesomefig...

Page 173: ...27 PART 3 ...

Page 174: ...erception motor development physical development social emotional development and reasoning and decision making ability Several questions are listed to help you determine if your youngster possesses the skills and capabilities to safely learn to operate an OHM ThebestwaytoutilizetheReadinessChecklistis toreadtheparticularability considertheanswersto thequestionsforthatability andcheckthoseabilitie...

Page 175: ... you Can youngster distinguish colors Has youngster demonstrated adequate vision in other activities riding bicycles running sports or other recreational activities When looking at two objects in the distance can youngster tell which is farther or closer Can youngster see objects 90 degrees to each side while looking straight ahead Does the youngster judge the speed of objects fast medium slow tha...

Page 176: ...e a basketball without looking at it Can youngster manipulate video game controls while following objects on a screen Can youngster describe a minor injury he or she received and correctly describe the causes Can youngster describe settings or situations that can produce injury if precautions are not taken Ability 5 Youngster can state the distances of objects in terms of feet yard miles 6 Youngst...

Page 177: ...se injury when doing such things as running swimming bicycling riding in a car Can youngster pick out or describe several items within a picture Can youngster assemble a puzzle without unusual problems or delays Can youngster describe what to do if a house fire should occur Can youngster complete school homework assignments without being easily distracted Can youngster assemble more difficult puzz...

Page 178: ...How about with the handlebars turned How about in different seating positions Can youngster stand with knees slightly bent and have a few inches of space from the seat Can youngster easily reach the foot controls Can youngster dress with proper protective gear including putting on helmet and fastening the chin strap Squeeze the hand controls Operate the shift lever if equipped Operate the choke an...

Page 179: ... for 10 feet Can youngster jump rope Can youngster catch a ball with hands rather than with arms Can youngster play outdoor games without fatigue Can youngster participate in indoor games and sports without tiring before other youngsters Ability 3 Youngster is sufficiently coordinated 4 Youngster has sufficient endurance to maintain strength over a period of time PART 4 ...

Page 180: ...listen and respond to adult supervision Does youngster comprehend the importance and seriousness of having rules and regulations Does youngster avoid challenging authority or rebelling when rules are imposed Does youngster show evidence of self control doesn t get easily frustrated or upset Does youngster understand consequences associated with certain actions like not wearing a safety belt in the...

Page 181: ...gster appreciate being safer than others Does youngster accept rules that are more stringent than what other youngsters have to follow Can youngster explain how land or grass gets worn Can youngster explain how even small damage to land can take years to recover Can youngster distinguish between untouched land and used land Can youngster complete a task in a step by step fashion assemble a toy cle...

Page 182: ... youngster notice impending accidents or potential injury producing events such as in sports activities or bicycle riding Can youngster explain why it takes distance to stop Can youngster explain how moving at even low speed can result in injury if stopped suddenly or by hitting something Does youngster know why rules are established Does youngster notice or recognize others being careful in actio...

Page 183: ...urning Points to Evaluate Can youngster explain the reason for rules at home or school Does youngster understand the value of prevention Of wearing protective gear Can youngster recognize that not following rules can eliminate future fun and enjoyment Can youngster explain what may happen if moving too fast while going around a curve on a bicycle On a skateboard On an off highway motorcycle ...

Page 184: ...ss slopes and other more advanced skills Youngsters should have a good understanding of riding skills before using unfamiliar areas They should ride on flat areas gentle hills and gradual slopes Be sure that your youngster rides slowly over unfamiliar terrain to locate and avoid bumps holes andotherpossiblehazards Youshouldcheck the area first The Motorcycle Safety Foundation also recommends a vid...

Page 185: ... axle to give a motorcycle motion ENGINE STOP SWITCH Switch used to stop the engine without removing the hands from the handlebars EXHAUST Leftover gases from the combustion process that come out of the tailpipe when the motorcycle engine is running Exhaust contains deadly carbon monoxide gases EYE PROTECTION Goggles or a shatter resis tant shield worn over the eyes while riding to protect against...

Page 186: ...ch is restricted by law from operating on public roads OHM Off Highway Motorcycle PSI Refers to air pressure in the tires and stands for Pounds per Square Inch READING THE TERRAIN Looking well ahead while riding anticipating hazards SHIFT LEVER On those motorcycles equipped with a shift lever it allows the operator to change gears The shift lever is operated by the left foot TAILPIPE That part of ...

Page 187: ...41 ANSWERS CROSSWORD PUZZLE 3 2 4 5 7 6 1 B O O T S F O O T P E G S H G E L L O S M V A E E E F T F C Y L R U D H A C ...

Page 188: ...THE MOTORCYCLE PARTS Typical 1 Clutch lever 2 Hand brake lever 3 Foot brake lever or pedal 4 Throttle 5 Choke or enrichening device 6 Engine stop switch 7 Gas cap tank vent 8 Starter kick 9 Electric starter if equipped ...

Page 189: ...43 NOTES ...

Page 190: ...44 NOTES ...

Page 191: ......

Page 192: ...For the rider training location nearest you call 877 288 7093 dirtbikeschool com 2015 Motorcycle Safety Foundation Inc 2 Jenner Suite 150 Irvine CA 92618 949 727 3227 msf usa org PN MSPU3444NC00 ...

Page 193: ...le setting 106 idle speed adjusting 108 installing 120 121 removing 117 118 Chain checking 70 cleaning 67 Chain guide adjusting 74 checking 70 Chain tension adjusting 69 checking 68 Choke 17 Cleaning 123 124 Clutch adjusting 110 setting checking 109 Clutch cover clutch cover installing 111 clutch cover removing 109 Coolant changing 103 draining 101 refilling 102 Coolant level checking 100 101 Cool...

Page 194: ...king 74 Lower triple clamp installing 48 removing 47 Low speed compression damping shock absorber adjusting 31 M Main silencer glass fiber yarn filling changing 65 installing 65 removing 64 Manufacturer warranty 10 Misuse 6 Motorcycle cleaning 123 lift stand raising with 42 lift stand removing from 42 O Oil level checking 112 Oil pump bleeding 112 Oil tank cap closing 17 opening 16 Owner s Manual ...

Page 195: ...g 60 removing 58 Spare parts 10 Spoke tension checking 98 Start number plate installing 55 removing 55 Starting 23 Steering head bearing lubricating 52 Steering head bearing play adjusting 51 checking 51 Stop button 15 Storage 125 T Technical data capacities 132 carburetor 131 chassis 132 chassis tightening torques 135 engine 130 engine tightening torques 130 fork 133 shock absorber 134 tires 133 ...

Page 196: ... 3402625en 3402625en 08 06 2022 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer KISKA Husqvarna Motorcycles GmbH ...

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