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Husqvarna TC 85 2017, Owner'S Manual, Page: 43 / 98

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Husqvarna TC 85 2017 Owner'S Manual Download Page 43

11 SERVICE WORK ON THE CHASSIS

41

11.20

Removing the seat

C00643-10

–

Remove screw

.

E00216-10

–

Raise the rear of the seat, pull the seat back, and lift it off.

11.21

Mounting the seat

E00216-11

–

Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at

the rear, and push the seat forward.

–

Make sure that the seat is correctly locked in.

C00643-10

–

Mount and tighten screw

of the seat fixing.

Guideline

Remaining screws, chassis

M6

10 Nm (7.4 lbf ft)

11.22

Removing the air filter box cover

E00217-10

–

Pull off the air filter box cover in area

sideways and remove it toward the

front.

Summary of Contents for TC 85 2017

Page 1: ...OWNER S MANUAL 2017 TC 85 Art no 3402093en ...

Page 2: ......

Page 3: ...esigns 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 Motorcy cles accepts no liability for delivery options deviations from illustrations and descriptions as well as misprints and other errors The models portrayed partly contain special equipment that does not b...

Page 4: ...tional information 24 9 2 Required work 24 9 3 Recommended work 25 10 TUNING THE CHASSIS 26 10 1 Checking the basic chassis setting with the rider s weight 26 10 2 Compression damping of the shock absorber 26 10 3 Adjusting the low speed compression damping of the shock absorber 26 10 4 Adjusting the high speed compression damping of the shock absorber 27 10 5 Adjusting the rebound damping of the ...

Page 5: ... Checking the rear brake fluid level 60 12 11 Adding rear brake fluid 61 12 12 Checking the rear brake linings 62 12 13 Changing the rear brake linings 62 13 WHEELS TIRES 65 13 1 Removing the front wheel 65 13 2 Installing the front wheel 65 13 3 Removing the rear wheel 66 13 4 Installing the rear wheel 66 13 5 Checking the tire condition 67 13 6 Checking the tire air pressure 68 13 7 Checking spo...

Page 6: ...shop There your motorcycle will be optimally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Indicates a p...

Page 7: ...onmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of ...

Page 8: ...hers must be replaced by new parts In some instances a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts After you complete the repair or service work check the operating safety of the vehicle 2 8 Environment If you use your motorcycle r...

Page 9: ...s accessories for your vehicle can be found on the Husqvarna Motorcycles website International Husqvarna Motorcycles website www husqvarna motorcycles com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual Incorrect adjustment and tuning of th...

Page 10: ...OF VEHICLE 8 4 1 View of vehicle front left example E00183 11 1 Hand brake lever p 11 2 Kill switch p 11 3 Clutch lever p 11 4 Air filter box cover 5 Chain guide 6 Shift lever p 13 7 Choke p 13 8 Fuel tap p 12 ...

Page 11: ...le E00187 11 1 Filler cap 2 Throttle grip p 11 3 Fork rebound adjustment 4 Fork compression adjustment 5 Foot brake lever p 13 6 Kick starter p 13 7 Shock absorber compression adjustment 8 Level viewer for brake fluid rear 9 Shock absorber rebound adjustment ...

Page 12: ... frame tube 5 3 Engine number S00480 10 Engine number is stamp into the engine case below the carburetor 5 4 Fork part number 401947 10 Fork part number is stamped on the inner side of the axle clamp 5 5 Shock absorber article number 0 0 1 1 401948 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 13: ...ble states Kill switch in basic position In this position the ignition circuit is closed and the engine can be started Kill switch pressed In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start 6 5 Opening the filler cap Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled ...

Page 14: ...ental 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 E00192 10 Turn filler cap counterclockwise and lift it off 6 6 Closing the filler cap E00192 11 Mount filler cap and turn it clockwise until the fuel tank is tightly closed Info Run fuel tank breather hose without kinks 6 7 Fuel tap S00484 10 The fuel tap i...

Page 15: ...stop Choke function deactivated The choke lever is pushed in to the stop 6 9 Shift lever 401950 10 Shift lever is mounted on the left side of the engine 401950 11 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears 6 10 Kick starter 0 0 1 1 401954 10 Kick starter is fitted on the right side of the engine The kick starter can be swivel...

Page 16: ...o Remove the plug in stand before riding 6 13 Service hour counter E00286 10 The service hour counter is fitted on the right side of the frame 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 It is not possible to delete or adjust anything on the service hour counter ...

Page 17: ...r suitable protective clothing Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic Different tire tread patterns can make the vehicle significantly more difficult to control Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel Warning Danger of accidents An unadapted riding style const...

Page 18: ...r child ride on terrain that exceed your child s capabilities and experience Your child should hold the handlebar firmly with both hands and keep his or her feet on the footrests when riding Do not exceed the maximum allowable rider weight Guideline Maximum rider weight 75 kg 165 lb Check the spoke tension p 68 Info The spoke tension must be checked after half an hour of operation Run the engine i...

Page 19: ... the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Change the radiator cap K00201 01 Fit a dust cover on the air filter Dust protection device for air filter 77206920100 Info See the Husqvarna Motorcycles accessories fitting instructions M01072 01 Fit a sand cover on the air filter Sand protection device fo...

Page 20: ...00200 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 77206921100 Info See the Husqvarna Motorcycles accessories fitting instructions Adjust the carburetor jetting and setting Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop 600868 01 Clean the chain Fit the steel sprocket Tip Do not grease the chain Clean t...

Page 21: ...ator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Change the radiator cap 600868 01 Adjust the secondary drive to the road conditions Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary drive Clean the chain Clean the radiator fins Straighten...

Page 22: ...k the fuel supply 8 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Note Engine failure High rpm with a cold engine negatively impacts the lifespan of the ...

Page 23: ...lower gear release the clutch lever slowly and either open the throttle or shift again Your child should switch off the engine if longer periods of engine idling or standing still are expected Guideline 2 min Your child should avoid frequent and extended slipping of the clutch As a result the engine oil engine and cooling system heat up Insist that your child ride with a low rpm instead of with a ...

Page 24: ... incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand Apply the brakes on the motorcycle Shift gear to neutral Press and hold the kill swi...

Page 25: ...ately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter t...

Page 26: ... engine sprocket and chain guide p 49 Check the chain tension p 47 Grease all moving parts e g hand lever chain and check for smooth operation Check the fluid level of the hydraulic clutch p 52 Check the front brake fluid level p 56 Check the free travel of the hand brake lever p 55 Check the play of the steering head bearing p 37 Change the gear oil p 76 Change the piston and check the cylinder u...

Page 27: ...k absorber Check adjust the carburetor components Perform minor engine service Change the piston Check the cylinder and Z dimension Change the spark plug Check the inlet membrane Check the exhaust control for functioning and smooth operation Perform major engine service including removing and installing engine Change the connecting rod conrod bear ing and crank pin Check the transmission and shift...

Page 28: ... not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more slowly These two ranges can be adjusted separately although the transition between high speed and low speed is gradual Th...

Page 29: ...rns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 5 Adjusting the rebound damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absor...

Page 30: ...ic sag is the difference between measurements and Check the static sag Static sag 30 mm 1 18 in If the static sag is less or more than the specified value Adjust the spring preload of the shock absorber p 29 10 8 Checking the riding sag of the shock absorber 400990 10 Measure distance of rear wheel unloaded p 28 With another person holding the motorcycle the rider wearing full protective clothing ...

Page 31: ...urement Guideline Spring preload Standard 10 mm 0 39 in Info The spring preload is the difference between the relaxed spring length and the tensioned spring length Depending on the static sag and or the riding sag it may be necessary to increase or decrease the spring preload Tighten screw Finishing work Install the shock absorber p 40 Remove the motorcycle from the lift stand p 32 10 10 Adjusting...

Page 32: ...on behavior 402496 10 Remove protection caps Turn adjusting screws clockwise all the way Info Adjusting screws are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping...

Page 33: ...anger 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 Take off the handlebar clamps Remove the handlebar and lay it to one side Info Cover the components to protect them against damage Do not kink the cable...

Page 34: ...ft stand Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 0 0 1 1 402001 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand into the left side of the wheel spindle Info Remove the plug in stand before riding 11 3 Bleeding the fork legs Preparatory work Raise the motorcycle wi...

Page 35: ...cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 90 Press the dust boots back into their normal position Remove excess oil Finishing work Install the fork protector p 35 Remove the motorcycle from the lift stand p 32 11 5 Removing the fork legs Preparatory work Raise the motorcycle with the lift stand p 32 Remove the front wheel p 65 E...

Page 36: ...clamp M8 15 Nm 11 1 lbf ft E00203 10 Connect the brake line at the start number plate E00202 10 Position the brake caliper with spacers and fit and tighten screws Guideline Screw of brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Position the brake line and clamp Mount and tighten screws Finishing work Install the front wheel p 65 Remove the motorcycle from the lift stand p 32 11 7 Removing the for...

Page 37: ...paratory work Raise the motorcycle with the lift stand p 32 Remove the front wheel p 65 Remove the fork legs p 33 Remove the start number plate p 39 Remove the front fender p 39 Remove the handlebar cushion E00206 10 Main work Pull fuel tank breather out of the steering stem Remove nut Remove screw pull off the upper triple clamp with the han dlebar in an upward direction and hang it to the side I...

Page 38: ...m Mount the upper steering head bearing Slide on O ring Position protective ring E00208 10 Position the upper triple clamp with the handlebar Mount nut but do not tighten it yet E00209 10 Position the fork legs Bleeder screws are positioned toward the front Info The second milled groove from the top must be flush with the top edge of the upper triple clamp E00210 10 Tighten screws Guideline Screw ...

Page 39: ...amp Mount and tighten screws Finishing work Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Install the front wheel p 65 Check the play of the steering head bearing p 37 Remove the motorcycle from the lift stand p 32 Position the handlebar cushion and secure with cable ties 11 11 Checking the play of the steering head bearing Warnin...

Page 40: ...ve the motorcycle from the lift stand p 32 11 12 Adjusting the steering head bearing play Preparatory work Raise the motorcycle with the lift stand p 32 C00640 10 Main work Pull fuel tank breather out of the steering stem Loosen screws Loosen screw Loosen and retighten nut Guideline Nut steering stem M20x1 5 10 Nm 7 4 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid str...

Page 41: ... 11 15 Installing the start number plate M00315 10 Position the start number plate Mount and tighten screw Guideline Start number plate screw M6 4 Nm 3 lbf ft The holding lugs engage Position brake line in the brake line guide 11 16 Removing the front fender Preparatory work Remove the start number plate p 39 C00641 11 Main work Remove screws and Remove the front fender ...

Page 42: ...ove screw and lower the rear wheel with the swingarm as far as possible without blocking the rear wheel Fix the rear wheel in this position Remove screw push splash protector to the side and remove the shock absorber 11 19 Installing the shock absorber E00215 11 Main work Push splash protector to the side and position the shock absorber Mount and tighten screw Guideline Screw top shock absorber M1...

Page 43: ... front of the seat on the collar bushing of the fuel tank lower the seat at the rear and push the seat forward Make sure that the seat is correctly locked in C00643 10 Mount and tighten screw of the seat fixing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 22 Removing the air filter box cover E00217 10 Pull off the air filter box cover in area sideways and remove it toward the front ...

Page 44: ...etc correctly and in compliance with the applicable regulations Preparatory work Remove the air filter box cover p 41 E00218 10 Main work Unhook air filter holder and swing it to the side Remove the air filter with the air filter support Remove the air filter from the air filter support 11 25 Installing the air filter L00943 10 Main work Mount the clean air filter onto the air filter support Apply...

Page 45: ...low it to dry properly Air filter cleaning agent p 90 Info Only squeeze the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil Oil for foam air filter p 90 Clean the air filter box Check the intake flange for damage and looseness Finishing work Install the air filter p 42 Install the air filter box cover p 42 11 27 Sealing the air filter box Preparatory w...

Page 46: ...Over a period the fibers of the glass fiber yarn vanish into the air and the silencer burns out Not only is the noise level higher the performance characteristic changes Preparatory work Remove the main silencer p 43 401544 10 Main work Remove screws Take off silencer cap with O ring and outer tube Pull glass fiber yarn filling from the inner tube Clean the parts that are to be reinstalled Mount n...

Page 47: ...d skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach o...

Page 48: ...contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children E00224 10 Mai...

Page 49: ...applicable regulations Info The service life of the chain depends largely on its maintenance Preparatory work Raise the motorcycle with the lift stand p 32 400725 01 Main work Clean the chain regularly and then treat with chain spray Offroad chain spray p 90 Finishing work Remove the motorcycle from the lift stand p 32 11 35 Checking the chain tension Warning Danger of accidents Incorrect chain te...

Page 50: ...procket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with the lift stand p 32 Check the chain tension p 47 E00227 10 Main work Loosen nut Loosen nuts Adjust the chain tension by turning adjusting screws on the left and right Guide...

Page 51: ...rs in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance at the longest chain section 219 mm 8 62 in If distance is greater than the specified measurement Change the drivetrain kit Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on an o...

Page 52: ...the chain guide If the dark part of the chain guide is worn Change the chain guide E00228 10 Check that the chain guide is firmly seated If the chain guide is loose Tighten the fitting on the chain guide Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Finishing work Remove the motorcycle from the lift stand p 32 11 38 Checking the frame 401542 01 C...

Page 53: ...tle cable routing and the play in throttle cable complies with the specification Preparatory work Remove the seat p 41 Turn tap handle on the fuel tap to the OFF position Figure S00484 10 p 12 Remove the fuel tank p 45 E00285 01 Main work Check the routing of the throttle cable The throttle cable must be routed to the carburetor on the left side above the fuel tank bracket If the throttle cable is...

Page 54: ...e Do not make any adjustments while riding 11 44 Checking the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch facing discs M00397 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Check the fluid level in viewer If the fluid has dropped below marking in the viewer Correct the fluid level of the hydraulic clutch p ...

Page 55: ...the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contac...

Page 56: ...e system until it escapes from opening of the master cylinder without bubbles Now and then extract fluid from the master cylinder reservoir to prevent overflow Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws Info...

Page 57: ... handlebar Turn the adjusting screw counterclockwise to increase free travel The pressure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply force Do not make any adjustments while riding 12 3 Checking the brake discs Warning Danger of accidents Worn out brake discs reduce the braking effect Make sure that worn out brake disc...

Page 58: ... not continue riding until the problem is eliminated Your authorized Husqvarna Motorcy cles workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake f...

Page 59: ...damage or cracking is visible Change the front brake linings p 57 12 7 Changing the front brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail Ensure that service work and repairs are performed professionally Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid ...

Page 60: ...y and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container E00237 11 Move the brake fluid reservoir mounted on the handlebar to a horizonta...

Page 61: ...evel below reservoir rim 5 mm 0 2 in Brake fluid DOT 4 p 88 E00237 11 Position cover with membrane Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water 12 8 Checking the free travel of 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...

Page 62: ...d tighten nut Guideline Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Hold push rod and tighten nut Guideline Remaining nuts chassis M6 10 Nm 7 4 lbf ft Attach spring 12 10 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake ...

Page 63: ...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 autho rized Husqvarna Motorcycles workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Dispose o...

Page 64: ...th 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 accordance with the service schedule Your autho rized Husqvarna Motorcycles workshop will be glad to help W...

Page 65: ...brake fluid does not flow out of the brake fluid reservoir sucking it away if necessary E00244 11 Take off cotter pin and remove bolt Take off retaining spring and remove the brake linings Clean the brake caliper E00245 10 Position the new brake linings Info Always change the brake linings in pairs E00244 11 Position retaining spring Mount pin Guideline Pin rear brake M6 4 Nm 3 lbf ft Info To make...

Page 66: ... SYSTEM 64 E00246 10 Add brake fluid to level Brake fluid DOT 4 p 88 Mount the cover with the washer and membrane Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water ...

Page 67: ...nd brake lever when the front wheel is removed H00934 10 Remove spacers 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 and grease Clean the brake discs with brake cleaner when necessary H00935 10 Main work Check the wheel bearing for damage and wear If the wheel bearing is damaged or wo...

Page 68: ...only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Info Cover the components to protect them against damage Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the rear wheel withdraw the wheel spindle ...

Page 69: ...n adjusters can be turned by 180 Check the chain tension p 47 Tighten nut Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 32 13 5 Checking the tire condition Info Only mount tires approved and or recomme...

Page 70: ...psi If the tire pressure does not meet specifications Correct the tire pressure Mount the protection cap 13 7 Checking spoke tension Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage The spokes break due to being overloaded if they are too tightly tensioned If the tension in the spokes is too low then lat eral and radial run ...

Page 71: ...compo nents of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty...

Page 72: ...upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level above the radiator fins 10 mm 0 39 in If the coolant level does not meet specifications Correct the coolant level Coolant p 88 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 open...

Page 73: ...tor 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 E00252 10 Main work Make sure that screw is tightened Position the motorcycle upright Take off radiator cap E00253 1...

Page 74: ... Start the engine and let it idle Move the handlebar to and fro over the entire steering range The idle speed should not change If the idle speed changes Adjust the play in the throttle cable p 72 15 2 Adjusting the play in the throttle cable Preparatory work Remove the seat p 41 Turn tap handle on the fuel tap to the OFF position Figure S00484 10 p 12 Remove the fuel tank p 45 Check the routing o...

Page 75: ... shape and position In the lower range the idle setting affects engine tuning in the upper range it is the main jet If during acceleration with a partially opened throttle slide the engine runs only at stuttering performance the jet needle must be lowered by one notch If the engine knocks particularly during acceleration when it is in the top performance engine speed range the jet needle must be r...

Page 76: ...The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel 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 poisonous and...

Page 77: ...dge of your boot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever p 75 15 7 Adjusting the basic position of the shift lever 401950 12 Remove screw with washers and take off shift lever 401951 10 Clean gear teeth of the shift lever and shift shaft Mount the shift le...

Page 78: ...nmental 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 the gear oil while the engine is warm Preparatory work Stand the motorcycle on the plug in stand on a horizontal surface Place a suitable container under the engine E00255 11 Main work Remove oil dr...

Page 79: ...mission Preparatory work Stand the motorcycle upright on a horizontal surface E00255 10 Main work Remove screw E00254 11 Remove filler plug Add gear oil until it flows out of the hole of the gear oil level screw Engine oil SAE 10W 40 p 88 Mount and tighten screw Guideline Screw engine case M6x25 10 Nm 7 4 lbf ft Mount and tighten filler plug Danger Danger of poisoning Exhaust gases are toxic and i...

Page 80: ... and then brush off with a soft brush Info Use warm water containing standard commercially available motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust system Empty the carburetor float chamber p 74 Warnin...

Page 81: ...he start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Refuel p 23 Clean the motorcycle p 78 Change the gear oil p 76 Check the antifreeze and coolant level p 69 Check the tire air pressure p 68 Empty the carburetor float chamber p 74 Store the vehicle in a dry location that is not subject to large fluctuations in tem per...

Page 82: ... dirty or worn Check set the carburetor components Loose carburetor jets Check set the carburetor components Fault in ignition system Check the ignition system Adjust the ignition Engine has too little power Fuel feed interrupted Check the fuel tank breather Clean the fuel tap Check set the carburetor components Air filter is very dirty Clean the air filter and air filter box p 43 Exhaust system l...

Page 83: ...ator hose Incorrect ignition point due to loose stator Adjust the ignition White smoke emission steam in exhaust gas Damaged cylinder head or cylinder head gasket Check the cylinder head and cylinder head gasket Gear oil exits at the vent hose Too much gear oil added Check the gear oil level p 76 Water in the gear oil Damaged shaft seal ring or water pump Check the shaft seal ring and water pump ...

Page 84: ...20 2 Engine tightening torques Stop screw for adjustment cable M4 4 Nm 3 lbf ft Loctite 243 Locking cap screw M5 8 Nm 5 9 lbf ft Screw clutch springs M5 6 Nm 4 4 lbf ft Screw control flap exhaust control M5 8 Nm 5 9 lbf ft Loctite 243 Screw exhaust control cover M5 6 Nm 4 4 lbf ft Screw ignition system stator M5 6 Nm 4 4 lbf ft Loctite 222 Screw water pump wheel M5 6 Nm 4 4 lbf ft Loctite 243 Lock...

Page 85: ...ctite 243 Oil drain plug with magnet M10 20 Nm 14 8 lbf ft Primary gear screw M10x1 25 80 Nm 59 lbf ft Loctite 243 Nut rotor M12x1 60 Nm 44 3 lbf ft Nut inner clutch hub M14x1 25 60 Nm 44 3 lbf ft Loctite 243 Spark plug M14x1 25 20 Nm 14 8 lbf ft 20 3 Carburetor Carburetor type KEIHIN PWK 28 Needle position 3rd position from top Idle air adjusting screw Open 1 5 turns Main jet 118 Jet needle N5HG ...

Page 86: ... adjusting screw open rotations IJ Idling jet NDL Jet needle POS Needle position from above MJ Main jet 0 0 4 4 0 0 3 3 0 0 5 5 0 0 2 2 0 0 1 1 B00075 10 1 5 Needle position from above The five possible needle positions are shown here The carburetor tuning depends on the defined ambient and operating conditions ...

Page 87: ...caliper Brake discs diameter TC 85 17 14 Front 220 mm 8 66 in Rear 210 mm 8 27 in Brake discs diameter TC 85 19 16 Front 240 mm 9 45 in Rear 210 mm 8 27 in Brake discs wear limit Front 3 5 mm 0 138 in Rear 3 5 mm 0 138 in Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Secondary ratio TC 85 17 14 14 46 Secondary ratio TC 85 19 16 14 49 Chain 1 2 x 5 16 Rear sprockets available ...

Page 88: ... kg 99 121 lb 3 4 N mm 19 4 lb in Weight of rider 55 kg 121 lb 3 6 N mm 20 6 lb in Spring length with preload spacer s 438 mm 17 24 in Fork length 835 mm 32 87 in Air chamber length 110 20 30 mm 4 33 0 79 1 18 in Fork oil per fork leg 378 ml 12 78 fl oz Fork oil SAE 4 48601166S1 p 88 20 8 Shock absorber Shock absorber article number 15 18 7Q 02 Shock absorber WP Performance Systems 4618 PDS DCC Co...

Page 89: ...ts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw of brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw bottom triple clamp M8 15 Nm 11 1 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw rear sprocket M8 35 Nm 25 8 lbf ft Loctite 243 Screw subframe M8 30 Nm 22 1 lbf ft Screw top triple clamp M8 20 Nm 14 8 lbf ft Engine...

Page 90: ... Recommended supplier Bel Ray Moto Chill Racing Coolant Engine oil SAE 10W 40 Standard classification JASO T903 MA p 91 SAE p 91 SAE 10W 40 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties mineral engine oil Recommended supplier Bel Ray EXL Mineral 4T Engine oil 2 stroke Standard classificatio...

Page 91: ...ontainer and that exhibit the corresponding properties Super unleaded ROZ 98 RON 98 PON 94 Standard classification DIN EN 228 ROZ 98 RON 98 PON 94 Super unleaded 98 octane mixed with 2 stroke engine oil 1 40 Standard classification DIN EN 228 JASO FD p 91 1 40 Mixture ratio 1 40 Engine oil 2 stroke p 88 Super unleaded ROZ 98 RON 98 PON 94 p 89 Recommended supplier Bel Ray Si 7 Synthetic 2T ...

Page 92: ...ended supplier SKF LGHB 2 Long life grease Recommended supplier Bel Ray Waterproof Grease Offroad chain spray Guideline Recommended supplier Bel Ray Blue Tac Chain Lube Oil for foam air filter Recommended supplier Bel Ray Foam Filter Oil Preserving materials for paints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil spray Recommended supplier Bel Ray ...

Page 93: ... In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity The viscosity describes only one property of oil and says nothing about quality JASO FD JASO FD is a class...

Page 94: ...24 LIST OF ABBREVIATIONS 92 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 95: ...Chassis number 10 Choke 13 Cleaning 78 Clutch fluid level checking 52 fluid level correcting 52 fluid changing 53 Clutch lever 11 basic position adjusting 52 Compression damping fork adjusting 30 Compression damping high speed shock absorber adjusting 27 Compression damping low speed shock absorber adjusting 26 Coolant draining 70 refilling 71 Coolant level checking 69 70 Cooling system 69 Custome...

Page 96: ...rage 79 checks and maintenance work when preparing for use 20 Protective clothing 6 R Rear sprocket checking 49 Rear wheel installing 66 removing 66 Rebound damping fork adjusting 30 shock absorber adjusting 27 Riding sag adjusting 29 Rubber grip checking 51 securing 52 S Safe operation 5 Seat mounting 41 removing 41 Service 7 Service hour counter 14 Service schedule 24 25 Shift lever 13 basic pos...

Page 97: ... cable play adjusting 72 checking 72 Throttle cable routing checking 51 Throttle grip 11 Tire air pressure checking 68 Tire condition checking 67 Transport 22 Troubleshooting 80 81 Type label 10 U Use definition 5 V View of vehicle front left 8 rear right 9 W Warranty 7 Work rules 6 ...

Page 98: ... 3402093en 3402093en 03 2016 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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