Husqvarna TC 85 2020 Page 112 Owner'S Manual Download

Page: 112 / 136

16 SERVICE WORK ON THE ENGINE

110

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
running the engine in an enclosed space.

–

Start the engine and check that it is oil-tight.

Finishing work

–

Check the gear oil level. (

p. 108)

Summary of Contents for TC 85 2020

Page 1: ...OWNER S MANUAL 2020 TC 85 Art no 3402330en ...

Page 2: ......

Page 3: ...s 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 speci...

Page 4: ...7 PREPARING FOR USE 21 7 1 Advice on preparing for first use 21 7 2 Running in the engine 23 7 3 Preparing the vehicle for difficult riding conditions 23 7 4 Preparing the vehicle for riding on dry sand 23 7 5 Preparing the vehicle for riding on wet sand 25 7 6 Preparing vehicle for rides on wet and muddy circuits 26 7 7 Preparing vehicle for high temperatures or slow riding 26 7 8 Preparing vehic...

Page 5: ... the main silencer 61 11 29 Changing the glass fiber yarn filling of the main silencer 61 11 30 Removing the right side cover 62 11 31 Installing the right side cover 63 11 32 Removing the fuel tank 63 11 33 Installing the fuel tank 64 11 34 Checking for chain dirt accumulation 65 11 35 Cleaning the chain 66 11 36 Checking the chain tension 66 11 37 Adjusting the chain tension 67 11 38 Checking th...

Page 6: ...06 15 9 Checking the basic position of the shift lever 106 15 10 Adjusting the basic position of the shift lever 106 16 SERVICE WORK ON THE ENGINE 108 16 1 Checking the gear oil level 108 16 2 Changing the gear oil 108 16 3 Adding the gear oil 109 17 CLEANING CARE 111 17 1 Cleaning the motorcycle 111 18 STORAGE 113 18 1 Storage 113 18 2 Preparing for use after storage 114 19 TROUBLESHOOTING 115 20...

Page 7: ...cially 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 a voltage measurement Indicates a current measurement Indicates the end of an activity including potential reworking 1 2 Formats used The typographical formats used in t...

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: ...g safety of the vehicle 2 9 Environment If you use your motorcycle responsibly you can ensure that problems and conflicts do not occur To protect the future of the motorcycle sport make sure that you use your motorcycle legally display environmental con sciousness and respect the rights of others When disposing of used oil other operating and auxiliary fluids and used components comply with the la...

Page 11: ... 9 The Owner s Manual is also available for download from your authorized Husqvarna Motorcycles dealer and on the Husqvarna Motorcycles website International Husqvarna Motorcycles website www husqvarna motorcycles com ...

Page 12: ...e glad to advise you The current Husqvarna Motorcycles 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...

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

Page 14: ...IEW OF VEHICLE 12 4 1 View of vehicle front left example S03422 10 1 Hand brake lever p 16 2 Clutch lever p 16 3 Fuel tank filler cap 4 Air filter box cover 5 Shift lever p 18 6 Choke p 18 7 Fuel tap p 18 ...

Page 15: ...VEHICLE 4 13 4 2 View of vehicle rear right example S03423 10 1 Kill switch p 16 2 Throttle grip p 16 3 Fork article number 4 Foot brake lever p 19 5 Kick starter lever p 19 6 Level viewer for brake fluid rear ...

Page 16: ... right side of the steering head 5 2 Type label 402154 10 Type label 1 is located on the front frame tube 5 3 Engine number 401949 10 The engine number 1 is located on the left side of the engine under the engine sprocket 5 4 Fork part number 401947 10 Fork part number 1 is stamped on the inner side of the axle clamp ...

Page 17: ...SERIAL NUMBERS 5 15 5 5 Shock absorber article number H02222 10 The shock absorber part number 1 is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 18: ...e is engaged using the hand brake lever 6 3 Throttle grip K00954 11 Throttle grip 1 is fitted on the right side of the handlebar 6 4 Kill switch K00955 10 Kill switch 1 is fitted on the left side of the handlebar Possible 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 in...

Page 19: ...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 Note Environmental hazard Improper handling...

Page 20: ...completely 6 8 Choke K00958 10 Choke 1 is fitted on the left side of the carburetor Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel This results in a richer fuel air mixture which is needed 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 pu...

Page 21: ...k starter lever can be swiveled Info Before riding swing the kick starter lever inwards towards the engine 6 11 Foot brake lever 401956 10 Foot brake lever 1 is located in front of the right footrest The foot brake lever is used to activate the rear brake 6 12 Plug in stand 402001 10 The support for plug in stand 1 is the left side of the wheel spindle The plug in stand is used to park the motorcy...

Page 22: ... is attached below the seat 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 23: ...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 24: ...vel of the handbrake lever p 76 Adjust the basic position of the foot brake lever p 82 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 ...

Page 25: ...spect or replace parts before the next scheduled service Clean the air filter and air filter box p 59 Info Check the air filter approx every 30 minutes Check the electrical connector for humidity and corrosion and to ensure it is firmly seated If humidity corrosion or damage is found Clean and dry the connector or change it if necessary Difficult riding conditions are Rides on dry sand p 23 Rides ...

Page 26: ...ge the radiator cap M01104 01 Mount the air filter dust cover Air filter dust cover 47206920000 Info Observe the fitting instructions for Husqvarna Motor cycles accessories M01105 01 Mount the air filter sand cover Air filter sand cover 79006922000 Info Observe the fitting instructions for Husqvarna Motor cycles accessories M01107 01 Adjust the carburetor jetting and setting Info The recommended c...

Page 27: ... cooling system are at operating temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Change the radiator cap M01107 01 Adjust the carburetor jetting and setting Info The recommended carburetor tuning is available fro...

Page 28: ...the setpoint value Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system compo nents if the engine or the cooling system are at operating temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooli...

Page 29: ...USE 7 27 7 8 Preparing vehicle for low temperatures or snow M01107 01 Adjust the carburetor jetting and setting Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop ...

Page 30: ...ion p 91 Check tire pressure p 92 Check the spoke tension p 93 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 47 Bleed the fork legs p 46 Check the air filter Check the settings of all controls and ensure that they can be operated smoothly Check all screws nuts and hose clamps regularly for tigh...

Page 31: ... Danger of accidents If you change down at high engine speed the rear wheel blocks and the engine races Make it clear to your child that he or she must not change into a low gear at high engine speed Info If unusual noises occur while riding stop immediately switch off the engine and contact an authorized Husqvarna Motorcycles workshop First gear is used for starting off and for steep inclines Whe...

Page 32: ...dirt impair the brake system Explain to your child that he or she must brake carefully several times to dry out and remove dirt from the brake linings and the brake discs On sandy wet or slippery surfaces use the rear brake Always finish braking before you go into a bend Your child should change down to a lower gear appropri ate to the road speed Insist that your child take advantage of the brakin...

Page 33: ...ition Park the motorcycle on firm ground 8 7 Transporting Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down before covering it 401475 01 Switch of...

Page 34: ...ontact with the eyes Change your clothing in case of fuel spills on them 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 Switch off the engine Open the fuel tank filler cap p 17 401522 10 Fill the fuel tank with fuel up to measurement A Guideline Measurement of A 35 mm 1 38 in Fuel tank capa...

Page 35: ... p 83 Check the free travel of the foot brake lever p 82 Check the frame p 70 Check the link fork p 70 Check the fork bearing for play Check the heim joint for play Check the tire condition p 91 Check tire pressure p 92 Check the wheel bearing for play Check the wheel hubs Check the rim run out Check the spoke tension p 93 Check the chain rear sprocket engine sprocket and chain guide p 68 Check th...

Page 36: ...ce after 10 operating hours Every 10 operating hours every 12 months Change the front brake fluid Change the rear brake fluid Change the hydraulic clutch fluid p 74 Grease the steering head bearing p 55 Service the fork Perform the shock absorber service Check adjust the carburetor components Perform minor engine service Check the inlet membrane Check the clutch Under difficult operating condition...

Page 37: ... 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 is frequently overloaded then the air pressure in the fork mu...

Page 38: ...ession damping in the low speed range and vice versa 10 4 Adjusting the low speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will 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 t...

Page 39: ... counterclockwise by the number of turns corresponding to the shock absorber type Guideline High speed compression damping Comfort 1 5 turns Standard 2 turns Sport 2 5 turns Info Turn clockwise to increase the damping turn counter clockwise to reduce the damping 10 6 Adjusting the rebound damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock...

Page 40: ...ch as a marking on the side cover Note the value as dimension A Finishing work Remove the motorcycle from the lift stand p 46 10 8 Checking the static sag of the shock absorber 400989 10 Measure dimension A of rear wheel unloaded p 38 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 i...

Page 41: ... The riding sag is the difference between measure ments A and C Check riding sag Riding sag 120 mm 4 72 in If the riding sag differs from the specified measurement Adjust the riding sag p 40 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 hig...

Page 42: ...ned 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 1 Guideline Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Finishing work Install the shock absorber p 57 Remove the motorcycle from the lift stand p 46 10 11 Adjusting the riding sag Preparatory work Raise the motorcycle with a lift stand p 46 Re...

Page 43: ... compression the fork air pressure must be increased within the specified values to avoid damage to the fork and frame 10 13 Adjusting the fork air pressure Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling charac teristic Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload ...

Page 44: ...companying instructions for Husq varna Motorcycles accessories Adjust the air pressure as specified Guideline Air pressure 5 bar 73 psi Changing the air pressure in steps of 0 2 bar 3 psi Minimum air pressure 4 bar 58 psi Maximum air pressure 8 bar 116 psi Info Never adjust the air pressure to a value outside the stated range Disconnect the fork airpump from the left fork leg When disconnecting ex...

Page 45: ...icks Standard 12 clicks Sport 7 clicks Info Turn clockwise to increase damping turn counter clockwise to reduce damping Mount protection cap 1 10 15 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior S03415 10 Turn red adjusting screw 1 clockwise as far as it will go Info Adjusting screw 1 is located at the upper end of the right fo...

Page 46: ...n 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 dam age Do not ...

Page 47: ...TUNING THE CHASSIS 10 45 Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure the gap widths are even ...

Page 48: ...lift stand Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 402001 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand 1 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 with a...

Page 49: ...eep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 128 Press the dust boots back into their installation position Remove excess oil Finishing work Install the fork protector p 50 Remove the motorcycle from the lift stand p 46 11 5 Removing the fork legs Preparat...

Page 50: ...e upper triple clamp The air suspension is located in the left fork leg The pressure and rebound damping is located in the right fork leg S03427 11 Tighten screws 2 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft S03428 10 Connect the brake line at the start number plate H00935 15 Check the wheel bearing for damage and...

Page 51: ...es until the brake linings are seated correctly against the brake disc Secure the hand brake lever in the activated position The brake caliper straightens Tighten screws 6 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Remove the locking piece of the hand brake lever Remove the motorcycle from the lift stand p 46 Operate the front brake and compress the fork a few times firml...

Page 52: ...reparatory work Raise the motorcycle with a lift stand p 46 Remove the front wheel p 88 Remove the fork legs p 47 Remove the start number plate p 55 Remove front fender p 56 Remove the handlebar cushion S03429 10 Main work Pull fuel tank breather 1 out of the steering stem Loosen screw 2 Remove nut 3 pull off the upper triple clamp with the handlebar in an upward direction and hang it to the side ...

Page 53: ... Position protective ring 3 S03429 11 Position the upper triple clamp with the handlebar Mount nut 4 but do not tighten it yet H02312 12 Position the fork legs Air bleeder screw 5 of the right fork leg is positioned to the front Valve A of the left fork leg faces the front Info The second milled groove from the top must be flush with the upper edge of the upper triple clamp The air suspension is l...

Page 54: ...0 Nm 14 8 lbf ft Position fuel tank breather in the steering stem S03431 11 Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws 8 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft H00935 17 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change front wheel bearing Clean and grease shaft seal rings 9 and contact surfa...

Page 55: ...brake disc Secure the hand brake lever in the activated position The brake caliper straightens Tighten screws bl Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Remove the locking piece of the hand brake lever Remove the motorcycle from the lift stand p 46 Operate the front brake and compress the fork a few times firmly The fork legs straighten Tighten screws bn Guideline Scre...

Page 56: ... should not be detectable on the steering head bear ing If there is detectable play Adjust the steering head bearing play p 54 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 54 Check the...

Page 57: ...y p 54 Remove the motorcycle from the lift stand p 46 11 13 Greasing the steering head bearing H02387 01 Remove the lower triple clamp p 50 Install the lower triple clamp p 51 11 14 Removing the start number plate A00137 10 Remove screw 1 Unhook the start number plate from the brake line and remove it 11 15 Installing the start number plate A00151 10 Attach the start number plate to the brake line...

Page 58: ...0 10 Mount and tighten screw 2 Guideline Start number plate screw M6 4 Nm 3 lbf ft 11 16 Removing front fender Preparatory work Remove the start number plate p 55 A00138 10 Main work Remove screws 1 Remove screws 2 Take off the front fender ...

Page 59: ...n work Detach brake line from the brake line guide Remove screw 1 and lower the rear wheel with the link fork as far as possible without blocking the rear wheel Secure the rear wheel in this position Remove screw 2 push splash protector 3 to the side and remove the shock absorber 11 19 Installing the shock absorber V01289 11 Main work Push splash protector 1 to the side and position the shock abso...

Page 60: ...eat K00987 01 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 K00964 10 Mount and tighten screw 1 of the seat fixing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 22 Removing the air filter box cover S03458 10 Pull off the air filter box cover laterally in areas A and ...

Page 61: ... fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Preparatory work Remove the air filter box cover p 58 K00972 10 Main work Detach retaining tab 1 Remove air filter with air filter sup port Remove air filter from air filter support 11 25 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental dama...

Page 62: ...oseness Finishing work Install the air filter p 60 Install the air filter box cover p 59 11 26 Installing the air filter V00839 10 Main work Mount the clean air filter on the air filter support Grease the air filter in area A Long life grease p 127 K00988 10 Insert the air filter and position top retaining pin 1 in bush ing B The air filter is correctly positioned Secure the bottom retaining pin 2...

Page 63: ...Mount the main silencer with rubber sleeve 1 Mount and tighten screw 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the right side cover p 63 11 29 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehi...

Page 64: ...o that the thermal protection foil is positioned on the right in the direction of travel Slide outer tube over the inner tube with the new glass fiber yarn filling Info Seal the connecting cap 5 to the outer tube with sili cone Mount and tighten the screws Guideline Screw main silencer M5 7 Nm 5 2 lbf ft Finishing work Install the main silencer p 61 Install the right side cover p 63 11 30 Removing...

Page 65: ...n hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly wit...

Page 66: ...ity 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 a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel...

Page 67: ...the rubber bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft K00968 11 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount fuel hose Position the fuel tank breather in the steering stem Finishing work Install the right side cover p 63 Install the air filter box cover p 59 Mount the seat p 58 11 34 Checking for chain dirt accumulation 400678 01 Check...

Page 68: ...e motorcycle with a lift stand p 46 400725 01 Main work Rinse off loose dirt with a soft jet of water Remove old grease residue with chain cleaner Chain cleaner p 127 After drying apply chain spray Off road chain spray p 127 Finishing work Remove the motorcycle from the lift stand p 46 11 36 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and resul...

Page 69: ...rear wheel bearings wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand p 46 Check the chain...

Page 70: ...to neutral Check the chain rear sprocket and engine sprocket for wear If the chain rear sprocket or engine sprocket is worn Change the drivetrain kit Info The engine sprocket rear sprocket and chain should always be replaced together 400987 10 Pull on the top section of the chain with the specified weight A Guideline Weight chain wear mea surement 10 15 kg 22 33 lb Measure distance B of 18 chain r...

Page 71: ...in sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten screws on the chain sliding guard Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft H02531 01 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 piec...

Page 72: ...Remove the motorcycle from the lift stand p 46 11 39 Checking the frame V00858 01 Check the frame for cracks and deformation If the frame exhibits cracks or deformation due to a mechanical impact Change the frame Info Always replace a frame that has been damaged due to a mechanical impact Repair of the frame is not authorized by Husqvarna Motorcycles 11 40 Checking the link fork V00857 01 Check th...

Page 73: ... Remove the seat p 58 Remove the air filter box cover p 58 Remove the right side cover p 62 Turn the tap handle of the fuel tap to the OFF position Remove the fuel tank p 63 V01292 01 Main work Check the throttle cable routing The throttle cable must be routed along the back of the handlebar to the right of the frame above the fuel tank bracket and to the carburetor If the throttle cable routing i...

Page 74: ...ckwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 11 44 Checking the fluid level of the hydraulic clutch Info The fluid leve...

Page 75: ...ke fluid spills on to your clothing change the clothing Info The fluid level rises with increasing wear of the clutch facing discs Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container K0098...

Page 76: ...the clothing 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 Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted...

Page 77: ...ct 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 Clean up overflowed or spilled brake fluid immediately with water ...

Page 78: ...free travel of the handbrake lever K00992 11 Check the free travel of the hand brake lever p 76 Adjust the free travel of the handbrake lever with adjustment screw 1 Info Turn the adjusting screw clockwise to reduce free travel The pressure point moves away from the han dlebar Turn the adjusting screw counterclockwise to increase free travel The pressure point moves towards the handlebar The range...

Page 79: ...An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and ensure that nobody drives the vehicle before the problem is elimi nated Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Danger of ...

Page 80: ...ntact 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 Note Environmental hazard Hazardous substances cause environmental damag...

Page 81: ...cidents Incorrect servicing will cause the brake system to fail Ensure that service work and repairs are performed professionally Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contac...

Page 82: ...Husqvarna motorcycles 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 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...

Page 83: ... ft Loctite 243 Tighten pin 5 Guideline Pin front brake M6 8 Nm 5 9 lbf ft Mount cotter pins 4 Operate the hand brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point Secure the hand brake lever in the activated position The brake caliper straightens Tighten screws 6 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Remov...

Page 84: ...t spring 1 12 9 Adjusting the basic position 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 V01302 10 Detach spring 1 Loosen nut 4 and with push rod 5 turn...

Page 85: ...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 V01303 10 Stand the vehicle upright Check the brake fluid level in level viewer 1 Tip Move the frame protector slightly to the side to make it easier to see the marking If the brake fluid level has dropped below the marking A Add rear ...

Page 86: ...e 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 grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines ar...

Page 87: ...hop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with...

Page 88: ...se environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and 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...

Page 89: ...aining spring is seated correctly Mount cotter pins 3 Operate the foot brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point K01001 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 125 Mount the cover with the washer and membrane 2 Mount and tighten screws 1 Info Immediately clean up any brake fluid that has over flowed or spilled...

Page 90: ...scs reduce the braking effect Always lay the wheel 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 bra...

Page 91: ...ake linings are correctly positioned Insert the wheel spindle Mount and tighten screw 2 Guideline Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc Remove the motorcycle from the lift stand p 46 Operate the front brake and compress the fork a few times firmly The fork legs straighten Ti...

Page 92: ... the rear wheel 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 H00936 10 Remove spacers 4 13 4 Installing the rear 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...

Page 93: ...ame chain length Chain adjusters 3 can be turned by 180 Check the chain tension p 66 Tighten nut 4 Guideline Nut rear wheel spin dle M20x1 5 80 Nm 59 lbf ft Operate the foot brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 46 13 5 Checking the tire condition Info Only mount ti...

Page 94: ...e DOT number The first two digits indicate the week of manufacture and the last two digits the year of manufacture Husqvarna Motorcycles recommends that the tires be changed after 5 years at the latest regardless of the actual wear If the tires are more than 5 years old Change the tires 13 6 Checking tire pressure Info Low tire pressure leads to abnormal wear and overheating of the tire Correct ti...

Page 95: ...k spoke tension regularly and in particular on a new vehicle Your authorized Husqvarna Motorcycles workshop will be glad to help 400694 01 Strike each spoke briefly using a screwdriver blade Info The frequency of the sound depends on the spoke length and spoke diameter If you hear different tone frequencies from different spokes of equal length and diameter this is an indica tion of different spok...

Page 96: ...01 The radiator covers are mounted in front of the radiator between the radiator shield and radiator Info Do not use radiator covers in difficult operating condi tions The radiator cover keeps the coolant temperature in the correct range Optimal coolant temperature 60 70 C 140 158 F V00884 10 The radiator covers are installed in front of the radiator depend ing on the ambient temperature Full radi...

Page 97: ...6 01 Position the corresponding radiator cover p 94 The holding lugs point toward the frame H02536 10 Position left radiator shield 4 Mount and tighten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position right radiator shield 2 Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 98: ... radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic an...

Page 99: ...ne to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately...

Page 100: ...nty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold V01304 11 Position the motorcycle upright Place an appropriate container under the water pump cover Remove screw 1 Take off radiator cap 2 Completely drain the coolant Mou...

Page 101: ... bleeding M6 8 Nm 5 9 lbf ft Completely fill the radiator with coolant Coolant p 125 Mount radiator cap 2 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Allow the engine to wa...

Page 102: ...ng 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 throttle cable play p 100 15 2 Adjusting the throttle cable play Preparatory work Remove the seat p 58 Remove the air fi...

Page 103: ...tuned both to one another and for the use intended Main jet MJ The main jet MJ has the greatest influence with the throttle slide open full throttle If the insulator of a new spark plug is very light or white after a brief ride at full throttle or if the engine knocks a larger main jet needs to be used If the insulator is dark brown or sooty a smaller main jet needs to be used Needle position POS ...

Page 104: ...rt of the needle and the clip position have only minimal influence When the throttle slide is 1 8 open the first cylindrical part of the needle the idling jet and the clip position have the greatest influence K00496 01 When the throttle slide is 1 4 open the idling jet and the clip position have the greatest influence The influence of the first cylindrical part of the needle is less When the throt...

Page 105: ...075 10 Clip position 1 5 Clip position from above The five possible clip positions are shown here The carburetor tuning depends on the defined ambient and oper ating conditions 15 4 Carburetor idle 402799 10 The idle setting of the carburetor has a big influence on the start ing behavior stable idling and the response to throttle opening This means that an engine with a correctly set idle speed is...

Page 106: ...in to the stop p 18 Idle speed 1 400 1 500 rpm Turn idle air adjusting screw 1 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 big engine speed rise reduce the id...

Page 107: ...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 Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allo...

Page 108: ...Soft Better rideability Alternative 2 Join plug in connector 1 of the ignition timing map adjustment Figure K00975 10 p 106 Performance Higher performance 15 9 Checking the basic position of the shift lever Info When driving the shift lever must not touch the rider s boot when in the basic position When the shift lever keeps touching the boot the transmission will be subject to an excessive load 4...

Page 109: ... on the shift shaft in the required position and engage gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during the shift procedure Locate and tighten screw 1 with the washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 110: ...ear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water 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 the...

Page 111: ...rting or running the engine in an enclosed space Start the engine and check that it is oil tight Finishing work Check the gear oil level p 108 16 3 Adding the gear oil Info Too little gear oil or poor quality gear oil results in premature wear to the transmission Preparatory work Stand the motorcycle upright on a horizontal surface V01305 10 Main work Remove screw 1 with the seal ring 401955 11 Re...

Page 112: ...hem may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and check that it is oil tight Finishing work Check the gear oil level p 108 ...

Page 113: ...period clean it regularly Avoid direct sunshine when cleaning the motorcycle 401061 01 Close off the exhaust system to keep water from entering Remove loose dirt first with a soft jet of water Spray very dirty parts with a normal commercially available engine cleaner and then brush off with a soft brush Motorcycle cleaner p 127 Info Use warm water containing normal motorcycle cleaner and a soft sp...

Page 114: ...ate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 66 Treat bare metal except for brake discs and the exhaust sys tem with a corrosion inhibitor Preserving materials for paints metal and rubber p 127 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 plast...

Page 115: ... less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 127 Refuel p 31 Clean the motorcycle p 111 Change the gear oil p 108 Check the antifreeze and coolant level p 96 Check tire pressure p 92 Empty the carburetor float chamb...

Page 116: ...18 STORAGE 114 18 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 46 Perform checks and maintenance measures when preparing for use p 28 Take a test ride ...

Page 117: ...gine has no idle Idling jet blocked Check set the carburetor compo nents Adjusting screws on carbure tor distorted Carburetor adjust the idle speed p 104 Spark plug defective Change the spark plug Ignition system defective Check the ignition coil Check the spark plug connector Engine does not speed up Carburetor running over because float needle dirty or worn Check set the carburetor compo nents L...

Page 118: ...ks Check the coolant level p 97 Too little air stream Switch off the engine when standing Radiator fins very dirty Clean the radiator fins Foam formation in cooling sys tem Drain the coolant p 98 Refill with coolant p 98 Damaged cylinder head or cylinder head gasket Check the cylinder head and cylinder head gasket Bent radiator hose Change the radiator hose Incorrect ignition point due to loose st...

Page 119: ...ssion claw shifted Transmission ratio 1st gear 11 29 2nd gear 14 28 3rd gear 16 26 4th gear 19 26 5th gear 21 25 6th gear 20 21 Ignition Kokusan 504 Spark plug NGK BR9 ECMVX Spark plug electrode gap 0 60 mm 0 0236 in Cooling Water cooled Starting aid Kick starter 20 2 Engine tightening torques Screw adjusting lever M5x16 6 Nm 4 4 lbf ft Loctite 243 Screw clutch spring retainer M5 6 Nm 4 4 lbf ft S...

Page 120: ...t Screw intermediate clutch cover M6x25 10 Nm 7 4 lbf ft Screw intermediate clutch cover M6x55 10 Nm 7 4 lbf ft Screw intermediate clutch cover M6x60 10 Nm 7 4 lbf ft Screw kick starter intermediate gear M6 10 Nm 7 4 lbf ft Loctite 243 Screw kick starter stop plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw outer clutch cover M6x25 8 Nm 5 9 lbf ft Screw outer clutch cover M6x55 8 Nm 5 9 lbf ft Screw ou...

Page 121: ... turns Main jet 142 140 145 148 Jet needle NRKC NRJC Idling jet 48 45 50 Throttle slide 3 Cold start jet 62 20 3 1 Basic carburetor setting for sandy surfaces Idle air adjusting screw 2 turns Idling jet 48 Jet needle NRJ C Needle position 4th position from top Main jet 148 Info If the engine is not running smoothly use a smaller main jet ...

Page 122: ...CHNICAL DATA 120 20 3 2 Carburetor tuning 402814 01 M FT ASL Above sea level TEMP Temperature ASO Open rotations idle air adjusting screw IJ Idling jet NDL Jet needle POS Needle position from top MJ Main jet ...

Page 123: ... 14 mm 0 55 in Brake system front Disc brake with 4 piston brake caliper rear Disc brake with 2 piston brake caliper Brake discs diameter 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 7 mm 0 146 in Offroad tire pressure front 1 0 bar 15 psi rear 1 0 bar 15 psi Secondary ratio TC 85 17 14 13 46 Secondary ratio TC 85 19 16 13 49 Chain 1 2 x 5 16 Rear sp...

Page 124: ...icle number 43 18 8T 04 Fork WP Suspension Upside down XACT 5543 Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Fork length 845 mm 33 27 in Oil capacity external mechanism right 363 10 ml 12 27 0 34 fl oz Fork oil SAE 4 48601166S1 p 126 Oil capacity external mechanism left 100 20 ml 3 38 0 68 fl oz Fork oi...

Page 125: ...ining nuts chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M6 10 Nm 7 4 lbf ft Screw for throttle grip M6 5 Nm 3 7 lbf ft Screw ball joint of push rod on foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw foot brake cylinder M6 10 Nm 7 4 lbf ft Screw front brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw front fender M6 6 Nm 4 4 lbf ft Screw rear brake disc M6 14 Nm 10 3 lbf ft Loctit...

Page 126: ...tite 243 Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Screw bottom shock absorber M12 60 Nm 44 3 lbf ft Loctite 2701 Screw top shock absorber M12 60 Nm 44 3 lbf ft Loctite 2701 Nut seat fixing M12x1 20 Nm 14 8 lbf ft Nut swingarm pivot M14x1 5 75 Nm 55 3 lbf ft Nut rear wheel spindle M20x1 5 80...

Page 127: ... 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 miscibility comp...

Page 128: ...ard classification SAE p 129 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container 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 129 1 40 Mixture r...

Page 129: ...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 130: ... 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 131: ... motorcycle engines the transmission and clutch are lubricated with the same oil The JASO T903 MA2 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 classificatio...

Page 132: ...24 LIST OF ABBREVIATIONS 130 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 133: ... idle 103 idle speed adjusting 104 Carburetor tuning 101 Chain checking 68 cleaning 66 Chain guide checking 68 Chain tension adjusting 67 checking 66 Choke 18 Cleaning 111 112 Clutch fluid level checking 72 fluid level correcting 73 fluid changing 74 Clutch lever 16 basic position adjusting 72 Compression damping fork adjusting 43 Coolant draining 98 refilling 98 Coolant level checking 96 97 Cooli...

Page 134: ... map changing 106 plug in connector 106 Implied warranty 10 Intended use 6 K Kick starter lever 19 Kill switch 16 L Link fork checking 70 Lower triple clamp installing 51 removing 50 Low speed compression damping shock absorber adjusting 36 M Main silencer glass fiber yarn filling changing 61 installing 61 removing 61 Manufacturer warranty 10 Misuse 6 Motorcycle cleaning 111 lift stand raising wit...

Page 135: ...3 Start number plate installing 55 removing 55 Starting 28 Steering head bearing greasing 55 Steering head bearing play adjusting 54 checking 54 Storage 113 T Technical data capacities 121 carburetor 119 chassis 121 chassis tightening torques 123 engine 117 engine tightening torques 117 fork 122 shock absorber 122 tires 122 Throttle cable play adjusting 100 checking 100 Throttle cable routing chec...

Page 136: ... 3402330en 3402330en 03 2019 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer KISKA Husqvarna Motorcycles GmbH ...

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