Husqvarna TC 85 Page 70 Owner'S Manual Download

Page: 70 / 131

11 SERVICE WORK ON THE CHASSIS

–

Turn the tap handle of the fuel tap to the

OFF

position.

–

Remove the fuel tank.

(

p. 60)

H02525-01

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 is not routed as specified:

–

Correct the throttle cable routing.

Finishing work

–

Install the fuel tank.

(

p. 61)

–

Install the right side cover. (

p. 60)

–

Install the air filter box cover. (

p. 56)

–

Mount the seat. (

p. 55)

11.42

Checking the rubber grip

401197-01

–

Check the rubber grips on the handlebar for damage and
wear and to ensure they are firmly seated.
» If a rubber grip is damaged, worn or loose:

–

Change and secure the rubber grip.

Grip adhesive (00062030051) (

p. 123)

11.43

Adjusting the basic position of the clutch lever

K00953-11

–

Adjust the basic position of the clutch lever to the size of the
rider's hand using adjusting screw

Summary of Contents for TC 85

Page 1: ...OWNER S MANUAL 2018 TC 85 Art no 3402163en ...

Page 2: ......

Page 3: ...ns equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice Husqvarna Motorcycles accepts no liability for delivery options devi ations from illustrations and descriptions as well as misprints and other errors The models portrayed partly contain special equipment that does not belon...

Page 4: ... 20 7 PREPARING FOR USE 21 7 1 Advice on first use 21 7 2 Running in the engine 23 7 3 Preparing the vehicle for difficult riding conditions 23 7 4 Preparing vehicle for rides on dry sand 23 7 5 Preparing vehicle for rides on wet sand 25 7 6 Preparing vehicle for rides on wet and muddy circuits 25 7 7 Preparing vehicle for high temperatures or slow riding 26 7 8 Preparing vehicle for low temperatu...

Page 5: ... 58 11 29 Changing the glass fiber yarn filling of the main silencer 58 11 30 Removing the right side cover 59 11 31 Installing the right side cover 60 11 32 Removing the fuel tank 60 11 33 Installing the fuel tank 61 11 34 Checking for chain dirt accumulation 62 11 35 Cleaning the chain 63 11 36 Checking the chain tension 63 11 37 Adjusting the chain tension 64 11 38 Checking the chain rear sproc...

Page 6: ...ic position of the shift lever 102 15 10 Adjusting the basic position of the shift lever 102 16 SERVICE WORK ON THE ENGINE 104 16 1 Checking the gear oil level 104 16 2 Changing the gear oil 104 16 3 Adding gear oil 105 17 CLEANING CARE 107 17 1 Cleaning the motorcycle 107 18 STORAGE 109 18 1 Storage 109 18 2 Preparing for use after storage 110 19 TROUBLESHOOTING 111 20 TECHNICAL DATA 113 20 1 Eng...

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

Page 8: ...ehicle safely Therefore read this manual carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info The vehicle has various information and warning labels at prominent locations Do not remove informa tion warning labels If they are missing you or others may not recognize dangers and may therefore be injured 2 4 Degrees of risk and symbols Danger...

Page 9: ... 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 sufficient...

Page 10: ...ing 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 ...

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: ...nd accessory products are specified in parentheses in the descriptions Your authorized Husqvarna Motorcycles dealer will be 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 pre...

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

Page 14: ...4 VIEW OF VEHICLE 12 4 1 View of vehicle front left example H02526 10 1 Hand brake lever p 16 2 Clutch lever p 16 3 Filler cap 4 Air filter box cover 5 Shift lever p 18 6 Choke p 18 7 Fuel tap p 18 ...

Page 15: ...W OF VEHICLE 13 4 2 View of vehicle rear right example H02527 10 1 Kill switch p 16 2 Throttle grip p 16 3 Fork article number 4 Foot brake lever p 19 5 Kick starter p 19 6 Level viewer for brake fluid rear ...

Page 16: ...e 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: ...5 SERIAL NUMBERS 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: ...mmediately 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 Warning Environmental hazard Imp...

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: ...r can be swiveled Info Before riding swing the kickstarter 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 0 0 1 1 402001 10 The fixture for plug in stand 1 is located on the frame on the left side of the vehicle The plug in stand is used to park the mo...

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: ...eased 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 Different...

Page 24: ...t the free travel of the handbrake lever p 72 Adjust the basic position of the foot brake lever p 78 Before using the vehicle for the first time ensure that the basic settings of the chassis are suitable for the weight of your child Accustom your child to the handling of the motorcycle on suitable terrain preferably on a large open meadow Info To give your child a feeling for the brake system you ...

Page 25: ...inspect or replace parts before the next scheduled service Clean the air filter and air filter box p 57 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 Ride...

Page 26: ...m water Change the radiator cap M01104 01 Mount a dust cover on the air filter Dust cover for air filter 47206920000 Info See the Husqvarna Motorcycles accessories fitting instructions M01105 01 Mount a sand cover on the air filter Sand cover for air filter 79006922000 Info See the Husqvarna Motorcycles accessories fitting instructions M01107 01 Adjust the carburetor jetting and setting Info The r...

Page 27: ...llow 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 from your authorized Husqvarna Motorcycles worksh...

Page 28: ...nt 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 cooling system In the event of scalding rinse the area affected immediately with lukewar...

Page 29: ...R USE 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: ...Check the tire air pressure p 88 Check the spoke tension p 89 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 46 Bleed the fork legs p 45 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 tight...

Page 31: ... 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 When conditio...

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: ...ark 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 off the e...

Page 34: ...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 the groundwater the soil or the sewage system Switch off the engine Open the filler cap p 17 A A 401522 10 Fill the fuel tank with fuel up to measurement A Guideline Measurement of A 35 mm 1 38 in Fuel tank c...

Page 35: ...on p 87 Check the tire air pressure p 88 Check the wheel bearing for play Check the wheel hubs Check the rim run out Check the spoke tension p 89 Check the chain rear sprocket engine sprocket and chain guide p 65 Check the chain tension p 63 Grease all moving parts e g hand lever chain and check for smooth operation Check the fluid level of the hydraulic clutch p 69 Check the front brake fluid lev...

Page 36: ...erating hours Change the front brake fluid Change the rear brake fluid Change the hydraulic clutch fluid p 70 Grease the steering head bearing p 52 Service the fork Service the shock absorber Check adjust the carburetor components Perform minor engine service Check the inlet membrane Check the clutch Change the piston under difficult operating conditions Check the cylinder and Z dimension Perform ...

Page 37: ... fork leg As fork springs are no longer required a significant weight advantage is achieved when compared to conven tional forks The response on slightly uneven surfaces is significantly improved In normal driving mode suspension is provided exclusively by an air cushion A steel spring is located in the left fork leg as an end stop Info If the fork is frequently overloaded then the air pressure in...

Page 38: ...ression damping in the low speed range and vice versa 10 4 Adjusting the low speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor rectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized Husqvarna Motorcycles workshop will be glad ...

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

Page 40: ...the side cover Make a note of the value as dimension A Finishing work Remove the motorcycle from the lift stand p 45 10 8 Checking the static sag of the shock absorber 400989 10 Measure distance A of rear wheel unloaded p 38 Hold the motorcycle upright with the aid of an assistant Measure the distance between the rear axle and the fixed point again Note down the value as dimension B Info The stati...

Page 41: ... The riding sag is the difference between measure ments A and C Check the 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 fly off if the shock absorber is disassembled incor rectly The shock absorber is filled with...

Page 42: ...ary to increase or decrease the spring preload Tighten screw 1 Finishing work Install the shock absorber p 54 Remove the motorcycle from the lift stand p 45 10 11 Adjusting the riding sag Preparatory work Raise the motorcycle with a lift stand p 45 Remove the shock absorber p 54 After removing the shock absorber clean it thoroughly B00292 10 Main work Choose and mount a suitable spring Guideline S...

Page 43: ...andling charac teristic Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components Only make adjustments within the recommended range Make sure your child rides slowly to start with after making adjustments in order that he or she can assess the new handling characteristic Info Check or adjust the air pressure under the ...

Page 44: ...fork pump from the left fork leg When disconnecting excess pressure will escape from the hose the fork leg does not lose any air The fork pump indicator switches off automatically after 80 seconds Mount the protection cap Finishing work Remove the motorcycle from the lift stand p 45 10 14 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspe...

Page 45: ...ing screw Turn counterclockwise by the number of clicks correspond ing to the fork type Guideline Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Info Turn clockwise to increase damping turn counter clockwise to reduce damping 10 16 Handlebar position C00248 10 On the upper triple clamp there are 2 holes at a distance of A to each other Hole distance A 15 mm 0 59 in The holes o...

Page 46: ...he handlebar and lay it to one side Info Cover the components to protect them against dam age Do not kink the cables and lines Remove screws 2 Remove the handlebar support Place the handlebar support in the required position Mount and tighten screws 2 Guideline Screw handle bar support M10 40 Nm 29 5 lbf ft Loctite 243 Position the handlebar Info Make sure the cables and wiring are positioned cor ...

Page 47: ... 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 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 wi...

Page 48: ... keep 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 123 Press the dust boots back into their installation position Remove excess oil Finishing work Install the fork protector p 48 Remove the motorcycle from the lift stand p 45 11 5 Removing the fork legs Prepar...

Page 49: ...t be flush with the upper edge of the upper triple clamp The air suspension is located in the left fork leg The pressure and rebound damping is located in the right fork leg A00144 10 Tighten screws 2 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft A00143 10 Position the brake caliper with spacers and fit and tighten s...

Page 50: ...g Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and clamp Mount and tighten screws 3 11 9 Removing the lower triple clamp Preparatory work Raise the motorcycle with a lift stand p 45 Remove the front wheel p 84 Remove the fork legs p 46 Remove the start number plate p 52 Remove front fender p 53 Remove the handlebar cushion A00145 10 Main...

Page 51: ...11 10 Installing the lower triple clamp V00859 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 123 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing Slide on O ring 1 Position protective ring 2 A00147 10 Position the upper triple clamp with the handlebar Mount nut 3 but do not tighten it yet ...

Page 52: ...5 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft A00148 10 Tighten nut 3 Guideline Nut steering stem M20x1 5 10 Nm 7 4 lbf ft Position the fuel tank breather in the steering stem Tighten screw 6 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws 7 Guideline Screw top triple clamp M8 20 Nm 14 ...

Page 53: ...ad bearing the bearing and the bearing seats in the frame can become damaged over time Preparatory work Raise the motorcycle with a lift stand p 45 H01167 01 Main work Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel No play should be noticeable in the steering head bearing If there is noticeable play present Adjust the steering head bearin...

Page 54: ...ew top triple clamp M8 20 Nm 14 8 lbf ft Tighten screws 2 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Position the fuel tank breather 1 in the steering stem Finishing work Check the play of the steering head bearing p 51 Remove the motorcycle from the lift stand p 45 11 13 Greasing the steering head bearing H02387 01 Remove the lower triple clamp p 48 Install the lower triple clamp p 49 ...

Page 55: ...rake line Position the start number plate Holding lugs 1 engage in the fender A00150 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 52 A00138 10 Main work Remove screws 1 Remove screws 2 Take off the front fender ...

Page 56: ...in work Detach brake line from the brake line guide Remove screw 1 and lower the rear wheel with the swingarm 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 K00978 11 Main work Push splash protector 1 to the side and position the shock abso...

Page 57: ...at 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 K00967 10 Pull off the air filter box cover sideways in areas A B and ...

Page 58: ...rvice life of the engine Dust and dirt will enter the engine without an air filter Never start to use the vehicle without an air filter Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Preparatory work Remove the air filter box cover p 55 K0097...

Page 59: ...d air filter box Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the air filter box cover p 55 Remove the air filter p 56 V0...

Page 60: ... the main silencer K00982 10 Main work 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 60 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...

Page 61: ...t the glass fiber yarn filling so 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 Mount and tighten the screws Guideline Screw main silencer M5 7 Nm 5 2 lbf ft Finishing work Install the main silencer p 58 Install the right side cover p 60 11 30 Removing the right side cover K00980 10 ...

Page 62: ... 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 with...

Page 63: ...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 64: ...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 60 Install the air filter box cover p 56 Mount the seat p 55 11 34 Checking for chain dirt accumulation 400678 01 Check...

Page 65: ...aintenance Preparatory work Raise the motorcycle with a lift stand p 45 400725 01 Main work Rinse off loose dirt with a soft jet of water Clean chain and apply chain spray Offroad chain spray p 123 Finishing work Remove the motorcycle from the lift stand p 45 11 36 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents If the chai...

Page 66: ...ear 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 45 Check the chain ...

Page 67: ...e rear sprocket or engine sprocket is worn Change the drivetrain kit Info The engine sprocket rear sprocket and chain should always be replaced together 400987 10 Pull at the top part of the chain with the specified weight A Guideline Weight chain wear mea surement 10 15 kg 22 33 lb Measure distance B of 18 chain rollers in the lower chain section Info Chain wear is not always even so you should r...

Page 68: ... 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 piece is firmly seated If the chain sliding piece is loose Tighten the screw on the chain sliding piece Guideline Screw chain slid ing piece M8 15 Nm 11 1 lbf ft 400985 0...

Page 69: ... frame is not authorized by Husqvarna Motorcycles 11 40 Checking the swingarm V00857 01 Check the swingarm for damage cracking and deformation If the swingarm shows signs of damage cracking or deformation Change the swingarm Info Always change a damaged swingarm Repair of the swingarm is not authorized by Husq varna Motorcycles 11 41 Checking the throttle cable routing Warning Danger of accidents ...

Page 70: ...e throttle cable routing Finishing work Install the fuel tank p 61 Install the right side cover p 60 Install the air filter box cover p 56 Mount the seat p 55 11 42 Checking the rubber grip 401197 01 Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated If a rubber grip is damaged worn or loose Change and secure the rubber grip Grip adhesive 00062030051 p...

Page 71: ...1 45 Correcting the fluid level of the hydraulic clutch 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 wat...

Page 72: ...d 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 contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Environmenta...

Page 73: ...w 5 and mount bleeding syringe 4 K00990 10 Inject the liquid into the system until it escapes from open ing A 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...

Page 74: ...e free travel of the handbrake lever K00992 11 Check the free travel of the hand brake lever p 72 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 ran...

Page 75: ...idents 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 Dan...

Page 76: ...contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental ...

Page 77: ...ce 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 contact with the skin the eyes ...

Page 78: ...sqvarna motorcycles Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid an...

Page 79: ...5 Nm 18 4 lbf 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 Fix 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...

Page 80: ...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 K00993 10 Detach spring 1 Loosen nut 4 and with push rod 5 turn...

Page 81: ...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 K00994 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 82: ...nce with the service schedule Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lin...

Page 83: ... 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 the skin Rinse eye...

Page 84: ...ause 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 fr...

Page 85: ...ure the retaining 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 p 121 Mount the cover with the washer and membrane 2 Mount and tighten screws 1 Info Clean up overflowed or spilled brake fluid immediately with water...

Page 86: ...iscs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork Info Do not pull 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 brak...

Page 87: ...tly 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 45 Operate the front brake and compress the fork a few times firmly The fork legs straighten Tighten screws 3 Guideli...

Page 88: ...ng the rear wheel withdraw the wheel spindle Take the rear wheel out of the swingarm Info Do not operate the foot brake lever when the rear wheel is removed H00936 10 Remove 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 89: ...the same chain length Chain adjusters 3 can be turned by 180 Check the chain tension p 63 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 45 13 5 Checking the tire condition Info Only mou...

Page 90: ...wo 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 state of wear If the tires are more than 5 years old Change the tires 13 6 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire ...

Page 91: ...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 92: ...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 93: ...2356 01 Position the matching radiator cover p 90 The projections point towards 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 94: ... 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 95: ...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 96: ...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 K00973 10 Position the motorcycle upright Place a suitable container under the water pump cover Remove screw 1 Take off radiator cap 2 Completely drain the coolant Mount a...

Page 97: ...ding M6 8 Nm 5 9 lbf ft Completely fill the radiator with coolant Coolant p 121 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 an effective exhaust extraction system when starting or running the engine in an enclosed space Allow the engine ...

Page 98: ...ing the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space 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 96 15 2 Adjusting the play in the throttle cable Preparatory work Remove the seat p 55 Remov...

Page 99: ...t be tuned both to one another and for the use intended Main jet MJ The main jet MJ has the greatest influence with the throttle slide open full throttle If the insulator of a new spark plug is very light or white after a brief ride at full throttle or if the engine 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...

Page 100: ... the clip position have only minimal influence When the throttle slide is 1 8 open the first cylindrical part of the needle the idling jet and the clip position have the greatest influence 1 4 1 8 1 2 3 4 0 1 1 4 1 8 1 2 3 4 0 1 K00496 01 When the throttle 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...

Page 101: ... 0 5 5 0 0 2 2 0 0 1 1 B00075 10 Clip position 1 5 Clip position from above The five possible clip positions are shown here The carburetor tuning depends on the defined ambient and oper ating conditions 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 c...

Page 102: ...hed 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 th...

Page 103: ...el 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 Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not all...

Page 104: ...ility Switching the ignition timing map from Soft to Performance Join plug in connector 1 of the ignition timing map adjustment Performance Higher performance 15 9 Checking the basic position of the shift lever Info When driving the shift lever must not touch the driver s boot when in the basic position When the shift lever keeps touching the boot the transmission will be subject to an excessive l...

Page 105: ... on the shift shaft in the required position and engage the 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 Mount and tighten screw 1 with washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 106: ...n the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Dispose 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 e...

Page 107: ...xhaust extraction system 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 104 16 3 Adding 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 K00976 10 Main work Remove screw 1 40...

Page 108: ...ay result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and check that it is oil tight Finishing work Check the gear oil level p 104 ...

Page 109: ...en 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 commercial engine cleaner 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 ri...

Page 110: ...otorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 63 Treat bare metal except for brake discs and the exhaust sys tem with a corrosion inhibitor Preserving materials for paints metal and rubber p 123 Treat all plastic parts and powder coated parts with a mild cleaning and care product ...

Page 111: ...period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Refuel p 31 Clean the motorcycle p 107 Change the gear oil p 104 Check the antifreeze and coolant level p 92 Check the tire air pressure p 88 Empty the carburetor float chamber p 1...

Page 112: ...18 STORAGE 110 18 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 45 Perform checks and maintenance measures when preparing for use p 28 Take a test ride ...

Page 113: ...mpo nents Engine has no idle Idling jet blocked Check set the carburetor compo nents Adjusting screws on carbure tor distorted Carburetor adjust the idle speed p 100 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 c...

Page 114: ...ks Check the coolant level p 93 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 94 Refill with coolant p 94 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 115: ...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 Screw c...

Page 116: ... 4 lbf ft 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 intermediate kick starter 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 M6 8 Nm 5 9 lbf ft Screw radiator bleeding M6 8 Nm 5 9 lbf ft Screw s...

Page 117: ... 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 118: ...CHNICAL DATA 116 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 119: ...ork offset 14 mm 0 55 in Brake system front Disc brake with four pot brake caliper rear Disc brake with two pot 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 Tire air pressure off road 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 ...

Page 120: ...43 18 8R 04 Fork WP Performance Systems Upside down AER 43 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 122 Oil capacity external mechanism left 100 20 ml 3 38 0 68 fl oz Fork oil SAE ...

Page 121: ... 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 10 Nm 7 4 lbf ft Screw rear brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Start number plate screw M6 4 Nm 3 lbf ft Nut ri...

Page 122: ...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 Nm 59 lbf ft Nut steering stem M20x1 5 10 Nm 7 4 l...

Page 123: ...er and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility compatibility with other coolants Recommended...

Page 124: ...ard classification SAE p 124 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 124 1 40 Mixture r...

Page 125: ...ecommended supplier Bel Ray Waterproof Grease Multi purpose grease 00062010051 Recommended supplier Klüber Lubrication CENTOPLEX 2 EP Offroad chain spray Guideline Recommended supplier Bel Ray Blue Tac Chain Lube Oil for foam air filter Recommended supplier Bel Ray Foam Filter Oil Preserving materials for paints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Unive...

Page 126: ...st motorcycle engines the transmission and clutch are lubricated with the same oil The JASO MA standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity The viscosity describes only one property of oil and says nothing about quality JASO FD JASO FD is a classification fo...

Page 127: ...24 LIST OF ABBREVIATIONS 125 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 128: ...ptying 101 idle 99 idle speed adjusting 100 Carburetor setting 97 Chain checking 65 cleaning 63 Chain guide checking 65 Chain tension adjusting 64 checking 63 Chassis number 14 Choke 18 Cleaning 107 108 Clutch fluid level checking 69 fluid level correcting 69 fluid changing 70 Clutch lever 16 basic position adjusting 68 Compression damping fork adjusting 42 Coolant draining 94 refilling 94 Coolant...

Page 129: ...ing map changing 102 plug in connector 102 Implied warranty 10 Intended use 6 K Kick starter 19 Kill switch 16 L Lower triple clamp installing 49 removing 48 Low speed compression damping shock absorber adjusting 36 M Main silencer glass fiber yarn filling changing 58 installing 58 removing 58 Misuse 6 Motorcycle cleaning 107 lift stand raising with 45 lift stand removing from 45 O Operating subst...

Page 130: ...ate installing 53 removing 52 Starting 28 Steering head bearing greasing 52 Steering head bearing play adjusting 51 checking 51 Storage 109 Swingarm checking 67 T Technical data capacities 117 carburetor 115 chassis 117 chassis tightening torques 119 engine 113 engine tightening torques 113 fork 118 shock absorber 118 tires 118 Throttle cable play adjusting 96 checking 96 Throttle cable routing ch...

Page 131: ... 3402163en 3402163en 06 2017 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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