Husqvarna TC - TE 449 2013 I.E. Manual Download Page 1

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TXC

TC - TE 449 2013 I.E.

TE - TXC 511 2013 I. E.

Ed. 03-2012 - Rev. 00

EN - 1

SPECIFICATIONS - OPERATION - MAINTENANCE

Unless specified, data and prescription are referred to all the models.

Summary of Contents for TC - TE 449 2013 I.E.

Page 1: ...TXC TC TE TC TE 449 2013 I E TE TXC 511 2013 I E Ed 03 2012 Rev 00 EN 1 EN SPECIFICATIONS OPERATION MAINTENANCE Unless specified data and prescription are referred to all the models ...

Page 2: ...RY INSPECTION 52 ALPHABETICAL INDEX 53 SCHEDULED MAINTENANCE APPENDIX A Note l References to the left or right of the motorcycle are considered from the point of view of a person facing forward l Z number of teeth lA Austria AUS Australia B Belgium BR Brazil CDN Canada CH Switzerland D Germany E Spain F France FIN Finland GB Great Britain I Italy J Japan USA United States of America l Unless other...

Page 3: ...l of the motorcycle hence it shall remain with the motorcycle even when sold to another user This motorcycle uses components designed thanks to systems and state of the art technologies which are thereafter tested in competitions In racing motorcycles every detail is verified after each race in order to always guarantee better performance To ensure trouble free operation of the vehicle it is nec e...

Page 4: ...he maintenance plan is charged to the Client NOTE the warranty is NULL AND VOID if the motorcycle is rented Important Notice Read this manual carefully and pay special attention to statements preceded by the following words WARNING Indicates the possibility of severe personal injury or death if instructions are not followed CAUTION Indicates the possibility of personal injury or vehicle damage if ...

Page 5: ...mber is stamped at the top of the crankcase while vehicle serial number is stamped on the frame steering tube Always quote the number stamped on the frame when ordering spare parts or requesting further details about your vehicle and note it on this booklet CHASSIS NUMBER Vehicle identification number V I N The full 17 digit serial or Vehicle Identification Number is stamped on the steering tube R...

Page 6: ...atio 2 618 CLUTCH Type oil bath multiple disc clutch hydraulic control TRANSMISSION Type constant mesh gear type Transmission ratio TC 1st gear 2 286 32 14 2nd gear 1 875 30 16 3rd gear 1 533 23 15 4th gear 1 260 29 23 5th gear 1 043 24 23 TE TXC 1st gear 2 286 32 14 2nd gear 1 875 30 16 3rd gear 1 533 23 15 4th gear 1 250 25 20 5th gear 1 043 24 23 6th gear 0 917 22 24 SECONDARY DRIVE Transmissio...

Page 7: ... 28 in 820 mm Max height 49 60 in 1260 mm Saddle height 37 91 in 963 mm Min ground clearance 13 19 in 335 mm Kerb weight without fuel TE 249 12 lb 113 kg TC 238 10 lb 108 kg TXC 242 50 lb 110 kg Fuel tank capacity reserve included TC 1 87 Imp Gall 2 25 U S Gall 8 5 l TE 499 511 1 87 Imp Gall 2 25 U S Gall 8 5 l TE 499 511 USA 2 09 Imp Gall 2 51 U S Gall 9 5 l TXC 2 09 Imp Gall 2 51 U S Gall 9 5 l ...

Page 8: ...19 18 21 20 17 16 15 14 13 12 11 10 1 2 3 4 5 6 7 8 9 EN 8 SPECIFICATIONS OPERATION MAINTENANCE MOTORCYCLE OVERALL VIEW TE ...

Page 9: ...t and second gear 6 Front sprocket 7 Side stand 8 Rear sprocket 9 Rear wheel 10 Number plate holder 11 Rear turning indicators 12 Tail light 13 Fuel tank filler cap 14 Saddle 15 Handlebar controls 16 Front turning indicators 17 Headlight 18 Rear brake control pedal 19 Rear brake master cylinder 20 Rear brake disc 21 Rear brake calliper 22 Instrument 23 L H switch 24 ENGINE STOP button 25 R H switc...

Page 10: ...TXC TC 14 13 16 15 12 11 10 1 2 3 4 5 6 7 8 9 23 EN 10 SPECIFICATIONS OPERATION MAINTENANCE MOTORCYCLE OVERALL VIEW TC TXC ...

Page 11: ...ards The neutral gear is between the first and second gear 6 Front sprocket 7 Side stand TXC 8 Rear sprocket 9 Rear wheel 10 Fuel tank filler cap 11 Saddle 12 Handlebar controls 13 Rear brake control pedal 14 Rear brake master cylinder 15 Rear brake disc 16 Rear brake calliper 17 DOUBLE MAP push button TC 18 R H switch 19 Front brake control lever 20 Throttle control twistgrip 21 Clutch control le...

Page 12: ... petrol with octane rating of 95 or higher Note If the engine knocks change fuel brand or use a higher octane rat ing fuel WARNING Do not continue operation if the engine pings or knocks The engine will be damaged and could seize WARNING Fuel is extremely flamma ble and can be explosive under certain conditions Always stop the engine and do not smoke or allow flames or sparks in the area where the...

Page 13: ...hicle Stand AUTOMATI CALLY folds back to rest position once the vehicle is vertical no longer resting on the ground TE TXC Periodically check the side stand see Scheduled Main tenance Chart make sure that the springs are not dam aged and the side stand freely moves If the side stand is noisy lubricate the fastening pivot A COLD START TE TXC These models feature an automatic starter positioned onto...

Page 14: ...t functions use the SCROLL button A The functions which can be selected in this sequence are as follows 1 SPEED ODO figure 1 2 SPEED CLOCK figure 2 3 SPEED TRIP figure 3 4 SPEED LAP TIMER figure 4 5 SPEED figure 5 1 SPEED ODO figure 1 IMPORTANT In the event of a FUEL INJECTION SYS TEM MALFUNCTION the word FAIL appears on the right side of the dashboard display When this is the case contact your HU...

Page 15: ...ion STP push the SCROLL button A and hold for more than 3 seconds 1st step activate function 2nd step stop counters 3rd step reset STP 4th step activate function 5th step stop counters and so on 5 SPEED figure 5 SPEED speed maximum value 299 Km h or 299 mph 3 SPEED TRIP 1 figure 3 SPEED speed maximum value 299 Km h or 299 mph TRIP 1 distance maximum value 999 9 Km or 621 31 mi data will be lost af...

Page 16: ...can be adjusted by loosening the two retaining screws CAUTION Do not forget to tighten the screws A after the adjustment FRONT BRAKE CONTROL The brake control lever 2 is located on the right hand side of the handlebar The position of the control on han dlebar can be adjusted by loosening the two retaining screws B CAUTION Do not forget to tighten the screws B after the adjustment ...

Page 17: ... right hand switch features the following controls TE TXC 1 Engine start button 2 ENGINE STOP button TC 1 Engine start button 2 Double map push button pressed for motorcycle SOFT performance released for motorcycle HARD performance to change the map from HARD to SOFT and vice versa you shall stop the vehicle and then with engine idling press button 2 LEFT HAND HANDLEBAR SWITCH TE The left hand han...

Page 18: ...icle REAR BRAKE CONTROL The rear brake control 1 is placed on the right hand side of the motorcycle TE A stop switch during the braking action causes the stop light on the tail light to come on CLUTCH CONTROL The hydraulic clutch control lever 1 is located on the left hand side of the handlebar and is protected against dirt The position of the clutch control on handlebar can be adjusted by looseni...

Page 19: ...k the tyre pressure check the chain tension check the throttle twistgrip and adjust it if necessary The two screw taps positioned on tanks left rear side shall always be left in fully OPEN position TE turn the key in the ignition switch to ON check dashboard display lighting TE check that parking lights low beam and high beam come on as well as the relevant warning light TE operate turning indicat...

Page 20: ...llowing list is used for troubleshooting and to find the necessary remedies The engine does not start the starting procedures are not correctly followed fol low the instructions given on paragraph Starting the engine dirty spark plug clean the spark plug does not spark adjust the electrodes gap faulty starter motor repair or replace faulty start button replace the switch The engine has starting tr...

Page 21: ... 2 shift gear pedal 2 to neutral position 3 press the starter button 3 then release clutch le ver 1 When a cold engine has just been started do not increase revs to ensure an adequate oil warm up and circulation Note A safety switch allowing to start engine ONLY when the clutch lever is pulled is assembled onto clutch lever mount IMPORTANT NEVER START ENGINE WITH BATTERY DIS CONNECTED FROM CIRCUIT...

Page 22: ... cold engine has just been started do not increase revs to ensure an adequate oil warm up and circulation Note A safety switch allowing to start engine ONLY when the clutch lever is pulled is assembled onto clutch lever mount IMPORTANT NEVER START ENGINE WITH BATTERY DIS CONNECTED FROM CIRCUIT IMPORTANT Do not operate the throttle con trol while starting up IMPORTANT NOTE IN CASE OF COLD START AT ...

Page 23: ...INE Close the throttle 1 completely in order to slow down the motorcycle Apply both front 2 and rear 3 brakes while down shifting for fast deceleration press firmly on both brake pedal and lever When stopped pull the clutch lever 4 and shift gear lever 5 into the neutral position To turn vehicle off press push button 6 ...

Page 24: ...ed on engine right hand crankcase Make sure the level is in between the MIN and MAX notches To top up remove filler cap 2 WARNING To check that the oil quantity does not exceed the MAX level notch set the motorcycle on the side stand and check that in this position the level goes below the MAX notch by look ing through the inspection sight glass 1 WARNING Independent use of the front or rear brake...

Page 25: ... engine and check the level as described in the relevant paragraph To check that the oil quantity does not exceed the MAX level notch set the motorcycle on the side stand and check that in this position the level goes below the MAX notch by look ing through the inspection sight glass 1 loosen the two caps 4 and remove the two mesh filters 5 and 6 check for O rings 7 conditions If worn change them ...

Page 26: ...NT REPLACEMENT WARNING Coolant shall be replaced with cold engine and coolant Place a container on cylinder right side under coolant drainage screw 1 FIRST remove the screw 1 then SLOWLY open the L H radiator cap 2 slope the mo torcycle on the right side to drain the coolant easily in the vessel Reassemble the screw 1 The radiator cap 2 features two locking positions the first being for the previo...

Page 27: ... explained under Coolant level check Periodically check the connecting hoses see Sched uled Maintenance Chart this will avoid coolant leakage and consequent engine seizure If hoses A show cracks swelling or hardening due to sheaths desiccation their replacement shall be advisable Check the correct tightening of the clamps B WARNING To fill in the system set motorcycle on a central stand or in any ...

Page 28: ... 2 mm 0 08 in should this not be the case loosen check nuts 4 and 5 turn and keep twistgrip 3 in the fully closed position loosen upper return cable 6 using adjuster screw 7 keeping twistgrip 3 fully closed reset cable 6 clearance by turning adjuster screw 7 tighten check nut 4 turn adjuster screw 8 until reaching an opening clearance of approx 2 mm 0 08 in tighten check nut 5 reassemble all parts...

Page 29: ...dling or poor performance at low speed Clean off any dirt around spark plug base before remov ing the spark plug It is very useful to examine the state of the spark plug just after it has been removed from the engine since the scale deposits on the plug and the colour of the insulator provide useful indications Correct heat rating The tip of the insulator should be dry and the colour should be lig...

Page 30: ...then remove spark plug CAUTION Carefully change the spark plug if necessary using one having the same rating Before refitting the plug thoroughly clean the electrodes and the insulator using a metal brush Apply graphitised grease on spark plug thread screw it by hand all the way down then tighten it to the torque of 10 12 Nm 7 38 8 85 ft Ib Loosen spark plug and tighten it again to 10 12 Nm 7 38 8...

Page 31: ...pin 1 counter clockwise and remove saddle from central retaining screw release retaining clips 4 and slide filter 5 out of vehicle right side taking special care not to damage the two retaining hooks remove right hand side panel 2 by loosening the five screws 3 using an 8 mm wrench ...

Page 32: ...ed Plunge the filter in special oil for filters CASTROL FOAM AIR FILTER OIL or similar then wring it to drain superfluous oil WARNING Do not use fuel or a low flash point solvent to clean the filtering element A fire or explosion could result WARNING Clean the filtering element in a well ventilated area and do not al low sparks or flames anywhere near the working area remove sponge 8 from subframe...

Page 33: ...nsion of the lever stroke WARNING If the brake lever feels mushy when pulled there may be air in the brake lines or the brake may be de fective Since it is dangerous to operate the motorcycle under such conditions have the brake system immediately checked by the Husqvarna Dealer CAUTION Do not spill brake fluid onto any painted surface or light lens CAUTION Do not mix two brands of flu id Complete...

Page 34: ...he operation done tighten the screw 1 Once this adjustment is completed adjust the free play of the pedal as follows REAR BRAKE PEDAL FREE PLAY ADJUSTMENT Before staring the braking action rear brake pedal 3 shall have a free play B of 5 mm 0 196 in Should this not happen operate as follows loosen nut 4 operate the pump rod 5 to increase or decrease the free play tighten nut 4 at the end of the op...

Page 35: ... Dealer CAUTION Do not spill brake fluid onto any painted surface or light lens CAUTION Do not mix two brands of flu id Completely change the brake fluid in the brake system if you wish to switch to another fluid brand CAUTION Brake fluid may cause irrita tion Avoid contact with skin or eyes In case of contact flush thoroughly with water and call a doctor if your eyes were exposed ADJUSTMENT OF TH...

Page 36: ...h a harder one Shock absorber harder compression and rebound set ting or replacement of standard spring with a harder one Work on the spring preload to lift the motorcycle riding height rear end Changing the springs front and rear is advised in order to compensate for increased mo torcycle weight due to caked on mud NOTES Should the fork be too soft or too hard under all adjust ment conditions che...

Page 37: ...ing action b REBOUND TC TXC LOWER ADJUSTER TE TOP ADJUSTER Standard setting 14 clicks TC TXC Standard setting 14 clicks TE To reset standard calibration turn adjuster C clockwise to reach the fully closed position then turn it back by the mentioned clicks In order to obtain a smooth braking action turn the adjuster counter clockwise Vice versa to obtain a harder braking action c BLEEDING to carry ...

Page 38: ...NG The shock absorber ad justment affects both the stability and the handling of the motorcycle After changing the standard suspension set ting ride with care Before making any change it is recommended to measure the A reference dimension with the motorcycle resting on central stand and the rear wheel raised off the ground Have motorcycle resting on ground without rider Measure dimension A The dif...

Page 39: ...m wrench Clean spring 6 lock ring nut 4 and adjuster ring nut 5 Loosen lock ring nut using a hook wrench or an alu minium drift Turn adjuster ring nut until reaching the desired position After having adjusted the suspension based on your weight and riding style tighten lock ring nut tighten ing torque 10 Nm 1 Kgm 7 38 ft lb Refit the right hand side panel and the saddle WARNING Be careful not to t...

Page 40: ...harder braking action B REBOUND Standard setting TC TXC 13 1 2 clicks TE 16 1 2 clicks To reset the standard setting turn lower adjuster 3 clockwise until reaching fully closed position Then turn it back by the mentioned clicks In order to obtain a smooth braking action turn the ad juster counter clockwise Vice versa to obtain a harder braking action CHAIN ADJUSTMENT Chain should be checked adjust...

Page 41: ...llows Set a stand or a block under the engine and see that the rear wheel is lifted from the ground Remove clip 1 master link 2 then remove chain 3 To reassemble follow the disassembly procedure in reverse order taking care to correctly position clip 1 master link 2 and the corresponding O rings TE TXC Make sure that chain is neither worn nor damaged If the rollers or the links are damaged replace...

Page 42: ...rm high viscosity en gine oil if warmed up oil will be more fluid Note As an alternative you can use suitable spray lubricants Lubricating the chain with O rings TE TXC Lubricate all metallic and rubber O ring elements using a brush and engine oil with SAE 80 90 viscosity inside and outside parts Note As an alternative you can use suitable spray lubricants CAUTION The chain lubricant shall NEV ER ...

Page 43: ...ed from the ground Loosen screws 1 securing wheel axle 2 onto fork leg mounts Hold wheel axle head and at the same time loosen screw 3 on the opposite side draw the wheel axle out Note Do not operate the front brake lever when the wheel has been removed this causes the calliper pistons to move outwards After removal lay down the wheel with brake disc on top ...

Page 44: ... 51 45 Nm 5 25 Kgm 38 ft lb and screws 1 on left fork leg 20 Nm 2 Kgm 14 75 ft lb Note After reassembly pull the brake control lever until the pads are against the brake disc Removing the rear wheel Unscrew the nut 1 of the wheel axle 3 and extract it It is not necessary to loosen the chain tensioners 2 in this way the chain tension will remain unchanged after reassembly Extract the complete rear ...

Page 45: ... MINIMUM HEIGHT OF THE TREAD BRAKES The key components of the braking systems are brake master cylinder with its lever front or pedal rear brake lines calliper assembly and disc LEGEND 1 Front brake lever 2 Front brake master cylinder with fluid reservoir 3 Front brake line 4 Front brake calliper 5 Front brake disc 6 Rear brake fluid reservoir 7 Rear brake line 8 Rear brake calliper 9 Rear brake d...

Page 46: ...e fluid or any oil gets on brake pads or discs Clean off with alcohol any fluid or oil that inadvertently gets on the pads or disc Replace the pads with new ones if they cannot be cleaned satisfactorily PADS INSTALLATION Install new brake pads Reassemble the two pins 2 and the clips 1 WARNING Do not attempt to ride the motorcycle until the brake lever or pedal are fully effective Pump with the bra...

Page 47: ... using a voltmeter that battery voltage is not less than 12 5 V If it is not so the battery needs to be charged Using a battery charger with a constant voltage first con nect the RED positive cable to the battery positive termi nal then the BLACK or BLUE negative cable to the battery negative terminal The voltage reaches a constant value only after a few hours therefore it is suggested NOT to meas...

Page 48: ...crew 1 using an 8 mm wrench loosen the two lower screws 2 using a Phillips screwdriver move headlight unit 3 aside release connector 4 slide off the rubber gaiter 5 release the bulb holder clips 6 and take out bulb 7 Note Headlamp bulb 7 is of the halogen type be care ful when replacing it since the glass part shall not be touched with bare hands ...

Page 49: ...everse the above pro cedure to reassemble Turning indicator BULB REPLACEMENT TE Loosen screw 1 using a Phillips screwdriver remove lens 2 and replace bulb 3 pushing it inside and turning it to remove it Once the bulb has been replaced reverse the above pro cedure to reassemble TAIL LIGHT TE The tail light 1 is a LED light Replace it when it does not function ...

Page 50: ...e have a person sit astride the motorcycle and set the motorcycle perpen dicular to its longitudinal axis In front of a wall or a screen positioned at a distance of 10 metres 32 8 ft draw a horizontal line correspond ing to headlight centre height and a vertical line aligned with vehicle longitudinal axis If possible execute this operation in a shaded place When the low beam is on the upper edge b...

Page 51: ...and dirt from collecting on it To set the motorcycle back ready for use after storage Make sure the spark plug is tight Fill the fuel tank Run the engine to warm the oil up then drain the oil Refill with fresh oil Check all the points listed under the inspection and Adjustment Section Appendix A Lubricate all the points listed under the Lubrication Section Appendix A CLEANING Before washing the mo...

Page 52: ...just Drive chain Check Adjust Tyres Check pressure Side stand Check operation Side stand switch Check operation Electrical equipment Check operation Instrument panel Check operation Lights Visual signals Check operation Horn Check operation Headlight Check operation Ignition switch Check operation Locks Check operation Screws and nuts Check Tighten Hose clamps Check Tighten General lubrication Gen...

Page 53: ...S 12 G GEAR SHIFT CONTROL 19 H HEADLAMP BULB REPLACEMENT TE 48 HEADLIGHT ADJUSTMENT TE 50 I IdENTIFICATION DATA 5 Idle adjustment 29 INSTRUCTIONS FOR RUNNING IN 19 L LEFT HAND HANDLEBAR SWITCH TE 17 LONG PERIOD OF INACTIVITY 51 LUBRICATING THE CHAIN 41 M MOTORCYCLE OVERALL VIEW TC TXC 10 MOTORCYCLE OVERALL VIEW TE 8 O OIL LEVEL CHECK 24 P PADS CLEANING 46 PADS INSTALLATION 46 PADS WEAR 46 PRE DELI...

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