Husqvarna TE 150 2023 Owner'S Manual Download Page 92

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13 BRAKE SYSTEM

S04459-10

–

Move the brake fluid reservoir mounted on the handlebar to a

horizontal position.

–

Remove screws

–

Take off cover

with membrane

S05112-10

–

Manually press the brake caliper toward the brake disc to

push back the brake pistons. Ensure that brake fluid does not

flow out of the brake fluid reservoir, extract some if neces-

sary.

Info

Make sure that you do not press the brake caliper

against the spokes when pushing back the brake pis-

tons.

–

Remove cotter pin

–

Pull out pin

–

Remove the brake linings.

–

Clean the brake caliper and the brake caliper bracket.

S04465-10

–

Check that spring plate

in the brake caliper and brake

pad sliding plate

in the brake caliper bracket are seated

correctly.

S05113-10

–

Insert the new brake linings.

–

Mount pin

Spring plate

engages in the groove on the pin.

Info

Always change the brake linings in pairs.

–

Mount cotter pins

Guideline

Mount the outer cotter pins from the front to the rear.
Mount the inner cotter pins from the rear to the front.

–

Operate the hand brake lever repeatedly until the brake lin-

ings are in contact with the brake disc and there is a pressure

point.

Summary of Contents for TE 150 2023

Page 1: ...OWNER S MANUAL 2023 TE 150 Art no 3402634en ...

Page 2: ......

Page 3: ...ons prices colors 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 part...

Page 4: ...13 Map switch 19 6 14 Overview of indicator lamps TE 150 EU 19 6 15 Overview of indicator lamps TE 150 US 19 6 16 Opening fuel tank filler cap 20 6 17 Closing the fuel tank filler cap 20 6 18 Opening 2 stroke oil tank cap 21 6 19 Closing 2 stroke oil tank cap 21 6 20 Cold start button 21 6 21 Idle speed adjusting screw 22 6 22 Shift lever 22 6 23 Kick starter lever 23 6 24 Foot brake lever 23 6 25...

Page 5: ...55 12 4 Cleaning the dust boots of the fork legs 56 12 5 Removing the fork legs 56 12 6 Installing the fork legs 57 12 7 Removing the fork protector 58 12 8 Installing the fork protector 58 12 9 Removing the lower triple clamp 58 12 10 Installing the lower triple clamp 59 12 11 Checking the steering head bearing play 61 12 12 Adjusting steering head bearing play 62 12 13 Lubricating the steering h...

Page 6: ... the turn signal bulb TE 150 EU 113 15 10 Checking the headlight setting 114 15 11 Adjusting the headlight range 115 15 12 Changing the combination instrument battery 115 15 13 Diagnostics connector 116 16 COOLING SYSTEM 117 16 1 Cooling system 117 16 2 Checking the antifreeze and coolant level 117 16 3 Checking the coolant level 118 16 4 Draining the coolant 118 16 5 Refilling with coolant 119 16...

Page 7: ...sis tightening torques 151 24 SUBSTANCES 154 25 AUXILIARY SUBSTANCES 156 26 STANDARDS 158 27 INDEX OF SPECIAL TERMS 159 28 LIST OF ABBREVIATIONS 160 29 LIST OF SYMBOLS 161 29 1 Red symbols 161 29 2 Yellow and orange symbols 161 29 3 Green and blue symbols 161 INDEX 162 ...

Page 8: ...to the highest degree by specially trained experts using the special tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Indicates the end of an activity including potential reworking 1 2 Formats used The typographical formats used in this document are explained below Pro...

Page 9: ...s Info This vehicle is not approved for use on public roads This vehicle is designed for use in offroad endurance competition and not primarily for use in motocross 2 2 Misuse The vehicle must only be used as intended Dangers can arise for people property and the environment through use not as intended Any use of the vehicle beyond the intended and defined use constitutes misuse Misuse also includ...

Page 10: ...f noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below 1 Removal or puncturing of the main silencers baffles header pipes or any other components which conduct exh...

Page 11: ...ons In the interest of your own safety Husqvarna Motorcycles recommends that you only operate the vehicle while wearing protective clothing 2 8 Work rules Unless specified otherwise the ignition must be turned off during all work models with ignition lock models with remote key or the engine must be at a standstill models without ignition lock or remote key Special tools are necessary for certain ...

Page 12: ...ntains useful information and many tips on how to operate handle and service your motor cycle This is the only way to find out how best to customize the vehicle for your own use and how you can protect yourself from injury Info Store the Owner s Manual on your terminal device for example so that you can read it whenever you need to If you would like to know more about the vehicle or have questions...

Page 13: ...les website International Husqvarna Motorcycles website www husqvarna motorcycles com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual An incorrect suspension setting can lead to damage and breakage of chassis components Use of the vehicle u...

Page 14: ...4 VIEW OF VEHICLE 12 4 1 View of vehicle front left example S05308 10 1 Clutch lever p 16 2 Fuel tank filler cap 3 Air filter box cover 4 Side stand p 23 5 Shift lever p 22 ...

Page 15: ...tank cap 2 Stop button p 16 TE 150 EU 2 Stop button p 17 TE 150 US 2 Horn button p 17 TE 150 EU 2 Light switch p 17 TE 150 EU 2 Turn signal switch p 18 TE 150 EU 3 Start button p 18 TE 150 US 4 Throttle grip p 16 5 Hand brake lever p 16 6 Kick starter lever p 23 7 Foot brake lever p 23 ...

Page 16: ... the steering head 5 2 Type label TE 150 EU 401946 10 Type label 1 is fixed to the front of the steering head 5 3 Key number TE 150 EU H02475 10 Key number 1 for the steering lock is stamped on a tag on the key ring 5 4 Engine number H01047 10 The engine number 1 is embossed on the left side of the engine above the engine sprocket ...

Page 17: ... 401947 10 Fork article number 1 is stamped on the inside of the axle clamp 5 6 Shock absorber article number H02222 10 Shock absorber article number 1 is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 18: ... using the hand brake lever 6 3 Throttle grip S04406 11 The throttle grip 1 is fitted on the right side of the handlebar 6 4 Stop button TE 150 EU S04407 10 The stop button 1 is fitted on the left side of the handlebar Possible states The stop button is in the basic position In this position the ignition circuit is closed and the engine can be started Stop button pressed In this position the ignit...

Page 19: ...on The horn button is pressed The horn is operated in this position 6 7 Light switch TE 150 EU S04407 11 Light switch 1 is fitted on the left side of the handlebar Possible states Low beam on Light switch is in the central posi tion In this position the low beam and tail light are switched on High beam on Light switch is turned to the left In this position the high beam and tail light are switched...

Page 20: ... Ignition off In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start Ignition on In this position the ignition circuit is closed and the engine can be started 6 11 Start button TE 150 EU S04823 11 Start button 1 is fitted on the right side of the handlebar Possible states The start button is in the basic position The start button is pres...

Page 21: ...ronics Come safely to a halt and contact an authorized Husqvarna Motorcycles workshop The fuel level warning lamp lights up yellow The fuel level has reached the reserve mark The oil level warning lamp lights up red Oil level has reached the MINmarking Ride for no more than until the remaining fuel in the tank is depleted and at the next opportunity refuel with 2 stroke oil 6 15 Overview of indica...

Page 22: ...tor 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 of fuel is a...

Page 23: ... the throttle valve body The electronic fuel injection system extends the injection time if the engine is cold and the ambient temperature is low To help the engine burn the increased fuel quantity it must be supplied with additional oxygen by pulling the cold start button Info If the engine is warm the cold start button must be deac tivated Possible states The cold start button is activated The c...

Page 24: ... the idle speed adjusting screw 1 Info If the idle speed is high the engine is slow to run the engine brake is low and the throttle response is aggres sive the adjustment screw must be turned clockwise If the idle speed is low the engine is running fast the engine brake is high and the throttle response is not clean the adjusting screw must be turned counterclockwise 6 22 Shift lever 401950 10 Shi...

Page 25: ...rter inward toward the engine 6 24 Foot brake lever 401956 10 The foot brake lever 1 is located in front of the right footrest The foot brake lever is used to activate the rear brake 6 25 Side stand 401943 10 The side stand 1 is located on the left of the vehicle 401944 10 The side stand is used for parking the motorcycle Info When you are riding side stand 1 must be folded up and secured with rub...

Page 26: ...lebar as far as possible to the right Insert the key for the steering lock into the steering lock turn it to the left press it in and turn it to the right Pull out the key for the steering lock Steering is no longer possible Info Never leave the key for the steering lock in the steer ing lock 6 28 Unlocking the steering TE 150 EU 400731 01 Insert the key for the steering lock into the steering loc...

Page 27: ...sor 7 3 Messages on the combination instrument 401901 01 Possible states Battery voltage of the combination instrument The battery voltage of the combination instrument is too low Change combination instrument battery Service A service is due Contact an authorized Husqvarna Motorcycles workshop 7 4 Adjusting the combination instrument Condition The motorcycle is stationary 401909 01 Press both but...

Page 28: ...e time Press the right button The value increases 401913 01 Wait for 5 seconds The combination instrument changes to the next menu item The symbol flashes Set the service Shortening the service interval Press the left button The value decreases Extending the service interval Press the right button The value increases 401914 01 Switching off the service interval display Press and hold the left butt...

Page 29: ... the 24h or 12h display of the clock 401912 01 Wait for 5 seconds The combination instrument changes to the next menu item The symbol flashes Resetting the time Press the left button The value decreases Advancing the time Press the right button The value increases 7 7 Setting the service display Condition The motorcycle is stationary 401913 01 Press both buttons for 3 5 seconds The Setup menu is d...

Page 30: ...ess the left button for 3 5 seconds DST can be preset to a value between 0 0 and 39999 9 by pressing the buttons Press the right button briefly Next display mode Press the right button for 3 5 sec onds DST is reset to 0 0 7 9 Speed time and DST2 distance 2 401902 01 Press one of the buttons until DST2 appears on the combina tion instrument KM H or M H shows the speed shows the time DST2 shows the ...

Page 31: ...VG ART and ODO appear on the combination instrument AVG shows the average speed since the last reset ART shows the operating hours ODO shows the total distance covered Press the left button briefly Next display mode Press the left button for 3 5 seconds The OPEN END WRENCH SYMBOL shows the remaining operating hours until the next service is due Press the right button briefly Next display mode Pres...

Page 32: ...racteristic Adapt your riding speed to the road conditions and your riding ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents The brake system fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously Take your foot off the foot brake lever if you do not wan...

Page 33: ... to the center of the vehicle and ensure even weight distribution between the front and rear wheels Info Motorcycles react sensitively to any changes of weight distribution The maximum permissible overall weight and the maximum permissible axle loads must not be exceeded Guideline Maximum permissible overall weight 335 kg 739 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible...

Page 34: ...attery warms up 8 4 Preparing the vehicle for difficult operating conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can result in significantly increased wear of components such as the drive train brake system or suspension components For this reason it may be necessary to inspect or replace parts before the next scheduled service Clean the ...

Page 35: ...rinse the area affected immediately with lukewarm water Change the radiator cap M01104 01 Mount the air filter dust cover Air filter dust cover 79006920000 Info Observe the fitting instructions for Husqvarna Motor cycles technical accessories M01105 01 Mount the air filter sand cover Air filter sand cover 79006922000 Info Observe the fitting instructions for Husqvarna Motor cycles technical access...

Page 36: ...rature 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 M01106 01 Mount the air filter rain cover Air filter rain cover 79006921000 Info Observe the fitting instructions for Husqvarna Motor cycles tech...

Page 37: ...Check the radiator cap Value on the radiator cap 1 8 bar 26 psi If the indicated value does not correspond to 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 syste...

Page 38: ...e to an excessively high sec ondary drive Clean the chain Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 118 8 9 Preparing the vehicle for low temperatures or snow M01106 01 Mount the air filter rain cover Air filter rain cover 79006921000 Info Observe the fitting instructions for Husqvarna Motor cycles technical accessories ...

Page 39: ...condition p 101 Check tire pressure p 101 Check the spoke tension p 102 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 56 Bleed the fork legs p 55 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...

Page 40: ...nds before a further attempt at start ing At temperatures below 15 C 60 F several attempts at starting may be necessary to warm up the lithium ion battery and thereby increase the starting power During the starting process the malfunction indicator lamp lights up 9 3 Starting off Info Switch on the light before riding the vehicle You will be seen earlier by other motorists When you are riding the ...

Page 41: ...his will barely reduce the speed but fuel consumption will be considerably lower Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption To shift down apply the brakes and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and either open the throttle or shift again Switch o...

Page 42: ...ver The components for parking the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand 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 d...

Page 43: ...contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Note Material damage Inadequate fuel quality causes the fuel filter to quickly become clog...

Page 44: ...e oil is sufficient for the remaining tank of fuel As soon as the oil level warning light lights up ride for no longer than until the remaining fuel in the tank is depleted At the next opportunity add 2 stroke oil before you refuel Time the oil pump if the 2 stroke oil hose has been removed or the 2 stroke oil tank has been fully depleted in error Open 2 stroke oil tank cap p 21 H03663 10 Fill the...

Page 45: ...gs p 88 Check the brake linings of the rear brake p 94 Check the brake discs p 86 Check the brake lines for damage and leakage Check the rear brake fluid level p 92 Check the free travel of the foot brake lever p 91 Check the frame p 81 Check the link fork p 81 Check the fork bearing for play Check the shock absorber heim joint for play Check the shock absorber linkage Check the tire condition p 1...

Page 46: ...l check Check the vehicle for operating safety and take a test ride Read out the fault memory after the test ride using the Husqvarna Motorcycles diag nostics tool Make a service entry in Husqvarna Motorcycles Dealer net One time interval Periodic interval 10 3 Recommended work Every 40 operating hours when used for motorsports Every 10 operating hours when used for motorsports every 48 months eve...

Page 47: ...the protection cap of the pressure sensor Change the coolant p 121 Perform minor engine service Check the exhaust control for functioning and smooth operation Check the clutch Perform major engine service including removing and installing the engine Change the connecting rod conrod bearing and crank pin Clean the hose connections of the pressure sensor Check the transmission and the shift mechanis...

Page 48: ...into two ranges high speed and low speed High speed and low speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed The high speed compression adjuster has an effect for example when landing after a jump the rear wheel suspension compresses quickly The low speed compression adjuster has an effect for example when riding over long ground swells the rear wheel ...

Page 49: ...ock absorber will move around if the shock absorber is detached incor rectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized Husqvarna Motorcycles workshop will be glad to help Info The effect of the high speed compression adjuster can be seen in the fast compression of the shock absorber S04870 11 Using an open end wrench turn ad...

Page 50: ...nterclockwise by the number of clicks correspond ing to the shock absorber type Guideline Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase the damping turn counterclockwise to reduce damping when the shock absorber rebounds 11 6 Measuring the dimension of the rear wheel unloaded Preparatory work Raise the motorcycle with a lift stand p 55 402415 ...

Page 51: ...oad of the shock absorber p 50 11 8 Checking the riding sag of the shock absorber 402417 10 Measure dimension A of rear wheel unloaded p 48 With another person holding the motorcycle the rider wear ing full protective clothing sits on the seat in a normal sitting position feet on footrests and bounces up and down a few times The rear wheel suspension levels out Another person again measures the di...

Page 52: ...4 After removing the shock absorber clean it thoroughly 402659 10 Main work Loosen screw 1 Turn adjusting ring 2 until the spring is no longer under ten sion Hook wrench 90129051000 Measure the total spring length while the spring is not under tension Info If the spring cannot be fully released the spring must be removed to accurately measure the spring length Tension the spring by turning adjusti...

Page 53: ...ork Install the shock absorber p 65 Remove the motorcycle from the lift stand p 55 Check the static sag of the shock absorber p 49 Check the riding sag of the shock absorber p 49 Adjust the rebound damping of the shock absorber p 48 11 11 Checking the basic setting of the fork Info For various reasons no exact riding sag can be determined for the fork 401000 01 As with the shock absorber smaller d...

Page 54: ...pression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping turn counter clockwise to reduce damping during compression 11 13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior S04824 11 Turn red adjuster 1 clockwise as far as it will go Info Adjuster 1 is located at the upper end of...

Page 55: ... spring preload to the numerical values only as the preload will not engage between the numerical values Turn clockwise to increase the spring preload turn counterclockwise to reduce the spring preload Adjusting the spring preload has no influence on the absorption setting of the rebound Basically however you should set the rebound damp ing higher with a higher spring preload Finishing work Remove...

Page 56: ...side Info Cover the components to protect them against dam age Do not kink the cables and lines Remove screws 2 Take off the handlebar supports Place the handlebar supports in the required position Mount and tighten screws 2 Guideline Screw handle bar support M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right handlebar supports evenly Position the handlebar Info Make sure the cable...

Page 57: ...e The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand 1 to the ground with your foot and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with the rubber strap 12 3 Bleeding the fork legs Preparatory ...

Page 58: ...il 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 157 Press the dust boots back into their installation position Remove excess oil Finishing work Install the fork protector p 58 Remove the motorcycle from the lift stand p 55 12 5 Removing the fork legs Preparatory work Remove the headlight...

Page 59: ... of the fork legs The second milled groove from the top must be flush with the upper edge of the upper triple clamp H03680 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 S04422 11 Position the brake caliper and mount and tighten screws 4 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loct...

Page 60: ...tighten screws 2 Position the fork protector on the right fork leg Mount and tighten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 9 Removing the lower triple clamp Preparatory work Remove the headlight mask with the headlight p 111 Raise the motorcycle with a lift stand p 55 Remove the front wheel p 97 Remove the fork legs p 56 Remove front fender p 62 H03682 10 Main work Rem...

Page 61: ...whether upper steering head seal 1 is correctly posi tioned Mount protective ring 2 and O ring 3 H03684 10 Position the upper triple clamp with the handlebar Mount screw 4 but do not tighten yet Mount the clutch line with cable holder 5 S04824 14 Position the fork legs Bleeder screws 6 are positioned toward the front Info The compression damping is located in left fork leg COMP white adjuster The ...

Page 62: ... Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws 9 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft S04422 12 Position the brake caliper and mount and tighten screws bk Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount the cable ties Position the brake line the wiring harness and the clamp Mount and tighten screws bl Finis...

Page 63: ... head bearing the bearings and the bearing seats in the frame can become damaged over time Preparatory work Raise the motorcycle with a lift stand p 55 400738 11 Main work Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel Play should not be detectable on the steering head bear ing If there is detectable play Adjust steering head bearing play...

Page 64: ...ew top triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw 2 Guideline Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Finishing work Check the steering head bearing for play p 61 Remove the motorcycle from the lift stand p 55 12 13 Lubricating the steering head bearing H02387 01 Remove the lower triple clamp p 58 Install the lower triple clamp p 59 Info The steering head bearing is...

Page 65: ... Take off the front fender 12 15 Installing front fender H03691 10 Main work Position front fender Mount and tighten screws 1 and 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the headlight mask with the headlight p 111 Check the headlight setting p 114 ...

Page 66: ...s Detach the frame protector in area A and take it off H03693 10 Remove screw 2 Remove fitting 3 Info Raise the link fork slightly to be able to remove the screws more easily H03694 10 Press angle lever 4 toward the rear Press linkage lever 5 downward S04828 12 TE 150 EU Disconnect the plug in connector of the brake light switch S04909 10 Remove screws 6 Pull off foot brake cylinder from the push ...

Page 67: ...ld the shock absorber and remove screw 8 Remove the shock absorber carefully at the bottom 12 17 Installing the shock absorber F02304 10 Main work Carefully position the shock absorber into the vehicle from the bottom Mount and tighten screw 1 Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 S04832 11 Position the link fork and mount the swingarm pivot Info Pay attention to fl...

Page 68: ... engages in the foot brake cylinder The dust boot is correctly positioned Mount and tighten screws 4 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft F02308 10 Position the angle lever and linkage lever Mount and tighten fitting 5 Guideline Nut linkage lever on angle lever M14x1 5 60 Nm 44 3 lbf ft Info Pay attention to flat area B Mount and tighten screw 6 Guideline Screw bottom shock absor...

Page 69: ...e the motorcycle from the lift stand p 55 12 18 Removing the seat Preparatory work Remove the air filter box cover p 68 F02310 10 Main work Remove screw 1 H02218 10 Raise the rear of the seat pull the seat back and lift it off 12 19 Mounting the seat H02218 11 Main work Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket Push the seat forward Make sure th...

Page 70: ... the air filter box cover p 68 12 20 Removing the air filter box cover F02311 10 Pull off the air filter box cover sideways in areas A B and C and take off toward the rear 12 21 Installing the air filter box cover F02312 10 Attach catch 1 of the air filter box in area A and push for ward F02311 11 Engage the air filter box cover in areas B C and D ...

Page 71: ...r with air filter sup port Remove air filter from air filter support 12 23 Cleaning the air filter and air filter box 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 Do not clean the air filter with fuel or petroleum since these substances a...

Page 72: ...shing B The air filter is correctly positioned Insert retaining tab 3 Retaining pin 2 is secured with retaining tab 3 Info If the air filter is not mounted correctly dust and dirt may enter the engine and result in damage Finishing work Install the air filter box cover p 68 12 25 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow th...

Page 73: ... Info Over time the fibers of the glass fiber yarn filling escape and the damper burns out Not only is the noise level higher but the performance characteristics change Preparatory work Remove main silencer p 70 V01636 10 Main work Remove screws 1 Pull out inner tube 2with O ring 3 Pull glass fiber yarn filling 4 from the inner tube Clean the parts that need to be reinstalled and check for damage ...

Page 74: ...7 H03700 10 Main work Detach side cover in area A pull off sideways in area B and take off toward the rear 12 29 Installing the right side cover H03701 10 Main work Attach side cover with the holding lugs A from below and push upward Engage the side cover in areas B and C Finishing work Mount the seat p 67 Install the air filter box cover p 68 ...

Page 75: ...ow 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 Preparatory work Remove the air filter box cover p 68 Remove the seat p ...

Page 76: ... not fuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately co...

Page 77: ...nd tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft H03702 11 Plug in connector 3 for the fuel pump Remove the wash cap set Clean the quick release coupling thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Spray silicone spray onto a lint free cleaning cloth and lightly lubricate t...

Page 78: ...ke discs free of oil and grease Clean the brake discs with brake cleaner when necessary 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 The service life of the chain depends largely on its maintenance Preparatory work Raise the motorcycle wi...

Page 79: ...fo Lower chain section 1 must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 55 58 mm 2 17 2 28 in If the chain tension does not meet the specification Adjust the chain tension p 77 Finishing work Remove the motorcycle from the lift stand p 55 12 35 Adjusting the chain tension Warning Danger of accidents Incorrect chain tensio...

Page 80: ... 1 Guideline Nut rear wheel spin dle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters 4 can be turned by 180 Finishing work Remove the motorcycle from the lift stand p 55 12 36 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle...

Page 81: ...n 272 mm 10 71 in If distance B is greater than the specified measurement Change the drivetrain kit Info When a new chain is mounted the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprockets V00914 10 Check the chain sliding guard for wear If the lower edge of the chain pins is in line with or below the chain sliding guard Change the chain slidin...

Page 82: ... sliding piece Guideline Screw chain slid ing piece M8 15 Nm 11 1 lbf ft 401760 01 Check the chain guide for wear Info Wear can be seen on the front of the chain guide If the light part of the chain guide is worn Change the chain guide H03711 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the screws on the chain guide Guideline Remaining screws chassis M6 10 Nm ...

Page 83: ...he link fork Info Always replace a damaged link fork Repair of the link fork is not authorized by Husqvarna Motorcycles 12 39 Checking the throttle cable routing Warning Danger of accidents The throttle cable can become kinked trapped or blocked if it is not routed cor rectly If the throttle cable is kinked trapped or blocked the speed can no longer be controlled Make sure that the throttle cable ...

Page 84: ...tall the right side cover p 72 Mount the seat p 67 Install the air filter box cover p 68 12 40 Checking the rubber grip 401197 01 Check the rubber grips on the handlebar for damage wear and looseness Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right The left sleeve is clamped onto the handlebar The rubber grip can only be repl...

Page 85: ...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 Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc corre...

Page 86: ... 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 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 u...

Page 87: ...rflowing Remove the bleeding syringe Mount and tighten the bleeder screw Mount the protection cap 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 Immediately clean up any brake fluid that has over flowed or spilled with water 12 44 Removing the engine guard H01655 01 Remove...

Page 88: ...ke discs Warning Danger of accidents Worn out brake discs reduce the braking effect Make sure that worn out brake discs are replaced immediately Your authorized Husqvarna Motor cycles workshop will be glad to help 400257 10 Check the front and rear brake disc thickness at multiple points for the dimension A Info Wear reduces the thickness of the brake disc around the contact surface of the brake l...

Page 89: ...s 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 do not continue riding until the problem is eliminated Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Skin irritation Brake flu...

Page 90: ...ke off cover 2 with membrane 3 Add brake fluid to level A Guideline Level A brake fluid level below reservoir rim 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 154 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water 13 5 Checking the front brake linings Warning Danger of accidents Worn out brake linings reduce the braki...

Page 91: ...rning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Warning Danger of accidents Brake linings which have not been approved alter the braking efficiency Not all brake linings are tested and approved for Husqvarna motorcycles The structure and friction coeffici...

Page 92: ...Remove cotter pin 4 Pull out pin 5 Remove the brake linings Clean the brake caliper and the brake caliper bracket S04465 10 Check that spring plate 6 in the brake caliper and brake pad sliding plate 7 in the brake caliper bracket are seated correctly S05113 10 Insert the new brake linings Mount pin 5 Spring plate 6 engages in the groove on the pin Info Always change the brake linings in pairs Moun...

Page 93: ...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 402026 10 Disconnect spring 1 Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free tr...

Page 94: ...er Guideline Free travel of foot brake lever 3 5 mm 0 12 0 2 in Hold screw 3 and tighten nut 2 Guideline Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Hold push rod 5 and tighten nut 4 Guideline Remaining nuts chassis M6 10 Nm 7 4 lbf ft Attach spring 1 13 9 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the...

Page 95: ...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 Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the fron...

Page 96: ...than specified Change the rear brake linings p 94 Check the brake linings for damage and cracking If damage or wear is encountered Change the rear brake linings p 94 13 12 Changing the rear brake linings Warning Danger of accidents Incorrect servicing will cause the brake system to fail Ensure that service work and repairs are performed professionally Your authorized Husqvarna Motorcycles workshop...

Page 97: ...vehicle no longer corresponds to its condition at delivery and the manufacturer warranty shall be void Only use brake linings approved and recommended by 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 b...

Page 98: ...ges in the groove on the pin Info Always change the brake linings in pairs 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 S04468 10 Correct brake fluid level to marking A Brake fluid DOT 4 DOT 5 1 p 154 Mount and tighten screw cap 1 with membrane 2 and the shim Info Use water to immediately clean...

Page 99: ...ng back the brake pis tons H03730 10 Loosen screw 1 by several rotations Loosen screws 2 Press on screw 1 to push the wheel spindle out of the axle clamp Remove screw 1 H03731 10 Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold front wheel and remove wheel spindle Take front wheel out of the fo...

Page 100: ...rs Clean and grease the wheel spindle Long life grease p 156 H03730 11 Jack up the front wheel into the fork position it and insert the wheel spindle The brake linings are correctly positioned 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 t...

Page 101: ...r sprocket Info Cover the components to protect them against dam age Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold 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 H03002 10 Remove spa...

Page 102: ... Mount the chain S04478 10 Position chain adjuster 3 Mount nut 4 but do not tighten it yet Make sure that chain adjusters 3 are fitted correctly on adjusting screws 5 Check the chain tension p 77 Tighten nut 4 Guideline Nut rear wheel spin dle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Ch...

Page 103: ...the tires Check the tread depth Info Adhere to the legally required minimum tread depth Minimum tread depth 2 mm 0 08 in If the tread depth is less than the minimum tread depth Change the tires H01144 01 Check the tire age Info The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT number The first two digits indicate the week of man...

Page 104: ...ion in the spokes is too low then lateral and radial run out will form in the wheel Other spokes will become looser as a result Check 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 diamete...

Page 105: ...Risk of injury 12 V batteries contain harmful sub stances Keep 12 V batteries out of the reach of children Keep sparks and open flames away from 12 V batteries Only charge 12 V batteries in well ventilated rooms Maintain a minimum clearance from inflammable materials when charging 12 V batteries Minimum clearance 1 m 3 ft Do not charge deeply discharged 12 V batteries if the charge is already belo...

Page 106: ...ter relay 5 and fuse box 6 from the battery compartment and hang to the side H03740 10 Detach wiring harness 7 disconnect relays 8 and plug 9 and hang to the side H03741 10 Remove screw bk and detach the battery compartment Lift out the 12 V battery ...

Page 107: ...ure with holding bracket 1 12 V battery HJTZ5S FP C p 149 Mount and tighten screw 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft H03740 11 Place relays 3 and connector 4 on the battery compart ment and attach the wiring harness 5 S04847 11 Attach starter relay 6 and fuse box 7 to the battery com partment S04846 11 Secure EFI control unit 8 with the rubber lugs 9 ...

Page 108: ...Keep 12 V batteries out of the reach of children Keep sparks and open flames away from 12 V batteries Only charge 12 V batteries in well ventilated rooms Maintain a minimum clearance from inflammable materials when charging 12 V batteries Minimum clearance 1 m 3 ft Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage Minimum voltage before the start of ...

Page 109: ...568 10 Main work Check the battery voltage Battery voltage 9 V Do not charge the 12 V battery Replace the 12 V battery and dispose of the old 12 V battery properly If the specifications have been met Battery voltage 9 V Charge the 12 V battery Guideline Maximum charging volt age 14 4 V Maximum charging cur rent 3 0 A Maximum charging time 24 h Recharge the 12 V bat tery regularly when the motorcyc...

Page 110: ...use fuses with the required ampere value Do not bypass or repair fuses Info The main fuse protects all electrical power consumers of the vehicle Preparatory work Remove the air filter box cover p 68 Remove the seat p 67 S04846 12 Main work Pull EFI control unit 1 upward off the rubber lugs 2 and hang to the side S04849 10 Pull starter relay 3 from the holder ...

Page 111: ... needed Attach the protection caps 4 Mount starter relay 3 onto the holder and route the cable S04846 12 Mount the EFI control unit 1 on the rubber lugs 2 Finishing work Mount the seat p 67 Install the air filter box cover p 68 15 5 Changing the fuses of individual electrical power consumers Info The fuse box containing the fuses of individual electrical power consumers is located under the seat P...

Page 112: ... nector ignition coil oil level sensor Fuse 2 10 A radiator fan optional Fuse 3 10 A low beam position light tail light Fuse 4 5 A fuel pump Fuses res 10 A spare fuse Info A faulty fuse has a burned out fuse wire A Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Insert the spare fuse with the correct rat...

Page 113: ...wiring harness from the headlight mask Pivot the headlight mask forwards and place it on the fender H03750 10 TE 150 EU Detach plug in connectors 3 and take off the headlight mask with the headlight H03751 10 TE 150 US Disconnect plug in connector 3 and take off the head light mask together with the headlight 15 7 Installing the headlight mask with the headlight H03750 11 Main work TE 150 EU Join ...

Page 114: ...03752 10 Position the brake line and the wiring harness in the cable guide Mount and tighten screw 2 Position the headlight mask The holding lugs engage in the fender H03749 11 Secure the headlight mask with rubber straps 3 Finishing work Check the headlight setting p 114 ...

Page 115: ... position light out of the reflector H03754 10 Pull out headlight bulb 3 Insert the new headlight bulb Headlight HS1 socket BX43t p 149 Insert the protection cap with the bulb socket into the reflec tor and turn it clockwise all the way O ring 4 is correctly positioned Insert the bulb socket of the position light into the reflector Finishing work Install the headlight mask with the headlight p 111...

Page 116: ...nterclockwise until it engages in the thread with a small jerk Tighten the screw lightly Finishing work Check that the turn signal system is functioning properly 15 10 Checking the headlight setting 400726 10 Park the vehicle on a horizontal surface in front of a light colored wall and make a mark at the height of the center of the low beam headlight Make another mark at a distance B under the fir...

Page 117: ...rk Remove the headlight mask with the headlight p 111 H03756 10 Main work Remove screws 1 with the washers Pull the combination instrument upward out of the holder H03757 10 Using a coin turn protection cap 2 all the way counter clockwise and take it off Remove combination instrument battery 3 Insert the combination instrument battery with the label fac ing outward Combination instrument battery C...

Page 118: ...nstall the headlight mask with the headlight p 111 Check the headlight setting p 114 Adjust the combination instrument p 25 15 13 Diagnostics connector H00933 12 The diagnostics connector 1 is located under the seat below the EFI control unit ...

Page 119: ...r 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 if coolant is swallowed Rinse the affected area immediately with...

Page 120: ...ater 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 400243 10 Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level A above the radiator fins 10 mm 0 39 i...

Page 121: ...der the water pump cover S03639 11 Remove screw 1 Take off radiator cap 2 Completely drain the coolant Mount and tighten screw 1 with a new seal ring Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 16 5 Refilling with coolant 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 ey...

Page 122: ... the O ring Guideline Screw cylinder head temperature sensor M10x1 25 12 Nm 8 9 lbf ft Plug in connector 3 Position protection cap 2 400243 10 Pour coolant in up to level A above the radiator fins Guideline Coolant level A above the radiator fins 10 mm 0 39 in Coolant p 154 S03643 10 Mount radiator cap 5 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconscious...

Page 123: ... out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty 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 clot...

Page 124: ...tion protection cap 3 400243 10 Pour coolant in up to level A above the radiator fins Guideline Coolant level A above the radiator fins 10 mm 0 39 in Coolant p 154 S04268 10 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 e...

Page 125: ...e in an enclosed space Start the engine and let it run at idle speed Move the handle bar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 123 17 2 Adjusting the play in the throttle cable Info If the correct routing of the throttle cables has already been secured the fuel tank does not need to be removed Prep...

Page 126: ...of the throttle response is changed by changing the guide plate A guide plate with a different characteristic map is supplied S04500 10 Main work Push back sleeve 1 Remove screws 2 and half shells 3 Detach the throttle cables and take off the grip tube 102246 10 Remove guide plate 4 from handle tube 5 Position the required guide plate on the grip tube Guideline The label OUTSIDE must be visible Ma...

Page 127: ...o out spontaneously if the idle speed is set too low Set the idle speed to the specified value Your authorized Husqvarna Motorcycles workshop will be glad to help S03529 11 Run the engine until warm The cold start button is deactivated A further turn returns the cold start button back to the basic position p 21 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unco...

Page 128: ... the vehicle is transported over great height differences the ambient pressure must be reprogrammed H02349 01 Start up the vehicle at a new height above sea level and switch off the engine again Wait for at least five seconds Start the vehicle again and check the response of the vehicle If the response has not improved Repeat the procedure 17 6 Checking the basic position of the shift lever Info W...

Page 129: ...eeth A of the shift lever and shift shaft Mount the shift lever 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 Mount and tighten screw 1 with washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 130: ...ed 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 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 F02317 10 Clean quick release coupling 1 thoroughly with compressed...

Page 131: ...pump if the 2 stroke oil hose has been removed or the 2 stroke oil tank has been fully depleted in error Preparatory work Stand the motorcycle upright on a horizontal surface F02318 10 Main work Check the 2 stroke oil level in the oil tank Info For one tank of fuel the 2 stroke oil tank must be filled up to at least the upper edge A The 2 stroke oil tank must be completely filled if possible If th...

Page 132: ...emove the seat p 67 Stand the motorcycle upright on a horizontal surface Check 2 stroke oil level p 129 S04856 10 Main work Pull EFI control unit 1 upward off the rubber lugs 2 and hang to the side Remove protection cap 3 of the diagnostics connector S04855 10 Put throttle grip 4 into full throttle position and secure ...

Page 133: ...0 Check whether air bubbles are visible in the hose 7 If air bubbles are visible Repeat the entire procedure until air bubbles are no longer visible Mount protection cap on the diagnostics connector Mount the EFI control unit on the rubber lugs Finishing work Mount the seat p 67 Install the air filter box cover p 68 18 4 Cleaning the oil screen in the oil tank Note Environmental hazard Hazardous s...

Page 134: ...bframe slightly and secure it Info Pay attention to intake flange 5 Pull throttle valve body 6 towards the rear out of the intake flange and hang it to the side F02330 10 Open hose clamp 7 using a screwdriver Pull off the angle piece and collect the 2 stroke oil in a suit able container F02331 10 Remove oil screen 8 and clean it Check the oil screen for damage If the oil screen is damaged Change t...

Page 135: ...he throttle valve body Guideline Screw intake flange reed valve housing M6 6 Nm 4 4 lbf ft S04857 11 Mount and tighten screws 1 Guideline Screw sub frame bottom M8 30 Nm 22 1 lbf ft Loctite 2701 Remove screws 2 Mount and tighten screws 2 Guideline Screw sub frame bottom M8 30 Nm 22 1 lbf ft Loctite 2701 Finishing work Remove the motorcycle from the lift stand p 55 Install the fuel tank p 74 Instal...

Page 136: ...nitoring M6 8 Nm 5 9 lbf ft 18 6 Changing the gear oil Warning Danger of scalding Engine and gear 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 age...

Page 137: ...and fill up with gear oil Gear oil 0 80 l 0 85 qt Engine oil 15W 50 p 154 Mount and tighten the filler plug together with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed s...

Page 138: ... tighten the gear oil level monitoring screw Guideline Screw gear oil level monitoring M6 8 Nm 5 9 lbf ft Mount and tighten filler plug 2 with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the en...

Page 139: ...rly Avoid direct sunshine when cleaning the motorcycle 401061 01 Close off exhaust system to keep water from entering Remove the coarse dirt particles with a gentle water jet Spray the heavily soiled parts with a normal commercial motorcycle cleaner and clean using a brush Motorcycle cleaner p 156 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cle...

Page 140: ...ns against aggressive road salt If the vehicle has been used on salted roads use cold water for cleaning after riding Warm water enhances the corrosive effects of salt 401060 01 Clean the motorcycle p 137 Clean the brakes Info After EVERY trip on salted roads thoroughly clean the brake calipers and brake linings after they have cooled down and without removing them with cold water and dry them car...

Page 141: ...d long workshop waiting times at the start of the new season 401058 01 Clean the motorcycle p 137 Change the gear oil p 134 Check the antifreeze and coolant level p 117 When refueling for the last time before taking the motorcycle out of service add fuel additive Refuel p 41 Check tire pressure p 101 Remove the 12 V battery p 103 Charge the 12 V battery p 106 Guideline Ideal charging and storage t...

Page 142: ...140 20 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 55 Install the 12 V battery p 105 Perform checks and maintenance measures when preparing for use p 37 Make a test ride ...

Page 143: ...de gap 1 20 mm 0 0472 in Faulty ignition Ignition coil check the primary wind ing Check the spark plug connector Check the stator winding of the alter nator Short circuit cable in wiring harness frayed stop button or emergency OFF switch faulty Check wiring harness visual check Check the electrical system The connector or ignition coil is loose or oxydized Clean the connector and treat with contac...

Page 144: ...e p 126 The engine dies during the trip Lack of fuel Refuel p 41 The engine takes in false air Check that the intake flange is firmly seated The connector or ignition coil is loose or oxydized Clean the connector and treat with contact spray Ambient pressure is incorrectly stored Program ambient air pressure p 126 Engine overheats Too little coolant in cooling system Check the cooling system for l...

Page 145: ... the fault memory using the Husqvarna Motorcycles diagnostics tool 12 V battery discharged The 12 V battery is not being charged by the alternator Check the charging voltage Check the stator winding of the alter nator Unwanted electrical power consumer Check the open circuit current Values in combination instrument deleted time stop watch lap times The combination instrument battery is empty Chang...

Page 146: ...Ambient air pressure sensor open short circuit to plus Blink code for malfunc tion indicator lamp 13 Malfunction indicator lamp flashes 1x long 3x short Error level condition Intake air temperature sensor input signal too low Intake air temperature sensor input signal too high Blink code for malfunc tion indicator lamp 12 Malfunction indicator lamp flashes 1x long 2x short Error level condition Co...

Page 147: ...function indicator lamp flashes 3x long 7x short Error level condition Ignition coil circuit fault Blink code for malfunc tion indicator lamp 02 Malfunction indicator lamp flashes 2x short Error level condition Crankshaft speed sensor synchronization faulty Crankshaft speed sensor signal implausible Crankshaft speed sensor signal irregular Crankshaft speed sensor no signal Blink code for malfunc t...

Page 148: ...rbox 6 gear transmission claw shifted Transmission ratio first gear 12 33 second gear 15 31 third gear 17 28 fourth gear 19 26 fifth gear 21 25 sixth gear 20 20 Alternator 12 V 168 W Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Spark plug NGK GR8DI 12 Spark plug electrode gap 1 20 mm 0 0472 in Cooling Water cooling permanent circulation of coolant by w...

Page 149: ...inder M6 10 Nm 7 4 lbf ft Screw control lever exhaust con trol M6 10 Nm 7 4 lbf ft Loctite 243 Screw engine case M6 10 Nm 7 4 lbf ft Screw exhaust flange M6 10 Nm 7 4 lbf ft Screw gear oil level monitoring M6 8 Nm 5 9 lbf ft Screw injection valve holder M6 8 Nm 5 9 lbf ft Loctite 243 Screw intake flange reed valve housing M6 6 Nm 4 4 lbf ft Screw kick starter stop plate M6 10 Nm 7 4 lbf ft Loctite...

Page 150: ...3 Nut inner clutch hub M18x1 5 100 Nm 73 8 lbf ft Loctite 243 23 3 Capacities 23 3 1 Gear oil Gear oil 0 80 l 0 85 qt Engine oil 15W 50 p 154 23 3 2 Coolant Coolant 1 2 l 1 3 qt Coolant p 154 23 3 3 Fuel Total fuel tank capacity approx 8 5 l 2 25 US gal Super unleaded ROZ 95 p 155 Fuel reserve approx 1 5 l 1 6 qt 2 stroke oil tank content approx 0 6 l 0 6 qt Engine oil 2 stroke p 154 23 4 Chassis ...

Page 151: ...out fuel approx 99 6 kg 219 6 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible rear axle load 190 kg 419 lb Maximum permissible overall weight 335 kg 739 lb 23 5 Electrical system 12 V battery HJTZ5S FP C Lithium ion battery Battery voltage 12 V Nominal capacity 2 0 Ah Maintenance free Combination instrument battery CR 2032 Battery voltage 3 V Headlight HS1 socket BX43t 12 ...

Page 152: ...23 7 Fork Fork article number 0266C161V401000 Fork WPXPLOR 5548 Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload preload adjuster Comfort 0 Standard 0 Sport 3 Spring length with preload spacer s 474 mm 18 66 in Spring rate Weight of rider 65 75 kg 143 165 lb 3 8 N mm 21 7 lb in Weight of rid...

Page 153: ...w air filter box EJOT PT K70x25 5 Nm 3 7 lbf ft Screw fuel pump EJOT PT 2 5 Nm 1 84 lbf ft Screw intake air temperature sen sor EJOT PT K50x18 0 7 Nm 0 52 lbf ft Screw oil fill level sensor G 3 4 7 Nm 5 2 lbf ft Screw oil pump holder on oil tank EJOT PT 45x12 Z 0 7 Nm 0 52 lbf ft Screw pressure regulator EJOT PT K60x25 Z 2 3 Nm 1 7 lbf ft Screw radiator hoses clip 2 4 Nm 1 77 lbf ft Nut throttle c...

Page 154: ...7 lbf ft Screw front brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw oil pump M6 6 Nm 4 4 lbf ft Screw oil tank on frame M6 5 Nm 3 7 lbf ft Screw rear brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw seat fixing M6 10 Nm 7 4 lbf ft Screw throttle grip M6 5 Nm 3 7 lbf ft Fuel connection on fuel pump M8 15 Nm 11 1 lbf ft Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Nut rear sprocket screw M8 35...

Page 155: ...10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw bottom shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Nut fuel pump fixation M12 15 Nm 11 1 lbf ft Nut angle lever to link fork M14x1 5 60 Nm 44 3 lbf ft Nut linkage lever on angle lever M14x1 5 60 Nm 44 3...

Page 156: ...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 compa...

Page 157: ... Standard classification SAE p 158 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 95 Standard classification DIN EN 228 ROZ 95 Guideline Only use super unleaded fuel that matches or is equivalent to the specified standard Fuel with an ethanol content of up to 10 E10 fuel i...

Page 158: ...g 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 Moto Protect Silicone spray Recommended supplier MOTOREX S...

Page 159: ...Y SUBSTANCES 25 157 Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Universal oil spray Recommended supplier MOTOREX Joker 440 Synthetic ...

Page 160: ... 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 161: ...INDEX OF SPECIAL TERMS 27 159 OBD On board diagnosis Vehicle system which monitors the specified param eters of the vehicle electronics ...

Page 162: ...28 LIST OF ABBREVIATIONS 160 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 163: ...n that requires prompt intervention Active driving aids are also represented by yellow or orange symbols Malfunction indicator lamp lights up flashes yellow The OBD has detected a malfunction in the vehicle electronics Come safely to a halt and contact an authorized Husqvarna Motor cycles workshop The fuel level warning lamp lights up yellow The fuel level has reached the reserve mark 29 3 Green a...

Page 164: ...e rear brake changing 94 rear brake checking 94 C Capacity Coolant 148 fuel 42 148 Gear oil 135 148 Chain checking 78 cleaning 76 Chain guide checking 78 Chain tension adjusting 77 checking 77 Characteristic map of the throttle response adjusting 124 Cleaning care 137 138 Clutch fluid level checking correcting 83 fluid changing 84 Clutch lever 16 basic position adjusting 83 Cold start button 21 Co...

Page 165: ...eel installing 98 removing 97 Fuel screen changing 128 Fuel tank installing 74 removing 73 Fuel tank filler cap closing 20 opening 20 Fuel oils etc 11 Fuse main fuse changing 108 of individual electrical power consumers changing 109 G Gear oil adding 135 changing 134 Gear oil level checking 134 H Hand brake lever 16 basic position adjusting 86 Handlebar position 53 adjusting 54 Headlight range adj...

Page 166: ...98 Rebound damping fork adjusting 52 shock absorber adjusting 48 Refueling 2 stroke oil 42 fuel 41 Riding sag adjusting 51 Right side cover installing 72 removing 72 Rubber grip checking 82 S Safe operation 8 Seat mounting 67 removing 67 Service 11 Service schedule 43 45 Shift lever 22 basic position adjusting 127 basic position checking 126 Shock absorber article number 15 compression damping gen...

Page 167: ...le cable routing checking 81 Throttle grip 16 Tire condition checking 101 Tire pressure checking 101 Transporting 40 Troubleshooting 141 143 Turn signal bulb changing 113 Turn signal switch 18 Type label 14 V Vehicle identification number 14 View of vehicle front left 12 rear right 13 W Winter operation checks and maintenance steps 138 Work rules 9 ...

Page 168: ... 3402634en 3402634en 16 03 2022 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer KISKA Husqvarna Motorcycles GmbH ...

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