Husqvarna TE 150 Owner'S Manual Download Page 74

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12 SERVICE WORK ON THE CHASSIS

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 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. 66)

–

Remove the seat. (

p. 65)

–

Remove the right side cover. (

p. 71)

V00980-10

Main work

–

Turn handle

of the fuel tap to the

OFF

position.

(Figure H02505-10

p. 20)

–

Pull off the fuel hose.

Info

Remaining fuel may flow out of the fuel hose.

–

Remove screws

with the collar bushings.

E00405-10

–

Remove screw

with the rubber bushing.

–

Remove the hose from the fuel tank breather.

V00928-10

–

Pull both spoilers off laterally from the radiator bracket and lift
off the fuel tank.

Summary of Contents for TE 150

Page 1: ...OWNER S MANUAL 2018 TX 125 TE 150 Art no 3402169en ...

Page 2: ......

Page 3: ...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 devi ations from illustrations and descriptions as well as misprints and other errors The models portrayed partly contain special...

Page 4: ... 150 US 18 6 13 Opening the filler cap 19 6 14 Closing the filler cap 19 6 15 Fuel tap 20 6 16 Choke 20 6 17 Shift lever 20 6 18 Kick starter 21 6 19 Foot brake lever 21 6 20 Side stand 21 6 21 Steering lock TX 125 EU 22 6 22 Locking the steering TX 125 EU 22 6 23 Unlocking the steering TX 125 EU 22 7 COMBINATION INSTRUMENT 23 7 1 Overview 23 7 2 Activation 23 7 3 Message on the combination instru...

Page 5: ...2 8 Installing the fork protector 56 12 9 Removing the lower triple clamp 56 12 10 Installing the lower triple clamp 57 12 11 Checking the play of the steering head bearing 59 12 12 Adjusting the play of the steering head bearing 60 12 13 Greasing the steering head bearing 60 12 14 Removing front fender 61 12 15 Installing front fender 61 12 16 Removing the shock absorber 62 12 17 Installing the s...

Page 6: ...tting 109 15 9 Adjusting the headlight range 110 15 10 Changing the combination instrument 110 16 COOLING SYSTEM 112 16 1 Cooling system 112 16 2 Checking the antifreeze and coolant level 112 16 3 Checking the coolant level 113 16 4 Draining the coolant 113 16 5 Refilling with coolant 114 17 TUNING THE ENGINE 116 17 1 Checking the play in the throttle cable 116 17 2 Adjusting the play in the throt...

Page 7: ...45 22 5 2 Coolant 145 22 5 3 Fuel 145 22 6 Chassis 145 22 7 Electrical system 146 22 8 Tires 146 22 9 Fork 146 22 10 Shock absorber 147 22 11 Chassis tightening torques 147 23 SUBSTANCES 150 24 AUXILIARY SUBSTANCES 152 25 STANDARDS 153 26 LIST OF ABBREVIATIONS 154 27 LIST OF SYMBOLS 155 27 1 Yellow and orange symbols 155 27 2 Green and blue symbols 155 INDEX 156 ...

Page 8: ...l be optimally maintained by spe cially 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 belo...

Page 9: ...ty instructions need to be followed to operate the vehicle 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 therefo...

Page 10: ... 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 ventilation when running the engine Us...

Page 11: ... future of the motorcycle sport make sure that you use your motorcycle legally be environmentally aware and respect the rights of others When disposing of used oil other operating and auxiliary fluids and used components comply with the laws and regulations of the respective country Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles there are no legal...

Page 12: ...ssory 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 premature ...

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 H02523 10 1 Filler cap 2 Air filter box cover 3 Choke p 20 4 Engine number p 14 5 Side stand p 21 6 Shift lever p 20 7 Fuel tap p 20 ...

Page 15: ... 125 EU 2 Horn button p 17 TX 125 EU 2 Light switch p 17 TX 125 EU 3 Clutch lever p 16 4 Electric starter button p 18 TE 150 US 5 Throttle grip p 16 6 Hand brake lever p 16 7 Fork rebound adjustment 8 Kick starter p 21 9 Foot brake lever p 21 bk Shock absorber compression adjustment bl Shock absorber rebound adjustment ...

Page 16: ...d 5 2 Key number TX 125 EU H02475 10 Key number 1 for the steering lock is stamped onto the key connector 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 article number 401947 10 Fork article number 1 is stamped on the inside of the axle clamp ...

Page 17: ...5 SERIAL NUMBERS 15 5 5 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: ...ed using the hand brake lever 6 3 Throttle grip H02501 11 The throttle grip 1 is fitted on the right side of the handlebar 6 4 Kill switch TX 125 EU H02502 10 The kill switch 1 is fitted on the left side of the handlebar Possible states Kill switch in the basic position In this position the igni tion circuit is closed and the engine can be started Kill switch is pressed In this position the igniti...

Page 19: ...s Horn button in neutral position Horn button pressed The horn is operated in this posi tion 6 7 Light switch TX 125 EU H02502 12 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 an...

Page 20: ...his position Map switch in position II The ignition timing map Soft is active in this position The engine characteristic can be altered with the map switch 6 11 Indicator lamps overview TX 125 EU H02503 01 Possible states The high beam indicator lamp lights up blue The high beam is switched on Malfunction indicator lamp lights up flashes yellow Inoperative The fuel level warning lamp lights up yel...

Page 21: ...lt 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 Improper handling o...

Page 22: ... the fuel tank to the carburetor The fuel tank empties completely 6 16 Choke H02506 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 Possib...

Page 23: ...s fitted on the right side of the engine The top part of the kick starter pivots Info Before riding swing the top part of the kick starter inward toward the engine 6 19 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 20 Side stand 401943 10 The side stand 1 is on the left side of the vehicle ...

Page 24: ...Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 400732 01 Park the vehicle Turn the handlebar as far as possible to the right Insert the key in the steering lock turn it to the left press it in and turn it to the right Remove the key Steering is no longer possible Info Never leave the key in the steering lock 6 23 Unlocking the steering T...

Page 25: ...the combination instrument 401901 01 Possible states Battery voltage of the combination instrument The battery voltage of the combination instrument is too low Change the 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 and hold both buttons for 3 5 seconds The Setup...

Page 26: ...ime 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 Adjust 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 27: ...ect 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 Adjusting the service display Condition The motorcycle is stationary 401913 01 Press and hold both buttons for 3 5 seconds The S...

Page 28: ... to 0 0 Press the left button briefly Next display mode Press 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 ...

Page 29: ...istance covered 401903 01 Press one of the buttons until AVG 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...

Page 30: ...eristic 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 when you are not brak...

Page 31: ...r feet on the footrests when riding If you carry luggage make sure you secure it firmly as close as possible 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 pe...

Page 32: ...p internally to increase its starting power current output The starting power increases as the battery warms up 8 4 Preparing the vehicle for difficult riding conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can lead to considerably more rapid wear of components such as the drive train brake system or suspension components For this reason i...

Page 33: ...e 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 M01104 01 Mount a dust cover on the air filter Dust cover for air filter 79006920000 Info Observe the fitting instructions for Husqvarna Motor cycles accessories M01105 01 Mount a san...

Page 34: ...s 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 lukewarm water Change the rad...

Page 35: ...roofing device for air filter 79006921000 Info Observe the fitting instructions for Husqvarna Motor cycles accessories Adjust the carburetor jetting and setting Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop 600868 01 Mount the steel sprocket Clean the motorcycle p 131 Straighten bent radiator fins carefully 8 8 Preparing vehicle for high te...

Page 36: ...ater Change the radiator cap 600868 01 Adjust the secondary drive to the road conditions Info The transmission oil heats up quickly when the clutch is operated frequently due to an excessively high sec ondary drive Clean the chain Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 113 8 9 Preparing vehicle for low temperatures or snow M01106 01 Fit a rain cov...

Page 37: ...e tire condition p 101 Check the tire air 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 54 Bleed the fork legs p 53 Check the air filter Check the settings of all controls and ensure that they can be operated smoothly Check all screws nuts and hose c...

Page 38: ...tle TE 150 US Press the electric starter button or push the kick starter robustly through its full range Info Press the electric starter button for a maximum of 5 seconds Wait for 30 seconds before a fur ther attempt at starting 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 Do not open the th...

Page 39: ...gear release the clutch lever slowly and either open the throttle or shift again Switch off the engine if running at idle or standing for a long time Guideline 2 min Avoid frequent and longer slipping of the clutch As a result the gear oil engine and cooling system heat up Ride at a low engine speed instead of at a high engine speed with a slipping clutch 9 5 Braking Warning Danger of accidents Ex...

Page 40: ...e 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 down before covering it Apply the brakes on the motorcycle Shift gear to neutral TX 125 EU...

Page 41: ...ith 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 clogged In so...

Page 42: ...ll the fuel tank with fuel up to level A Guideline Level A 35 mm 1 38 in Total fuel tank capacity approx 10 l 2 6 US gal Super unleaded 95 octane mixed with 2 stroke engine oil 1 60 p 151 Engine oil 2 stroke p 150 Close the filler cap p 19 ...

Page 43: ...ake lever p 90 Check the frame p 79 Check the swingarm p 79 Check the swingarm bearing for play Check the heim joint for play Check the shock absorber linkage Check the tire condition p 101 Check the tire air pressure p 101 Check the wheel bearing for play Check the wheel hubs Check the rim run out Check the spoke tension p 102 Check the chain rear sprocket engine sprocket and chain guide p 77 Che...

Page 44: ...ded work Every 40 operating hours when used for motorsports Every 10 operating hours when used for motorsports Annually Every 80 operating hours Every 40 operating hours Once after 20 operating hours Once after 10 operating hours Change the front brake fluid Change the rear brake fluid Change the hydraulic clutch fluid p 82 Grease the steering head bearing p 60 Service the fork Service the shock a...

Page 45: ...k absorber is divided 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 setting for example has an effect on the landing after a jump the rear wheel suspension com presses quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel s...

Page 46: ...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 to help Info The effect of the high speed setting can be seen in fast compression of the shock absorber E00408 10 Using an open end wrench turn adjusting ...

Page 47: ...ckwise up to the last perceptible click Turn counterclockwise 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 damping turn counter clockwise to reduce damping 11 6 Measuring the rear wheel dimension unloaded Preparatory work Raise the motorcycle with a lift stand p 53 40...

Page 48: ...ed value Adjust the spring preload of the shock absorber p 47 11 8 Checking the riding sag of the shock absorber 402417 10 Measure dimension A of rear wheel unloaded p 45 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 Anoth...

Page 49: ... 53 Remove the shock absorber p 62 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 Holding wrench 90129051000 Measure the overall spring length while the spring is not under tension Tighten the spring by turning adjusting ring 2 to measure ment A Guideline Spring preload 11 mm 0 43 in Info D...

Page 50: ...orber p 63 Check the free travel of the foot brake lever p 90 Remove the motorcycle from the lift stand p 53 Check the static sag of the shock absorber p 46 Check the riding sag of the shock absorber p 46 Adjust the rebound damping of the shock absorber p 45 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 th...

Page 51: ...cks correspond ing to the fork type Guideline Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping turn counter clockwise to reduce damping 11 13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior F00352 10 Turn red adjusting screw 1 clockwise as far as it will go Info Adju...

Page 52: ... use a tool Make the same adjustment on both fork legs Turn the adjusting wings clockwise Guideline Spring preload Preload Adjuster Comfort 0 Standard 0 Sport 3 The adjusting wings engage noticeably at the numerical values Info Adjust the 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 counte...

Page 53: ...becomes fatigued The handlebar may break as a result Change the handlebar if the handlebar is damaged or bent 0 0 2 2 0 0 1 1 0 0 2 2 1 1 B00375 10 Remove screws 1 Take off the handlebar clamps Remove the handlebar and lay it to one side Info Cover the components to protect them against dam age Do not kink the cables and lines Remove screws 2 Take off the handlebar supports Place the handlebar sup...

Page 54: ...11 TUNING THE CHASSIS 52 Info Make sure the gap widths are even ...

Page 55: ...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 band 12 3 Bleeding the fork legs Preparatory w...

Page 56: ...f 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 152 Press the dust boots back into their normal position Remove excess oil Finishing work Install the fork protector p 56 Remove the motorcycle from the lift stand p 53 12 5 Removing the fork legs Preparatory work Remove the headlight ma...

Page 57: ...the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the upper triple clamp V01005 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 V00930 10 Position the brake caliper and mount and tighten screws 4 Guideline Screw front brake caliper M8 25 Nm 18 4 ...

Page 58: ...t and 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 107 Raise the motorcycle with a lift stand p 53 Remove the front wheel p 97 Remove the fork legs p 54 Remove front fender p 61 V00988 10 Main wo...

Page 59: ...ple clamp B01632 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 152 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing Check whether upper steering head seal 1 is correctly posi tioned Mount protective ring 2 and O ring 3 V00989 10 Position the upper triple clamp with the handlebar Mount screw 4 but do...

Page 60: ...to the side of the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the upper triple clamp V01006 10 Tighten screws 8 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft V00990 10 Tighten screw 4 Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft V00991 10 Mount and tighten screw 9 Guideline Screw top steering stem M8 17 Nm 12 5 lbf f...

Page 61: ...t steering head bearing play impairs the handling characteristic and damages components Correct incorrect steering head bearing play immediately Your authorized Husqvarna Motorcycles workshop will be glad to help Info If the vehicle is operated for a lengthy period with play in the steering head bearing the bearings and the bearing seats in the frame can become damaged over time Preparatory work R...

Page 62: ...w 2 Loosen and retighten screw 3 Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Tighten screws 1 Guideline Screw 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 play of the steering head bearing p 59 Re...

Page 63: ...992 10 Main work Remove screws 1 Remove screws 2 Take off the front fender 12 15 Installing front fender V00993 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 108 Check the headlight setting p 109 ...

Page 64: ...ve screws 1 Remove screws 2 with the washers Remove the frame protectors on the left and right F00284 10 Remove screw 3 Remove fitting 4 Info Raise the wheel slightly to be able to remove the screws more easily F00285 10 Press angle lever 5 toward the rear Press linkage lever 6 downward V01009 10 TX 125 EU Remove the cable tie and rubber band Disconnect the plug in connector ...

Page 65: ...l out the swingarm pivot Push the swingarm back and secure it against falling over V00398 11 Hold the shock absorber and remove screw 9 Remove the shock absorber carefully at the bottom 12 17 Installing the shock absorber V00399 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 Loct...

Page 66: ...face in the direction of travel V01009 10 TX 125 EU Join the plug in connector Fit the new rubber band and cable tie V00947 10 Position the foot brake cylinder Push rod 4 engages in the foot brake cylinder The dust boot is correctly positioned Mount and tighten screws 5 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft F00284 11 Position the angle lever and linkage lever Mount and tighten fit...

Page 67: ...nd tighten screws 8 Guideline Screw frame pro tector M5 3 Nm 2 2 lbf ft Mount and tighten screws 9 with the washers Guideline Screw frame pro tector M5 3 Nm 2 2 lbf ft Mount the new cable ties Finishing work Check the free travel of the foot brake lever p 90 Remove the motorcycle from the lift stand p 53 12 18 Removing the seat Preparatory work Remove the air filter box cover p 66 H02511 10 Main w...

Page 68: ...t at the rear and push the seat forward Make sure that the seat is locked in correctly Mount and tighten screw 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the air filter box cover p 67 12 20 Removing the air filter box cover H02513 10 Pull off the air filter box cover sideways in areas A B and C and remove toward the front ...

Page 69: ...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 66 H0251...

Page 70: ...Remove the air filter p 67 V00979 10 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaning agent p 152 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil Oil for foam air filter p 152 Clean the air filter box Clean the intake flange and check it for damage and tight ness Fi...

Page 71: ...in damage Finishing work Install the air filter box cover p 67 12 25 Sealing the air filter box F00248 01 Seal the air filter box in the marked area A 12 26 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Preparatory work Remove the right side cover p 71 V0...

Page 72: ...o Over time the fibers of the glass fiber yarn escape and the damper burns out Not only is the noise level higher the performance characteristic changes Preparatory work Remove the right side cover p 71 Remove the main silencer p 69 H01759 10 Main work Remove screws 1 Pull out inner tube 2 Remove the glass fiber yarn filling 3 from the inner tube Clean the parts that need to be reinstalled and che...

Page 73: ...in areas A and B Mount and tighten screw 3 Guideline Remaining screws chassis M5 5 Nm 3 7 lbf ft 12 31 Removing the fuel tank Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly...

Page 74: ...n 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 66 Remove the seat p 65 Remove the right side cover p 71 V00980 10 Main work Turn handle 1 of the fuel tap to the OFF position Figure H02505 10 p 20 Pull off the fuel hose Info Remaining fuel may flow out of the fuel hose Remove screws 1 with...

Page 75: ... 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 water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Main work Check throttle cable routing p 79 V...

Page 76: ...idents Oil or grease on the tires reduces the road grip Remove the lubricant from the tires using a suitable cleaning agent Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Disp...

Page 77: ...he 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 53 V00410 10 Main work Pull the chain at the end of the chain sliding component upwards to measure c...

Page 78: ...le with a lift stand p 53 Check the chain tension p 75 V00913 10 Main work Loosen nut 1 Loosen nuts 2 Adjust the chain tension by turning the left and right adjusting screws 3 Guideline Chain tension 55 58 mm 2 17 2 28 in Turn adjusting screws 3 on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks A The rear wheel is ...

Page 79: ...s 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 repeat this measurement at different chain positions Maximum distance B at the longest chain section 272 mm 10 71 in If distance B ...

Page 80: ...ing guard M6 14 Nm 10 3 lbf ft Loctite 243 H02520 10 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 4...

Page 81: ...mpact Repair of the frame is not authorized by Husqvarna Motorcycles 12 39 Checking the swingarm S01340 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 12 40 Checking throttle cable routing Warning Dange...

Page 82: ... Correct throttle cable routing Finishing work Install the fuel tank p 73 Mount the seat p 66 Install the air filter box cover p 67 Install the right side cover p 71 12 41 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 T...

Page 83: ...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 eyes thoroughly with water immediately and consult a doctor if brake fluid come...

Page 84: ...safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing ch...

Page 85: ... Now press the fluid into the system until it emerges from the hole 6 of the master cylinder without bubbles Now and then extract fluid from the master cylinder reservoir to prevent overflow Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position the cover with the membrane Mo...

Page 86: ...ON THE CHASSIS 84 12 46 Installing the engine guard H01655 01 Attach the engine guard on the frame at the rear and swing up at the front Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 87: ... 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 A A 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...

Page 88: ...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 89: ...ion Remove screws 1 Remove 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 p 150 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 redu...

Page 90: ...Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary 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 coeffi...

Page 91: ...gainst the spokes when pushing back the brake pis tons Remove cotter pin 4 Push leaf spring 5 upwards and remove pin 6 Remove brake linings Clean the brake caliper and brake caliper support H02377 10 Check that leaf spring 5 in the brake caliper and sliding plate 7 in the brake caliper support are seated correctly K00944 11 Insert the new brake linings Mount pin 6 Leaf spring 5 engages in the groo...

Page 92: ...vel 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 travel A Guideline Free travel of foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the basic position of the foot brake lever p 90 Reco...

Page 93: ...t 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 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 Husqvar...

Page 94: ...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 front and rear brake is changed in accordance with the service schedule Your author...

Page 95: ...the braking effect Ensure that worn out brake linings are replaced immediately Your authorized Husqvarna Motorcy cles workshop will be glad to help V00917 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings p 93 Check the brake linings for damage and cracking If damage or wear is encounter...

Page 96: ...nd 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 coefficient of the brake linings and thus their brake power may vary greatly from that of original brake linings If brake linings are u...

Page 97: ... the spokes Remove cotter pin 3 Push leaf spring 4 downwards and remove pin 5 Remove brake linings Clean the brake caliper and brake caliper support K00948 10 Check that leaf spring 4 in the brake caliper and sliding plate 6 in the brake caliper support are seated correctly H02370 10 Insert the new brake linings Mount pin 5 Leaf spring 4 engages in the groove on the pin Info Always change the brak...

Page 98: ...10 Add brake fluid to level A Brake fluid DOT 4 p 150 Mount and tighten screw cap 1 with membrane 2 and the shim Info Clean up overflowed or spilled brake fluid immediately with water Mount new cable ties on the frame protector ...

Page 99: ... back the brake pis tons V00919 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 V00972 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 Holding the front wheel withdraw the wheel spindle Take the front wheel ou...

Page 100: ...ers Clean and grease the wheel spindle Long life grease p 152 V00919 11 Lift 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 the...

Page 101: ...ar 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 Holding 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 sp...

Page 102: ...ed Mount the chain V00913 11 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 75 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 ...

Page 103: ...ck 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 manufacture and ...

Page 104: ...ral 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 diameter If you hear different tone frequenci...

Page 105: ...tteries if charge is already below the minimum voltage Minimum voltage before the start of the charge 9 V Dispose of batteries with less than the minimum voltage correctly Preparatory work Press and hold the kill switch while the engine is idling until the engine stops Remove the air filter box cover p 66 Remove the seat p 65 H01190 10 Main work Pull back the negative terminal cover 1 and disconne...

Page 106: ...ery termi nal M5 2 5 Nm 1 84 lbf ft Contact disks A must be mounted under the screw 3 and the cable lug 4 with the claws toward the battery terminal Slide negative terminal cover 8 over the negative terminal Finishing work Mount the seat p 66 Install the air filter box cover p 67 15 3 Recharging the battery TE 150 US Warning Risk of injury Batteries contain harmful substances Keep batteries out of...

Page 107: ...is depleted by repeated starting the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sul fated destroying the battery The battery is maintenance free Preparatory work Press and hold the kill switch while the engine is idling until the engine stops Remove the air filter box cover p 66 Remove the seat p 65 Rem...

Page 108: ...om the battery Finishing work Install the battery p 104 Mount the seat p 66 Install the air filter box cover p 67 15 4 Changing the main fuse TE 150 US Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Info The main fuse protects all power consumers of the vehicle Preparatory work Press and hold the kill s...

Page 109: ... that the electrical system is functioning properly Tip Insert a spare fuse so that it is available if needed Mount the protection caps Mount the starter relay onto the holder and route the cable Finishing work Mount the seat p 66 Install the air filter box cover p 67 15 5 Removing the headlight mask with the headlight V00995 11 Detach brake line 1 and wiring harness 2 V00420 11 Release rubber ban...

Page 110: ...6 Installing the headlight mask with the headlight V00419 11 Main work Join plug in connector 1 V00420 10 Position the headlight mask and secure it with rubber bands 2 The holding lugs engage V00995 10 Position brake line 3 and wiring harness 4 in the brake line guide Finishing work Check the headlight setting p 109 ...

Page 111: ...headlight bulb Headlight HS1 socket BX43t p 146 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 parking light into the reflector Finishing work Install the headlight mask with the headlight p 108 Check the headlight setting p 109 15 8 Checking the headlight setting 400726 10 Position...

Page 112: ...torcycle with rider instructions on how to apply the marking Checking the headlight set ting Info If you have a payload you may have to correct the headlight range Tighten screw 1 15 10 Changing the combination instrument Preparatory work Remove the headlight mask with the headlight p 107 V00421 10 Main work Remove screws 1 with the washers Pull the combination instrument upward out of the holder ...

Page 113: ...any button on the combination instrument The combination instrument is activated Position the combination instrument in the holder Mount and tighten the screws with washers Finishing work Install the headlight mask with the headlight p 108 Check the headlight setting p 109 Adjust the combination instrument p 23 ...

Page 114: ...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 115: ...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 116: ...diator cap 2 Completely drain the coolant Mount and tighten screw 1 with a new seal ring Guideline Drain plug water pump cover TX 125 EU M6 8 Nm 5 9 lbf ft Drain plug water pump cover TE 150 US M6 8 Nm 5 9 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 s...

Page 117: ...ompletely fill the radiator with coolant Coolant p 150 Mount the radiator cap 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 to warm up and cool dow...

Page 118: ... 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 let it run idle Move the handlebar 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 116 17 2 Adjusting th...

Page 119: ...t 3 400192 11 Turn barrel adjuster 2 so that there is play A in the throttle cable at the throttle grip Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut 3 Slide on sleeve 1 Finishing work Check the throttle grip for smooth operation Install the fuel tank p 73 Mount the seat p 66 Install the air filter box cover p 67 Install the right side cover p 71 Check the play in the throttle ca...

Page 120: ...ence in the mid throttle slide range If the engine stutters when accelerating with a partially open throttle slide the jet needle must be lowered If the engine knocks when accelerating at the full power rpm range the jet needle must be raised Cylindrical part of the needle CYL The cylindrical part of the needle has the greatest influence when the throttle slide is almost closed Idling jet IJ The i...

Page 121: ... open the idling jet and the clip position have the greatest influence The influence of the first cylindrical part of the needle is less When the throttle slide is 1 2 open the position of the needle has the greatest influence The influence of the main jet and the idling jet is only minimal 1 4 1 8 1 2 3 4 0 1 1 4 1 8 1 2 3 4 0 1 K00497 01 When the throttle slide is 3 4 open the influence of the m...

Page 122: ...respective model 0 0 4 4 0 0 3 3 0 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 17 4 Carburetor idle V00996 11 The idle setting of the carburetor has a big influence on the start ing behavior stable idling and the response to throttle opening ...

Page 123: ...he choke lever is pushed in to the stop p 20 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...

Page 124: ...eability Performance The plug in connector is connected to achieve higher performance 17 7 Changing the ignition timing map Preparatory work Remove the air filter box cover p 66 Remove the seat p 65 Remove the right side cover p 71 Remove the fuel tank p 71 V01004 10 Switching the ignition timing map from Performance to Soft Disconnect plug in connector 1 of the ignition timing map adjustment Soft...

Page 125: ...ft lever must not touch the rider s boot when in the basic position When the shift lever keeps touching the boot the transmission will be subject to an excessive load 0 0 0 A A 400692 10 Sit on the vehicle in the riding position and determine distance A between the upper edge of your boot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance ...

Page 126: ...Possible states Auxiliary spring with green color coding Auxiliary spring for soft performance Auxiliary spring with yellow color coding Auxiliary spring for more aggressive performance than with a green spring Auxiliary spring with blue color coding Auxiliary spring for more aggressive performance than with a yellow spring Auxiliary spring with red color coding Auxiliary spring for more aggressiv...

Page 127: ... 0 0 0 4 4 0 0 3 3 0 0 5 5 0 0 2 2 B00056 11 Remove cap 2 adjusting spring 3 auxiliary spring 4 and spring insert 5 from the clutch cover Pull both springs off of the spring insert E00440 10 Mount the required auxiliary spring p 124 4 and adjust ing spring 3 and position them together in the clutch cover TX 125 EU Auxiliary spring with yellow marking 54637072300 Auxiliary spring with green marking...

Page 128: ...17 TUNING THE ENGINE 126 Mount and tighten the screws Guideline Screw exhaust control cover TX 125 EU M5 5 Nm 3 7 lbf ft Screw exhaust control cover TE 150 US M5 5 Nm 3 7 lbf ft ...

Page 129: ...s 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 allow fuel ...

Page 130: ... Screw gear oil level check TE 150 US M6 8 Nm 5 9 lbf ft 18 3 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 Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils ...

Page 131: ... 2 with a new seal ring Guideline Gear oil drain plug TX 125 EU M10x1 15 Nm 11 1 lbf ft Gear oil drain plug TE 150 US M10x1 15 Nm 11 1 lbf ft K00530 10 Remove filler plug 3 and fill up with gear oil Gear oil 0 80 l 0 85 qt Engine oil SAE 10W 40 p 150 Mount and tighten the oil filler plug Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Al...

Page 132: ...ll hole of the gear oil monitoring screw Engine oil SAE 10W 40 p 150 Mount and tighten the gear oil monitoring screw Guideline Screw gear oil level check TX 125 EU M6 8 Nm 5 9 lbf ft Screw gear oil level check TE 150 US M6 8 Nm 5 9 lbf ft Mount and tighten filler plug 2 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure the...

Page 133: ...pearance will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning 401061 01 Close off the exhaust system to prevent water from entering Remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Info Use warm water containing normal motorcycle cleaner and a soft sponge Never...

Page 134: ...ake pre cautions 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 131 Clean the brakes Info After EVERY trip on salted roads thoroughly wash the cool and installed brake calipers and brake linings with cold water and dry carefully After riding on salt...

Page 135: ...vice repairs or replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 401058 01 Clean the motorcycle p 131 Change the gear oil p 128 Check the antifreeze and coolant level p 112 When refueling for the last time before taking the motorcycle out of service add fuel additive R...

Page 136: ...ause the engine will not warm up sufficiently the water vapor produced during combustion will condense causing engine parts and the exhaust system to rust 20 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 53 TE 150 US Install the battery p 104 Perform checks and maintenance measures when preparing for use p 35 Make a test ride ...

Page 137: ...e it if necessary Electrode distance plug gap of spark plug too wide Adjust the plug gap Guideline Spark plug electrode gap TX 125 EU 0 60 mm 0 0236 in Spark plug electrode gap TE 150 US 0 60 mm 0 0236 in Fault in ignition system Check the ignition system Short circuit cable in wiring harness frayed kill switch faulty Check the kill switch The connector or ignition coil is loose or oxydized Clean ...

Page 138: ...urn handle 1 of the fuel tap to the RES position Figure H02505 10 p 20 Refuel p 39 Engine takes in bad air Check the intake flange and carbure tor for tightness The connector or ignition coil is loose or oxydized Clean the connector and treat with contact spray Engine overheats Too little coolant in cooling system Check the cooling system for leakage Check the coolant level p 113 Too little air st...

Page 139: ...ically activated Gearbox 6 gear 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 75 W Ignition Contactless controlled fully electronic ignition with digital ignition adjustment type Kokusan Spark plug NGK BR9 ECMVX Spark plug electrode gap 0 60 mm 0 0236 in Cooling Water cooling permanent circula...

Page 140: ...t by water pump Starting aid Electric starter and kick starter 22 2 Engine tightening torques 22 2 1 TX 125 EU Screw inner membrane sheets EJOTDELTA PT 35x25 1 Nm 0 7 lbf ft Screw membrane support plate EJOTDELTA PT 30x12 1 Nm 0 7 lbf ft Screw outer membrane sheets EJOTDELTA PT 30x6 1 Nm 0 7 lbf ft Screw control lever exhaust con trol M5 6 Nm 4 4 lbf ft Loctite 243 Screw crankshaft position sensor...

Page 141: ...r M6x20 8 Nm 5 9 lbf ft Screw outer clutch cover M6x50 8 Nm 5 9 lbf ft Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 Screw stop plate of exhaust con trol M6 10 Nm 7 4 lbf ft Loctite 243 Screw water pump cover M6 10 Nm 7 4 lbf ft Screw cylinder head M7 18 Nm 13 3 lbf ft Nut cylinder base M8 23 Nm 17 lbf ft Screw cylinder base M8 20 Nm 1...

Page 142: ... 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 check M6 8 Nm 5 9 lbf ft Screw intake flange M6 6 Nm 4 4 lbf ft Screw intermediate clutch cover M6x20 10 Nm 7 4 lbf ft Screw intermediate clutch cover M6x25 10 Nm 7 4 lbf ft Screw intermediate clutch cover M6x30 10 N...

Page 143: ...ocket M10 60 Nm 44 3 lbf ft Loctite 2701 Gear oil drain plug M10x1 15 Nm 11 1 lbf ft Nut rotor M12x1 50 Nm 36 9 lbf ft Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Spark plug M14x1 25 25 Nm 18 4 lbf ft Nut primary gear M16LHx1 5 130 Nm 95 9 lbf ft Loctite 243 Nut inner clutch hub M18x1 5 100 Nm 73 8 lbf ft Loctite 243 ...

Page 144: ... 480 490 500 Idling jet 32 5 30 35 Starting jet 80 Needle jet S 7 Idle air adjusting screw open 2 turns Throttle slide 4 22 3 2 TE 150 US Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 79 Needle position 2nd position from top Jet needle 6BFY43 74 6BFY42 74 Main jet 470 460 480 490 Idling jet 30 32 5 35 Starting jet 80 Needle jet S 4 Idle air adjusting screw open 1 5 turns Th...

Page 145: ...arburetor tuning 22 4 1 Carburetor tuning TX 125 EU 402816 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from top MJ Main jet Info Do not use on sandy terrain ...

Page 146: ... 144 22 4 2 Carburetor tuning TE 150 US 402818 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from top MJ Main jet Info Do not use on sandy terrain ...

Page 147: ...vel front 300 mm 11 81 in rear 330 mm 12 99 in Fork offset 22 mm 0 87 in Brake system Disc brakes brake calipers on floating bearings Brake discs diameter front 260 mm 10 24 in rear 220 mm 8 66 in Brake discs wear limit front 2 5 mm 0 098 in rear 3 5 mm 0 138 in Tire air pressure off road front 1 0 bar 15 psi rear 1 0 bar 15 psi Secondary ratio 13 50 Chain 5 8 x 1 4 Rear sprockets available 48 50 ...

Page 148: ... M C 65M M S TT Metzeler MCE 6 DAYS EXTREME TE 150 US 90 90 21 54M TT Dunlop Geomax AT81 F 110 100 18 64M TT Dunlop Geomax AT81 The tires specified represent one of the possible series production tires Additional information is available in the Service section under www husqvarna motorcycles com 22 9 Fork Fork article number 14 15 8R 61 Fork WP Performance SystemsXplor 48 PA Compression damping Co...

Page 149: ...ate Weight of rider 65 75 kg 143 165 lb 39 N mm 223 lb in Weight of rider 75 85 kg 165 187 lb 42 N mm 240 lb in Weight of rider 85 95 kg 187 209 lb 45 N mm 257 lb in Spring length 260 mm 10 24 in Gas pressure 10 bar 145 psi Static sag 35 mm 1 38 in Riding sag 110 mm 4 33 in Fitted length 477 mm 18 78 in Shock absorber fluid p 151 SAE 2 5 22 11 Chassis tightening torques Remaining screws chassis EJ...

Page 150: ...ket screw M8 35 Nm 25 8 lbf ft Loctite 2701 Nut rim lock M8 12 Nm 8 9 lbf ft Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw bottom triple clamp M8 15 Nm 11 1 lbf ft Screw chain sliding piece M8 15 Nm 11 1 lbf ft Screw engine brace M8 25 Nm 18 4 lbf ft Loctite 2701 Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Lo...

Page 151: ... lbf ft Nut linkage lever on angle lever M14x1 5 80 Nm 59 lbf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Screw in nozzles cooling system M20x1 5 12 Nm 8 9 lbf ft Loctite 243 ...

Page 152: ...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 153: ...ainer and that exhibit the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 ...

Page 154: ...ife grease Recommended supplier Bel Ray Waterproof Grease Offroad chain spray Guideline Recommended supplier Bel Ray Blue Tac Chain Lube Oil for foam air filter Recommended supplier Bel Ray Foam Filter Oil Preserving materials for paints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil spray Recommended supplier Bel Ray 6 in 1 ...

Page 155: ...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 156: ...26 LIST OF ABBREVIATIONS 154 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 157: ...tion Active driving aids are also represented by yellow or orange symbols Malfunction indicator lamp lights up flashes yellow Inoperative The fuel level warning lamp lights up yellow Inoperative 27 2 Green and blue symbols Green and blue symbols reflect information The high beam indicator lamp lights up blue The high beam is switched on ...

Page 158: ...l 129 145 Carburetor float chamber emptying 127 idle 120 idle speed adjusting 121 Carburetor setting 118 Chain checking 77 cleaning 74 Chain guide checking 77 Chain tension adjusting 76 checking 75 Chassis number 14 Choke 20 Cleaning care 131 132 Clutch fluid level checking correcting 81 fluid changing 82 Clutch lever 16 basic position adjusting 81 Combination instrument adjusting 23 adjusting the...

Page 159: ...g 61 Front wheel installing 98 removing 97 Fuel tank installing 73 removing 71 Fuel tap 20 Fuse main fuse changing 106 G Gear oil adding 130 changing 128 Gear oil level checking 128 H Hand brake lever 16 basic position adjusting 85 Handlebar position 51 adjusting 51 Headlight range adjusting 110 Headlight adjustment checking 109 Headlight bulb changing 109 Headlight mask with headlight installing ...

Page 160: ... operation 8 Seat mounting 66 removing 65 Service 10 Service schedule 41 42 Shift lever 20 basic position adjusting 123 basic position checking 123 Shock absorber article number 15 compression damping general 43 installing 63 removing 62 riding sag checking 46 spring preload adjusting 47 static sag checking 46 Side stand 21 Spare parts 10 Spoke tension checking 102 Starting 35 Starting power of li...

Page 161: ... Throttle grip 16 Tire air pressure checking 101 Tire condition checking 101 Transporting 38 Troubleshooting 135 136 U Use definition 7 V View of vehicle front left 12 rear right 13 W Warranty 10 Winter operation checks and maintenance steps 132 Work rules 9 ...

Page 162: ... 3402169en 3402169en 06 2017 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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Husqvarna TE 150, Owner'S Manual

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