Husqvarna TE 250 Page 72 Owner'S Manual Download

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12 SERVICE WORK ON THE CHASSIS

–

Clean the intake flange and check it for damage and tight-

ness.

Finishing work

–

Install the air filter.

(

p. 70)

–

Install the air filter box cover. (

p. 68)

12.24

Installing the air filter

H02459-01

Main work

–

Mount the clean air filter on the air filter support.

–

Grease the air filter in area

Long-life grease (

p. 157)

F02314-10

–

Insert air filter and position retaining pin

in bushing

The air filter is correctly positioned.

–

Insert retaining tab

Retaining pin

is secured with retaining tab

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 the exhaust system to cool down before performing any work on the vehicle.

F02315-10

–

Remove screws

with the washers.

–

Pull off the main silencer with exhaust sleeve

and the

spring ring from the manifold.

Summary of Contents for TE 250

Page 1: ...OWNER S MANUAL 2023 TE 250 TE 300 Art no 3402635en ...

Page 2: ......

Page 3: ...rials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice Husqvarna Motorcycles accepts no liability for delivery options deviations from illustrations and descriptions as well as misprints and other errors The models por trayed partly contain special equipment...

Page 4: ...switch All US standard models 17 6 9 Turn signal switch All EU AR standard models 18 6 10 Emergency OFF switch All EU AR CN standard models 18 6 11 Start button All US standard models 18 6 12 Start button All EU AR CN standard models 18 6 13 Map switch 19 6 14 Overview of indicator lights All EU AR CN standard models 19 6 15 Overview of indicator lamps All US standard models 19 6 16 Opening fuel t...

Page 5: ...ompression damping of the fork 52 11 13 Adjusting the rebound damping of the fork 52 11 14 Adjusting the spring preload of the fork 53 11 15 Handlebar position 53 11 16 Adjusting the handlebar position 54 12 SERVICE WORK ON THE CHASSIS 55 12 1 Raising the motorcycle with a lift stand 55 12 2 Removing the motorcycle from the lift stand 55 12 3 Bleeding the fork legs 55 12 4 Cleaning the dust boots ...

Page 6: ...ing the 12 V battery 106 15 4 Changing main fuse 108 15 5 Changing the fuses of individual electrical power consumers 109 15 6 Removing the headlight mask with the headlight 111 15 7 Installing the headlight mask with the headlight 111 15 8 Changing the headlight bulb 113 15 9 Changing the turn signal bulb All EU AR standard models 113 15 10 Checking the headlight setting 114 15 11 Adjusting the h...

Page 7: ...olant 149 23 3 3 Fuel 149 23 4 Chassis 149 23 5 Electrical system 150 23 6 Tires 150 23 7 Fork 151 23 8 Shock absorber 151 23 9 Chassis tightening torques 152 24 SUBSTANCES 155 25 AUXILIARY SUBSTANCES 157 26 STANDARDS 159 27 INDEX OF SPECIAL TERMS 160 28 LIST OF ABBREVIATIONS 161 29 LIST OF SYMBOLS 162 29 1 Red symbols 162 29 2 Yellow and orange symbols 162 29 3 Green and blue symbols 162 INDEX 16...

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: ...tions Info Only operate this vehicle in closed off areas remote from public road traffic 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 constitu...

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 S05313 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: ...s 2 Horn button p 17 All EU AR standard models 2 Light switch p 17 All EU AR CN standard models 2 Turn signal switch p 18 All EU AR standard models 3 Emergency OFF switch p 18 All EU AR CN standard models 3 Start button p 18 All US standard models 3 Start button p 18 All EU AR CN standard models 3 Map switch p 19 4 Throttle grip p 16 5 Hand brake lever p 16 6 Foot brake lever p 23 ...

Page 16: ...d 5 2 Type label All EU AR CN standard models 401946 10 Type label 1 is fixed to the front of the steering head 5 3 Key number All EU AR standard models 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: ...he 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 All EU AR CN standard models 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 positio...

Page 19: ... The horn button is pressed The horn is operated in this position 6 7 Light switch All EU AR CN standard models 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 l...

Page 20: ...nition 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 All US standard models H03656 10 Start button 1 is fitted on the right side of the handlebar Possible states The start button is in the basic position The start butt...

Page 21: ...lectronics 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 in...

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: ...d 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 rubber strap 2 6 25 Steering lock All EU AR standard models H03662 10 Steering lock 1 is fitted on the left side of the steering head The steering lock is used to lock the steering Steering and therefore riding is no longer p...

Page 26: ...n 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 27 Unlocking the steering All EU AR standard models 400731 01 Insert the key for the steering lock into the steering lock turn it to the left pull it out and turn it to the right Pull out the key for the s...

Page 27: ... wheel speed sensor 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 0...

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: ...haracteristic 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 w...

Page 33: ...o 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 r...

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: ...er 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 side stand must be...

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: ...ts 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 down before cover...

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: ...ings 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...

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 H03673 10 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 Info If the spring cannot be fully released the spring must be removed to accurately measure the spring length Measure the total spring length while the spring is not under tension 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: ... 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 158 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 m...

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 S04826 10 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 and handlebar Mount screw 4 but do not tighten it 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 r...

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 S04826 11 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 H03690 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: ...h 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 10 All EU AR standard models Disconnect plug in connector 6 on the brake light switch S04829 10 Remove screws 7 Pull off foot brake cylinder from th...

Page 67: ...ld the shock absorber and remove screw 9 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 F02305 10 Position the link fork and mount the swingarm pivot Info Pay attention to fl...

Page 68: ...ush 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 S04834 10 Position the angle lever and linkage lever Mount and tighten fitting 6 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 7 Guideline Screw bottom sh...

Page 69: ...ove 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 ...

Page 70: ... 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: ...nfo 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 the 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 damag...

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: ...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 consult...

Page 77: ...bracket H03705 11 Mount and 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 clot...

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 S04837 01 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: ...ted 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 correctly and ...

Page 86: ... 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 correctly and in compliance with the applicable regulations...

Page 87: ...prevent overflowing 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 Use water to immediately clean up any brake fluid that has overflowed or spilled 12 44 Removing the engine guard H016...

Page 88: ... 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 lin...

Page 89: ... 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 Husqvarna Motorcycles workshop will be glad to help Warning Skin irritati...

Page 90: ...ff 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 155 Position the cover with the membrane Mount and tighten the screws Info Use water to immediately clean up any brake fluid that has overflowed or spilled 13 5 Checking the front brake linings Warning Danger of accidents Worn out brake linings reduc...

Page 91: ...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 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: ...mmediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake flui...

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: ...he 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 ...

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 155 Mount and tighten screw cap 1 with membrane 2 and the shim Info Use water to immediately clean...

Page 99: ... back the brake pis tons S04841 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 S04842 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 the front wheel out of the ...

Page 100: ...rs Clean and grease the wheel spindle Long life grease p 157 S04841 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: ...oned Mount the chain S04835 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 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 lengt...

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: ...the tension 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...

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 150 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: ...0 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 motorcycle is...

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: ...tion diagnostics con 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 ...

Page 113: ...dlight mask Pivot the headlight mask forwards and place it on the fender H03750 10 All EU AR standard models Detach plug in connectors 3 and take off the headlight mask with the headlight H03751 10 All US standard models TE 250 CN 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 All...

Page 114: ...onnector 1 H03752 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: ...n light out of the reflector H03754 10 Pull out headlight bulb 3 Insert the new headlight bulb Headlight HS1 socket BX43t p 150 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 Check t...

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: ...Finishing work Install the headlight mask with the headlight p 111 Check the headlight setting p 114 Adjust the combination instrument p 25 15 13 Diagnostics connector S05293 10 Diagnostics connector 1 is located under the seat ...

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: ... an appropriate container under the water pump cover H03759 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 ...

Page 122: ...line 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 155 H03763 10 Mount radiator cap 5 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Al...

Page 123: ...he 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 clothing Prep...

Page 124: ... connector 4 Mount protection cap 3 S04265 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 extraction when starting or running the engine in an enclosed space Allow the engine to warm up and cool down again Check the coo...

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: ...68 Remove 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 Pull diagnostics connector 3 off the holder S04855 10 Put throttle grip 4 into full throttle position and secure ...

Page 133: ...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 sub...

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 10 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: ...ective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Drain the gear oil while the engine is at operating temperature Preparatory wo...

Page 137: ...heck it for leaks Finishing work Check the gear oil level p 134 Install the engine guard p 85 18 7 Adding the gear oil Info Too little gear oil or poor quality gear oil results in premature wear to the transmission Gear oil must only be topped up when the engine is cold Preparatory work Park the motorcycle on a level surface F02322 10 Main work Remove gear oil level monitoring screw 1 401955 11 Re...

Page 138: ...es are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and check it for leaks ...

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 157 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cle...

Page 140: ...e 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 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 ...

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: ...gap of spark plug too wide Adjust plug gap Guideline Spark plug electrode gap 0 6 mm 0 024 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 ignitio...

Page 144: ...of the alter nator Diaphragm or reed valve hous ing damaged Check the diaphragm and reed valve housing Ambient pressure is incorrectly stored Program ambient air pressure 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 con...

Page 145: ... injection Check wiring for damage and electri cal plug in connectors for corrosion and damage Read out 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 com...

Page 146: ...ow 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 Coolant temperature sensor input signal too low Coolant temperature sensor input signal too high Blink code for malfunc tion indicator lamp 06 Malfunction indicator lamp flashes 6x short Error level condition Throttle valve p...

Page 147: ...shaft speed sensor synchronization faulty Crankshaft speed sensor signal implausible Crankshaft speed sensor signal irregular Crankshaft speed sensor no signal Blink code for malfunc tion indicator lamp 42 Malfunction indicator lamp flashes 4x long 2x short Error level condition Oil pump input signal too low Oil pump input signal too high Blink code for malfunc tion indicator lamp 21 Malfunction i...

Page 148: ...3 Clutch Multidisc clutch in oil bath hydraulically activated Transmission 6 gear transmission claw shifted Transmission ratio first gear 14 32 second gear 16 26 third gear 20 25 fourth gear 22 23 fifth gear 25 22 sixth gear 26 20 Alternator 12 V 196 W Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Spark plug NGK BR 7 ES Spark plug electrode gap 0...

Page 149: ...mm 0 024 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter system 23 2 Engine tightening torques 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 angle lever exhaust con trol M5 6 Nm 4 4 lbf ft Loctite ...

Page 150: ...rew outer clutch cover M6 8 Nm 5 9 lbf ft Screw reed valve housing M6 6 Nm 4 4 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 starter motor M6 10 Nm 7 4 lbf ft Screw starter motor bearing bush M6 10 Nm 7 4 lbf ft Loctite 243 Screw starter motor protection cap M6 8 Nm 5 9 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Vac...

Page 151: ...155 23 4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WPXPLOR 5548 Shock absorber WPXACT 5750 Suspension travel front 300 mm 11 81 in rear 300 mm 11 81 in Fork offset 22 mm 0 87 in Brake system Disc brakes floating brake calipers 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 Street ti...

Page 152: ... 3 V Headlight HS1 socket BX43t 12 V 35 35 W Position light W5W socket W2 1x9 5d 12 V 5 W Indicator lamps W2 3W socket W2x4 6d 12 V 2 3 W Turn signal All EU AR standard models R10W socket BA15s 12 V 10 W Brake tail light LED License plate lamp All EU AR standard models LED Fuse 75011088005 5 A Fuse 75011088010 10 A Fuse 58011109120 20 A 23 6 Tires Validity Front tire Rear tire All EU AR CN standar...

Page 153: ...er 85 95 kg 187 209 lb 4 6 N mm 26 3 lb in Fork length 928 mm 36 54 in Fork oil per fork leg 636 10 ml 21 5 0 34 fl oz Fork oil SAE 4 48601166S1 p 156 23 8 Shock absorber Shock absorber article number 0266C463V408000 Shock absorber WPXACT 5750 Lowspeed compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Highspeed compression damping Comfort 2 5 turns Standard 2 turns Sport 1 5...

Page 154: ... models M4 0 4 Nm 0 3 lbf ft Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 Screw stop button All US stan dard models M4 0 4 Nm 0 3 lbf ft Screw throttle valve body cover M4 2 6 Nm 1 92 lbf ft Screw throttle valve body hose clamp M4 2 8 Nm 2 07 lbf ft Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Remaining nuts chassis M5 5 Nm 3 7 lbf ft Remaining scre...

Page 155: ...uts 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 M8x15 25 Nm 18 4 lbf ft Loctite 2701 Screw engine sprocket cover M8 15 Nm 11 1 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 2...

Page 156: ...r 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 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 f...

Page 157: ...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 158: ... Standard classification SAE p 159 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 159: ...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 160: ...IARY SUBSTANCES 158 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 161: ... 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 162: ...27 INDEX OF SPECIAL TERMS 160 OBD On board diagnosis Vehicle system which monitors the specified param eters of the vehicle electronics ...

Page 163: ...LIST OF ABBREVIATIONS 28 161 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 164: ...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 165: ... front brake changing 89 of the rear brake changing 94 C Capacity Coolant 149 fuel 42 149 Gear oil 135 149 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 butto...

Page 166: ...el 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 changing for individual electrical power consumers 109 main fuse changing 108 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 167: ... removing 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 d...

Page 168: ...outing 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 U Use definition 7 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 169: ... 3402635en 3402635en 18 03 2022 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer KISKA Husqvarna Motorcycles GmbH ...

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Husqvarna TE 250, Owner'S Manual

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