Husqvarna TE 250i 2022 User Manual Download

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SERVICE WORK ON THE CHASSIS 12

400227-01

Main work

–

Shift the transmission into neutral.

–

Check the chain, rear sprocket, and engine sprocket for
wear.
» If the chain, rear sprocket or engine sprocket is worn:

–

Change the drivetrain kit.

Info

The engine sprocket, rear sprocket, and chain
should always be replaced together.

400987-10

–

Pull on the top section of the chain with the specified
weight

Guideline

Weight, chain wear mea-
surement

10 … 15 kg (22 … 33 lb.)

–

Measure distance

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

from

18 chain rollers at the
longest chain section

272 mm (10.71 in)

» If distance

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.

Summary of Contents for TE 250i 2022

Page 1: ...OWNER S MANUAL 2022 TE 250i TE 300i TE 300i ROCKSTAR EDITION Art no 3402538en ...

Page 2: ......

Page 3: ...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 that does not belong to the regular scope of...

Page 4: ... switch All EU AR models 20 6 10 Emergency OFF switch All EU AR CN models 21 6 11 Start button All US models 21 6 12 Start button All EU AR CN models 22 6 13 Map switch 22 6 14 Overview of indicator lights All EU AR CN models 23 6 15 Overview of indicator lamps All US models 23 6 16 Opening fuel tank filler cap 23 6 17 Closing the fuel tank filler cap 24 6 18 Opening 2 stroke oil tank cap 24 6 19 ...

Page 5: ...ound damping of the fork 56 11 14 Adjusting the spring preload of the fork 57 11 15 Handlebar position 57 11 16 Adjusting the handlebar position 58 12 SERVICE WORK ON THE CHASSIS 59 12 1 Raising the motorcycle with a lift stand 59 12 2 Removing the motorcycle from the lift stand 59 12 3 Bleeding the fork legs 59 12 4 Cleaning the dust boots of the fork legs 60 12 5 Removing the fork legs 60 12 6 I...

Page 6: ...re condition 116 14 6 Checking tire pressure 116 14 7 Checking spoke tension 117 15 ELECTRICAL SYSTEM 118 15 1 Removing the 12 V battery 118 15 2 Installing the 12 V battery 120 15 3 Charging the 12 V battery 121 15 4 Changing main fuse 123 15 5 Changing the fuses of individual electrical power consumers 124 15 6 Removing the headlight mask with the headlight 126 15 7 Installing the headlight mask...

Page 7: ...161 23 2 Engine tightening torques 162 23 3 Capacities 164 23 3 1 Gear oil 164 23 3 2 Coolant 164 23 3 3 Fuel 164 23 4 Chassis 164 23 5 Electrical system 165 23 6 Tires 166 23 7 Fork 166 23 8 Shock absorber 166 23 9 Chassis tightening torques 167 24 SUBSTANCES 170 25 AUXILIARY SUBSTANCES 172 26 STANDARDS 174 27 INDEX OF SPECIAL TERMS 175 28 LIST OF ABBREVIATIONS 176 29 LIST OF SYMBOLS 177 29 1 Red...

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: ...o 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 constitutes misus...

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: ... you The current Husqvarna Motorcycles technical accessories for your vehicle are available from your authorized Husqvarna Motorcycles dealer and 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 wear is that the service care and tuning work on the engine and ch...

Page 14: ...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 15: ...VIEW OF VEHICLE 4 13 4 1 View of vehicle front left example S04818 10 1 Clutch lever p 17 2 Fuel tank filler cap 3 Air filter box cover 4 Engine number p 15 5 Side stand p 27 6 Shift lever p 26 ...

Page 16: ... p 19 All US models 2 Horn button p 19 All EU AR models 2 Light switch p 20 All EU AR CN models 2 Turn signal switch p 20 All EU AR models 3 Emergency OFF switch p 21 All EU AR CN models 3 Start button p 21 All US models 3 Start button p 22 All EU AR CN models 3 Map switch p 22 4 Throttle grip p 18 5 Hand brake lever p 17 6 Foot brake lever p 27 ...

Page 17: ...ering head 5 2 Type label All EU AR CN models 401946 10 Type label 1 is fixed to the front of the steering head 5 3 Key number All EU AR 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 18: ... 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 19: ...ecial models Clutch lever 1 is fitted on the handlebar on the left The clutch is activated hydraulically and adjusts itself auto matically 6 2 Hand brake lever S04406 10 All TE standard models Hand brake lever 1 is located on the right side of the han dlebar S04961 10 All TE special models Hand brake lever 1 is located on the right side of the han dlebar The front brake is engaged using the hand b...

Page 20: ...4407 10 All EU AR CN standard models The stop button 1 is fitted on the left side of the handlebar S04962 10 TE 300i ROCKSTAR EDITION EU The stop button 1 is fitted on the left side of the handlebar Possible states The stop button is in the basic position In this position the ignition circuit is closed and the engine can be started Stop button pressed In this position the ignition circuit is inter...

Page 21: ...circuit is closed and the engine can be started Stop button pressed In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start 6 6 Horn button All EU AR models S04407 12 All EU AR standard models Horn button 1 is fitted on the left side of the handlebar S04962 11 TE 300i ROCKSTAR EDITION EU Horn button 1 is fitted on the left side of the han...

Page 22: ... beam on Light switch is turned to the left In this position the high beam and tail light are switched on 6 8 Light switch All US models H03655 10 The light switch 1 is located to the left of the combination instrument Possible states Light off Light switch is pressed in up to the stop In this position the light is switched off Light on Light switch is pulled out to the stop In this posi tion the ...

Page 23: ...F switch 1 is fitted on the right side of the handlebar S04965 10 TE 300i ROCKSTAR EDITION EU The emergency OFF switch 1 is fitted on the right side of the handlebar Possible states Ignition off In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start Ignition on In this position the ignition circuit is closed and the engine can be started...

Page 24: ...motor is actuated 6 13 Map switch H03656 11 All TE standard models The map switch 1 is fitted on the right side of the handle bar S04967 10 All TE special models The map switch 1 is fitted on the right side of the handle bar Possible states Map switch in position I The ignition timing map Perfor mance is active in this position Map switch in position II The ignition timing map Soft is active in th...

Page 25: ...03655 11 Possible states High beam indicator lamp inoperative 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 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 r...

Page 26: ...s correctly in a suitable canister and out of the reach of children 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 F02302 10 Press release button 1 turn the fuel tank filler cap counter clockwise and lift it off 6 17 Closing the fuel tank filler cap F02302 11 Mount the fuel tank filler cap ...

Page 27: ...temperature is low the electronic fuel injection system extends the injection time To help the engine burn the increased fuel quantity it must be sup plied 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 cold start button is pulled out all the way and turned by a tur...

Page 28: ... 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 29: ... stand 1 is located on the left of the vehicle 401944 10 The side stand is used for parking the motorcycle Info When you are riding side stand 1 must be folded up and secured with rubber strap 2 6 25 Steering lock All EU AR 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 possi...

Page 30: ...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 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 steering l...

Page 31: ...eed 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 01 Press b...

Page 32: ...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 33: ... 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 34: ... 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 35: ...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 36: ...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 37: ...y 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 permissible overall weight 335 kg 739 lb Maximum ...

Page 38: ...be warmed up internally to increase its starting power current output The starting power increases as the battery 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 F...

Page 39: ...ooling 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 radiator cap M01104 01 Mount the air filter dust cover Air filter dust cover 79006920000 Info Observe the fitting instruct...

Page 40: ...g 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 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...

Page 41: ...s on wet and muddy circuits M01106 01 Mount the air filter rain cover Air filter rain cover 79006921000 Info Observe the fitting instructions for Husqvarna Motor cycles technical accessories 600868 01 Mount the steel sprocket Clean the motorcycle p 152 Straighten the bent radiator fins carefully 8 8 Preparing vehicle for high temperatures or slow riding V00899 01 Check the radiator cap Value on th...

Page 42: ...n the event of scalding rinse the area affected immediately with lukewarm water 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 133 ...

Page 43: ... condition p 116 Check tire pressure p 116 Check the spoke tension p 117 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 60 Bleed the fork legs p 59 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 regularl...

Page 44: ...tempt 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 fold...

Page 45: ...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 46: ... components for parking the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down bef...

Page 47: ...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 48: ...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 24 H03663 10 Fill the...

Page 49: ...ery Check the front brake linings p 98 Check the brake linings of the rear brake p 106 Check the brake discs p 95 Check the brake lines for damage and leakage Check the rear brake fluid level p 104 Check the free travel of the foot brake lever p 103 Check the frame p 87 Check the link fork p 87 Check the fork bearing for play Check the shock absorber heim joint for play Check the shock absorber li...

Page 50: ...screen p 143 Check the fuel pressure Check the headlight setting p 129 Check the idle speed Final 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 ...

Page 51: ...he oil screen in the oil tank p 146 Clean the protection cap of the pressure sensor Change the coolant p 136 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 Che...

Page 52: ...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 53: ...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 54: ...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 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...

Page 55: ...ed value Adjust the spring preload of the shock absorber p 54 11 8 Checking the riding sag of the shock absorber 402417 10 Measure dimension A of rear wheel unloaded p 52 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 56: ...9 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 57: ...ork Install the shock absorber p 70 Remove the motorcycle from the lift stand p 59 Check the static sag of the shock absorber p 53 Check the riding sag of the shock absorber p 53 Adjust the rebound damping of the shock absorber p 52 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 58: ...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 59: ... 3 The T grips 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 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 re...

Page 60: ... 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 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 h...

Page 61: ...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 62: ...r 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 Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 173 Press the dust boots back into their installation position Remove excess oil Finishing work Install the fork protector p 62 Remove the motorcycl...

Page 63: ...ight fork leg 12 6 Installing the fork legs S04824 13 Main work Position the fork legs Bleeder screws 1 are positioned toward the front Info The compression damping is located in left fork leg COMP white adjuster The rebound damping is located in right fork leg REB red adjuster Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush wi...

Page 64: ...amp Mount and tighten screws 5 Finishing work Install the front wheel p 111 Install the headlight mask with the headlight p 126 Check the headlight setting p 129 12 7 Removing the fork protector H03681 10 Remove screws 1 and take off the clamp Remove screws 2 and take off the left fork protector Remove screws 3 and take off the right fork protector 12 8 Installing the fork protector H03681 11 Posi...

Page 65: ...e front fender p 67 H03682 10 Main work Remove screw 1 Remove screw 2 Open cable holder 3 in front of the left radiator and detach the clutch line Take off the upper triple clamp with the handlebar and set aside Info Cover the components to protect them against dam age Do not kink the cables and lines H03683 10 Remove O ring 4 Remove protective ring 5 Remove the lower triple clamp with the steerin...

Page 66: ...on the upper triple clamp with the handlebar Mount screw 4 but do not tighten yet Mount the clutch line with cable holder 5 S04824 14 Position the fork legs Bleeder screws 6 are positioned toward the front Info The compression damping is located in left fork leg COMP white adjuster The rebound damping is located in right fork leg REB red adjuster Grooves are milled into the side of the upper end o...

Page 67: ...ition 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 S04969 11 All TE special models 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...

Page 68: ... 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 59 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 69: ...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 66 Remove the motorcycle from the lift stand p 59 12 13 Lubricating the steering head bearing H02387 01 Remove the lower triple clamp p 63 Install the lower triple clamp p 64 Info The steering head bearing is...

Page 70: ... 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 126 Check the headlight setting p 129 ...

Page 71: ...rame 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 models Disconnect plug in connector 6 on the brake light switch S04829 10 All TE standard models Remove screws 7 Pull off foot brake cylinder ...

Page 72: ...he chain S04831 10 Remove nut 8 and pull out the swingarm pivot Push the link fork back and secure it against falling over S04866 10 Hold 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 s...

Page 73: ...ion of travel S04828 11 All EU AR models Join plug in connector 3 of the brake light switch S04833 10 All TE standard models 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 S04971 10 All TE special models Position the foot brake cylinder Push rod 4 ...

Page 74: ...sorber M10 60 Nm 44 3 lbf ft Loctite 2701 Info Raise the link fork slightly to be able to mount the screw more easily S04827 11 Attach the frame protector in area C and position it Mount and tighten screws 8 with the washers Guideline Screw frame pro tector M5 3 Nm 2 2 lbf ft Mount the new cable ties Finishing work Remove the motorcycle from the lift stand p 59 12 18 Removing the seat Preparatory ...

Page 75: ...ing of the fuel tank and the rear in the bracket Push the seat forward Make sure the seat is latched in place correctly F02310 10 Mount and tighten screw 1 Guideline Screw seat fixing M6 10 Nm 7 4 lbf ft Finishing work Install the air filter box cover p 74 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 ...

Page 76: ...life of the engine Dust and dirt will enter the engine without an air filter Only operate the vehicle if it is equipped with an air filter 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 Preparatory work Remove the air filter box cover p 73 F0231...

Page 77: ... Remove the air filter p 74 K00518 01 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 172 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high grade air filter oil Oil for foam air filter p 172 Clean the air filter box Clean the intake flange and check it for damage and tight ness Finish...

Page 78: ...he vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle F02315 10 Remove screws 1 with the washers Pull off the main silencer with exhaust sleeve 2 and the spring ring from the manifold 12 26 Installing the main silencer F02316 10 Mount the main silencer with rubber sleeve 1 and the spring rings Mount and tighten screws 2 with the washers Guideline Rema...

Page 79: ...ner tube Clean the parts that need to be reinstalled and check for damage Mount new glass fiber yarn filling 4 on the inner tube Push outer tube 5over the inner tube with the new glass fiber yarn filling and the O ring Mount and tighten all screws 1 Guideline Screws on main silencer M5 7 Nm 5 2 lbf ft Finishing work Install the main silencer p 76 12 28 Removing the right side cover Preparatory wor...

Page 80: ...for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse th...

Page 81: ...ine Dirt in the fuel line clogs the injection valve H03703 10 Disconnect the quick release coupling Info Remaining fuel may flow out of the fuel hose Mount wash cap set 3 Wash cap set 81212016100 H03705 10 Remove screws 4 All EU AR models Hang the horn and horn bracket to one side H03704 10 Remove screw 5 with the rubber bushing Pull the fuel tank breather hose off the fuel tank lid H03706 10 Pull...

Page 82: ...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 the throttle cable routing p 87 H03706 11 Position the fuel tank ...

Page 83: ...e Dirt in the fuel line clogs the injection valve Spray silicone spray onto a lint free cleaning cloth and lightly lubricate the O ring of the quick release coupling Silicone spray p 172 Join quick release coupling 4 Info Route the cable and fuel line at a safe distance from the exhaust system Finishing work Install the right side cover p 78 Mount the seat p 73 Install the air filter box cover p 7...

Page 84: ...e motorcycle with a lift stand p 59 400725 01 Main work Rinse off loose dirt with a soft jet of water Remove old grease residue with chain cleaner Chain cleaner p 172 After drying apply chain spray Off road chain spray p 172 Finishing work Remove the motorcycle from the lift stand p 59 12 34 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and resul...

Page 85: ...bearings wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand p 59 Check the chain tension p ...

Page 86: ...t 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 then correctly aligned Tighten nuts 2 Make sure that chain adjusters 4 are fitted correctly on adjusting screws 3 Tighten nut 1 Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables diffe...

Page 87: ...th 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 from 18 chain rollers at the longest chain section 272 mm 10 71 in If distance B is greater than the specified measurement Chang...

Page 88: ...ing guard M6 10 Nm 7 4 lbf ft Loctite 243 S04836 01 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten screw on the chain sliding piece Guideline Screw chain slid ing piece M8 15 Nm 11 1 lbf ft 401760...

Page 89: ...eformation If the frame shows signs of damage cracks or deforma tion Change the frame Guideline Repairs on the frame are not permitted 12 38 Checking the link fork S01340 01 Check the link fork for damage cracking and deformation If the link fork exhibits damage cracking or deformation Change the link fork Info Always replace a damaged link fork Repair of the link fork is not authorized by Husqvar...

Page 90: ...tall the right side cover p 78 Mount the seat p 73 Install the air filter box cover p 74 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 91: ...clockwise the clutch lever moves closer to the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 12 42 Checking correcting the fluid level of hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing a...

Page 92: ...n If the level of the fluid does not meet specifications Correct the fluid level of the hydraulic clutch Brake fluid DOT 4 DOT 5 1 p 170 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 S04974 10 All TE special models Move the hydraulic clutch fluid reservoir mounted on the handlebar into a horiz...

Page 93: ...lothing Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted part...

Page 94: ... 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 S04975 10 All TE special models Now press the fluid into the system until it emerges from hole 6 of the master cylinder without bubbles Occasionally extract the fluid from...

Page 95: ...ngine guard H01655 01 Remove screws 1 and engine guard 12 45 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 96: ...ding 13 2 Checking the free travel of the hand brake lever All TE special models Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the hand brake lever pressure builds up on the front brake circuit Set the free travel on the hand brake lever in accordance with the specification E00409 10 Push the hand brake lever to the handlebar and check...

Page 97: ...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 linings Brake discs wear limit front 2 5 mm 0 098 in rear 3 5 mm 0 138 in If the brak...

Page 98: ...ard models Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in level viewer 1 When the brake fluid level has dropped to lower edge A of the level viewer Add front brake fluid p 96 S04977 10 All TE special models Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in level viewer 1 W...

Page 99: ...kshop will be glad to help Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake flui...

Page 100: ... out brake linings are replaced immediately Your authorized Husqvarna Motorcy cles workshop will be glad to help S04461 10 All TE standard models 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 brake linings of the front brake p 99 Check the brake linings for damage and cracking If damage or wear is encount...

Page 101: ...rning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Warning Danger of accidents Brake linings which have not been approved alter the braking efficiency Not all brake linings are tested and approved for Husqvarna motorcycles The structure and friction coeffici...

Page 102: ...ake pistons Ensure that brake fluid does not flow out of the brake fluid reservoir extract some if necessary Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons 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 ...

Page 103: ...edly until the brake linings are in contact with the brake disc and there is a pressure point S04460 10 Add brake fluid up 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 170 Position cover 2 with membrane 3 Mount and tighten screws 1 Info Use water to immediately clean up any brake fluid that has overflowed or spilled S04990 10 All TE spe...

Page 104: ...ter 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 S04980 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 Mount cotter p...

Page 105: ...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 106: ...ver 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 11 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If t...

Page 107: ... workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contac...

Page 108: ...s on the frame protector 13 13 Checking the brake linings of the rear brake Warning Danger of accidents Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Your authorized Husqvarna Motorcy cles workshop will be glad to help S04469 10 All TE standard models Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If t...

Page 109: ...g 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 coefficient ...

Page 110: ...lean the brake caliper and the brake caliper bracket Check that spring plate in the brake caliper and brake pad sliding plate in the brake caliper bracket are fitted correctly S04472 01 Insert the new brake linings Mount pin 4 The spring plate engages 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 l...

Page 111: ...ean the brake caliper and the brake caliper bracket Check that spring plate in the brake caliper and brake pad sliding plate in the brake caliper bracket are fitted correctly S04984 10 Insert the new brake linings Mount pin 4 The spring plate engages 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 li...

Page 112: ... toward the brake disc to push back the brake pistons Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons 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...

Page 113: ...Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change front wheel bearing Clean and grease shaft seal rings 1 and contact sur faces A of the spacers Long life grease p 172 Insert the spacers Clean and grease the wheel spindle Long life grease p 172 S01631 10 All TE special models Check the wheel bearing for damage and wear If the wheel bearing is damaged or wor...

Page 114: ...ress the fork a few times firmly The fork legs straighten Tighten screws 3 Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 14 3 Removing the rear wheel Preparatory work Raise the motorcycle with a lift stand p 59 S04843 10 Main work All TE standard models Manually press the brake caliper toward the brake disc to push back the brake piston Info Make sure that you do not press the brake caliper again...

Page 115: ...at you do not press the brake caliper against the spokes when pushing back the brake piston Remove nut 1 Take off chain adjuster 2 Pull out wheel spindle 3 far enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Info Cover the components to protect them against damage Warning Danger of accidents Damaged brake di...

Page 116: ...leaner when necessary H03001 10 Main work Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the rear wheel bearing Clean and grease shaft seal rings 1 and contact surfaces A of the spacers Long life grease p 172 Insert the spacers S04844 10 Clean and lightly grease the wheel spindle Long life grease p 172 Position rear wheel and insert wheel spindle 2 The b...

Page 117: ...e brake linings are in contact with the brake disc and there is a pressure point S04987 10 All TE special models 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 82 Tighten nut 4 Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adj...

Page 118: ...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 119: ...ension 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 diam...

Page 120: ...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 121: ...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 122: ...ure with holding bracket 1 12 V battery HJTZ5S FP C p 165 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 123: ...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 124: ...10 Main work Check the battery voltage Battery voltage 9 V Do not charge the 12 V battery Replace the 12 V battery and dispose of the old 12 V battery properly If the specifications have been met Battery voltage 9 V Charge the 12 V battery Guideline Maximum charging volt age 14 4 V Maximum charging cur rent 3 0 A Maximum charging time 24 h Recharge the 12 V bat tery regularly when the motorcycle i...

Page 125: ...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 73 Remove the seat p 72 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 126: ... 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 73 Install the air filter box cover p 74 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 127: ...ics 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 with the corr...

Page 128: ...ness from the headlight mask Pivot the headlight mask forwards and place it on the fender H03750 10 All EU AR models Detach plug in connectors 3 and take off the headlight mask with the headlight H03751 10 All US CN models 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 EU AR m...

Page 129: ... 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 129 ...

Page 130: ...ition light out of the reflector H03754 10 Pull out headlight bulb 3 Insert the new headlight bulb Headlight HS1 socket BX43t p 165 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 126 Che...

Page 131: ...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 132: ...rk Remove the headlight mask with the headlight p 126 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 133: ...Finishing work Install the headlight mask with the headlight p 126 Check the headlight setting p 129 Adjust the combination instrument p 29 15 13 Diagnostics connector H00933 12 Diagnostics connector 1 is located under the seat ...

Page 134: ...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 135: ...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 136: ... 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 137: ... temperature sensor 4 with O ring Guideline Screw cylinder head temperature sensor M10x1 25 12 Nm 8 9 lbf ft Plug in connector 3 Position protection cap 2 400243 10 Pour coolant in up to level A above the radiator fins Guideline Coolant level A above the radiator fins 10 mm 0 39 in Coolant p 170 H03763 10 Mount radiator cap 5 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may...

Page 138: ...d 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 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...

Page 139: ... 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 140: ...osed 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 138 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 Preparatory work...

Page 141: ...ere is play in the throt tle cable at the throttle grip Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Unscrew the adjusting screw 5 until the smooth opera tion or play in throttle cable is worsened Turn adjusting screw 5 approx two turns further Tighten nut 4 Tighten nut 2 Slide on sleeve 1 Check the throttle grip for smooth operation Finishing work Check the play in the throttle cable p 138...

Page 142: ...e valve more slowly The black guide plate opens the throttle valve more quickly The gray guide plate is mounted upon delivery S04501 10 Clean the outside of the handlebar and the inside of the grip tube Mount the grip tube on the handlebar Attach the throttle cables to the guide plate and route cor rectly Position half shells 3 mount and tighten screws 2 Guideline Screw throttle grip M6 5 Nm 3 7 l...

Page 143: ...e Adjust the idle speed by turning idle speed adjusting screw 1 Guideline Idle speed 1 400 1 500 rpm Tachometer 45129075000 Info Turn clockwise to decrease the idle speed Turn counterclockwise to increase the idle speed Make the setting in small steps An incorrect idle speed can have a negative impact on overall engine running 17 5 Programming ambient air pressure Danger Danger of poisoning Exhaus...

Page 144: ...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 does not meet specifications Adjust the basic position of the shift lever p 142 17 7 Adjusting the basic position of the shift lever 401950 12 Remove screw 1 with the washers and take off shift lever 2 401951 10 Clean gear teeth ...

Page 145: ...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 146: ...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 147: ...73 Remove the seat p 72 Stand the motorcycle upright on a horizontal surface Check 2 stroke oil level p 144 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 148: ...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 73 Install the air filter box cover p 74 18 4 Cleaning the oil screen in the oil tank Note Environmental hazard Hazardous sub...

Page 149: ...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 150: ... 3 of the 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 M8 30 Nm 22 1 lbf ft Loctite 2701 Remove screws 2 Mount and tighten screws 2 Guideline Screw sub frame M8 30 Nm 22 1 lbf ft Loctite 2701 Finishing work Remove the motorcycle from the lift stand p 59 Install the fuel tank p 80 Install the r...

Page 151: ...cycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Drain the gear oil while the engine is at op...

Page 152: ...closed space Start the engine and check for leaks Finishing work Check the gear oil level p 149 Install the engine guard p 93 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...

Page 153: ...ases 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 for leaks ...

Page 154: ...f the motorcycle over a long period clean it regularly 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 172 Info Use warm water containing normal motorcycle c...

Page 155: ...ected on the roads You should therefore take 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 152 Clean the brakes Info After EVERY trip on salted roads thoroughly clean the brake calipers and brake linings after they have cooled down and...

Page 156: ...ion and wear If service 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 152 Change the gear oil p 149 Check the antifreeze and coolant level p 132 When refueling for the last time before taking the motorcycle out of service ...

Page 157: ...ecause 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 59 Install the 12 V battery p 120 Perform checks and maintenance measures when preparing for use p 41 Make a test ride ...

Page 158: ...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 159: ...ary wind ing Check the spark plug connector Check the stator winding 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 141 The engine dies during the trip Lack of fuel Refuel p 45 The engine takes in false air Check that the intake flange is firmly seated The connector or igni...

Page 160: ...dicator lamp lights up or flashes Malfunction in the electronic fuel 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 el...

Page 161: ...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 162: ...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 163: ...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 164: ...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 165: ...crew 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 Va...

Page 166: ... stroke p 170 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...

Page 167: ...00i ROCKSTAR EDITION US 105 4 kg 232 4 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible rear axle load 190 kg 419 lb Maximum permissible overall weight 335 kg 739 lb 23 5 Electrical system 12 V battery HJTZ5S FP C Lithium ion battery Battery voltage 12 V Nominal capacity 2 0 Ah Maintenance free Combination instrument battery CR 2032 Battery voltage 3 V Headlight HS1 socket ...

Page 168: ...401000 Fork WPXPLOR 5548 Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload preload adjuster Comfort 0 Standard 0 Sport 3 Spring length with preload spacer s 474 mm 18 66 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 2 N mm 24 lb in Weight of rider 75 85 kg 165 187 lb 4 4 N mm 25 1 lb i...

Page 169: ...Screw intake air temperature sen sor EJOT PT K50x18 0 7 Nm 0 52 lbf ft Screw oil fill level sensor G 3 4 7 Nm 5 2 lbf ft Screw oil pump holder on oil tank EJOT DELTA PT 45x12 Z 0 7 Nm 0 52 lbf ft Screw pressure regulator EJOT PT K60x25 Z 2 3 Nm 1 7 lbf ft Screw radiator hoses clip 2 4 Nm 1 77 lbf ft Nut throttle cable on throttle valve body M4 3 Nm 2 2 lbf ft Screw emergency OFF switch All EU AR C...

Page 170: ...43 Screw rear brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw seat fixing M6 10 Nm 7 4 lbf ft Screw throttle grip M6 5 Nm 3 7 lbf ft Fuel connection on the fuel pump M8 15 Nm 11 1 lbf ft Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Nut rear sprocket screw M8 35 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 2...

Page 171: ...hock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Nut fuel pump fixation M12 15 Nm 11 1 lbf ft Nut angle lever to link fork M14x1 5 60 Nm 44 3 lbf ft Nut linkage lever on angle lever M14x1 5 60 Nm 44 3 lbf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft Nut rear wheel spindle M20x1...

Page 172: ...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 173: ... Standard classification SAE p 174 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 174: ...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 175: ...Y SUBSTANCES 25 173 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 176: ... 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 177: ...tion in the transfer ducts Electronic fuel injection in which two injection valves in the transfer ducts of the cylinders are used OBD On board diagnosis Vehicle system which monitors the specified param eters of the vehicle electronics ...

Page 178: ...28 LIST OF ABBREVIATIONS 176 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 179: ...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 180: ...he front brake changing 99 of the rear brake changing 107 C Capacity Coolant 164 fuel 46 164 Gear oil 150 164 Chain checking 84 cleaning 82 Chain guide checking 84 Chain tension adjusting 83 checking 82 Characteristic map of the throttle response adjusting 139 Cleaning care 152 153 Clutch fluid level checking correcting 89 fluid changing 91 Clutch lever 17 basic position adjusting 89 Cold start bu...

Page 181: ... installing 111 removing 110 Fuel screen changing 143 Fuel tank installing 80 removing 78 Fuel tank filler cap closing 24 opening 23 Fuel oils etc 11 Fuse changing for individual electrical power consumers 124 main fuse changing 123 G Gear oil adding 150 changing 149 Gear oil level checking 149 H Hand brake lever 17 basic position adjusting 94 free travel adjusting 94 free travel checking 94 Handl...

Page 182: ...cket checking 84 Rear wheel installing 114 removing 112 Rebound damping fork adjusting 56 shock absorber adjusting 52 Refueling 2 stroke oil 46 fuel 45 Riding sag adjusting 55 Right side cover installing 78 removing 77 Rubber grip checking 88 S Safe operation 8 Seat mounting 73 removing 72 Service 11 Service schedule 47 49 Shift lever 26 basic position adjusting 142 basic position checking 142 Sho...

Page 183: ... 166 Throttle cable routing checking 87 Throttle grip 18 Tire condition checking 116 Tire pressure checking 116 Transporting 44 Troubleshooting 156 158 Turn signal bulb changing 128 Turn signal switch 20 Type label 15 U Use definition 7 V Vehicle identification number 15 View of vehicle front left 13 rear right 14 W Winter operation checks and maintenance steps 153 Work rules 9 ...

Page 184: ... 3402538en 3402538en 11 2021 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer KISKA Husqvarna Motorcycles GmbH ...

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Husqvarna TE 250i 2022, User Manual

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