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Husqvarna TE 250i, Owner'S Manual, Page: 136 / 165

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Husqvarna TE 250i Owner'S Manual Download Page 136

18 SERVICE WORK ON THE ENGINE

134

–

Mount and tighten the gear oil monitoring screw.
Guideline

Screw, gear oil level
check

M6

10 Nm (7.4 lbf ft)

–

Attach the foot brake lever spring.

18.5

Changing the gear oil

Warning

Danger of scalding

 

Engine and gear oil get very hot when the motorcycle is ridden.

–

Wear suitable protective clothing and safety gloves.

–

In the event of scalding, rinse the area affected immediately with lukewarm water.

Warning

Environmental hazard

 

Hazardous substances cause environmental damage.

–

Dispose of oils, 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 work

–

Remove the engine guard. (

p. 87)

–

Park the motorcycle on a level surface.

–

Place a suitable container under the engine.

E00450-10

Main work

–

Remove gear oil drain plug

1

with magnet.

–

Let the gear oil drain fully.

–

Thoroughly clean the gear oil drain plug with magnet.

–

Clean the sealing surface on the engine.

–

Mount and tighten gear oil drain plug

1

with the magnet

and a new seal ring.
Guideline

Gear oil drain plug
with magnet

M12x1.5

20 Nm (14.8 lbf ft)

401955-11

–

Remove filler plug

2

and fill up with gear oil.

Gear oil

0.80 l
(0.85 qt.)

Engine oil
(SAE 10W/40)
(

p. 152)

–

Mount and tighten the oil filler plug.

Summary of Contents for TE 250i

Page 1: ...OWNER S MANUAL 2018 TE 250i TE 300i Art no 3402171en ...

Page 2: ......

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

Page 4: ... Indicator lamps overview All EU models 19 6 13 Indicator lamps overview TE 250i US 20 6 14 Opening the filler cap 20 6 15 Closing the filler cap 21 6 16 Opening 2 stroke oil tank cap 21 6 17 Closing 2 stroke oil tank cap 21 6 18 Cold start button 22 6 19 Idle speed adjusting screw 22 6 20 Shift lever 22 6 21 Kick starter 23 6 22 Foot brake lever 23 6 23 Side stand 23 6 24 Steering lock All EU mod...

Page 5: ...motorcycle from the lift stand 56 12 3 Bleeding the fork legs 56 12 4 Cleaning the dust boots of the fork legs 57 12 5 Removing the fork legs 57 12 6 Installing the fork legs 58 12 7 Removing the fork protector 59 12 8 Installing the fork protector 59 12 9 Removing the lower triple clamp 59 12 10 Installing the lower triple clamp 60 12 11 Checking the play of the steering head bearing 62 12 12 Adj...

Page 6: ...sk with the headlight 113 15 7 Installing the headlight mask with the headlight 114 15 8 Changing the headlight bulb 115 15 9 Changing the turn signal bulb All EU models 116 15 10 Checking the headlight setting 117 15 11 Adjusting the headlight range 117 15 12 Changing the combination instrument 118 15 13 Diagnostics connector 118 16 COOLING SYSTEM 119 16 1 Cooling system 119 16 2 Checking the ant...

Page 7: ... 148 22 6 Tires 148 22 7 Fork 149 22 8 Shock absorber 149 22 9 Chassis tightening torques 150 23 SUBSTANCES 152 24 AUXILIARY SUBSTANCES 154 25 STANDARDS 155 26 INDEX OF SPECIAL TERMS 156 27 LIST OF ABBREVIATIONS 157 28 LIST OF SYMBOLS 158 28 1 Red symbols 158 28 2 Yellow and orange symbols 158 28 3 Green and blue symbols 158 INDEX 159 ...

Page 8: ...l be optimally maintained by spe cially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Indicates the end of an activity including potential rework 1 2 Formats used The typographical formats used in this document are explained belo...

Page 9: ...ational motorsport organizations 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 intend...

Page 10: ...than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of 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 tam...

Page 11: ...Adhere to the information and warning labels on the vehicle 2 7 Protective clothing Warning Risk of injury Missing or poor protective clothing presents an increased safety risk Wear appropriate protective clothing such as helmet boots gloves as well as trousers and a jacket with protectors on all rides Always wear protective clothing that is in good condition and meets the legal regulations In the...

Page 12: ...important that you read this Owner s Manual carefully and completely before making your first trip The Owner s Manual contains useful information and many tips on how to operate handle and maintain your motorcycle Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable yo...

Page 13: ...ssory products are specified in parentheses in the descriptions Your authorized Husqvarna Motorcycles dealer will be glad to advise you The current Husqvarna Motorcycles accessories for your vehicle can be found on the Husqvarna Motorcycles website International Husqvarna Motorcycles website www husqvarna motorcycles com 3 4 Service A prerequisite for perfect operation and prevention of premature ...

Page 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: ...4 VIEW OF VEHICLE 13 4 1 View of vehicle front left example V00922 10 1 Clutch lever p 17 2 Filler cap 3 Air filter box cover 4 Side stand p 23 5 Engine number p 15 6 Shift lever p 22 ...

Page 16: ...ap 2 Kill switch p 17 All EU models 2 Kill switch p 18 TE 250i US 2 Horn button p 18 All EU models 2 Light switch p 18 All EU models 2 Turn signal switch p 19 All EU models 3 Electric starter button p 19 4 Throttle grip p 17 5 Hand brake lever p 17 6 Kick starter p 23 7 Foot brake lever p 23 ...

Page 17: ...d 5 2 Type label All EU models 401946 10 Type label 1 is fixed to the front of the steering head 5 3 Key number All EU models H02475 10 Key number 1 for the steering lock is stamped onto the key connector 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: ... using the hand brake lever 6 3 Throttle grip K00924 10 The throttle grip 1 is fitted on the right side of the handlebar 6 4 Kill switch All EU models K00925 10 The kill switch 1 is fitted on the left side of the handlebar Possible states Kill switch in the basic position In this position the igni tion circuit is closed and the engine can be started Kill switch is pressed In this position the igni...

Page 20: ...orn button pressed The horn is operated in this posi tion 6 7 Light switch All EU models K00925 12 Light switch 1 is fitted on the left side of the handlebar Possible states Low beam on Light switch is in the central posi tion In this position the low beam and tail light are switched on High beam on Light switch is turned to the left In this position the high beam and tail light are switched on 6 ...

Page 21: ...tch V00986 10 The map switch 1 is fitted on the right side of the handlebar 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 this position The engine characteristic can be altered with the map switch Info The map switch has no function in the homologated restricted condition ...

Page 22: ...h 2 stroke oil 6 14 Opening the filler cap Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Obs...

Page 23: ...lockwise until release but ton 1 locks in place Info Route fuel tank breather hose 2 without kinks 6 16 Opening 2 stroke oil tank cap V00895 10 Fold loop 1upward Turn the 2 stroke oil tank cap counterclockwise and pull it up 6 17 Closing 2 stroke oil tank cap V00896 10 Put the 2 stroke oil tank cap on and turn it clockwise Fold loop 1down The 2 stroke oil tank cap engages ...

Page 24: ...urn The cold start button is deactivated A further turn returns the cold start button back to the basic position 6 19 Idle speed adjusting screw V00898 10 The idle setting of the throttle valve body has a big influence on the vehicle s starting behavior on stable idling and on vehicle response when the throttle is opened An engine with a correctly set idle speed is easier to start than an engine w...

Page 25: ...s fitted on the right side of the engine The top part of the kick starter pivots Info Before riding swing the top part of the kick starter inward toward the engine 6 22 Foot brake lever 401956 10 The foot brake lever 1 is located in front of the right footrest The foot brake lever is used to activate the rear brake 6 23 Side stand 401943 10 The side stand 1 is on the left side of the vehicle ...

Page 26: ...e Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 400732 01 Park the vehicle Turn the handlebar as far as possible to the right Insert the key in the steering lock turn it to the left press it in and turn it to the right Remove the key Steering is no longer possible Info Never leave the key in the steering lock 6 26 Unlocking the steering...

Page 27: ...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 the battery Service A service is due Contact an authorized Husqvarna Motorcycles workshop 7 4 Adjusting the combination instrument Condition The motorcycle is stationary 401909 01 Press both buttons for 3...

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: ... 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 31: ...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 32: ...dapt your riding speed to the road conditions and your riding ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents The brake system fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously Take your foot off the foot brake lever when you are not braking Warni...

Page 33: ...enter 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 rear axl...

Page 34: ...p internally to increase its starting power current output The starting power increases as the battery warms up 8 4 Preparing the vehicle for difficult riding conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can lead to considerably more rapid wear of components such as the drive train brake system or suspension components For this reason i...

Page 35: ...oling 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 a dust cover on the air filter Dust cover for air filter 79006920000 Info Observe the fitting ...

Page 36: ...r 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 scaldi...

Page 37: ...et and muddy circuits M01106 01 Fit a rain cover on the air filter Waterproofing device for air filter 79006921000 Info Observe the fitting instructions for Husqvarna Motor cycles accessories 600868 01 Mount the steel sprocket Clean the motorcycle p 137 Straighten bent radiator fins carefully 8 8 Preparing vehicle for high temperatures or slow riding V00899 01 Check the radiator cap Value on the r...

Page 38: ...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 120 8 ...

Page 39: ...nd chain guide p 81 Check the chain tension p 79 Check the tire condition p 105 Check the tire air pressure p 105 Check the spoke tension p 106 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 57 Bleed the fork legs p 56 Check the air filter Check the settings of all controls and ensure that they ...

Page 40: ... button for a maximum of 5 seconds Wait for 30 seconds before a further attempt at starting At temperatures below 15 C 60 F several attempts at starting may be necessary to warm up the lithium ion battery and thereby increase the starting power During the starting process the malfunction indicator lamp lights up 9 3 Starting off Info Switch on the light before riding This will make it easier for o...

Page 41: ...en This 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 Swit...

Page 42: ...ls over The components for parking the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to co...

Page 43: ...g 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 cl...

Page 44: ...evel warning light lights up the 2 stroke 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 str...

Page 45: ...e fluid level p 95 Check the free travel of the foot brake lever p 94 Check the frame p 83 Check the swingarm p 83 Check the swingarm bearing for play Check the heim joint for play Check the shock absorber linkage Check the tire condition p 105 Check the tire air pressure p 105 Check the wheel bearing for play Check the wheel hubs Check the rim run out Check the spoke tension p 106 Check the chain...

Page 46: ...headlight setting p 117 Check idle 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 the service entry in the Husqvarna Motorcycles Dealer net and in the Service and Warranty Booklet One time interval Periodic interval 10 3 Recommended work Every 40 operating hours when used f...

Page 47: ...uel filter Change the piston and check the cylinder Replace the oil pump Perform minor engine service Check the exhaust control for functioning and smooth operation Check the clutch Perform major engine service including removing and installing engine Change the connecting rod conrod bearing and crank pin Clean the pressure sensor cylinder connection Check the transmission and shift mechanism Chan...

Page 48: ...k absorber is divided into two ranges high speed and low speed High speed and low speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension com presses quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel s...

Page 49: ...of the shock absorber will fly off if the shock absorber is disassembled incor rectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized Husqvarna Motorcycles workshop will be glad to help Info The effect of the high speed setting can be seen in fast compression of the shock absorber V00901 10 Using an open end wrench turn adjusting ...

Page 50: ...ckwise up to the last perceptible click Turn counterclockwise by the number of clicks correspond ing to the shock absorber type Guideline Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping turn counter clockwise to reduce damping 11 6 Measuring the rear wheel dimension unloaded Preparatory work Raise the motorcycle with a lift stand p 56 40...

Page 51: ...ed value Adjust the spring preload 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 Anoth...

Page 52: ... 56 Remove the shock absorber p 65 After removing the shock absorber clean it thoroughly 402659 10 Main work Loosen screw 1 Turn adjusting ring 2 until the spring is no longer under ten sion Holding wrench 90129051000 Measure the overall spring length while the spring is not under tension Tighten the spring by turning adjusting ring 2 to measure ment A Guideline Spring preload 14 mm 0 55 in Info D...

Page 53: ...orber p 66 Check the free travel of the foot brake lever p 94 Remove the motorcycle from the lift stand p 56 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 th...

Page 54: ...cks correspond ing to the fork type Guideline Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping turn counter clockwise to reduce damping 11 13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior K00930 10 Turn red adjusting screw 1 clockwise as far as it will go Info Adju...

Page 55: ... use a tool Make the same adjustment on both fork legs Turn the adjusting wings clockwise Guideline Spring preload Preload Adjuster Comfort 0 Standard 0 Sport 3 The adjusting wings engage noticeably at the numerical values Info Adjust the spring preload to the numerical values only as the preload will not engage between the numerical values Turn clockwise to increase the spring preload turn counte...

Page 56: ...becomes fatigued The handlebar may break as a result Change the handlebar if the handlebar is damaged or bent 0 0 2 2 0 0 1 1 0 0 2 2 1 1 B00375 10 Remove screws 1 Take off the handlebar clamps Remove the handlebar and lay it to one side Info Cover the components to protect them against dam age Do not kink the cables and lines Remove screws 2 Take off the handlebar supports Place the handlebar sup...

Page 57: ...11 TUNING THE CHASSIS 55 Info Make sure the gap widths are even ...

Page 58: ...e The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand 1 to the ground with your foot and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with the rubber band 12 3 Bleeding the fork legs Preparatory w...

Page 59: ...f oil and grease Clean the brake discs with brake cleaner when necessary Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 154 Press the dust boots back into their normal position Remove excess oil Finishing work Install the fork protector p 59 Remove the motorcycle from the lift stand p 56 12 5 Removing the fork legs Preparatory work Remove the headlight ma...

Page 60: ...the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the upper triple clamp V00931 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 S02106 10 Position the brake caliper and mount and tighten screws 4 Guideline Screw front brake caliper M8 25 Nm 18 4 ...

Page 61: ...t and tighten screws 2 Position the fork protector on the right fork leg Mount and tighten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 9 Removing the lower triple clamp Preparatory work Remove the headlight mask with the headlight p 113 Raise the motorcycle with a lift stand p 56 Remove the front wheel p 101 Remove the fork legs p 57 Remove front fender p 64 V00932 10 Main w...

Page 62: ...ple clamp B01632 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 154 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing Check whether upper steering head seal 1 is correctly posi tioned Mount protective ring 2 and O ring 3 V00934 10 Position the upper triple clamp with the handlebar Mount screw 4 but do...

Page 63: ...to the side of the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the upper triple clamp V00935 10 Tighten screws 8 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft V00936 10 Tighten screw 4 Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft V00937 10 Mount and tighten screw 9 Guideline Screw top steering stem M8 17 Nm 12 5 lbf f...

Page 64: ...ct steering head bearing play impairs the handling characteristic and damages components Correct incorrect steering head bearing play immediately Your authorized Husqvarna Motorcycles workshop will be glad to help Info If the vehicle is operated for a lengthy period with play in the steering head bearing the bearings and the bearing seats in the frame can become damaged over time Preparatory work ...

Page 65: ...w 2 Loosen and retighten screw 3 Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Tighten screws 1 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw 2 Guideline Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Finishing work Check the play of the steering head bearing p 62 Re...

Page 66: ...938 10 Main work Remove screws 1 Remove screws 2 Take off the front fender 12 15 Installing front fender V00939 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 114 Check the headlight setting p 117 ...

Page 67: ...Remove screws 2 with the washers Remove the frame protectors on the left and right F00284 10 Remove screw 3 Remove fitting 4 Info Raise the wheel slightly to be able to remove the screws more easily F00285 10 Press angle lever 5 toward the rear Press linkage lever 6 downward V00940 10 All EU models Remove the cable tie and rubber band Separate plug in connector of the brake light switch ...

Page 68: ...l out the swingarm pivot Push the swingarm back and secure it against falling over V00944 10 Hold the shock absorber and remove screw 9 Remove the shock absorber carefully at the bottom 12 17 Installing the shock absorber V00945 10 Main work Carefully position the shock absorber into the vehicle from the bottom Mount and tighten screw 1 Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loct...

Page 69: ...irection of travel V00940 10 All EU models Join plug in connector of the brake light switch Fit the new rubber band and cable tie V00947 10 Position the foot brake cylinder Push rod 4 engages in the foot brake cylinder The dust boot is correctly positioned Mount and tighten screws 5 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft F00284 11 Position the angle lever and linkage lever Mount an...

Page 70: ...nd tighten screws 8 Guideline Screw frame pro tector M5 3 Nm 2 2 lbf ft Mount and tighten screws 9 with the washers Guideline Screw frame pro tector M5 3 Nm 2 2 lbf ft Mount the new cable ties Finishing work Check the free travel of the foot brake lever p 94 Remove the motorcycle from the lift stand p 56 12 18 Removing the seat Preparatory work Remove the air filter box cover p 69 V00977 10 Main w...

Page 71: ...t at the rear and push the seat forward Make sure that the seat is locked in correctly Mount and tighten screw 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the air filter box cover p 70 12 20 Removing the air filter box cover V00904 10 Pull off the air filter box cover sideways in areas A B and C and remove toward the front ...

Page 72: ...rvice life of the engine Dust and dirt will enter the engine without an air filter Never start to use the vehicle without an air filter Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Preparatory work Remove the air filter box cover p 69 V0090...

Page 73: ...Remove the air filter p 70 V00979 10 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaning agent p 154 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil Oil for foam air filter p 154 Clean the air filter box Clean the intake flange and check it for damage and tight ness Fi...

Page 74: ...shing work Install the air filter box cover p 70 12 25 Sealing the air filter box F00248 01 Seal the air filter box in the marked area A 12 26 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Preparatory work Remove the right side cover p 74 V00908 10 Main w...

Page 75: ...ehicle Info Over time the fibers of the glass fiber yarn escape and the damper burns out Not only is the noise level higher the performance characteristic changes Preparatory work Remove the right side cover p 74 Remove the main silencer p 72 H01759 10 Main work Remove screws 1 Pull out inner tube 2 Remove the glass fiber yarn filling 3 from the inner tube Clean the parts that need to be reinstall...

Page 76: ...in areas A and B Mount and tighten screw 3 Guideline Remaining screws chassis M5 5 Nm 3 7 lbf ft 12 31 Removing the fuel tank Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly...

Page 77: ...ut of the reach of children Preparatory work Remove the air filter box cover p 69 Remove the seat p 68 Remove the right side cover p 74 V00948 10 Main work Unplug connector 1 of the fuel pump Remove tube 2 from the fuel tank breather V00973 10 Thoroughly clean the plug in connection of the fuel line using compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the f...

Page 78: ...or 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 the...

Page 79: ...s Position the horn with the horn bracket V00926 11 Mount and tighten screws 2 with the collar bushings Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft V00974 10 Remove the wash cap set Thoroughly clean the plug in connection of the fuel line using compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the O ...

Page 80: ...ires reduces the road grip Remove the lubricant from the tires using a suitable cleaning agent Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fu...

Page 81: ...he chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand p 56 V00912 10 Main work Pull the chain at the end of the chain sliding component upwards to measure c...

Page 82: ...le with a lift stand p 56 Check the chain tension p 79 V00913 10 Main work Loosen nut 1 Loosen nuts 2 Adjust the chain tension by turning the left and right adjusting screws 3 Guideline Chain tension 55 58 mm 2 17 2 28 in Turn adjusting screws 3 on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks A The rear wheel is ...

Page 83: ...s be replaced together 400987 10 Pull at the top part of the chain with the specified weight A Guideline Weight chain wear mea surement 10 15 kg 22 33 lb Measure distance B of 18 chain rollers in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance B at the longest chain section 272 mm 10 71 in If distance B ...

Page 84: ...ing guard M6 14 Nm 10 3 lbf ft Loctite 243 V00915 10 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the screw on the chain sliding piece Guideline Screw chain slid ing piece M8 15 Nm 11 1 lbf ft 4...

Page 85: ... due to a mechanical impact Change the frame Info Always replace a frame that has been damaged due to a mechanical impact Repair of the frame is not authorized by Husqvarna Motorcycles 12 39 Checking the swingarm S01340 01 Check the swingarm for damage cracking and deformation If the swingarm shows signs of damage cracking or deformation Change the swingarm Info Always change a damaged swingarm Re...

Page 86: ...seat p 69 Install the air filter box cover p 70 Install the right side cover p 74 12 41 Checking the rubber grip 401197 01 Check the rubber grips on the handlebar for damage wear and looseness Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right The left sleeve is clamped onto the handlebar The rubber grip can only be replaced wi...

Page 87: ...as 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 Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning a...

Page 88: ...ter 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 Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the ...

Page 89: ...6 of the master cylinder without bubbles Now and then extract fluid from the master cylinder reservoir to prevent overflow Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake...

Page 90: ...ON THE CHASSIS 88 12 46 Installing the engine guard H01655 01 Attach the engine guard on the frame at the rear and swing up at the front Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 91: ... discs Warning Danger of accidents Worn out brake discs reduce the braking effect Make sure that worn out brake discs are replaced immediately Your authorized Husqvarna Motor cycles workshop will be glad to help A A 400257 10 Check the front and rear brake disc thickness at multiple points for the dimension A Info Wear reduces the thickness of the brake disc around the contact surface of the brake...

Page 92: ...s An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Skin irritation Brake flu...

Page 93: ...ion Remove screws 1 Remove cover 2 with membrane 3 Add brake fluid to level A Guideline Level A brake fluid level below reservoir rim 5 mm 0 2 in Brake fluid DOT 4 p 152 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water 13 5 Checking the front brake linings Warning Danger of accidents Worn out brake linings redu...

Page 94: ...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 95: ...gainst the spokes when pushing back the brake pis tons Remove cotter pin 4 Push leaf spring 5 upwards and remove pin 6 Remove brake linings Clean the brake caliper and brake caliper support H02377 10 Check that leaf spring 5 in the brake caliper and sliding plate 7 in the brake caliper support are seated correctly K00944 11 Insert the new brake linings Mount pin 6 Leaf spring 5 engages in the groo...

Page 96: ...vel on the foot brake lever in accordance with the specification 402026 10 Disconnect spring 1 Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free travel A Guideline Free travel of foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the basic position of the foot brake lever p 94 Reco...

Page 97: ...t spring 1 13 9 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Your authorized Husqvar...

Page 98: ...the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your author...

Page 99: ...he braking effect Ensure that worn out brake linings are replaced immediately Your authorized Husqvarna Motorcy cles workshop will be glad to help V00917 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings p 97 Check the brake linings for damage and cracking If damage or wear is encountere...

Page 100: ...nd grease Clean the brake discs with brake cleaner when necessary Warning Danger of accidents Brake linings which have not been approved alter the braking efficiency Not all brake linings are tested and approved for Husqvarna motorcycles The structure and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original brake linings If brake linings are u...

Page 101: ...he spokes Remove cotter pin 3 Push leaf spring 4 downwards and remove pin 5 Remove the brake linings Clean the brake caliper and brake caliper support K00948 10 Check that leaf spring 4 in the brake caliper and sliding plate 6 in the brake caliper support are seated correctly H02370 10 Insert the new brake linings Mount pin 5 Leaf spring 4 engages in the groove on the pin Info Always change the br...

Page 102: ... 10 Add brake fluid to level A Brake fluid DOT 4 p 152 Mount and tighten screw cap 1 with membrane 2 and the shim Info Clean up overflowed or spilled brake fluid immediately with water Mount new cable ties on the frame protector ...

Page 103: ... back the brake pis tons V00919 10 Loosen screw 1 by several rotations Loosen screws 2 Press on screw 1 to push the wheel spindle out of the axle clamp Remove screw 1 V00972 10 Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel ou...

Page 104: ...ers Clean and grease the wheel spindle Long life grease p 154 V00919 11 Lift the front wheel into the fork position it and insert the wheel spindle The brake linings are correctly positioned Mount and tighten screw 2 Guideline Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc Remove the...

Page 105: ...ear sprocket Info Cover the components to protect them against dam age Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the rear wheel withdraw the wheel spindle Take the rear wheel out of the swingarm Info Do not operate the foot brake lever when the rear wheel is removed H00936 10 Remove s...

Page 106: ...ed Mount the chain V00913 11 Position chain adjuster 3 Mount nut 4 but do not tighten it yet Make sure that chain adjusters 3 are fitted correctly on adjusting screws 5 Check the chain tension p 79 Tighten nut 4 Guideline Nut rear wheel spin dle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length ...

Page 107: ...ck the tread depth Info Adhere to the legally required minimum tread depth Minimum tread depth 2 mm 0 08 in If the tread depth is less than the minimum tread depth Change the tires H01144 01 Check the tire age Info The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT number The first two digits indicate the week of manufacture and ...

Page 108: ...sion 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 diamet...

Page 109: ...imum voltage before the start of the charge 9 V Dispose of batteries with less than the minimum voltage correctly Preparatory work All EU models Press and hold the kill switch while the engine is idling until the engine stops TE 250i US Press and hold the kill switch while the engine is idling until the engine stops Remove the air filter box cover p 69 Remove the seat p 68 H01190 10 Main work Pull...

Page 110: ...ery termi nal M5 2 5 Nm 1 84 lbf ft Contact disks A must be mounted under the screw 3 and the cable lug 4 with the claws toward the battery terminal Slide negative terminal cover 8 over the negative terminal Finishing work Mount the seat p 69 Install the air filter box cover p 70 15 3 Recharging the battery Warning Risk of injury Batteries contain harmful substances Keep batteries out of the reach...

Page 111: ...g current or charging voltage are exceeded the battery will be destroyed If the battery is depleted by repeated starting the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sul fated destroying the battery The battery is maintenance free Preparatory work All EU models Press and hold the kill switch while the...

Page 112: ...the battery The battery is maintenance free Never remove cover 1 Switch off the battery charger after charging and disconnect from the battery Finishing work Install the battery p 108 Mount the seat p 69 Install the air filter box cover p 70 15 4 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or ...

Page 113: ...y fuse by a burned out fuse wire A A spare fuse 5 is located in the starter relay Install a new main fuse Fuse 58011109120 p 148 Check that the electrical system is functioning properly Tip Insert a spare fuse so that it is available if needed Attach the protection caps 3 Mount the starter relay 2 onto the holder and route the cable R02958 10 Mount the EFI control unit 1on the rubber lugs Finishin...

Page 114: ...e rubber plugs and hang to the side V00970 10 Open fuse box cover 2 Remove the defective fuse Guideline All EU models Fuse 1 10 A EFI control unit lambda sensor oil pump combination instrument fuel injection diagnos tics connector Fuse 2 10 A horn brake light radiator fan optional turn signal optional Fuse 3 10 A high beam low beam parking light tail light license plate lamp Fuse 4 5 A fuel pump T...

Page 115: ...88010 p 148 Fuse 75011088005 p 148 Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover 2 R02958 10 Mount the EFI control unit 1on the rubber lugs Finishing work Mount the seat p 69 Install the air filter box cover p 70 15 6 Removing the headlight mask with the headlight V00957 10 Detach brake li...

Page 116: ...h plug in connectors 4 and take off the headlight mask with the headlight V00982 10 TE 250i US Detach plug in connector 4 and take off the headlight mask with the headlight 15 7 Installing the headlight mask with the headlight V00959 11 Main work All EU models Connect plug in connectors 1 V00982 11 TE 250i US Connect plug in connector 1 ...

Page 117: ...ge to reflector Grease on the reflector reduces the brightness Grease on the bulb will evaporate due to the heat and be deposited on the reflector Clean and degrease the bulbs before mounting Do not touch the bulbs with your bare hands Preparatory work Remove the headlight mask with the headlight p 113 F00343 10 Main work Turn protection cap 1 together with the underlying bulb socket counterclockw...

Page 118: ...rease the bulbs before mounting Do not touch the bulbs with your bare hands F00362 10 Main work Remove the screw on the rear of the turn signal housing Carefully remove turn signal glass 1 Lightly squeeze orange cap 2 in the area of the holding lugs and take it off Press the turn signal bulb lightly into the socket turn it coun terclockwise by about 30 and take it out of the socket Info Do not tou...

Page 119: ...am Check the headlight setting The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver If the light dark border does not meet specifications Adjust the headlight range p 117 15 11 Adjusting the headlight range Preparatory work Check the headlight setting p 117 V00960 10 Main work Loosen screw 1 Adjust the headlight range by pivoting the headlight Guidelin...

Page 120: ...facing outward Combination instrument battery CR 2032 p 148 Check the O ring of the protection cap for correct seating V00963 10 Position protection cap 2 and turn all the way clockwise using a coin Press any button on the combination instrument The combination instrument is activated Position the combination instrument in the holder Mount and tighten the screws with washers Finishing work Install...

Page 121: ...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 122: ...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 123: ...r the water pump cover V00964 11 Remove screw 1 Take off radiator cap 2 Completely drain the coolant Mount and tighten screw 1 with a new seal ring Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 16 5 Refilling with coolant Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes...

Page 124: ...der 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 measurement A above the radiator fins Guideline Coolant level A above the radiator fins 10 mm 0 39 in Coolant p 152 V00966 10 Mount radiator cap 5 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make ...

Page 125: ...16 COOLING SYSTEM 123 Finishing work Check the coolant level p 120 ...

Page 126: ...and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and let it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 124 17 2 Adjusting the...

Page 127: ...oth operation or play in throttle cable is worsened Turn the 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 124 17 3 Setting the characteristic map of the throttle response Info On the throttle grip the characteristic map of the throttle response is changed b...

Page 128: ...rip 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 lbf ft Slide on sleeve 1 and check the throttle grip for ease of movement Finishing work Check the play in the throttle cable p 124 17 4 Adjusting the idle speed Warning Danger of accidents The e...

Page 129: ...e setting in small steps An incorrect idle speed can have a negative impact on overall engine running The idle speed adjusting screw is unscrewed 1 5 turns ex works 17 5 Programming ambient pressure Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective ex...

Page 130: ...ity Performance The plug in connector of the ignition timing map adjustment is joined to achieve higher performance 17 7 Changing the ignition timing map Info The ignition timing map connector has no function in the homologated restricted condition of the motorcycle Preparatory work Remove the air filter box cover p 69 Remove the seat p 68 Remove the right side cover p 74 Remove the fuel tank p 74...

Page 131: ...r 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 129 17 9 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 A of the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage the ...

Page 132: ...ase 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 Warning 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 V00921 10 Clean plug in conn...

Page 133: ...light lights up the 2 stroke 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 Preparatory work Stand ...

Page 134: ...ghts 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 Condition The engine is off Preparatory work Remove the air filter box cover p 69 Remove the seat p 68 V00985 10 Main work Remove protection c...

Page 135: ...connector from the diagnostics con nector V00997 10 Check where air bubbles are visible in the hose 5 If air bubbles are visible Repeat the entire procedure until air bubbles are no longer visible Mount protection cap on the diagnostics connector Finishing work Mount the seat p 69 Install the air filter box cover p 70 18 4 Checking the gear oil level Info The gear oil level must be checked when th...

Page 136: ...nts brake fluid etc correctly and in compliance with the applicable regulations Info Drain the gear oil while the engine is at operating temperature Preparatory work Remove the engine guard p 87 Park the motorcycle on a level surface Place a suitable container under the engine E00450 10 Main work Remove gear oil drain plug 1 with magnet Let the gear oil drain fully Thoroughly clean the gear oil dr...

Page 137: ...p 133 Install the engine guard p 88 18 6 Adding 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 E00433 10 Main work Remove screw for checking gear oil level 1 401955 11 Remove filler plug 2 Add gear oil until it emerges from the dr...

Page 138: ...xic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and check that it is oil tight ...

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

Page 140: ...e 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 wash the cool and installed brake calipers and brake linings with cold water and dry carefully After riding on salted roads thoroughly wash the vehi cle with cold wat...

Page 141: ... function 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 137 Change the gear oil p 134 Check the antifreeze and coolant level p 119 When refueling for the last time before taking the motorcycle out of se...

Page 142: ...y Because 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 56 Install the battery p 108 Perform checks and maintenance measures when preparing for use p 37 Make a test ride ...

Page 143: ...y Electrode distance plug gap of spark plug too wide Adjust the plug gap Guideline Spark plug electrode gap 1 3 mm 0 051 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 kill switch or emergency OFF switch defec tive Check wiring harness visual check Check the electric...

Page 144: ...nd 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 pressure p 127 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 ...

Page 145: ...dicator lamp lights up or flashes Defect in the fuel injection sys tem Check the cabling for damage and the electrical plug in connections for corrosion and damage Read out the fault memory using the Husqvarna Motorcycles diagnostics tool The battery is discharged The battery is not being charged by the alternator Check the charging voltage Check the stator winding of the alter nator Unwanted powe...

Page 146: ...sion 26 73 Clutch Multidisc clutch in oil bath hydraulically activated Transmission 6 gear 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 type Kokusan Spark plug NGK ZGR 7 G1 Spark plug elect...

Page 147: ...pe Kokusan Spark plug NGK ZGR 7 G1 Spark plug electrode gap 1 3 mm 0 051 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Kick starter and electric starter 22 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...

Page 148: ...ft Loctite 243 Screw kick starter stop plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw outer clutch cover M6 8 Nm 5 9 lbf ft Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 Screw 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 vacuu...

Page 149: ...e approx 1 5 l 1 6 qt 2 stroke oil tank content approx 0 7 l 0 7 qt Engine oil 2 stroke p 152 22 4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Performance SystemsXplor 48 PA Shock absorber WP Performance Systems 5018 DCC Link Suspension travel front 300 mm 11 81 in rear 330 mm 12 99 in Fork offset 22 mm 0 87 in Brake system Disc brakes brake calipers on floating...

Page 150: ...n battery Battery voltage 12 V Nominal capacity 2 0 Ah Maintenance free Combination instrument battery CR 2032 Battery voltage 3 V Headlight HS1 socket BX43t 12 V 35 35 W Parking 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 models R10W socket BA15s 12 V 10 W Brake tail light LED License plate lamp All EU mod els LED Fuse 75011088005 5 A Fus...

Page 151: ... 24 lb in Weight of rider 85 95 kg 187 209 lb 4 4 N mm 25 1 lb in Fork length 928 mm 36 54 in Fork oil per fork leg 635 10 ml 21 47 0 34 fl oz Fork oil SAE 4 48601166S1 p 153 22 8 Shock absorber Shock absorber article number 18 15 7R 63 Shock absorber WP Performance Systems 5018 DCC Link Compression damping low speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping high spe...

Page 152: ...t Screw intake air temperature sen sor M5 2 Nm 1 5 lbf ft Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Nut starter motor M6 4 Nm 3 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M6 10 Nm 7 4 lbf ft Screw absorbing element on frame M6 6 Nm 4 4 lbf ft Screw absorbing element on manifold M6 6 Nm 4 4 lbf ft Screw ball joint of push rod on foot brake cylinder M6 10...

Page 153: ...w top triple clamp M8 17 Nm 12 5 lbf ft Engine bracket screw M10 60 Nm 44 3 lbf ft Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw bottom shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Nut fuel pump fixation M12 15 Nm 11 1 lbf ft...

Page 154: ...er and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility compatibility with other coolants Recommended...

Page 155: ...sification SAE p 155 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 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up ...

Page 156: ...ife grease Recommended supplier Bel Ray Waterproof Grease Offroad chain spray Guideline Recommended supplier Bel Ray Blue Tac Chain Lube Oil for foam air filter Recommended supplier Bel Ray Foam Filter Oil Preserving materials for paints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil spray Recommended supplier Bel Ray 6 in 1 ...

Page 157: ...st motorcycle engines the transmission and clutch are lubricated with the same oil The JASO MA standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity The viscosity describes only one property of oil and says nothing about quality JASO FD JASO FD is a classification fo...

Page 158: ...26 INDEX OF SPECIAL TERMS 156 OBD On board diagnosis Vehicle system which monitors the specified param eters of the vehicle electronics ...

Page 159: ...27 LIST OF ABBREVIATIONS 157 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 160: ...tion 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 an error in the vehicle electronics Come safely to a halt and contact an authorized Husqvarna Motorcy cles workshop The fuel level warning lamp lights up yellow The fuel level has reached the reserve mark 28 3 Green and...

Page 161: ...ake checking 91 of rear brake changing 97 rear brake checking 97 C Capacity coolant 147 fuel 42 147 Gear oil 134 147 Chain checking 81 cleaning 78 Chain guide checking 81 Chain tension adjusting 80 checking 79 Characteristic map of the throttle response adjusting 125 Chassis number 15 Cleaning care 137 138 Clutch fluid level checking correcting 85 fluid changing 86 Clutch lever 17 basic position a...

Page 162: ...lling 64 removing 64 Front wheel installing 102 removing 101 Fuel screen changing 130 Fuel tank installing 76 removing 74 Fuse individual power consumers changing 112 main fuse changing 110 G Gear oil adding 135 changing 134 Gear oil level checking 133 H Hand brake lever 17 basic position adjusting 89 Handlebar position 54 adjusting 54 Headlight range adjusting 117 Headlight adjustment checking 11...

Page 163: ... installing 103 removing 102 Rebound damping fork adjusting 52 shock absorber adjusting 48 Refueling 2 stroke oil 42 fuel 41 Riding sag adjusting 51 Right side cover installing 74 removing 74 Rubber grip checking 84 S Safe operation 8 Seat mounting 69 removing 68 Service 11 Service schedule 43 45 Shift lever 22 basic position adjusting 129 basic position checking 129 Shock absorber article number ...

Page 164: ...rottle cable play checking 124 Throttle cable routing checking 83 Throttle grip 17 Tire air pressure checking 105 Tire condition checking 105 Transporting 40 Troubleshooting 141 143 Turn signal bulb changing 116 Turn signal switch 19 Type label 15 U Use definition 7 V View of vehicle front left 13 rear right 14 W Warranty 11 Winter operation checks and maintenance steps 138 Work rules 9 ...

Page 165: ... 3402171en 3402171en 06 2017 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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