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OWNER'S MANUAL 2017
TC 125
TC 250
TX 300
Art. no. 3402094en
DEAR HUSQVARNA MOTORCYCLES CUSTOMER
DEAR HUSQVARNA MOTORCYCLES CUSTOMER
Congratulations on your decision to purchase a Husqvarna motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it properly.
1
We hope you enjoy your new vehicle!
Enter the serial numbers of your vehicle below.
Dealer's stamp
The Owner's Manual contained the latest information for this model series at the time of going to print. Minor differences due to developments in design cannot be ruled out completely.
All specifications are non-binding. Husqvarna Motorcycles GmbH specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. Husqvarna Motorcycles accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.
© 2016 Husqvarna Motorcycles GmbH, Mattighofen Austria
All rights reserved
Reprinting, including excerpts, and duplication of any kind only with the written consent of the publisher.
ISO 9001(12 100 6061)
Husqvarna Motorcycles applies quality assurance processes that lead to the highest possible product quality as defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service
Husqvarna Motorcycles GmbH
5230 Mattighofen, Austria
This document is valid for the following models:
TC 125 (F2101Q0)
TC 250 (F2301Q1)
TX 300 (F2401Q5)
*3402094en*
3402094en
04/2016
TABLE OF CONTENTS
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION........................................ 5
Symbols used ....................................................... 5
Formats used........................................................ 5
2 SAFETY ADVICE ............................................................... 6
Use definition – intended use ............................... 6
Safety advice ........................................................ 6
Degrees of risk and symbols ................................ 6
Tampering warning ............................................... 6
Safe operation....................................................... 7
Protective clothing ................................................ 7
Work rules............................................................. 7
Environment.......................................................... 7
Owner's Manual.................................................... 8
3 IMPORTANT NOTES ......................................................... 9
Manufacturer and implied warranty...................... 9
Operating and auxiliary substances ..................... 9
Spare parts, accessories ...................................... 9
Service .................................................................. 9
Figures .................................................................. 9
Customer service.................................................. 9
4 VIEW OF VEHICLE .......................................................... 10
View of vehicle, front left (example) .................... 10
View of vehicle, rear right (example) ................... 11
5 SERIAL NUMBERS.......................................................... 12
Chassis number .................................................. 12
Type label............................................................ 12
Engine number.................................................... 12
Fork part number ................................................ 12
Shock absorber article number .......................... 13
6 CONTROLS ..................................................................... 14
Clutch lever......................................................... 14
Hand brake lever................................................. 14
Throttle grip......................................................... 14
Kill switch............................................................ 14
Electric starter button (TX 300) ........................... 14
Opening the filler cap.......................................... 15
Closing the filler cap ........................................... 15
Fuel tap (All TC models)...................................... 16
Fuel tap (TX 300)................................................. 16
Choke.................................................................. 17
Shift lever ............................................................ 17
Kick starter.......................................................... 18
Foot brake lever .................................................. 18
Plug-in stand (All TC models) ............................. 18
Side stand (TX 300)............................................. 18
Service hour counter........................................... 19
7 PREPARING FOR USE.................................................... 20
Advice on first use .............................................. 20
Running in the engine ......................................... 21
Preparing for rides on dry sand .......................... 21
Preparing for rides on wet sand.......................... 23
8 RIDING INSTRUCTIONS ................................................. 26
Starting ............................................................... 26
Starting off .......................................................... 27
Shifting, riding..................................................... 27
Braking................................................................ 27
Stopping, parking ............................................... 28
Transport............................................................. 28
Refueling ............................................................. 29
9 SERVICE SCHEDULE...................................................... 30
All TC models...................................................... 30
Additional information .................................... 30
Required work ................................................ 30
Recommended work ...................................... 31
TX 300................................................................. 31
Additional information .................................... 31
Required work ................................................ 31
Recommended work ...................................... 32
10 TUNING THE CHASSIS................................................... 33
Air suspension AER 48 ....................................... 33
Compression damping of the shock absorber ... 33
Adjusting the low-speed compression damping of the shock absorber.......................... 34
Adjusting the high-speed compression damping of the shock absorber.......................... 34
10.11 Adjusting the riding sag .................................. 38
10.12 Checking the basic setting of the fork................ 38
10.13 Adjusting the fork air pressure............................ 39
10.15 Adjusting the rebound damping of the fork........ 40
10.16 Handlebar position.............................................. 41
10.17 Adjusting the handlebar position .................... 41
11 SERVICE WORK ON THE CHASSIS ............................... 43
Raising the motorcycle with a lift stand.............. 43
Removing the motorcycle from the lift stand...... 43
Bleeding the fork legs ......................................... 44
Cleaning the dust boots of the fork legs............. 44
Removing the fork legs ................................... 44
Installing the fork legs ..................................... 45
Removing the fork protector............................... 45
Installing the fork protector................................. 46
Removing the lower triple clamp .................... 46
11.10 Installing the lower triple clamp ...................... 47
11.12 Adjusting the steering head bearing play ....... 49
11.13 Greasing the steering head bearing ................ 49
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TABLE OF CONTENTS
11.14 Removing the start number plate ....................... 50
11.15 Installing the start number plate ......................... 50
11.16 Removing the front fender .................................. 50
11.17 Installing the front fender .................................... 51
11.18 Removing the shock absorber ........................ 51
11.19 Installing the shock absorber .......................... 52
11.20 Removing the seat .............................................. 53
11.21 Mounting the seat ............................................... 54
11.22 Removing the air filter box cover........................ 55
11.23 Installing the air filter box cover.......................... 56
11.24 Removing the air filter ..................................... 56
11.25 Cleaning the air filter and air filter box ............ 57
11.26 Installing the air filter ....................................... 58
11.27 Sealing the air filter box .................................. 58
11.28 Removing the main silencer................................ 58
11.29 Installing the main silencer.................................. 59
11.31 Removing the right side cover ............................ 60
11.32 Installing the right side cover.............................. 61
11.33 Removing the fuel tank ................................... 61
11.34 Installing the fuel tank ..................................... 63
11.35 Checking the chain for dirt.................................. 64
11.36 Cleaning the chain .............................................. 64
11.37 Checking the chain tension ................................ 65
11.38 Adjusting the chain tension................................. 65
11.40 Checking the frame ......................................... 68
11.41 Checking the swingarm .................................. 68
11.42 Checking the throttle cable routing .................... 68
11.43 Checking the rubber grip .................................... 69
11.46 Changing the hydraulic clutch fluid ................ 70
12 BRAKE SYSTEM ............................................................. 72
Checking the brake discs ................................... 72
Checking the front brake fluid level .................... 73
Adding front brake fluid .................................. 73
Checking the front brake linings ......................... 74
Changing the front brake linings ..................... 74
Checking the free travel of foot brake lever........ 76
12.10 Checking the rear brake fluid level ..................... 77
12.11 Adding rear brake fluid .................................... 78
12.12 Checking the rear brake linings .......................... 79
12.13 Changing the rear brake linings ...................... 79
13 WHEELS, TIRES.............................................................. 81
Removing the front wheel ............................... 81
Installing the front wheel ................................. 81
Removing the rear wheel ................................ 82
Installing the rear wheel .................................. 83
Checking the tire condition................................. 84
Checking the tire air pressure............................. 84
Checking spoke tension ..................................... 84
14 ELECTRICAL SYSTEM.................................................... 86
Removing the battery (TX 300)........................ 86
Installing the battery (TX 300) ......................... 86
Recharging the battery (TX 300) ..................... 87
Changing the main fuse (TX 300)........................ 88
15 COOLING SYSTEM......................................................... 90
Cooling system ................................................... 90
Radiator cover (TC 125)...................................... 90
Installing the radiator cover (TC 125).................. 90
Removing the radiator cover (TC 125)................ 91
Checking the antifreeze and coolant level.......... 91
Checking the coolant level.................................. 92
Draining the coolant ........................................ 93
Refilling with coolant ....................................... 93
16 TUNING THE ENGINE..................................................... 96
Checking the play in the throttle cable ............... 96
Adjusting the play in the throttle cable ........... 96
Carburetor setting............................................... 97
Carburetor – idle ................................................. 99
Carburetor – adjusting the idle speed ............. 99
Emptying the carburetor float chamber ........ 100
Changing the ignition timing map..................... 102
16.11 Engine characteristic – auxiliary spring
(TC 250, TX 300) ............................................... 103
17 SERVICE WORK ON THE ENGINE ............................... 105
Checking the gear oil level................................ 105
Changing the gear oil .................................... 105
Adding gear oil .............................................. 107
18 CLEANING, CARE ......................................................... 108
Cleaning the motorcycle................................... 108
19 STORAGE...................................................................... 109
Storage ............................................................. 109
Preparing for use after storage ......................... 109
20 TROUBLESHOOTING ................................................... 110
21 TECHNICAL DATA ........................................................ 112
Engine ............................................................... 112
TC 125.......................................................... 112
TC 250.......................................................... 112
TX 300 .......................................................... 113
Engine tightening torques................................. 113
TC 125.......................................................... 113
TC 250.......................................................... 114
TX 300 .......................................................... 115
Carburetor......................................................... 117
TC 125.......................................................... 117
Carburetor - basic setting for sandy surfaces (TC 125) ......................................... 117
Carburetor tuning (TC 125)........................... 118
TC 250.......................................................... 119
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TABLE OF CONTENTS
Carburetor - basic setting for sandy surfaces (TC 250) ......................................... 119
Carburetor tuning (TC 250)........................... 120
TX 300 .......................................................... 121
Carburetor tuning (TX 300) ....................... 121
Capacities ......................................................... 122
Gear oil ......................................................... 122
Coolant......................................................... 122
Fuel............................................................... 122
Chassis ............................................................. 122
Electrical system............................................... 123
TX 300 .......................................................... 123
Tires .................................................................. 123
Fork................................................................... 123
TC 125.......................................................... 123
TC 250.......................................................... 124
TX 300 .......................................................... 124
Shock absorber ................................................ 124
TC 125.......................................................... 124
TC 250.......................................................... 125
TX 300 .......................................................... 125
21.10 Chassis tightening torques ............................... 126
22 SUBSTANCES............................................................... 128
23 AUXILIARY SUBSTANCES............................................ 130
24 STANDARDS ................................................................. 131
25 LIST OF ABBREVIATIONS ............................................ 132
INDEX .................................................................................... 133
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1 MEANS OF REPRESENTATION
1.1
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interests of your own safety, have these jobs performed by an authorized Husqvarna Motorcycles workshop. There, your motorcycle will be optimally cared for by specially 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.
1.2
Formats used
The typographical formats used in this document are explained below.
Proprietary name
Indicates a proprietary name.
Name
®
Indicates a protected name.
Indicates a brand available on the open market.
Brand™
Underlined terms
Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.
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2 SAFETY ADVICE
2.1
Use definition – intended use
(All TC models)
Husqvarna sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle may only be used in closed off areas remote from public road traffic.
(TX 300)
Husqvarna sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.
Info
This motorcycle is designed for use in offroad endurance competition and not primarily for use in motocross.
2.2
Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.
2.3
Degrees of risk and symbols
Danger
Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.
Warning
Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
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2.4
Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1 The removal or rendering inoperative by any person other 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 tampering are the acts listed below:
1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.
2 SAFETY ADVICE
2.5
Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner.
The vehicle should only be used by trained persons.
Have malfunctions that impair safety promptly eliminated by an authorized Husqvarna Motorcycles workshop.
Adhere to the information and warning labels on the vehicle.
2.6
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 interest of your own safety, Husqvarna Motorcycles recommends that you only operate the vehicle while wearing protective clothing.
2.7
Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts.
In some instances, a thread locker (e.g. Loctite
®
) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
2.8
Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized Husqvarna Motorcycles dealer will be glad to advise you.
7
2 SAFETY ADVICE
2.9
Owner's Manual
It is 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 you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized Husqvarna Motorcycles dealer.
The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold.
8
3 IMPORTANT NOTES
3.1
Manufacturer and implied warranty
The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles workshop only and confirmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motorcycles Dealer.net; otherwise, all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty.
Additional information on the manufacturer or implied warranty and the procedures involved can be found in the Service & Warranty
Booklet.
3.2
Operating and auxiliary substances
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.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
3.3
Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by Husqvarna Motorcycles and have them installed by an authorized Husqvarna Motorcycles workshop. Husqvarna Motorcycles accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory 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 wear is that the service, care, and tuning work on the engine and chassis is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis can lead to damage and breakage of components.
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, it may be necessary to inspect or replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.
3.5
Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
3.6
Customer service
Your authorized Husqvarna Motorcycles 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
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4 VIEW OF VEHICLE
4.1
View of vehicle, front left (example)
10
H01551-10
3
4
5
6
7
1
2
Filler cap
Air filter box cover
4 VIEW OF VEHICLE
4.2
View of vehicle, rear right (example)
11
3
4
5
1
2
8
9
6
7
10
11
Fork air pressure adjustment
Fork compression adjustment
Shock absorber compression adjustment
Shock absorber rebound adjustment
Level viewer for brake fluid, rear
H01550-10
5 SERIAL NUMBERS
5.1
Chassis number
The chassis number
is stamped on the right side of the steering head.
12
5.2
Type label
401945-10
The type label
is fixed to the front of the steering head.
5.3
Engine number
401946-10
(TC 125)
The engine number sprocket.
is located on the left side of the engine under the engine
401949-10
(TC 250, TX 300)
The engine number sprocket.
is located on the left side of the engine over the engine
5.4
H01047-10
Fork part number
The fork part number
is stamped on the inner side of the fork stub.
401947-10
5 SERIAL NUMBERS
5.5
Shock absorber article number
The shock absorber article number
is stamped on the top of the shock absorber above the adjusting ring towards the engine side.
13
401948-10
6 CONTROLS
6.1
Clutch lever
Clutch lever
is fitted on the handlebar on the left.
The clutch is activated hydraulically and adjusts itself automatically.
14
6.2
Hand brake lever
F00223-10
Hand brake lever
is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
6.3
Throttle grip
F00225-11
Throttle grip
is fitted on the right side of the handlebar.
F00225-10
6.4
Kill switch
The kill switch
is fitted on the left side of the handlebar.
Possible states
• Kill switch in basic position – In this position, the ignition circuit is closed, and the engine can be started.
• Kill switch pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.
6.5
F00224-10
Electric starter button (TX 300)
The electric starter button is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the electric starter is actuated.
F00226-10
6 CONTROLS
6.6
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.
– 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 affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
(All TC models)
– Turn filler cap
counterclockwise and lift it off.
F00227-10
(TX 300)
– Press release button
, turn the filler cap counterclockwise, and lift it off.
6.7
F00228-10
Closing the filler cap
(All TC models)
– Mount filler cap
and turn it clockwise until the fuel tank is tightly closed.
Info
Route fuel tank breather hose without kinks.
F00227-11
15
6 CONTROLS
(TX 300)
– Mount filler cap
and turn it clockwise until the release button engages.
Info
Route fuel tank breather hose without kinks.
16
6.8
F00229-10
Fuel tap (All TC models)
Fuel tap
is on the left of the fuel tank.
Open or close the supply of fuel to the carburetor using tap handle tap.
on the fuel
Possible states
• Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor.
• Fuel supply open ON – Fuel can flow from the fuel tank to the carburetor. The fuel tank empties completely.
6.9
Fuel tap (TX 300)
F00230-10
Fuel tap
is on the left of the fuel tank.
Open or close the supply of fuel to the carburetor using tap handle tap.
on the fuel
Possible states
• Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor.
• Fuel supply open ON – Fuel can flow from the fuel tank to the carburetor. The fuel tank empties down to the reserve level.
• Fuel reserve supply open RES – Fuel can flow from the fuel tank to the carburetor. The fuel tank empties completely.
F00231-10
6 CONTROLS
6.10
Choke
(TC 125)
Choke
is fitted on the left side of the carburetor.
F00232-10
(TC 250)
Choke is fitted on the left side of the carburetor.
6.11
Shift lever
F00233-10
F00234-10
(TX 300)
Choke
is fitted on the left side of the carburetor.
Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel. This results in a richer fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
Possible states
• Choke function activated – The choke lever is pulled out to the stop.
• Choke function deactivated – The choke lever is pushed in to the stop.
Shift lever
is mounted on the left of the engine.
17
401950-10
(TC 125)
The gear positions can be seen in the figure.
The neutral or idle position is between the first and second gears.
401950-11
6 CONTROLS
(TC 250, TX 300)
The gear positions can be seen in the figure.
The neutral or idle position is between the first and second gears.
18
6.12
Kick starter
401950-13
Kick starter
is 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.
6.13
Foot brake lever
401954-10
Foot brake lever
is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
6.14
401956-10
Plug-in stand (All TC models)
Support for plug-in stand
is the left side of the wheel spindle.
The plug-in stand is used to park the motorcycle.
Info
Remove the plug-in stand before riding.
6.15
402001-10
Side stand (TX 300)
The side stand
is on the left side of the vehicle.
401943-10
6 CONTROLS
The side stand is used to park the motorcycle.
Info
When you are riding, side stand ber band
.
must be folded up and secured with rub-
19
6.16
401944-10
Service hour counter
The service hour counter
is fitted in front of the handlebar.
It shows the total number of service hours of the engine.
The service hour counter begins counting when the engine is started and stops when the engine is switched off.
Info
The value indicated by the service hour counter cannot be cleared or adjusted.
K00483-10
7 PREPARING FOR USE
20
7.1
Advice on first use
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
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.
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidents An unadapted riding style impairs the handling characteristic.
– Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidents The vehicle is not designed to carry passengers.
– Do not ride with a passenger.
Warning
Danger of accidents The brake system fails in the event of overheating.
If the foot brake lever is not released, the brake linings drag continuously.
– Take your foot off the foot brake lever when you are not braking.
Warning
Danger of accidents Total weight and axle loads influence the handling characteristic.
– Do not exceed the maximum permissible overall weight or the axle loads.
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-delivery inspection work has been carried out by an authorized Husqvarna Motorcycles workshop.
You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.
– Before your first trip, read the entire Owner's Manual carefully.
– Get to know the controls.
– Adjust the basic position of the clutch lever. ( p. 69)
– Adjust the basic position of the hand brake lever. ( p. 72)
– Adjust the basic position of the foot brake lever. ( p. 76)
– Adjust the basic position of the shift lever. ( p. 102)
– Become accustomed to the handling of the motorcycle on suitable terrain.
Info
Your motorcycle is not authorized for riding on public roads.
When offroad, being accompanied by another person on another vehicle so that you can help each other is recommended.
7 PREPARING FOR USE
21
– Try also to ride as slowly as possible and in a standing position to get a better feeling for the motorcycle.
– Do not make any off-road trips that exceed your ability and experience.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
– Do not take luggage along.
– Do not exceed the maximum permissible weight and the maximum permissible axle loads.
Guideline
Maximum permissible overall weight
Maximum permissible front axle load
Maximum permissible rear axle load
335 kg (739 lb.)
145 kg (320 lb.)
190 kg (419 lb.)
– Check the spoke tension. ( p. 84)
Info
The spoke tension must be checked after half an hour of operation.
7.2
Running in the engine
– During the running-in phase, do not exceed the specified engine performance.
Guideline
Maximum engine performance
During the first 3 operating hours
During the first 5 operating hours
< 70 %
< 100 %
– Avoid fully opening the throttle!
7.3
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, it may be necessary to inspect or replace parts before the next scheduled service.
– Seal the air filter box.
– Clean the air filter and air filter box. ( p. 57)
Info
Check the air filter approx. every 30 minutes.
– Check the electrical connector for humidity and corrosion and to ensure it is firmly seated.
» If humidity, corrosion, or damage is found:
– Clean and dry the connector, or change it if necessary.
Difficult riding conditions are:
– Rides on wet and muddy surfaces. ( p. 24)
– Riding at high temperatures and low speeds. ( p. 24)
– Rides at low temperature or in snow. ( p. 25)
7.4
Preparing for rides on dry sand
– Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
» If the indicated value does not correspond to the required value:
M01129-01
7 PREPARING FOR USE
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
– Change the radiator cap.
– Fit a dust cover on the air filter.
Dust cover for air filter (79006920000)
Info
Observe the fitting instructions for Husqvarna Motorcycles accessories.
22
M01272-01
– Fit a sand cover on the air filter.
Sand cover for air filter (79006922000)
Info
Observe the fitting instructions for Husqvarna Motorcycles accessories.
M01273-01
– Adjust the carburetor jetting and setting.
Info
The recommended carburetor tuning is available from your authorized
Husqvarna Motorcycles workshop.
M01107-01
600868-01
– Clean the chain.
– Fit the steel sprocket.
Tip
Do not grease the chain.
– Clean the radiator fins.
– Straighten bent radiator fins carefully.
Condition
Regular use in sand
– Change the piston every 10 operating hours.
7 PREPARING FOR USE
7.5
Preparing for rides on wet sand
– Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
» If the indicated value does not correspond to the required value:
M01129-01
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
– Change the radiator cap.
– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (79006921000)
Info
Observe the fitting instructions for Husqvarna Motorcycles accessories.
23
M01274-01
– Adjust the carburetor jetting and setting.
Info
The recommended carburetor tuning is available from your authorized
Husqvarna Motorcycles workshop.
M01107-01
600868-01
– Clean the chain.
– Fit the steel sprocket.
Tip
Do not grease the chain.
– Clean the radiator fins.
– Straighten bent radiator fins carefully.
Condition
Regular use in sand
– Change the piston every 10 operating hours.
7 PREPARING FOR USE
7.6
Preparing for rides on wet and muddy surfaces
– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (79006921000)
Info
Observe the fitting instructions for Husqvarna Motorcycles accessories.
24
M01274-01
– Adjust the carburetor jetting and setting.
Info
The recommended carburetor tuning is available from your authorized
Husqvarna Motorcycles workshop.
M01107-01
– Fit the steel sprocket.
– Clean the motorcycle. ( p. 108)
– Straighten bent radiator fins carefully.
7.7
600868-01
Preparations for riding at high temperatures and low speeds
– Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
» If the displayed value does not equal the setpoint value:
M01129-01
600868-01
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
– Change the radiator cap.
– Adjust the secondary ratio to the terrain.
Info
The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary drive.
– Clean the chain.
– Clean the radiator fins.
– Carefully align bent radiator fins.
– Check the coolant level. ( p. 92)
7 PREPARING FOR USE
7.8
Preparing for rides at low temperature or in snow
– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (79006921000)
Info
Observe the fitting instructions for Husqvarna Motorcycles accessories.
25
M01274-01
– Adjust the carburetor jetting and setting.
Info
The recommended carburetor tuning is available from your authorized
Husqvarna Motorcycles workshop.
M01107-01
8 RIDING INSTRUCTIONS
8.1
Checks and maintenance work when preparing for use
Info
Before riding the vehicle, always check its condition and operating safety.
The vehicle must be in perfect technical condition when used.
– Check the gear oil level. ( p. 105)
– Check the front brake fluid level. ( p. 73)
– Check the rear brake fluid level. ( p. 77)
– Check the front brake linings. ( p. 74)
– Check the rear brake linings. ( p. 79)
– Check that the brake system is functioning properly.
– Check the coolant level. ( p. 92)
– Check the chain for dirt. ( p. 64)
– Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 66)
– Check the chain tension. ( p. 65)
– Check the tire condition. ( p. 84)
– Check the tire air pressure. ( p. 84)
– Check the spoke tension. ( p. 84)
– Clean the dust boots of the fork legs. ( p. 44)
– Bleed the fork legs. ( p. 44)
– Check the air filter.
– Check the settings of all controls and ensure that they can be operated smoothly.
– Check all screws, nuts and hose clamps regularly for tightness.
– Check the fuel supply.
8.2
Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
– Always run the engine warm at a low speed.
Info
If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.
The motorcycle has been out of use for more than 1 week
– Empty the carburetor float chamber. ( p. 100)
(All TC models)
– Turn handle
of the fuel tap to the ON position. (Figure F00230-10 p. 16)
Fuel can flow from the fuel tank to the carburetor.
– Remove the plug-in stand.
– Shift gear to neutral.
Condition
The engine is cold
– Pull the choke lever out as far as possible.
– Press the kick starter robustly through its full range.
Info
Do not open the throttle.
26
8 RIDING INSTRUCTIONS
(TX 300)
– Turn handle
of the fuel tap to the ON position. (Figure F00231-10 p. 16)
Fuel can flow from the fuel tank to the carburetor.
– Remove the motorcycle from the side stand.
– Shift gear to neutral.
Condition
The engine is cold
– Pull the choke lever out as far as possible.
– Press the electric starter button or press the kick starter robustly through its full range.
Info
Do not open the throttle.
8.3
Starting off
Info
The plug-in stand must be removed before riding.
While riding, the side stand must be folded up and secured with the rubber band.
– Pull the clutch lever, shift into first gear, release the clutch lever slowly and at the same time open the throttle gently.
8.4
Shifting, riding
Warning
Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races.
– Do not change into a low gear at high engine speed.
27
Info
If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized Husqvarna
Motorcycles workshop.
First gear is used for starting off and for steep inclines.
– Shift into a higher gear when conditions allow (incline, road situation, etc.). To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever and open the throttle.
– If the choke function was activated, deactivate it after the engine has warmed up.
– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. 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.
– Switch off the engine if running at idle or standing for a long time.
Guideline
≥ 2 min
– Avoid frequent and longer slipping of the clutch. As a result the engine oil, engine and cooling system heat up.
– Ride at a low engine speed instead of at a high engine speed with a slipping clutch.
8.5
Braking
Warning
Danger of accidents Excessively forceful application of the brakes blocks the wheels.
– Adjust application of the brakes to the respective riding situation and riding surface conditions.
Warning
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
8 RIDING INSTRUCTIONS
28
Warning
Danger of accidents Moisture and dirt impair the brake system.
– Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.
– On sandy, wet or slippery surfaces, use the rear brake.
– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
– Make use of the braking effect of the engine when driving down long downhill stretches. To do so, shift back one or two gears, but do not overrev the engine. You will need to apply the brakes far less often and the brake system will not overheat.
8.6
Stopping, parking
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls 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 cool down before covering it.
– Apply the brakes on the motorcycle.
– Shift gear to neutral.
– Press and hold the kill switch while the engine is idling until the engine stops.
(All TC models)
– Turn handle
of the fuel tap to the OFF position. (Figure F00230-10
– Rest the vehicle on the plug-in stand.
(TX 300)
– Turn handle
of the fuel tap to the OFF position. (Figure F00231-10 p. 16)
– Rest the vehicle on the side stand.
8.7
Transport
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.
8 RIDING INSTRUCTIONS
29
– Switch off the engine.
– Use tension belts or other suitable devices to secure the motorcycle against accidents or falling over.
401475-01
8.8
Refueling
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.
– 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 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.
401522-10
– Switch off the engine.
– Open the filler cap. ( p. 15)
– Fill the fuel tank with fuel up to level
.
Guideline
Level
35 mm (1.38 in)
Total fuel tank capacity, approx.
(All TC models)
7 l (1.8 US gal)
Total fuel tank capacity, approx.
(TX 300)
10 l (2.6 US gal)
Engine oil, 2-stroke ( p. 128)
– Close the filler cap. ( p. 15)
Super unleaded (98 octane) mixed with 2-stroke engine oil (1:40)
Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60)
Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60)
9 SERVICE SCHEDULE
9.1
All TC models
9.1.1
Additional information
Any further work that results from the required work or from the recommended work must be ordered separately and can be invoiced separately.
9.1.2
Required work
Change the gear oil.
Change the gear oil.
(TC 125)
(TC 250)
Check the front brake linings. ( p. 74)
Check the rear brake linings. ( p. 79)
Check the brake lines for damage and leakage.
Check the rear brake fluid level. ( p. 77)
Check the free travel of the foot brake lever. ( p. 76)
Check the frame and swingarm.
Check the swingarm bearing.
Check the heim joints at the top of the shock absorber.
Check the shock absorber linkage.
Check the tire air pressure. ( p. 84) p. 84)
Check the wheel bearing for play.
Check the wheel hubs.
Check the rim run-out.
Check the chain, rear sprocket, engine sprocket, and chain guide. (
Check the chain tension. ( p. 65)
Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation.
Check/correct the fluid level of the hydraulic clutch. ( p. 70)
Check the front brake fluid level. ( p. 73)
Check the free travel of the hand brake lever. ( p. 72)
Check the play of the steering head bearing. ( p. 48)
Change the spark plug and spark plug connector.
(TC 125)
Change the spark plug and spark plug connector.
(TC 250)
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect routing.
Check the antifreeze and coolant level. ( p. 91)
Check the cables for damage and routing without sharp bends.
Every 20 operating hours
Every 10 operating hours/after every race
Once after 1 operating hour
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Check that the throttle cables are undamaged, routed without sharp bends, and set correctly.
Clean the air filter and air filter box.
Change glass fiber yarn filling in the main silencer.
Check the screws and nuts for tightness.
Check idle.
Final check: Check the vehicle for safe operation and take a test ride.
Make the service entry in the Husqvarna Motorcycles Dealer.net and in the Service and Warranty Booklet.
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○ One-time interval
● Periodic interval
30
9 SERVICE SCHEDULE
9.1.3
Recommended work
Annually
Every 40 operating hours
Once after 20 operating hours / Every 20 operating hours
Every 10 operating hours/after every race
Once after 10 operating hours
●
Change the front brake fluid.
Change the rear brake fluid.
Change the hydraulic clutch fluid.
Grease the steering head bearing.
Check/adjust the carburetor components.
Service the fork.
Service the shock absorber.
Perform minor engine service. (Change the piston and check the cylinder and Z dimension (under difficult operating conditions). Check the inlet membrane. Check the clutch.)
Perform the intermediate engine service. (Change the piston and check the cylinder and Z dimension.
Check the exhaust control for functioning and smooth operation.)
Perform major engine service including removing and installing the engine. (Change the connecting rod, conrod bearing, and crank pin. Check the transmission and shift mechanism. Change all engine bearings.)
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● Periodic interval
9.2
TX 300
9.2.1
Additional information
Any further work that results from the required work or from the recommended work must be ordered separately and can be invoiced separately.
9.2.2
Required work
Check and charge the battery.
Change the gear oil.
Check the front brake linings. ( p. 74)
Check the rear brake linings. ( p. 79)
Check the brake discs. ( p. 72)
Check the brake lines for damage and leakage.
Check the rear brake fluid level. ( p. 77)
Check the free travel of the foot brake lever. ( p. 76)
Check the frame and swingarm.
Check the swingarm bearing.
Check the heim joints at the top of the shock absorber.
Check the shock absorber linkage.
Check the tire condition. ( p. 84)
Check the tire air pressure. ( p. 84)
Check the wheel bearing for play.
Check the wheel hubs.
Check the rim run-out.
Check the spoke tension. ( p. 84)
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 66)
Check the chain tension. ( p. 65)
Every 40 operating hours/after every race
Every 20 operating hours
Once after 1 operating hour
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31
9 SERVICE SCHEDULE
Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation.
Check/correct the fluid level of the hydraulic clutch. (
Check the front brake fluid level. ( p. 73)
Check the free travel of the hand brake lever. ( p. 72)
Check the play of the steering head bearing. ( p. 48)
Change the spark plug and spark plug connector.
Every 40 operating hours/after every race
Every 20 operating hours
Once after 1 operating hour
● ●
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Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect routing.
Check the antifreeze and coolant level. ( p. 91)
Check the cables for damage and routing without sharp bends.
Check that the throttle cables are undamaged, routed without sharp bends, and set correctly.
○ ●
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Clean the air filter and air filter box.
Change glass fiber yarn filling in the main silencer.
Check the screws and nuts for tightness.
Check idle.
Final check: Check the vehicle for safe operation and take a test ride.
Make the service entry in the Husqvarna Motorcycles Dealer.net and in the Service and Warranty Booklet.
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● Periodic interval
9.2.3
Recommended work
Change the front brake fluid.
Change the rear brake fluid.
Change the hydraulic clutch fluid.
Service the fork.
Service the shock absorber.
Annually
Every 80 operating hours/every 40 operating hours when used for motorsports
Every 40 operating hours/after every race
Every 20 operating hours
Once after 10 operating hours
●
Grease the steering head bearing.
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Check the starter drive.
Check the inlet membrane.
Check/adjust the carburetor components.
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 piston and check the cylinder. Change the connecting rod, conrod bearing, and crank pin. Check the transmission and shift mechanism. Change all engine bearings.)
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● Periodic interval
32
10 TUNING THE CHASSIS
33
10.1
Checking the basic chassis setting with the rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
– For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspension components must match the rider's weight.
– As delivered, Husqvarna offroad motorcycles are adjusted for an average rider's weight (with full protective clothing).
Guideline
Standard rider weight 75… 85 kg (165… 187 lb.)
– If the rider's weight is above or below the standard range, the basic setting of the suspension components must be adjusted accordingly.
– Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the springs must be replaced.
401030-01
10.2
Air suspension AER 48
M01110-01
Air suspension WP Performance Systems AER 48 is used in the fork.
In this system, suspension is located in the left fork leg and damping in the right fork leg.
As fork springs are no longer required, a significant weight advantage is achieved when compared to conventional forks. The response on slightly uneven surfaces is significantly improved.
In normal driving mode, suspension is provided exclusively by an air cushion. A steel spring is located in the left fork leg as an end stop.
Info
If the fork is frequently overloaded, then the air pressure in the fork must be increased to avoid damage to the fork and frame.
The air pressure in the fork can be quickly adjusted for the rider's weight, surface conditions and the rider's preference using a fork pump. The fork does not have to be detached. The time consuming mounting of harder or softer fork springs is not required.
If the air chamber loses air due to a damaged seal, the fork will still not sag. In this case the air is retained in the fork. The suspension travel is maintained as far as possible. The damping becomes harder and the riding comfort reduces.
As with a conventional fork, the damping can be adjusted in rebound and compression stages.
The rebound adjuster is located at the lower end of the right fork leg.
The compression adjuster is located at the upper end of the right fork leg.
10.3
Compression damping of the shock absorber
The compression damping of the shock 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 compresses quickly.
The low-speed setting, for example, has an effect when riding over long ground swells: the rear wheel suspension compresses slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in the high-speed range affect the compression damping in the low-speed range and vice versa.
10 TUNING THE CHASSIS
10.4
Adjusting the low-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly.
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 low-speed setting can be seen in slow to normal compression of the shock absorber.
H01520-10
– Turn adjusting screw click.
clockwise with a screwdriver up to the last perceptible
Info
Do not loosen fitting
!
– Turn counterclockwise by the number of clicks corresponding to the shock absorber type.
Guideline
Compression damping, low-speed (TC 125)
Comfort 17 clicks
Standard
Sport
15 clicks
13 clicks
Compression damping, low-speed (TC 250)
Comfort 17 clicks
Standard
Sport
15 clicks
13 clicks
Compression damping, low-speed (TX 300)
Comfort
Standard
Sport
17 clicks
15 clicks
13 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
10.5
Adjusting the high-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly.
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.
– Using an open end wrench, turn adjusting screw
clockwise all the way.
Info
Do not loosen fitting
!
– Turn counterclockwise by the number of turns corresponding to the shock absorber type.
34
H01521-10
10 TUNING THE CHASSIS
Guideline
Compression damping, high-speed (TC 125)
Comfort
Standard
2.5 turns
2 turns
Sport 1.5 turns
Compression damping, high-speed (TC 250)
Comfort
Standard
Sport
2.5 turns
2 turns
1.5 turns
Compression damping, high-speed (TX 300)
Comfort 2.5 turns
Standard
Sport
2 turns
1.5 turns
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
35
10.6
Adjusting the rebound damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
H01522-10
– Turn adjusting screw
clockwise up to the last perceptible click.
– Turn counterclockwise by the number of clicks corresponding to the shock absorber type.
Guideline
Rebound damping (TC 125)
Comfort
Standard
Sport
Rebound damping (TC 250)
Comfort
Standard
Sport
Rebound damping (TX 300)
Comfort
Standard
Sport
17 clicks
15 clicks
13 clicks
17 clicks
15 clicks
13 clicks
17 clicks
15 clicks
13 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
10 TUNING THE CHASSIS
10.7
36
Measuring the rear wheel dimension unloaded
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work
– Position the sag gauge in the rear axle and measure the distance to marking SAG on the rear fender.
Sag gauge (00029090500)
Pin for sag gauge (00029990010)
– Note down the value as dimension
.
10.8
402415-10
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)
Checking the static sag of the shock absorber
– Measure dimension
of rear wheel unloaded. ( p. 36)
– Hold the motorcycle upright with the aid of an assistant.
– Again measure the distance between the rear axle and marking SAG on the rear fender using the sag gauge.
– Note down the value as dimension
.
Info
The static sag is the difference between measurements
and
.
– Check the static sag.
Static sag (TC 125) 35 mm (1.38 in)
Static sag (TC 250) 35 mm (1.38 in)
Static sag (TX 300) 35 mm (1.38 in)
» If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber. ( p. 37)
402416-10
10 TUNING THE CHASSIS
10.9
Checking the riding sag of the shock absorber
– Measure dimension
of rear wheel unloaded. ( p. 36)
– With another person holding the motorcycle, the rider, wearing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.
The rear wheel suspension levels out.
– Another person again measures the distance between the rear axle and marking SAG on the rear fender using the sag gauge.
– Note down the value as dimension
.
Info
The riding sag is the difference between measurements
and
.
402417-10
– Check the riding sag.
Guideline
Riding sag (TC 125)
Riding sag (TC 250)
Riding sag (TX 300)
105 mm (4.13 in)
105 mm (4.13 in)
105 mm (4.13 in)
» If the riding sag differs from the specified measurement:
– Adjust the riding sag.
10.10
Adjusting the spring preload of the shock absorber
Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
37
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
402659-10
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
– Remove the shock absorber.
– After removing the shock absorber, clean it thoroughly.
Main work
– Loosen screw
.
– Turn adjusting ring
until the spring is no longer under tension.
Hook wrench (T106S)
– Measure the overall spring length while the spring is not under tension.
– Tighten the spring by turning adjusting ring
to measurement
.
Guideline
Spring preload (TC 125)
Spring preload (TC 250)
Spring preload (TX 300)
6 mm (0.24 in)
5 mm (0.2 in)
7 mm (0.28 in)
Info
Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload.
– Tighten screw
.
Guideline
Screw, shock absorber adjusting ring M5
Finishing work
– Install the shock absorber.
5 Nm (3.7 lbf ft)
10 TUNING THE CHASSIS
– Remove the motorcycle from the lift stand. ( p. 43)
10.11
Adjusting the riding sag
B00292-10
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
– Remove the shock absorber.
– After removing the shock absorber, clean it thoroughly.
Main work
– Choose and mount a suitable spring.
Guideline
Spring rate (TC 125)
Weight of rider: 65… 75 kg (143…
165 lb.)
Weight of rider: 75… 85 kg (165…
187 lb.)
Weight of rider: 85… 95 kg (187…
209 lb.)
Spring rate (TC 250)
Weight of rider: 65… 75 kg (143…
165 lb.)
Weight of rider: 75… 85 kg (165…
187 lb.)
36 N/mm (206 lb/in)
39 N/mm (223 lb/in)
42 N/mm (240 lb/in)
39 N/mm (223 lb/in)
42 N/mm (240 lb/in)
Weight of rider: 85… 95 kg (187…
209 lb.)
Spring rate (TX 300)
Weight of rider: 65… 75 kg (143…
165 lb.)
Weight of rider: 75… 85 kg (165…
187 lb.)
Weight of rider: 85… 95 kg (187…
209 lb.)
45 N/mm (257 lb/in)
39 N/mm (223 lb/in)
42 N/mm (240 lb/in)
45 N/mm (257 lb/in)
Info
The spring rate is shown on the outside of the spring.
Finishing work
– Install the shock absorber.
– Remove the motorcycle from the lift stand. ( p. 43)
– Check the static sag of the shock absorber. ( p. 36)
– Check the riding sag of the shock absorber. ( p. 37)
– Adjust the rebound damping of the shock absorber. ( p. 35)
10.12
Checking the basic setting of the fork
Info
For various reasons, no exact riding sag can be determined for the fork.
– Smaller differences in the rider's weight can be compensated for by the fork air pressure.
– However, if the fork frequently bottoms out (hard end stop on compression), the fork air pressure must be increased, within the specified values, to avoid damage to the fork and frame.
– If the fork feels unusually hard after extended periods of operation, the fork legs need to be bled.
38
401000-01
10 TUNING THE CHASSIS
10.13
Adjusting the fork air pressure
Warning
Danger of accident Modifications to the suspension setting may seriously alter the handling characteristic.
Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components.
– Only make adjustments within the recommended range.
– Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.
39
Info
Check or adjust the air pressure under the same conditions at the earliest 5 minutes after switching off the engine.
The air suspension is located in the left fork leg. The pressure and rebound damping is located in the right fork leg.
K00475-10
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work
– Remove protection cap
– Push fork pump
.
together fully.
Fork pump (79412966000)
Info
The fork pump is included as part of the motorcycle's separate enclosure.
– Connect the fork pump to the left fork leg.
The fork pump indicator switches on automatically.
A little air escapes from the fork leg when connecting.
Info
This is due to the volume of the hose and not due to a defect in the fork pump or the fork.
Read the accompanying instructions for Husqvarna Motorcycles accessories.
– Adjust the air pressure as specified.
Guideline
Air pressure (TC 125)
Air pressure (TC 250)
Air pressure (TX 300)
Gradual changing of the air pressure in steps of
Minimum air pressure
Maximum air pressure
8.2 bar (119 psi)
10.2 bar (148 psi)
9.6 bar (139 psi)
0.2 bar (3 psi)
7 bar (102 psi)
15 bar (218 psi)
Info
Never set the air pressure to a value outside the stated range.
– Disconnect the fork pump from the left fork leg.
When disconnecting, excess pressure will escape from the hose – the fork leg itself does not lose any air.
The fork pump indicator switches off automatically after 80 seconds.
– Mount the protection cap.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)
10 TUNING THE CHASSIS
10.14
Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
H01178-13
– Turn adjusting screw
clockwise all the way.
Info
Adjusting screw
is located at the upper end of the right fork leg.
– Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping (TC 125)
Comfort
Standard
Sport
Compression damping (TC 250)
15 clicks
12 clicks
9 clicks
Comfort
Standard
Sport
Compression damping (TX 300)
Comfort
Standard
Sport
15 clicks
12 clicks
9 clicks
15 clicks
12 clicks
10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
10.15
Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
M01100-10
– Remove protection cap
– Turn adjusting screw
.
clockwise all the way.
Info
Adjusting screw
is located at the lower end of the right fork leg.
– Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping (TC 125)
Comfort
Standard
Sport
Rebound damping (TC 250)
20 clicks
17 clicks
14 clicks
Comfort
Standard
Sport
Rebound damping (TX 300)
Comfort
Standard
Sport
20 clicks
17 clicks
14 clicks
15 clicks
12 clicks
10 clicks
40
10 TUNING THE CHASSIS
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
– Mount protection cap
.
41
10.16
Handlebar position
The holes on the handlebar supports are placed at a distance of
from the center.
Hole distance A 3.5 mm (0.138 in)
The handlebar can be mounted in 2 different positions. In this way, the handlebar can be mounted in the most comfortable position for the rider.
H01188-10
10.17
Adjusting the handlebar position
Warning
Danger of accidents A repaired handlebar poses a safety risk.
If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result.
– Change the handlebar if the handlebar is damaged or bent.
H01189-10
Preparatory work
– Remove the handlebar cushion.
Main work
– Remove screws lay it to one side.
. Take off the handlebar clamp. Remove the handlebar and
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
– Remove screws
. Take off handlebar supports
.
– Position rubber bushings
and push through nuts
– Place the handlebar supports in the required position.
from below.
Info
The handlebar supports are longer and higher on one side.
Position the left and right handlebar supports evenly.
– Mount and tighten screws
.
Guideline
Screw, handlebar support M10 40 Nm
(29.5 lbf ft)
Loctite ® 243™
– Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
– Position the handlebar clamp.
– Mount screws
but do not tighten yet.
– First bolt the handlebar clamp with screws
handlebar supports so that both parts touch.
onto the longer, higher side of the
– Tighten screws
evenly.
Guideline
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft)
10 TUNING THE CHASSIS
Finishing work
– Mount the handlebar cushion.
42
11 SERVICE WORK ON THE CHASSIS
11.1
Raising the motorcycle with a lift stand
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls 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.
– Raise the motorcycle at the frame underneath the engine.
Lift stand (81329955100)
Neither wheel is in contact with the ground.
– Secure the motorcycle against falling over.
43
401942-01
11.2
Removing the motorcycle from the lift stand
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls 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.
(All TC models)
– Remove the motorcycle from the lift stand.
– Remove the lift stand.
– To park the motorcycle, insert plug-in stand spindle.
into the left side of the wheel
Info
Remove the plug-in stand before riding.
402001-10
(TX 300)
– Remove the motorcycle from the lift stand.
– Remove the lift stand.
– To park the motorcycle, press side stand lean the motorcycle on it.
to the ground with your foot and
Info
While riding, the side stand must be folded up and secured with the rubber band.
401943-10
11 SERVICE WORK ON THE CHASSIS
11.3
Bleeding the fork legs
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work
– Release bleeder screws
.
Any excess pressure escapes from the interior of the fork.
– Tighten the bleeder screws.
11.4
11.5
H01182-12
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)
Cleaning the dust boots of the fork legs
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
– Remove the fork protector. ( p. 45)
Main work
– Push dust boots
of both fork legs downward.
Info
The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.
E00260-10
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.
– Clean and oil the dust boots and inner fork tubes of both fork legs.
– Press the dust boots back into their installation position.
– Remove excess oil.
Finishing work
– Install the fork protector. ( p. 46)
– Remove the motorcycle from the lift stand. ( p. 43)
Removing the fork legs
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
– Remove the front wheel.
Main work
– Remove screws
and take off the clamp.
– Remove screws
and take off the brake caliper.
– Allow the brake caliper and brake line to hang tension-free to the side.
Info
Do not activate the hand brake lever while the front wheel is removed.
H01524-10
44
11 SERVICE WORK ON THE CHASSIS
– Unscrew screws
– Unscrew screws
. Take out the left fork leg.
. Take out the right fork leg.
45
11.6
H01547-10
Installing the fork legs
H01182-10
Main work
– Position the fork legs.
Bleeder screw
of the right fork leg is positioned to the front.
Valve
of the left fork leg faces the front.
Info
Grooves are milled into 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.
The air suspension is located in the left fork leg. The pressure and rebound damping is located in the right fork leg.
– Tighten screws
.
Guideline
Screw, top triple clamp
– Tighten screws
.
Guideline
Screw, bottom triple clamp
M8
M8
17 Nm (12.5 lbf ft)
12 Nm (8.9 lbf ft)
H01547-11
– Position the brake caliper. Mount and tighten screws
.
Guideline
Screw, front brake caliper M8 25 Nm
(18.4 lbf ft)
Loctite ® 243™
– Position the brake line and clamp. Mount and tighten screws
.
11.7
H01526-10
Finishing work
– Install the front wheel.
Removing the fork protector
– Remove screws
– Remove screws
– Remove screws
. Take off the clamp.
. Take off the left fork protector.
. Take off the right fork protector.
F00047-10
11 SERVICE WORK ON THE CHASSIS
11.8
11.9
Installing the fork protector
– Position the fork protector on the left fork leg. Mount and tighten screws
.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
– Position the brake line and clamp. Mount and tighten screws
.
– Position the fork protector on the right fork leg. Mount and tighten screws
.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
F00047-11
Removing the lower triple clamp
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
– Remove the front wheel.
– Remove the fork legs.
– Remove the start number plate. ( p. 50)
– Remove the front fender. ( p. 50)
– Remove the handlebar cushion.
Main work
– Take off cable holder
– Remove screw
.
– Remove screw
.
in front of the left radiator.
– Take off the upper triple clamp with the handlebar and set it aside.
F00236-10
Info
Protect the components against damage by covering them.
Do not bend the cables and lines.
– Remove O-ring
. Remove protective ring
.
– Take off the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.
46
H01528-10
11 SERVICE WORK ON THE CHASSIS
11.10
Installing the lower triple clamp
Main work
– Clean the bearing and sealing elements, check for damage, and grease.
High viscosity grease ( p. 130)
– Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
– Check whether upper steering head seal
is correctly positioned.
– Slide on protective ring
and O-ring
.
47
102146-10
– Position the upper triple clamp with the handlebar.
– Mount screw
but do not tighten yet.
H01529-10
H01182-11
– Position the fork legs.
Bleeder screw
of the right fork leg is positioned to the front.
Valve
of the left fork leg faces the front.
Info
Grooves are milled into 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.
The air suspension is located in the left fork leg. The pressure and rebound damping is located in the right fork leg.
– Tighten screws
.
Guideline
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
H01525-12
– Tighten screw
.
Guideline
Screw, top steering head M20x1.5
12 Nm (8.9 lbf ft)
H01530-10
11 SERVICE WORK ON THE CHASSIS
– Mount and tighten screw
.
Guideline
Screw, top steering stem M8 20 Nm
(14.8 lbf ft)
Loctite ® 243™
48
H01531-10
– Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.
– Tighten screws
.
Guideline
Screw, top triple clamp M8 17 Nm (12.5 lbf ft)
– Secure wiring harness and clutch line with cable holder
.
H01525-13
– Position the brake caliper. Mount and tighten screws
.
Guideline
Screw, front brake caliper M8 25 Nm
(18.4 lbf ft)
Loctite ® 243™
– Position the brake line and clamp. Mount and tighten screws
.
H01526-11
Finishing work
– Install the front fender. ( p. 51)
– Install the start number plate. ( p. 50)
– Install the front wheel.
– Check that the wiring harness, throttle cables, and brake and clutch lines can move freely and are routed correctly.
– Check the play of the steering head bearing. ( p. 48)
– Remove the motorcycle from the lift stand. ( p. 43)
– Mount the handlebar cushion.
11.11
Checking the play of the steering head bearing
Warning
Danger of accidents Incorrect 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 bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become damaged over time.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
11 SERVICE WORK ON THE CHASSIS
H01167-01
Main work
– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel.
No play should be noticeable in the steering head bearing.
» If there is noticeable play present:
– Adjust the steering head bearing play. ( p. 49)
– Move the handlebar to and fro over the entire steering range.
The handlebar must be able to move easily over the entire steering range.
There should be no perceptible detent positions.
» If detent positions are noticeable:
– Adjust the steering head bearing play. ( p. 49)
– Check the steering head bearing and replace if required.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)
11.12
Adjusting the steering head bearing play
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
– Remove the handlebar cushion.
Main work
– Loosen screws
.
– Remove screw
.
– Loosen and retighten screw
.
Guideline
Screw, top steering head M20x1.5
H01532-10
12 Nm (8.9 lbf ft)
– Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.
– Tighten screws
.
Guideline
Screw, top triple clamp M8 17 Nm (12.5 lbf ft)
– Mount and tighten screw
.
Guideline
Screw, top steering stem M8 20 Nm
(14.8 lbf ft)
Loctite ® 243™
Finishing work
– Check the play of the steering head bearing. ( p. 48)
– Remove the motorcycle from the lift stand. ( p. 43)
– Mount the handlebar cushion.
11.13
Greasing the steering head bearing
– Remove the lower triple clamp. ( p. 46)
– Install the lower triple clamp. ( p. 47)
49
800010-10
11 SERVICE WORK ON THE CHASSIS
11.14
Removing the start number plate
– Remove screw
– Remove screw
.
and take off the brake line guide and start number plate.
50
H01533-10
11.15
Installing the start number plate
– Position the brake line and brake line guide on the start number plate.
– Mount and tighten screw
.
– Position the start number plate.
The holding lugs engage in the fender.
– Mount and tighten screw
.
S01297-10
11.16
Removing the front fender
Preparatory work
– Remove the start number plate. ( p. 50)
Main work
– Remove screws
and
. Remove the front fender.
H01535-10
11 SERVICE WORK ON THE CHASSIS
11.17
Installing the front fender
Main work
– Position the front fender. Mount and tighten screws
and
.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
51
H01535-10
Finishing work
– Install the start number plate. ( p. 50)
11.18
Removing the shock absorber
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work
– Remove the cable ties.
– Remove screws
.
– Remove screws
with the washers.
– Remove the frame protectors on the left and right.
H01536-10
– Remove screw
– Remove fitting
.
.
Info
Raise the wheel slightly to be able to remove the screws more easily.
H01537-10
– Press angle lever
– Press linkage lever
toward the rear.
downward.
H01538-10
11 SERVICE WORK ON THE CHASSIS
– Remove screws
.
– Pull off foot brake cylinder from the push rod.
H01539-10
– Remove the connecting link of the chain.
– Take off the chain.
H01540-01
– Remove nut
and pull out the swingarm pivot.
– Push the swingarm back and secure it against falling over.
H01541-10
– Hold the shock absorber and remove screw
.
– Remove the shock absorber carefully at the bottom.
H01542-10
11.19
Installing the shock absorber
Main work
– Carefully position the shock absorber into the vehicle from the bottom.
– Mount and tighten screw
.
Guideline
Screw, top shock absorber
M10 60 Nm
(44.3 lbf ft)
Loctite ® 2701™
H01543-10
– Position the swingarm and mount the swingarm pivot.
Info
Pay attention to flat area
.
– Mount and tighten nut
Guideline
Nut, swingarm pivot
.
M16x1.5
H01544-10
100 Nm
(73.8 lbf ft)
52
11 SERVICE WORK ON THE CHASSIS
– Mount the chain.
– Connect the chain with the connecting link.
Guideline
The closed side of the chain joint lock must face in the direction of travel.
53
H01540-01
– Position the foot brake cylinder.
Push rod
engages in the foot brake cylinder.
The dust boot is correctly positioned.
– Mount and tighten screws
.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
H01545-10
H01546-10
H01536-11
– Position the angle lever and linkage lever.
– Mount and tighten fitting
.
Guideline
Nut, linkage lever to angle lever M14x1.5
Info
Pay attention to flat area
.
– Mount and tighten screw
.
Guideline
Screw, bottom shock absorber
M10 60 Nm
(44.3 lbf ft)
80 Nm (59 lbf ft)
Loctite ® 2701™
Info
Raise the wheel slightly to be able to mount the screw more easily.
– Position the frame protectors on the left and right.
– Mount and tighten screws
.
Guideline
Screw, frame protector M5
– Mount and tighten screws
with the washers.
Guideline
Screw, frame protector M5
– Mount the cable tie(s).
– Check the free travel of the foot brake lever. ( p. 76)
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)
3 Nm (2.2 lbf ft)
3 Nm (2.2 lbf ft)
11.20
Removing the seat
Preparatory work
– Remove the air filter box cover. ( p. 55)
11 SERVICE WORK ON THE CHASSIS
Main work
(All TC models)
– Remove screw
.
– Pull seat back and lift it off.
54
F00237-10
(TX 300)
– Remove screw
.
– Pull seat back and lift it off.
F00107-10
11.21
Mounting the seat
Main work
(All TC models)
– Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket.
– Push the seat forward.
– Make sure that the seat is correctly locked in.
– Mount and tighten screw
.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
F00238-10
11 SERVICE WORK ON THE CHASSIS
(TX 300)
– Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket.
– Push the seat forward.
– Make sure that the seat is correctly locked in.
– Mount and tighten screw
.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
55
F00108-10
Finishing work
– Install the air filter box cover. ( p. 56)
11.22
Removing the air filter box cover
(All TC models)
– Pull off the air filter box cover sideways in areas toward the front.
,
and
, and remove
F00242-10
(TX 300)
– Pull off the air filter box cover sideways in areas toward the front.
,
and
, and remove
F00245-10
11 SERVICE WORK ON THE CHASSIS
11.23
Installing the air filter box cover
(All TC models)
– Position air filter box cover on collar bushings the rear.
– Engage the air filter box cover in areas
,
and and
.
and push toward
56
F00243-10
(TX 300)
– Position air filter box cover on collar bushings the rear.
– Engage the air filter box cover in areas
,
and and
.
and push toward
F00244-10
11.24
Removing the air filter
Note
Engine damage Unfiltered intake air has a negative effect on the service 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. 55)
11 SERVICE WORK ON THE CHASSIS
Main work
(All TC models)
– Detach retaining tab
. Remove air filter with air filter support.
– Take off air filter from air filter support.
57
F00246-10
(TX 300)
– Detach retaining tab
. Remove air filter with air filter support.
– Take off air filter from air filter support.
F00247-10
11.25
Cleaning the air filter and air filter box
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
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
K00518-01
Preparatory work
– Remove the air filter box cover. ( p. 55)
– Remove the air filter.
Main work
– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
Air filter cleaning agent ( p. 130)
Info
Only squeeze 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. 130)
– Clean the air filter box.
– Clean the intake flange and check it for damage and tightness.
Finishing work
– Install the air filter. ( p. 58)
– Install the air filter box cover. ( p. 56)
11 SERVICE WORK ON THE CHASSIS
11.26
Installing the air filter
Main work
– Mount the clean air filter on the air filter support.
– Grease the air filter in area
.
102178-10
– Insert the air filter and position the top retaining pin
in bushing
.
The air filter is correctly positioned.
– Secure the bottom retaining pin with holding tab
.
Info
If the air filter is not mounted correctly, dust and dirt may enter the engine and result in damage.
M01303-10
Finishing work
– Install the air filter box cover. ( p. 56)
11.27
Sealing the air filter box
Preparatory work
– Remove the air filter box cover. ( p. 55)
Main work
– Seal the air filter box cover in marked area
.
58
F00248-01
Finishing work
– Install the air filter box cover. ( p. 56)
11.28
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. 60)
Main work
(TC 125)
– Remove screws
with the washers.
– Pull off the main silencer from the manifold at rubber sleeve
.
F00249-10
11 SERVICE WORK ON THE CHASSIS
(TC 250, TX 300)
– Remove screws
with the washers.
– Pull off the main silencer from the manifold at rubber sleeve
.
59
F00250-10
11.29
Installing the main silencer
Main work
(TC 125)
– Position the main silencer with rubber sleeve
.
– Mount and tighten screws
with the washers.
Guideline
Remaining screws, chassis M6
F00249-11
(TC 250, TX 300)
– Position the main silencer with rubber sleeve
.
– Mount and tighten screws
with the washers.
Guideline
Remaining screws, chassis M6
F00250-11
Finishing work
– Install the right side cover. ( p. 61)
11.30
Changing the glass fiber yarn filling in 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.
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. 60)
– Remove the main silencer. ( p. 58)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
11 SERVICE WORK ON THE CHASSIS
Main work
– Remove screws
. Pull out inner tube
– Remove the glass fiber yarn filling
.
from the inner tube.
– Clean the parts that need to be reinstalled and check for damage.
– Fit the new glass fiber yarn filling
into the inner tube.
– Slide outer tube
over the inner tube with the new glass fiber yarn filling.
– Mount and tighten all screws
.
Guideline
Screws on the main silencer M5 7 Nm (5.2 lbf ft)
60
402580-11
Finishing work
– Install the main silencer. ( p. 59)
– Install the right side cover. ( p. 61)
11.31
Removing the right side cover
(All TC models)
– Remove screw
.
– Pull off the side cover sideways in areas front.
and
, and remove toward the
H01561-10
(TX 300)
– Remove screw
.
– Pull off the side cover sideways in areas front.
and
, and remove toward the
H01562-10
11 SERVICE WORK ON THE CHASSIS
11.32
Installing the right side cover
(All TC models)
– Position the side cover on collar bushings rear.
– Engage the side cover in areas
and
.
and
, and push toward the
– Mount and tighten screw
.
Guideline
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
61
H01563-10
(TX 300)
– Position the side cover on collar bushings rear.
– Engage the side cover in areas
and
.
and
, and push toward the
– Mount and tighten screw
.
Guideline
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
H01564-10
11.33
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 not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
11 SERVICE WORK ON THE CHASSIS
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Preparatory work
(All TC models)
– Turn handle
of the fuel tap to the OFF position.
(TX 300)
– Turn handle
of the fuel tap to the OFF position.
– Remove the air filter box cover. ( p. 55)
– Remove the right side cover. ( p. 60)
Main work
– Pull off the fuel hose.
Info
Remaining fuel may flow out of the fuel hose.
– Remove screws
.
H01413-12
(All TC models)
– Remove screw
with the rubber bushing.
– Pull the fuel tank breather hose off the tank lid.
H01414-12
(TX 300)
– Remove screw
with the rubber bushing.
– Pull the fuel tank breather hose off the tank lid.
F00113-12
– Pull both spoilers off the sides of the radiator bracket and lift off the fuel tank.
62
H01415-10
11 SERVICE WORK ON THE CHASSIS
11.34
Installing 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 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 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. 68)
– Position the fuel tank and fit the two spoilers to the sides of the radiator bracket.
– Make sure that no cables or throttle cables are trapped or damaged.
63
H01415-11
(All TC models)
– Mount the fuel tank breather hose.
– Mount and tighten screw
with the rubber bushing.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
H01414-11
(TX 300)
– Mount the fuel tank breather hose.
– Mount and tighten screw
with the rubber bushing.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
F00113-11
– Mount and tighten screws
.
Guideline
Remaining screws, chassis
– Connect the fuel hose.
M6 10 Nm (7.4 lbf ft)
H01413-11
11 SERVICE WORK ON THE CHASSIS
Finishing work
– Install the right side cover. ( p. 61)
– Install the air filter box cover. ( p. 56)
11.35
Checking the chain for dirt
– Check the chain for heavy soiling.
» If the chain is very dirty:
400678-01
11.36
Cleaning the chain
Warning
Danger of accidents Oil or grease on the tires reduces the road grip.
– Remove the lubricant from the tires using a suitable cleaning agent.
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
The service life of the chain depends largely on its maintenance.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work
– Clean the chain regularly and then treat with chain spray.
400725-01
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)
64
11 SERVICE WORK ON THE CHASSIS
11.37
Checking the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel 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. 43)
Main work
– Pull the chain at the end of the chain sliding component upwards to measure chain tension
.
Info
The bottom chain section positions.
must be taut.
Chain wear is not always even; repeat this measurement at different chain
F00251-10
Chain tension 55… 58 mm (2.17… 2.28 in)
» If the chain tension does not meet specifications:
– Adjust the chain tension. ( p. 65)
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)
11.38
Adjusting the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel 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. 43)
– Check the chain tension. ( p. 65)
65
11 SERVICE WORK ON THE CHASSIS
M01311-10
Main work
– Loosen nut
– Loosen nuts
.
.
– Adjust the chain tension by turning adjusting screws
left and right.
Guideline
Chain tension 55… 58 mm (2.17… 2.28 in)
Turn adjusting screws left and right chain adjusters are in the same position relative to reference marks
on the left and right so that the markings on the
. The rear wheel is then correctly aligned.
– Tighten nuts
.
– Make sure that chain adjusters
are fitted correctly on adjusting screws .
– Tighten nut
Guideline
.
Nut, rear wheel spindle M25x1.5
80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters (32 mm (1.26 in)) enables different secondary ratios with the same chain length.
Chain adjusters
can be turned by 180°.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)
11.39
Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work
– Shift the transmission to idle.
– Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket and engine sprocket are worn:
– Change the drivetrain kit.
Info
The engine sprocket, rear sprocket, and chain should always be replaced together.
400227-01
– Pull at the top part of the chain with the specified weight
.
Guideline
Weight, chain wear measurement 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 chain section
at the longest
272 mm (10.71 in)
» If distance
is greater than the specified measurement:
– Change the drivetrain kit.
Info
When the chain is replaced, the rear sprocket and engine sprocket should also be changed.
New chains wear out faster on old, worn sprockets.
400987-10
66
11 SERVICE WORK ON THE CHASSIS
– Check the chain sliding guard for wear.
» If the lower edge of the chain pins is in line with or below the chain sliding guard:
– Change the chain sliding guard.
– Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
– Tighten the screws on the chain sliding guard.
Guideline
Screw, chain sliding guard
M6 6 Nm
(4.4 lbf ft)
Loctite ® 243™
67
H01555-10
– 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 sliding piece M8 15 Nm
(11.1 lbf ft)
H01556-10
– Check the chain guide for wear.
Info
Wear can be seen on the front of the chain guide.
» If the light part of the chain guide is worn:
– Change the chain guide.
401760-01
– Check that the chain guide is firmly seated.
» If the chain guide is loose:
– Tighten the fitting on the chain guide.
Guideline
Remaining screws, chassis M6
Remaining nuts, chassis M6
M01368-01
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)
10 Nm
(7.4 lbf ft)
10 Nm
(7.4 lbf ft)
11 SERVICE WORK ON THE CHASSIS
11.40
Checking the frame
– Check the frame for cracks and deformation.
» If the frame exhibits cracks or deformation 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.
M01314-01
11.41
Checking the swingarm
– Check the swingarm for damage, cracking, and deformation.
» If the swingarm shows signs of damage, cracking, or deformation:
– Change the swingarm.
Info
Always change a damaged swingarm. Repair of the swingarm is not authorized by Husqvarna Motorcycles.
68
401520-01
11.42
Checking the throttle cable routing
Preparatory work
(All TC models)
– Turn handle
of the fuel tap to the OFF position.
(TX 300)
– Turn handle
of the fuel tap to the OFF position.
– Remove the air filter box cover. ( p. 55)
– Remove the right side cover. ( p. 60)
– Remove the fuel tank.
Main work
(TC 125)
– Check the throttle cable routing.
The throttle cable must be routed along the back of the handlebar, to the right of the frame, above the fuel tank bracket, and to the carburetor. The throttle cable must be secured behind the fuel tank contact area rubber band.
» If the throttle cable is not routed as specified:
– Correct the throttle cable routing.
H01554-01
11 SERVICE WORK ON THE CHASSIS
(TC 250, TX 300)
– Check the throttle cable routing.
The throttle cable must be routed along the back of the handlebar, to the right of the frame, above the fuel tank bracket, and to the carburetor. The throttle cable must be fixed on the fuel tank bracket with a rubber band.
» If the throttle cable is not routed as specified:
– Correct the throttle cable routing.
69
H01552-10
Finishing work
– Install the fuel tank.
– Install the right side cover. ( p. 61)
– Install the air filter box cover. ( p. 56)
11.43
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 with the sleeve or the throttle tube.
» If a rubber grip is damaged or worn
– Change the rubber grip.
– Check that screw
Guideline
Screw, fixed grip
is firmly seated.
M4 5 Nm
(3.7 lbf ft)
Loctite ® 243™
Diamond
must be located at the top.
M01455-10
11.44
Adjusting the basic position of the clutch lever
– Adjust the basic position of the clutch lever to your hand size by turning adjusting screw
.
H01557-10
Info
When the adjusting screw is turned counterclockwise, the clutch lever moves away from the handlebar.
When the adjusting screw is turned 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.
11 SERVICE WORK ON THE CHASSIS
11.45
Checking/correcting the fluid level of the hydraulic clutch
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 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.
70
Info
The fluid level rises with increasing wear of the clutch facing discs.
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 parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
H01558-10
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws
.
– Remove cover
with membrane
.
– Check the fluid level.
Fluid level below container rim 4 mm (0.16 in)
» If the fluid level does not meet specifications:
– Correct the fluid level of the hydraulic clutch.
– Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilled brake fluid immediately with water.
11.46
Changing the hydraulic clutch fluid
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 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 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 parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
11 SERVICE WORK ON THE CHASSIS
71
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws
.
– Remove cover
with membrane
.
H01558-10
(TC 125)
– Fill bleeding syringe
with the appropriate hydraulic fluid.
Bleed syringe (50329050000)
– Remove bleeder screw
– Mount bleeding syringe
.
on the clutch slave cylinder.
F00252-10
(TC 250, TX 300)
– Fill bleeding syringe
with the appropriate hydraulic fluid.
Bleed syringe (50329050000)
– Remove bleeder screw
– Mount bleeding syringe
.
on the clutch slave cylinder.
F00253-10
H01559-10
– Now inject the liquid into the system until it emerges from drill hole master cylinder without bubbles.
of the
– 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 fluid immediately with water.
12 BRAKE SYSTEM
12.1
Checking the free travel of the hand brake lever
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.
– Push the hand brake lever forward and check free travel
.
Free travel of hand brake lever
≥ 3 mm (≥ 0.12 in)
» If the free travel does not meet specifications:
– Adjust the basic position of the hand brake lever. ( p. 72)
12.2
K00531-11
Adjusting the basic position of the hand brake lever
– Check the free travel of the hand brake lever. ( p. 72)
– Adjust the basic position of the hand brake lever to your hand size by turning adjusting screw
.
K00531-10
Info
Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar.
The range of adjustment is limited.
Only turn the adjusting screw by hand, and do not use force.
Do not make any adjustments while riding.
12.3
Checking the brake 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 Motorcycles workshop will be glad to help.)
400257-10
– Check the thickness of the front and rear brake discs at multiple points on each brake disc to ensure it is at least thickness
.
Info
Wear reduces the thickness of the brake disc around the area used by the brake linings.
Brake discs - wear limit
Front
Rear
2.5 mm (0.098 in)
3.5 mm (0.138 in)
» If the brake disc thickness is less than the specified value:
– Change the front brake disc.
– Change the rear brake disc.
– Check the front and rear brake discs for damage, cracking, and deformation.
» If the brake disc exhibits damage, cracking, or deformation:
– Change the front brake disc.
– Change the rear brake disc.
72
12 BRAKE SYSTEM
73
12.4
Checking the front 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 Husqvarna Motorcycles workshop will be glad to help.)
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 authorized Husqvarna Motorcycles workshop will be glad to help.)
Preparatory work
– Check the front brake linings. ( p. 74)
Main work
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in the viewer
.
» If the brake fluid level is below the
marking:
– Add front brake fluid.
K00538-10
12.5
Adding front brake fluid
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 Husqvarna Motorcycles 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 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 authorized Husqvarna Motorcycles workshop will be glad to help.)
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.
12 BRAKE SYSTEM
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 fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
Preparatory work
– Check the front brake linings. ( p. 74)
Main work
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws
– Remove cover
.
with membrane
.
– Add brake fluid to level
.
Guideline
Level
(brake fluid level below reservoir rim)
5 mm (0.2 in)
– Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilled brake fluid immediately with water.
74
K00532-10
12.6
Checking the front brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
– Check the brake linings for minimum thickness
.
Minimum thickness
≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the front brake linings.
– Check the brake linings for damage and cracking.
» If damage or cracking is visible:
– Change the front brake linings.
F00062-10
12.7
Changing the front brake linings
Warning
Danger of accidents Incorrect maintenance will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
12 BRAKE SYSTEM
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 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 authorized Husqvarna Motorcycles workshop will be glad to help.)
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.
75
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 fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws
.
– Remove cover
with membrane
.
K00533-10
F00064-10
– Manually press the brake caliper toward the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, if necessary extract excess.
Info
Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.
– Remove cotter pins
, pull out pin
, and remove the brake linings.
– Clean the brake caliper and brake caliper support.
– Check that leaf spring
in the brake caliper and sliding plate caliper support are seated correctly.
in the brake
100397-01
12 BRAKE SYSTEM
76
– Insert the new brake linings, insert pin
, and mount cotter pins .
Info
Always change the brake linings in pairs.
– Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.
F00064-11
– Correct the brake fluid quantity to level
.
Guideline
Level
(brake fluid level below reservoir rim)
5 mm (0.2 in)
– Position cover
with membrane
– Mount and tighten screws
.
.
Info
Clean up overflowed or spilled brake fluid immediately with water.
K00532-10
12.8
Checking the free travel of foot brake lever
Warning
Danger of accidents 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.
– Disconnect spring
.
– Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel
.
Guideline
Free travel at 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. 76)
– Reconnect spring
.
402026-10
12.9
Adjusting the basic position of the foot brake lever
Warning
Danger of accidents 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.
12 BRAKE SYSTEM
77
K00534-10
– Detach spring
.
– Loosen nut travel.
and, with push rod
, turn it back until you have maximum free
– To adjust the basic position of the foot brake lever to individual requirements, loosen nut and turn screw accordingly.
Info
The range of adjustment is limited.
– Turn push rod
accordingly until you have free travel the basic position of the foot brake lever.
. If necessary, adjust
Guideline
Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)
– Hold screw
and tighten nut
.
Guideline
Nut, foot brake lever stop
– Hold push rod
and tighten nut
.
Guideline
Remaining nuts, chassis
– Attach spring
.
M8
M6
20 Nm (14.8 lbf ft)
10 Nm (7.4 lbf ft)
12.10
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 Husqvarna Motorcycles workshop will be glad to help.)
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 authorized Husqvarna Motorcycles workshop will be glad to help.)
Preparatory work
– Check the rear brake linings. ( p. 79)
Main work
– Stand the vehicle upright.
– Check the brake fluid level in level viewer
.
» If the brake fluid has dropped below marking
– Add rear brake fluid.
:
K00535-10
12 BRAKE SYSTEM
78
12.11
Adding rear brake fluid
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 Husqvarna Motorcycles 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 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 authorized Husqvarna Motorcycles workshop will be glad to help.)
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
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 fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
K00536-10
Preparatory work
– Check the rear brake linings. ( p. 79)
Main work
– Stand the vehicle upright.
– Remove screw cap
with membrane
and the O-ring.
– Add brake fluid to level
.
– Mount the screw cap with the membrane and the O-ring.
Info
Clean up overflowed or spilled brake fluid immediately with water.
12 BRAKE SYSTEM
12.12
Checking the rear brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
– Check the brake linings for minimum thickness
.
Minimum thickness
≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the rear brake linings.
– Check the brake linings for damage and cracking.
» If damage or cracking is visible:
– Change the rear brake linings.
M01327-10
12.13
Changing the rear brake linings
Warning
Danger of accidents Incorrect maintenance will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized Husqvarna Motorcycles 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 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 authorized Husqvarna Motorcycles workshop will be glad to help.)
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 coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the warranty shall be void.
– Only use brake linings approved and recommended by Husqvarna motorcycles.
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.
79
12 BRAKE SYSTEM
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 fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
– Stand the vehicle upright.
– Remove screw cap
with membrane
and the O-ring.
80
K00537-10
M01328-10
– Manually press the brake caliper to the brake disc to push back the brake piston.
Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does.
Info
Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.
– Remove cotter pins
, pull out pin , and remove the brake linings.
– Clean the brake caliper and brake caliper support.
– Check that leaf spring
in the brake caliper and sliding plate caliper support are seated correctly.
in the brake
Info
The arrow on the leaf spring points in the rotation direction of the brake disc.
M00288-10
M01329-10
– Insert the new brake linings, insert pin
, and mount cotter pins
.
Info
Always change the brake linings in pairs.
Make sure that decoupling plate lining.
is mounted on the piston side brake
– Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.
– Add brake fluid to level
.
– Mount and tighten screw cap
with membrane
and the O-ring.
Info
Clean up overflowed or spilled brake fluid immediately with water.
K00536-10
13 WHEELS, TIRES
13.1
Removing the front wheel
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work
– Press the brake caliper onto the brake disc by hand in order 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.
81
F00066-10
– Loosen screw
– Remove screw
by several rotations.
– Loosen screws
– Press on screw
.
to push the wheel spindle out of the axle clamp.
.
F00067-10
F00068-10
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 out of the fork.
Info
Do not pull the hand brake lever when the front wheel is removed.
– Remove spacers
.
H00934-10
13.2
Installing the front wheel
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.
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change the front wheel bearing.
– Clean and grease shaft seal rings
and contact surface
of the spacers.
H00935-10
13 WHEELS, TIRES
13.3
F00067-11
M01332-10
– Insert the spacers.
– Lift the front wheel into the fork, position it, and insert the wheel spindle.
The brake linings are correctly positioned.
– Mount and tighten screw
.
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 motorcycle from the lift stand. ( p. 43)
– Operate the front brake and compress the fork a few times firmly.
The fork legs straighten.
– Tighten screws
.
Guideline
Screw, fork stub M8 15 Nm (11.1 lbf ft)
Removing the rear wheel
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work
– Press the brake caliper onto the brake disc by hand in order to push back the brake piston.
Info
Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.
– Remove nut
.
– Remove chain adjuster
. Withdraw wheel spindle rear wheel to be pushed forward.
only enough to allow the
– 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 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.
– Remove spacers
.
82
H00936-10
13 WHEELS, TIRES
13.4
Installing the rear wheel
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.
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
and contact surface
of the spacers.
– Insert the spacers.
H00937-10
– Position the rear wheel and insert wheel spindle
.
The brake linings are correctly positioned.
– Mount the chain.
83
M01333-10
– Position chain adjuster
.
. Mount nut
, but do not tighten it yet.
– Make sure that chain adjusters
– Check the chain tension. ( p. 65)
are fitted correctly on adjusting screws
.
– Tighten nut
Guideline
Nut, rear wheel spindle M25x1.5
80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters (32 mm (1.26 in)) enables different secondary ratios with the same chain length.
Chain adjusters
can be turned by 180°.
– Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.
M01334-10
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)
13 WHEELS, TIRES
84
13.5
Checking the tire condition
Info
Only mount tires approved and/or recommended by Husqvarna Motorcycles.
Other tires could have a negative effect on handling characteristics.
The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcycle.
The tires mounted on the front and rear wheels must have a similar profile.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
400602-10
H01144-01
– Check the front and rear tires for cuts, run-in objects, and other damage.
» If the tires have cuts, run-in objects, or other damage:
– Change 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.
– 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 the last two digits the year of manufacture.
Husqvarna Motorcycles recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear.
» If the tires are more than 5 years old:
– Change the tires.
13.6
Checking the tire air pressure
Info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
400695-01
– Remove the dust cap.
– Check the tire air pressure when the tires are cold.
Tire air pressure off road
Front
Rear
1.0 bar (15 psi)
1.0 bar (15 psi)
» If the tire pressure does not meet specifications:
– Correct the tire pressure.
– Mount the dust cap.
13.7
Checking spoke tension
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a result.
– Check spoke tension regularly, and in particular on a new vehicle. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
13 WHEELS, TIRES
85
400694-01
– Strike each spoke briefly using a screwdriver blade.
Info
The frequency of the sound depends on the spoke length and spoke diameter.
If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions.
You should hear a high note.
» If the spoke tension differs:
– Correct the spoke tension.
– Check the spoke torque.
Guideline
Spoke nipple, front wheel
Spoke nipple, rear wheel
M4.5
M4.5
Torque wrench with various accessories in set (58429094000)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
14 ELECTRICAL SYSTEM
14.1
Removing the battery (TX 300)
Warning
Risk of injury Batteries contain harmful substances.
– Keep batteries out of the reach of children.
– Keep sparks and open flames away from the batteries.
– Only charge batteries in well-ventilated rooms.
– Maintain a minimum clearance from inflammable materials when charging batteries.
Minimum clearance 1 m (3 ft)
– Do not charge deeply discharged batteries if charge is already below the minimum voltage.
Minimum voltage before the start of the charge 9 V
– Dispose of batteries with less than the minimum voltage correctly.
Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the air filter box cover. ( p. 55)
Main work
– Pull back the negative terminal cover the battery.
– Pull back the positive terminal cover the battery.
and disconnect negative cable
from
and disconnect positive cable
from
– Remove screw
.
– Pull holding bracket
forward and take out the battery toward the top.
86
14.2
H01190-10
Installing the battery (TX 300)
Main work
– Position the battery in the battery compartment with the terminals facing forward, and secure with holding bracket .
– Mount and tighten screw
.
Guideline
Screw, battery support bracket M6
– Connect positive cable
to the battery.
Guideline
Screw, battery terminal M5
10 Nm (7.4 lbf ft)
2.5 Nm
(1.84 lbf ft)
Contact disks
must be mounted under screws with the claws toward the battery terminal.
and cable sockets
– Slide positive terminal cover
over the positive terminal.
H00388-10
14 ELECTRICAL SYSTEM
– Connect negative cable
to the battery.
Guideline
Screw, battery terminal M5 2.5 Nm
(1.84 lbf ft)
– Slide negative terminal cover
over the negative terminal.
Finishing work
– Install the air filter box cover. ( p. 56)
14.3
Recharging the battery (TX 300)
Warning
Risk of injury Batteries contain harmful substances.
– Keep batteries out of the reach of children.
– Keep sparks and open flames away from the batteries.
– Only charge batteries in well-ventilated rooms.
– Maintain a minimum clearance from inflammable materials when charging batteries.
Minimum clearance 1 m (3 ft)
– Do not charge deeply discharged batteries if charge is already below the minimum voltage.
Minimum voltage before the start of the charge 9 V
– Dispose of batteries with less than the minimum voltage correctly.
Warning
Environmental hazard Batteries contain environmentally-hazardous materials.
– Do not dispose of batteries as household waste.
– Return batteries to your authorized Husqvarna Motorcycles dealer or dispose of them at a collection point for used batteries.
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.
87
Info
Even when there is no load on the battery, it discharges steadily.
The charging level and the method of charging are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, or charging time 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 sulfated, destroying the battery.
The battery is maintenance-free.
Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the air filter box cover. ( p. 55)
– Remove the battery.
Main work
– Check the battery voltage.
» Battery voltage: < 9 V
– Do not charge the battery.
– Replace the battery and dispose of the old battery properly.
» If the specifications have been met:
Battery voltage: ≥ 9 V
F00114-10
14 ELECTRICAL SYSTEM
– Recharge the battery.
Guideline
The charging current, charging voltage, and charging time must not be exceeded.
Maximum charging voltage 14.4 V
Maximum charging current
Charge the battery regularly when the motorcycle is not in use
3.0 A
6 months
Info
Never remove cover
.
– Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (81229074000)
In addition, this battery charger can be used to test the quiescent current, the start ability of the battery, and the alternator. With this device, you cannot overcharge the battery. The charging time may be longer at low temperatures.
– Switch off the battery charger after charging and disconnect from the battery.
Finishing work
– Install the battery.
– Install the air filter box cover. ( p. 56)
14.4
Changing the main fuse (TX 300)
Warning
Fire hazard Incorrect fuses overload the electrical system.
– Only use fuses with the required ampere value.
– Do not bypass or repair fuses.
88
Info
The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the seat.
Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the air filter box cover. ( p. 55)
Main work
– Pull starter relay
from the holder.
E00308-10
14 ELECTRICAL SYSTEM
– Take off protection caps
– Remove faulty main fuse
.
.
Info
You can recognize a defective fuse by a burned-out fuse wire
A spare fuse
is located in the starter relay.
.
– Install a new main fuse.
– Check that the electrical equipment is functioning properly.
Tip
Insert a spare fuse so that it is available if needed.
– Mount the protection caps.
– Mount the starter relay onto the holder and route the cable.
89
E00309-10
Finishing work
– Install the air filter box cover. ( p. 56)
15 COOLING SYSTEM
15.1
15.2
90
Cooling system
S01292-11
(TC 125)
Water pump
in the engine ensures forced circulation of the coolant.
The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap
. This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.
(TC 250, TX 300)
Water pump in the engine ensures forced circulation of the coolant.
The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap
. This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.
S01293-11
Radiator cover (TC 125)
The radiator cover is mounted in front of the left radiator between the radiator shield and radiator.
The radiator cover keeps the coolant temperature in the correct range.
Coolant temperature 65… 70 °C (149… 158 °F)
15.3
S01296-01
M01121-10
The radiator cover is installed in front of the left radiator, depending on the ambient temperature.
Full radiator cover
< 7 °C (< 45 °F)
Half radiator cover
No radiator cover
7… 16 °C (45… 61 °F)
> 16 °C (> 61 °F)
Info
Do not use both radiator covers at the same time.
Installing the radiator cover (TC 125)
– Remove screws
– Remove screws
.
.
– Take off radiator shield
.
S01294-10
15 COOLING SYSTEM
– Position the matching radiator cover ( p. 90).
The larger catch is located at the top left.
Info
Do not use both radiator covers at the same time.
15.4
S01295-10
– Position radiator shield
.
– Mount and tighten screws
.
Guideline
Remaining screws, chassis
– Mount and tighten screws
.
Guideline
Remaining screws, chassis
S01294-10
Removing the radiator cover (TC 125)
S01294-10
– Remove screws
– Remove screws
.
.
– Take off radiator shield
.
– Remove the radiator cover.
– Position radiator shield
.
– Mount and tighten screws
.
Guideline
Remaining screws, chassis
– Mount and tighten screws
.
Guideline
Remaining screws, chassis
M6
M6
M6
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
M6 10 Nm (7.4 lbf ft)
15.5
Checking the antifreeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
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 plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
91
15 COOLING SYSTEM
400243-10
– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the antifreeze in the coolant.
−25… −45 °C (−13… −49 °F)
» If the antifreeze in the coolant does not match the specified value:
– Correct the antifreeze in the coolant.
– Check the coolant level in the radiator.
Coolant level fins
above the radiator
10 mm (0.39 in)
» If the coolant level does not match the specified value:
– Correct the coolant level.
– Mount the radiator cap.
15.6
Checking the coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
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 plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
400243-10
Condition
The engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the coolant level in the radiator.
Coolant level fins
above the radiator
10 mm (0.39 in)
» If the coolant level does not match the specified value:
– Correct the coolant level.
– Mount the radiator cap.
92
15 COOLING SYSTEM
15.7
Draining the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
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 plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
– Position the motorcycle upright.
– Place a suitable container under the water pump cover.
(TC 125)
– Remove screw
. Take off radiator cap
.
– Completely drain the coolant.
– Mount and tighten screw
with a new seal ring.
Guideline
Drain plug, water pump cover M6 8 Nm (5.9 lbf ft)
93
S01292-10
(TC 250, TX 300)
– Remove screw
. Take off radiator cap
.
– Completely drain the coolant.
– Mount and tighten screw
with a new seal ring.
Guideline
Screw, water pump cover (TC 250)
Screw, water pump cover (TX 300)
M6
M6
S01293-10
15.8
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 and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
15 COOLING SYSTEM
(TC 125)
– Make sure that screw
is tightened.
– Position the motorcycle upright.
– Completely fill the radiator with coolant.
94
M01337-10
– Loosen screw
until coolant escapes without bubbles.
– Mount and tighten screw
.
Guideline
Bleeder screw, cylinder head M6
– Completely fill the radiator with coolant.
8 Nm (5.9 lbf ft)
M01338-10
S01287-10
– Mount radiator cap
.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
– Allow the engine to warm up and cool down again.
– Check the cooling system for leaks.
– Check the coolant level. ( p. 92)
(TC 250, TX 300)
– Make sure that screw
is tightened.
– Position the motorcycle upright.
– Completely fill the radiator with coolant.
S01288-10
S01289-10
– Loosen screw
until coolant escapes without bubbles.
– Mount and tighten screw
.
Guideline
M6 Bleeder screw, cylinder head
(TC 250)
Bleeder screw, cylinder head
(TX 300)
M6
– Completely fill the radiator with coolant.
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
15 COOLING SYSTEM
S01287-10
95
– Mount radiator cap
.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
– Allow the engine to warm up and cool down again.
– Check the cooling system for leaks.
– Check the coolant level. ( p. 92)
16 TUNING THE ENGINE
16.1
16.2
96
Checking the play in the throttle cable
– Check the throttle grip for smooth operation.
– Move the handlebar to the straight-ahead position. Move the throttle grip back and forth slightly to determine the play in throttle cable
.
Play in throttle cable 2… 3 mm (0.08… 0.12 in)
» If the throttle cable play does not meet specifications:
– Adjust the play in the throttle cable. ( p. 96)
400192-11
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
– 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. 96)
Adjusting the play in the throttle cable
Preparatory work
(All TC models)
– Turn handle
of the fuel tap to the OFF position.
(TX 300)
– Turn handle
of the fuel tap to the OFF position.
– Remove the air filter box cover. ( p. 55)
– Remove the right side cover. ( p. 60)
– Remove the fuel tank.
– Check the throttle cable routing. ( p. 68)
Main work
– Move the handlebar to the straight-ahead position.
– Push back sleeve
.
– Ensure that the throttle cable sleeve is pushed all the way into barrel adjuster
– Loosen nut
.
.
S01285-10
– Turn adjusting screw tle grip.
Guideline
in such a way there is throttle cable play
in the throt-
Play in throttle cable 2… 3 mm (0.08… 0.12 in)
– Tighten nut
.
– Slide on sleeve
.
400192-11
Finishing work
– Check the throttle grip for smooth operation.
– Install the fuel tank.
– Install the right side cover. ( p. 61)
16 TUNING THE ENGINE
– Install the air filter box cover. ( p. 56)
– Check the play in the throttle cable. ( p. 96)
16.3
Carburetor setting
Effects of the carburetor setting
97
H01400-01
The different carburetor components must be tuned both to one another and for the use intended.
Main jet MJ
The main jet MJ has the greatest influence with the throttle slide open (full throttle).
If the insulator of a new spark plug is very light or white after a brief ride at full throttle, or if the engine knocks, a larger main jet needs to be used. If the insulator is dark brown or sooty, a smaller main jet needs to be used.
Needle position POS
The needle position has the greatest influence in the mid throttle slide range.
If the engine stutters when accelerating with a partially open throttle slide, the jet needle must be lowered. If the engine knocks when accelerating at the full power rpm range, the jet needle must be raised.
Cylindrical part of the needle CYL
The cylindrical part of the needle has the greatest influence when the throttle slide is almost closed.
Idling jet IJ
The idling jet has the greatest influence in the low to mid throttle slide range.
If the engine stutters when idling or accelerating with a partially open throttle slide, a smaller idling jet must be used. If the engine knocks in this power range, then a larger idling jet must be used.
Idle air adjusting screw open ASO
The idle air adjusting screw has the greatest influence during idling.
16 TUNING THE ENGINE
98
Influence of throttle slide adjustment
1 1
3
1
/
/
4
2
3
/
4
1
/
2
1
1
/
/
4
0
8
/
/
1
1
4
0
8
K00495-01
The idling jet has the greatest influence when the throttle slide is closed. The first cylindrical part of the needle and the clip position have only minimal influence.
When the throttle slide is 1/8 open, the first cylindrical part of the needle, the idling jet and the clip position have the greatest influence.
1 1
3
1
/
/
4
2
3
/
4
1
/
2
/
/
1
1
4
0
8
/
/
1
1
4
0
8
K00496-01
When the throttle slide is 1/4 open, the idling jet and the clip position have the greatest influence. The influence of the first cylindrical part of the needle is less.
When the throttle slide is 1/2 open, the position of the needle has the greatest influence. The influence of the main jet and the idling jet is only minimal.
1 1
3
1
/
/
4
2
3
/
4
1
/
2
1
1
/
/
4
0
8
/
/
1
1
4
0
8
K00497-01
When the throttle slide is 3/4 open, the influence of the main jet is greatest. The clip position and the idling jet have only minimal influence.
When the throttle slide is fully open, the influence of the main jet is greatest. The clip position and the idling jet have only minimal influence.
Needle overview
The jet needles available are shown in the following table.
402674-01
Column 2 corresponds to a needle in the standard position.
Column 1 corresponds to a needle which is half a clip leaner.
Column 3 corresponds to a needle which is half a clip richer.
Column 4 specifies the diameter of the first cylindrical part of the needle. The smaller the diameter of the first cylindrical part of the needle, the richer the carburation. The larger the diameter of the first cylindrical part of the needle, the leaner the carburation. The first cylindrical part of the needle has the greatest influence in the lowest load adjustment.
16 TUNING THE ENGINE
Info
The top right jet needle A3 corresponds to the richest setting of the carburetor, and the bottom left jet needle F1 corresponds to the leanest. The optimal carburetor tuning is shown under the respective model.
Clip position
1... 5 Clip position from above
The five possible clip positions are shown here.
The carburetor tuning depends on the defined ambient and operating conditions.
99
16.4
16.5
B00075-10
Carburetor – idle
S01283-11
The idle setting of the carburetor has a big influence on the starting behavior, stable idling, and the response to throttle opening. This means that an engine with a correctly set idle speed is easier to start than if the idle speed is set wrongly.
Info
The carburetor and its components are subject to increased wear caused by engine vibration. Wear can result in malfunctioning.
The factory setting for the carburetor is set for the following values.
(TC 125)
Height above sea level 301… 750 m (988… 2,461 ft)
Ambient temperature 16… 24 °C (61… 75 °F)
Super unleaded (98 octane) mixed with 2-stroke engine oil (1:40) ( p. 129)
(TC 250, TX 300)
Height above sea level 301… 750 m (988… 2,461 ft)
Ambient temperature 6… 15 °C (43… 59 °F)
Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60) ( p. 129)
The idle speed is adjusted with adjusting screw
.
The idle mixture is adjusted with idle air adjusting screw
.
Carburetor – adjusting the idle speed
– Screw in idle air adjusting screw position.
all the way and turn it to the specified basic
Info
The basic adjustment is shown under the respective model.
– Run the engine until warm.
Guideline
Warm-up time
≥ 5 min
S01283-10
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
– Adjust the idle speed with adjusting screw
.
16 TUNING THE ENGINE
100
Guideline
Choke function deactivated – The choke lever is pushed in to the stop.
Idle speed 1,400… 1,500 rpm
– Turn idle air adjusting screw speed begins to fall.
slowly in a clockwise direction until the idle
– Note the position and turn the idle air adjusting screw slowly counterclockwise until the idle speed again begins to fall.
– Adjust to the point between these two positions with the highest idle speed.
Info
If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps.
If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet.
If you can turn the idle air adjusting screw to the end without any change of engine speed, mount a smaller idling jet.
After changing the jet, start from the beginning with the adjusting steps.
Following extreme air temperature or altitude changes, adjust the idle speed again.
16.6
Emptying the carburetor float chamber
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.
– 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 affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Info
Carry out this work with a cold engine.
Water in the float chamber results in malfunctioning.
Preparatory work
(All TC models)
– Turn handle
of the fuel tap to the OFF position.
Fuel no longer flows from the fuel tank to the carburetor.
16 TUNING THE ENGINE
(TX 300)
– Turn handle
of the fuel tap to the OFF position.
Fuel no longer flows from the fuel tank to the carburetor.
Main work
– Place a cloth under the carburetor to capture the draining fuel.
(TC 125)
– Remove screw plug
.
– Fully drain the fuel.
– Mount and tighten the screw plug.
101
S01290-10
(TC 250, TX 300)
– Remove screw plug
– Fully drain the fuel.
.
– Mount and tighten the screw plug.
16.7
S01291-10
Plug-in connector of ignition timing map adjustment
(All TC models)
Plug-in connector
of the ignition timing map adjustment is located on the frame under the fuel tank.
S01279-10
S01280-10
(TX 300)
Plug-in connector
of the ignition timing map adjustment is located on the frame under the fuel tank.
Possible states
(All TC models)
• Soft – The plug-in connector of the ignition timing map adjustment is disconnected to achieve better rideability.
• Performance – The plug-in connector of the ignition timing map adjustment is joined to achieve higher performance.
(TX 300)
• Soft – The plug-in connector of the ignition timing map adjustment is disconnected to achieve better rideability.
• Performance – The plug-in connector of the ignition timing map adjustment is joined to achieve higher performance.
16 TUNING THE ENGINE
16.8
Changing the ignition timing map
Switch the ignition timing map from Performance to Soft
(All TC models)
– Disconnect plug-in connector
of the ignition timing map adjustment. (Figure S01279-10 p. 101)
Soft – better rideability
(TX 300)
– Disconnect plug-in connector
of the ignition timing map adjustment. (Figure S01280-10 p. 101)
Soft – better rideability
Switch the ignition timing map from Soft to Performance
(All TC models)
– Join plug-in connector
of the ignition timing map adjustment. (Figure S01279-10 p. 101)
Performance – better performance
(TX 300)
– Join plug-in connector
of the ignition timing map adjustment. (Figure S01280-10 p. 101)
Performance – better performance
16.9
Checking the basic position of the shift lever
Info
When driving, the shift lever must not touch the rider's boot when in the basic position.
When the shift lever keeps touching the boot, the transmission will be subject to an excessive load.
– Sit on the vehicle in the riding position and determine distance upper edge of your boot and the shift lever.
between the
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. 102)
102
400692-10
16.10
Adjusting the basic position of the shift lever
– Remove screw
with washers and take off shift lever .
401950-12
401951-10
– Clean gear teeth
of the shift lever and shift shaft.
– Mount the shift lever on the shift shaft in the required position and engage the gearing.
Info
The range of adjustment is limited.
The shift lever must not come into contact with any other vehicle components during the shift procedure.
– Locate and tighten screw
with washers.
Guideline
Screw, shift lever M6 14 Nm
(10.3 lbf ft)
Loctite ® 243™
16 TUNING THE ENGINE
103
16.11
Engine characteristic – auxiliary spring (TC 250, TX 300)
The auxiliary spring is located on the right side of the engine below the water pump cover.
Possible states
• Auxiliary spring with yellow marking – Auxiliary spring mounted at the factory with medium tuning (standard) for good rideability.
• Auxiliary spring with green marking – Auxiliary spring for even softer performance.
• Auxiliary spring with red marking – Auxiliary spring for aggressive performance.
B00056-10
The engine characteristic can be influenced by different spring strengths of auxiliary spring
.
16.12
Engine characteristic – setting the auxiliary spring (TC 250, TX 300)
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Preparatory work
– Tilt the motorcycle to the left and secure against falling in this position.
Guideline
Angle of title approx.
45°
Main work
– Remove screws
.
S01281-10
– Remove cap
, adjusting spring from the clutch cover.
, auxiliary spring
, and spring insert
– Pull both springs off of the spring insert.
B00056-11
S01282-10
– Mount the required auxiliary spring them together in the clutch cover.
and adjusting spring
and position
Auxiliary spring with yellow marking (54637072300)
Auxiliary spring with green marking (54837072100)
Auxiliary spring with red marking (54837072000)
The recess in spring insert
engages in the angle lever.
Info
Screw istic.
must not be turned as this would worsen the engine character-
– Check the O-ring in the cap.
– Position the cap.
16 TUNING THE ENGINE
– Mount and tighten the screws.
Guideline
Screw, exhaust control cover (TC 250) M5
Screw, exhaust control cover (TX 300) M5
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
104
17 SERVICE WORK ON THE ENGINE
105
17.1
Checking the gear oil level
Info
The gear oil level must be checked when the engine is cold.
M01341-10
S01276-10
Preparatory work
– Stand the motorcycle upright on a horizontal surface.
Main work
(TC 125)
– Remove gear oil monitoring screw
– Check the gear oil level.
.
A small quantity of gear oil must run out of the drilled hole.
» If no gear oil runs out:
– Add gear oil.
– Mount and tighten the gear oil monitoring screw.
Guideline
Screw, gear oil level check M6 8 Nm (5.9 lbf ft)
(TC 250, TX 300)
– Remove gear oil monitoring screw
– Check the gear oil level.
.
A small quantity of gear oil must run out of the drilled hole.
» If no gear oil runs out:
– Add gear oil.
– Mount and tighten the gear oil monitoring screw.
Guideline
Screw, gear oil level check (TC 250) M6
Screw, gear oil level check (TX 300) M6
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
17.2
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
– Park the motorcycle on a level surface.
– Place a suitable container under the engine.
17 SERVICE WORK ON THE ENGINE
S01278-10
S01277-10
106
Main work
(TC 125)
– Remove the gear oil drain plug with magnet
.
– Remove gear oil drain plug
.
– Remove filler plug
.
– Let the gear oil drain fully.
– Clean the gear oil drain plug thoroughly.
– Clean the sealing surface on the engine.
– Mount and tighten gear oil drain plug with the magnet ring.
and the new seal
Guideline
Gear oil drain plug with magnet M12x1.5
20 Nm
(14.8 lbf ft)
– Mount gear oil drain plug
with the new seal ring and tighten.
Guideline
Gear oil drain plug M10x1 15 Nm
(11.1 lbf ft)
– Fill in gear oil.
Gear oil 0.8 l (0.8 qt.)
– Mount and tighten filler plug
.
Engine oil (SAE 10W/40) ( p. 128)
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
– Start the engine and check that it is oil-tight.
(TC 250, TX 300)
– Remove the gear oil drain plug with magnet
.
– Remove filler plug
.
– 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 with the magnet ring.
and the new seal
Guideline
Gear oil drain plug with magnet
(TC 250)
Gear oil drain plug with magnet
(TX 300)
M12x1.5
M12x1.5
20 Nm
(14.8 lbf ft)
20 Nm
(14.8 lbf ft)
– Fill in gear oil.
Gear oil 0.8 l (0.8 qt.)
– Mount and tighten filler plug
.
Engine oil (SAE 10W/40) ( p. 128)
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
17 SERVICE WORK ON THE ENGINE
– Start the engine and check that it is oil-tight.
Finishing work
– Check the gear oil level. ( p. 105)
17.3
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.
Main work
(TC 125)
– Remove gear oil monitoring screw
.
M01341-10
(TC 250, TX 300)
– Remove gear oil monitoring screw
.
107
S01276-10
401955-11
– Remove filler plug
.
– Add gear oil until it emerges from the drill hole of the gear oil monitoring screw.
Engine oil (SAE 10W/40) ( p. 128)
– Mount and tighten the gear oil monitoring screw.
Guideline
(TC 125)
Screw, gear oil level check M6
(TC 250, TX 300)
Screw, gear oil level check (TC 250) M6
Screw, gear oil level check (TX 300) M6
– Mount and tighten filler plug
.
Finishing work
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
– Start the engine and check that it is oil-tight.
18 CLEANING, CARE
18.1
Cleaning the motorcycle
Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
– Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
– Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance 60 cm (23.6 in)
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.
108
Info
To maintain the value and appearance of the motorcycle over a long period, clean 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 spray of water.
– Spray dirty parts with a normal commercial engine cleaner and then brush off with a soft brush.
Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle with water first.
– After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.
– Empty the carburetor float chamber. ( p. 100)
– Remove the closure of the exhaust system.
Warning
Danger of accidents Moisture and dirt impair the brake system.
– Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.
– After cleaning, ride the vehicle a short distance until the engine warms up.
Info
The heat produced causes water at inaccessible locations in the engine and on the brake system to evaporate.
– After the motorcycle has cooled off, lubricate all moving parts and bearings.
– Treat bare metal (except for brake discs and the exhaust system) with a corrosion inhibitor.
Preserving materials for paints, metal and rubber ( p. 130)
– Treat all plastic parts and powder-coated parts with a mild cleaning and care product.
19 STORAGE
19.1
Storage
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
109
19.2
Info
If you plan to garage the motorcycle for a longer period, perform the following steps or have them performed.
Before storing the motorcycle, check all parts for 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
– When refueling for the last time before taking the motorcycle out of service, add fuel additive.
– Clean the motorcycle. ( p. 108)
– Change the gear oil.
– Check the antifreeze and coolant level. ( p. 91)
– Empty the carburetor float chamber. ( p. 100)
– Check the tire air pressure. ( p. 84)
– Store the vehicle in a dry location that is not subject to large fluctuations in temperature.
Info
Husqvarna Motorcycles recommends raising the motorcycle.
– Raise the motorcycle with a lift stand. ( p. 43)
– Cover the vehicle with a tarp or similar cover that is permeable to air.
Info
Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.
Avoid running the engine for a short time only. 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.
Preparing for use after storage
– Remove the motorcycle from the lift stand. ( p. 43)
– Perform checks and maintenance work when preparing the vehicle for use.
– Make a test ride.
401059-01
20 TROUBLESHOOTING
110
Faults
The engine cannot be cranked (electric starter)
(TX 300)
Engine turns but does not start
Engine has no idle
Engine does not speed up
Possible cause
Operating error
Battery discharged
Main fuse blown
Starter relay faulty
Starter motor faulty
Operating error
Motorcycle was out of use for a long time and there is old fuel in the float chamber
Fuel feed interrupted
Spark plug oily or wet
Electrode distance (plug gap) of spark plug too wide
Fault in ignition system
Kill switch cable in wiring harness frayed, kill switch defective
The connector or ignition coil is loose or oxidized
Water in carburetor or jets blocked
Idling jet blocked
Adjusting screws on carburetor distorted
Spark plug defective
Ignition system defective
Action
– Carry out the start procedure. ( p. 26)
– Recharge the battery.
– Check the charging voltage.
– Check the closed current.
– Check the alternator.
– Change the main fuse. ( p. 88)
– Check the starter relay.
– Check the starter motor.
– Carry out the start procedure. ( p. 26)
– Empty the carburetor float chamber.
– Check the fuel tank breather.
– Clean the fuel tap.
– Check/set the carburetor components.
– Clean and dry the spark plug, or change it if necessary.
– Adjust the plug gap.
Guideline
(TC 125)
Spark plug electrode gap
0.60 mm (0.0236 in)
(TC 250)
Spark plug electrode gap
0.60 mm (0.0236 in)
(TX 300)
Spark plug electrode gap
0.60 mm (0.0236 in)
– Check the ignition system.
– Check the kill switch.
– Clean the connector and treat it with contact spray.
– Check/set the carburetor components.
– Check/set the carburetor components.
– Carburetor – adjust the idle speed.
– Change the spark plug.
– Check the ignition coil.
– Check the spark plug connector.
– Check/set the carburetor components.
Engine has too little power
Carburetor running over because float needle dirty or worn
Loose carburetor jets
Fault in ignition system
Fuel feed interrupted
Air filter very dirty
Exhaust system leaky, deformed or too little glass fiber yarn filling in main silencer
Fault in ignition system
Diaphragm or reed valve housing damaged
– Check/set the carburetor components.
– Check the ignition system.
– Check the fuel tank breather.
– Clean the fuel tap.
– Check/set the carburetor components.
– Clean the air filter and air filter box.
– Check exhaust system for damage.
– Change glass fiber yarn filling in the main silencer.
– Check the ignition system.
– Check the diaphragm and reed valve housing.
20 TROUBLESHOOTING
Faults
Engine stalls or is popping into the carburetor
Engine overheats
White smoke emission (steam in exhaust gas)
Gear oil exits at the vent hose
Water in the gear oil
Possible cause
Lack of fuel
Engine takes in bad air
The connector or ignition coil is loose or oxidized
Too little coolant in cooling system
Too little air stream
Radiator fins very dirty
Foam formation in cooling system
Damaged cylinder head or cylinder head gasket
Bent radiator hose
Incorrect ignition point due to loose stator
Damaged cylinder head or cylinder head gasket
Too much gear oil added
Damaged shaft seal ring or water pump
Action
(All TC models)
– Turn handle
of the fuel tap to the ON
position. (Figure F00230-10 p. 16)
(TX 300)
– Turn handle
of the fuel tap to the ON
position. (Figure F00231-10 p. 16)
(TX 300)
– Turn handle
of the fuel tap to the RES
position. (Figure F00231-10 p. 16)
– Check the intake flange and carburetor for tightness.
– Clean the connector and treat it with contact spray.
– Check the cooling system for leakage.
– Check the coolant level. ( p. 92)
– Switch off engine when stationary.
– Clean the radiator fins.
– Drain the coolant.
– Refill with coolant.
– Check the cylinder head and cylinder head gasket.
– Change the radiator hose.
– Adjust the ignition.
– Check the cylinder head and cylinder head gasket.
– Check the gear oil level. ( p. 105)
– Check the shaft seal ring and water pump.
111
21 TECHNICAL DATA
21.1
Engine
21.1.1
TC 125
Design
Displacement
Stroke
Bore
Crankshaft bearing
Conrod bearing
Piston pin bearing
Pistons
Piston rings
X (upper edge of piston to upper edge of cylinder)
Z (height of control flap)
Primary transmission
Clutch
Gearbox
Transmission ratio
First gear
Second gear
Third gear
Fourth gear
Fifth gear
Sixth gear
Ignition
Spark plug
Spark plug electrode gap
Starting aid
21.1.2
TC 250
Design
Displacement
Stroke
Hole
Exhaust valve, beginning of adjustment
Crankshaft bearing
Conrod bearing
Piston pin bearing
Piston
Piston rings
X distance (upper edge of piston to upper edge of cylinder)
Z distance (height of control flap)
Primary transmission
Clutch
Transmission
Transmission ratio
First gear
Second gear
Third gear
1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control
124.8 cm³ (7.616 cu in)
54.5 mm (2.146 in)
54 mm (2.13 in)
1 grooved ball bearing/1 roller bearing
Needle bearing
Needle bearing
Cast aluminum
2 half keystone rings
0… 0.10 mm (0… 0.0039 in)
36.5 mm (1.437 in)
23:73
Multidisc clutch in oil bath/hydraulically activated
6-gear, claw shifted
14:32
15:30
17:28
20:28
19:23
22:24
Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan
NGK BR9 ECMVX
0.60 mm (0.0236 in)
Kick starter
1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control
249 cm³ (15.19 cu in)
72 mm (2.83 in)
66.4 mm (2.614 in)
5,125 rpm
1 grooved ball bearing/1 roller bearing
Needle bearing
Needle bearing
Cast aluminum
2 half keystone rings
0… 0.10 mm (0… 0.0039 in)
49 mm (1.93 in)
26:73
Multidisc clutch in oil bath/hydraulically activated
5-gear, claw shifted
14:28
16:26
18:24
112
21 TECHNICAL DATA
Fourth gear
Fifth gear
Ignition system
Spark plug
Spark plug electrode gap
Starting aid
21.1.3
TX 300
Design
Displacement
Stroke
Hole
Exhaust valve, beginning of adjustment
Crankshaft bearing
Conrod bearing
Piston pin bearing
Piston
Piston rings
X distance (upper edge of piston to upper edge of cylinder)
Z distance (height of control flap)
Primary transmission
Clutch
Transmission
Transmission ratio
First gear
Second gear
Third gear
Fourth gear
Fifth gear
Sixth gear
Ignition system
Spark plug
Spark plug electrode gap
Starting aid
21.2
Engine tightening torques
21.2.1
TC 125
Screw, inner membrane sheets
Screw, membrane core plate
Screw, outer membrane sheets
Screw, control lever, exhaust control
EJOT DELTA PT ®
EJOT DELTA PT
EJOT DELTA PT
Screw, crankshaft position sensor
Screw, exhaust control cover
M5
M5
M5
Screw, locking lever M5
Screw, retaining bracket, rotary valve M5
®
®
35x25
30x12
30x6
Screw, stator
Screw, water pump wheel
Bleeder screw, cylinder head
M5
M5
M6
21:24
22:21
Contactless controlled, fully electronic ignition with digital ignition adjustment, type Kokusan
NGK BR 8 ECM
0.60 mm (0.0236 in)
Kick starter
1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control
293.2 cm³ (17.892 cu in)
72 mm (2.83 in)
72 mm (2.83 in)
5,150 rpm
1 grooved ball bearing/1 roller bearing
Needle bearing
Needle bearing
Cast aluminum
2 rectangular rings
0… 0.10 mm (0… 0.0039 in)
49.5 mm (1.949 in)
26:73
Multidisc clutch in oil bath/hydraulically activated
6-gear, claw shifted
15:31
16:25
20:25
22:23
25:22
26:20
Contactless controlled, fully electronic ignition with digital ignition adjustment, type Kokusan
NGK BR 7 ES
0.60 mm (0.0236 in)
Kick starter and electric starter
1 Nm (0.7 lbf ft)
1 Nm (0.7 lbf ft)
1 Nm (0.7 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
8 Nm (5.9 lbf ft)
–
–
–
Loctite
®
243™
Loctite
®
243™
–
Loctite
®
–
243™
Loctite
®
243™
Loctite
®
243™
–
113
21 TECHNICAL DATA
Drain plug, water pump cover
Nut, adjusting screw, power valve
Screw, alternator cover
Screw, bearing retainer
Screw, clutch slave cylinder
Screw, clutch spring retainer
Screw, control lever, exhaust control
Screw, engine case
Screw, exhaust flange
Screw, gear oil level check
Screw, intake flange/reed valve housing
Screw, intermediate clutch cover
Screw, intermediate clutch cover
Screw, intermediate clutch cover
Screw, kick starter stop plate
Screw, outer clutch cover
Screw, outer clutch cover
Screw, shift drum locating
Screw, shift lever
Screw, stop plate of exhaust control
Screw, water pump cover
Screw, cylinder head
Nut, cylinder base
Screw, cylinder base
Screw, kick starter
Gear oil drain plug
Nut, rotor
Gear oil drain plug with magnet
Spark plug
Nut, primary gear
Nut, inner clutch hub
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6x20
M6x25
M6x30
M6
M6x20
M6x50
M6
M6
M6
M6
M7
M8
M8
M8
M10x1
M12x1
M12x1.5
M14x1.25
M16LHx1.5
M18x1.5
21.2.2
TC 250
Screw, inner membrane sheets
Screw, membrane support plate
Screw, outer membrane sheets
Screw, angle lever, exhaust control
Screw, bearing retainer
Screw, clutch spring retainer
Screw, crankshaft position sensor
Screw, exhaust control bearing support
Screw, exhaust control cap
Screw, exhaust control cover
Screw, locking lever
Screw, retaining bracket of exhaust control
Screw, stator
Screw, water pump impeller
Bleeder screw, cylinder head
Outer clutch cover
M5
M5
M6
M6
M5
M5
M5
M5
EJOT DELTA PT
®
EJOT DELTA PT
®
35x25
30x12
EJOT DELTA PT
®
30x6
M5
M5
M5
M5
M5
1 Nm (0.7 lbf ft)
1 Nm (0.7 lbf ft)
1 Nm (0.7 lbf ft)
6 Nm (4.4 lbf ft)
7 Nm (5.2 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
5 Nm (3.7 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
7 Nm (5.2 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
10 Nm (7.4 lbf ft)
8 Nm (5.9 lbf ft)
8 Nm (5.9 lbf ft)
8 Nm (5.9 lbf ft)
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
8 Nm (5.9 lbf ft)
6 Nm (4.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
8 Nm (5.9 lbf ft)
8 Nm (5.9 lbf ft)
8 Nm (5.9 lbf ft)
14 Nm (10.3 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
18 Nm (13.3 lbf ft)
23 Nm (17 lbf ft)
20 Nm (14.8 lbf ft)
25 Nm (18.4 lbf ft)
15 Nm (11.1 lbf ft)
60 Nm (44.3 lbf ft)
20 Nm (14.8 lbf ft)
25 Nm (18.4 lbf ft)
130 Nm (95.9 lbf ft)
100 Nm (73.8 lbf ft)
–
–
–
–
–
–
Loctite
®
243™
–
–
Loctite
®
243™
–
–
–
–
Loctite
®
243™
–
–
Loctite
®
243™
Loctite
®
243™
Loctite
®
–
243™
–
–
–
Loctite
®
243™
–
–
–
–
Loctite
®
243™
Loctite ® 243™
–
–
–
Loctite ® 243™
Loctite
®
243™
–
Loctite
®
243™
Loctite
®
243™
–
–
Loctite
®
243™
Loctite
®
2701™
–
–
Loctite
®
243™
Loctite
®
243™
114
21 TECHNICAL DATA
Screw, alternator cover
Screw, clutch slave cylinder
Screw, control flap, exhaust control
Screw, engine case
Screw, exhaust flange
Screw, gear oil level check
Screw, idler gear retaining bracket
Screw, intake flange/reed valve housing
Screw, intermediate clutch cover
Screw, kick starter stop plate
Screw, shift drum locating
Screw, shift lever
Screw, water pump cover
Screw, balancer shaft
Screw, cylinder head
Screw, kick starter
Nut, cylinder base
Screw, drive chain engine sprocket
Nut, rotor
Gear oil drain plug with magnet
Spark plug
Nut, inner clutch hub
Nut, primary gear
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M8
M8
M8
M10
M10
M12x1
M12x1.5
M14x1.25
M18x1.5
M18LHx1.5
21.2.3
TX 300
Screw, inner membrane sheets
Screw, membrane support plate
Screw, outer membrane sheets
Screw, angle lever, exhaust control
Screw, bearing retainer
Screw, clutch spring retainer
Screw, exhaust control bearing support
Screw, exhaust control cap
Screw, exhaust control cover
Screw, locking lever
Screw, retaining bracket of exhaust control
Screw, starter motor protection cap
Screw, water pump impeller
Bleeder screw, cylinder head
Outer clutch cover
Screw, alternator cover
Screw, clutch slave cylinder
Screw, control flap, exhaust control
Screw, engine case
Screw, exhaust flange
Screw, gear oil level check
Screw, intake flange/reed valve housing
Screw, intermediate clutch cover
Screw, kick starter stop plate
M5
M5
M5
M5
M6
M6
M6
M6
M6
M6
M5
M5
M6
M6
M6
EJOT DELTA PT
®
EJOT DELTA PT
®
EJOT DELTA PT
®
35x25
30x12
30x6
M5
M5
M5
M5
M6
M6
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
6 Nm (4.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
14 Nm (10.3 lbf ft)
10 Nm (7.4 lbf ft)
30 Nm (22.1 lbf ft)
27 Nm (19.9 lbf ft)
25 Nm (18.4 lbf ft)
35 Nm (25.8 lbf ft)
60 Nm (44.3 lbf ft)
60 Nm (44.3 lbf ft)
20 Nm (14.8 lbf ft)
25 Nm (18.4 lbf ft)
100 Nm (73.8 lbf ft)
150 Nm (110.6 lbf ft)
1 Nm (0.7 lbf ft)
1 Nm (0.7 lbf ft)
1 Nm (0.7 lbf ft)
6 Nm (4.4 lbf ft)
7 Nm (5.2 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
5 Nm (3.7 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
7 Nm (5.2 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
10 Nm (7.4 lbf ft)
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
6 Nm (4.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
–
–
–
Loctite
®
243™
Loctite ® 243™
–
Loctite
®
243™
–
–
Loctite
®
243™
Loctite
®
2701™
–
–
–
–
Loctite ® 243™
–
–
–
Loctite
®
243™
–
–
–
Loctite ® 243™
–
–
–
–
–
–
Loctite
®
243™
–
–
Loctite ® 243™
Loctite
®
243™
Loctite
®
243™
–
Loctite
®
243™
–
–
–
Loctite
®
–
2701™
Loctite
®
2701™
–
Loctite
®
648™
Loctite
®
648™
115
21 TECHNICAL DATA
Screw, shift drum locating
Screw, shift lever
Screw, starter motor
Screw, stator
Screw, water pump cover
Screw, balancer shaft
Screw, cylinder head
Screw, kick starter
Nut, cylinder base
Screw, drive chain engine sprocket
Nut, rotor
Gear oil drain plug with magnet
Spark plug
Nut, inner clutch hub
Nut, primary gear
M6
M6
M6
M6
M6
M8
M8
M8
M10
M10
M12x1
M12x1.5
M14x1.25
M18x1.5
M18LHx1.5
10 Nm (7.4 lbf ft)
14 Nm (10.3 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
30 Nm (22.1 lbf ft)
27 Nm (19.9 lbf ft)
25 Nm (18.4 lbf ft)
35 Nm (25.8 lbf ft)
60 Nm (44.3 lbf ft)
60 Nm (44.3 lbf ft)
20 Nm (14.8 lbf ft)
25 Nm (18.4 lbf ft)
100 Nm (73.8 lbf ft)
150 Nm (110.6 lbf ft)
Loctite
®
243™
Loctite
®
243™
Loctite
®
243™
Loctite
®
243™
–
Loctite ® 243™
–
Loctite
®
2701™
–
Loctite
®
2701™
–
–
–
Loctite
®
648™
Loctite
®
648™
116
21 TECHNICAL DATA
21.3
Carburetor
21.3.1
TC 125
Carburetor type
Carburetor identification number
Needle position
Jet needle
Main jet
Idling jet
Starting jet
Needle jet
Idle air adjusting screw
Open
MIKUNI TMX 38
TMX 38 82
3rd position from top
6BFY43-74 (6BFY44-74, 6BFY44-73, 6BFY43-73)
480 (490, 500, 520, 540)
45 (42.5/47.5)
80
S‑1
1.5 turns
21.3.2
Carburetor - basic setting for sandy surfaces (TC 125)
Idle air adjusting screw
Open
Idling jet
Jet needle
Needle position
Main jet
1.5 turns
45
6BFY44‑73
3rd position from top
560
Info
If the engine is not running smoothly, use a smaller main jet.
117
21 TECHNICAL DATA
21.3.3
Carburetor tuning (TC 125)
118
M/FT ASL
TEMP
ASO
IJ
NDL
POS
MJ
Info
Do not use on sandy terrain.
Sea level
Temperature
Idle air adjusting screw open
Idling jet
Needle
Needle position from top
Main jet
402669-01
21 TECHNICAL DATA
21.3.4
TC 250
Carburetor type
Carburetor identification number
Needle position
Jet needle
Main jet
Idling jet
Starting jet
Needle jet
Idle air adjusting screw
Open
MIKUNI TMX 38
TMX 38 84
3rd position from top
6BFY43-73 (6BFY44-73)
440 (430, 450, 460)
42.5 (45/47.5)
80
S‑1
1.5 turns
21.3.5
Carburetor - basic setting for sandy surfaces (TC 250)
Idle air adjusting screw
Open
Idling jet
Jet needle
Needle position
Main jet
1.5 turns
45
6BFY44‑73
3rd position from top
480
Info
If the engine is not running smoothly, use a smaller main jet.
119
21 TECHNICAL DATA
21.3.6
Carburetor tuning (TC 250)
120
M/FT ASL
TEMP
ASO
IJ
NDL
POS
MJ
Info
Do not use on sandy terrain.
Sea level
Temperature
Idle air adjusting screw open
Idling jet
Needle
Needle position from top
Main jet
402671-01
21 TECHNICAL DATA
21.3.7
TX 300
Carburetor type
Carburetor identification number
Needle position
Jet needle
Main jet
Idling jet
Starting jet
Needle jet
Idle air adjusting screw
Open
21.3.8
Carburetor tuning (TX 300)
MIKUNI TMX 38
TMX 38 81
3rd position from top
6BFY44-73 (6BFY43-73)
430 (420, 440, 450, 460)
37.5 (35/40)
80
R‑8
1.5 turns
121
M/FT ASL
TEMP
ASO
IJ
Sea level
Temperature
Idle air adjusting screw open
Idling jet
402675-01
21 TECHNICAL DATA
NDL
POS
MJ
Needle
Needle position from top
Main jet
Info
Do not use on sandy terrain.
21.4
Capacities
21.4.1
Gear oil
Gear oil
21.4.2
Coolant
Coolant
21.4.3
Fuel
Total fuel tank capacity, approx. (All TC models)
0.8 l (0.8 qt.)
1.2 l (1.3 qt.)
7 l (1.8 US gal)
Engine oil (SAE 10W/40) ( p. 128)
Super unleaded (98 octane) mixed with 2-stroke engine oil
Super unleaded (95 octane) mixed with 2-stroke engine oil
Super unleaded (95 octane) mixed with 2-stroke engine oil
1.5 l (1.6 qt.)
Total fuel tank capacity, approx. (TX 300)
Fuel reserve approx. (TX 300)
10 l (2.6 US gal)
21.5
Chassis
Frame
Fork
Suspension travel
Front
Rear
Fork offset
Shock absorber (TC 125)
Shock absorber (TC 250)
Shock absorber (TX 300)
Brake system
Brake discs - diameter
Front
Rear
Brake discs - wear limit
Front
Rear
Tire air pressure off road
Front
Rear
Secondary ratio (TC 125)
Secondary ratio (TC 250)
Secondary ratio (TX 300)
Chain
Rear sprockets available
Steering head angle
Wheelbase
Central tube frame made of chrome molybdenum steel tubing
WP Performance Systems Upside down AER 48
310 mm (12.2 in)
300 mm (11.81 in)
22 mm (0.87 in)
WP Performance Systems 5018 DCC Link
WP Performance Systems 5018 DCC Link
WP Performance Systems 5018 DCC Link
Disc brakes, brake calipers on floating bearings
260 mm (10.24 in)
220 mm (8.66 in)
2.5 mm (0.098 in)
3.5 mm (0.138 in)
1.0 bar (15 psi)
1.0 bar (15 psi)
1:50 PM
2:50 PM
1:50 PM
5/8 x 1/4"
48, 50, 52
63.9°
1,485±10 mm (58.46±0.39 in)
122
21 TECHNICAL DATA
Seat height unloaded
Ground clearance unloaded (All TC models)
Ground clearance unloaded (TX 300)
Weight without fuel, approx. (TC 125)
Weight without fuel, approx. (TC 250)
Weight without fuel, approx. (TX 300)
Maximum permissible front axle load
Maximum permissible rear axle load
Maximum permissible overall weight
21.6
Electrical system
21.6.1
TX 300
Battery HJTZ5S-FP
960 mm (37.8 in)
375 mm (14.76 in)
370 mm (14.57 in)
87.4 kg (192.7 lb.)
95.8 kg (211.2 lb.)
98.4 kg (216.9 lb.)
145 kg (320 lb.)
190 kg (419 lb.)
335 kg (739 lb.)
Fuse 58011109110
21.7
Tires
Validity Front tires
(TC 125)
(TC 250)
80/100 - 21 51M TT
Dunlop GEOMAX MX3S
80/100 - 21 51M TT
Dunlop GEOMAX MX3S
(TX 300)
90/90 - 21 54M TT
Dunlop GEOMAX AT81F
Additional information is available in the Service section under: www.husqvarna-motorcycles.com
21.8
Fork
21.8.1
TC 125
Fork part number
Fork
Compression damping
Comfort
Standard
Sport
Rebound damping
Comfort
Standard
Sport
Air pressure
Fork length
Oil capacity external mechanism left
Oil capacity external mechanism right
200
200
+40
−20
+40
−20 ml (6.76
+1.35
−0.68
ml (6.76
+1.35
−0.68
fl. oz.) fl. oz.)
Grease capacity, left cartridge 11 ml (0.37 fl. oz.)
Oil capacity, right cartridge 380 ml (12.85 fl. oz.)
34.18.8Q.01
WP Performance Systems Upside down AER 48
15 clicks
12 clicks
9 clicks
Lithium-ion battery
Battery voltage: 12 V
Nominal capacity: 2.0 Ah
Maintenance-free
10 A
Rear tires
100/90 - 19 57M TT
Dunlop GEOMAX MX3S
110/90 - 19 62M TT
Dunlop GEOMAX MX3S
110/100 - 18 64M TT
Dunlop GEOMAX AT81
20 clicks
17 clicks
14 clicks
8.2 bar (119 psi)
950 mm (37.4 in)
Fork oil (SAE 4) (48601166S1) ( p. 128)
Fork oil (SAE 4) (48601166S1) ( p. 128)
Multi-purpose grease (00062010051) ( p. 129)
Fork oil (SAE 4) (48601166S1) ( p. 128)
123
21 TECHNICAL DATA
21.8.2
TC 250
Fork part number
Fork
Compression damping
Comfort
Standard
Sport
Rebound damping
Comfort
Standard
Sport
Air pressure
Fork length
Oil capacity external mechanism left
Oil capacity external mechanism right
200
200
+40
−20
+40
−20 ml (6.76
+1.35
−0.68
ml (6.76
+1.35
−0.68
fl. oz.) fl. oz.)
Grease capacity, left cartridge 11 ml (0.37 fl. oz.)
Oil capacity, right cartridge 380 ml (12.85 fl. oz.)
21.8.3
TX 300
Fork part number
Fork
Compression damping
Comfort
Standard
Sport
Rebound damping
Comfort
Standard
Sport
Air pressure
Fork length
Oil capacity external mechanism left
Oil capacity external mechanism right
200
200
+40
−20
+40
−20 ml (6.76
+1.35
−0.68
ml (6.76
+1.35
−0.68
fl. oz.) fl. oz.)
Grease capacity, left cartridge 11 ml (0.37 fl. oz.)
Oil capacity, right cartridge 380 ml (12.85 fl. oz.)
21.9
Shock absorber
21.9.1
TC 125
Shock absorber article number
Shock absorber
Compression damping, low-speed
Comfort
Standard
Sport
Compression damping, high-speed
Comfort
34.18.8Q.03
WP Performance Systems Upside down AER 48
15 clicks
12 clicks
9 clicks
20 clicks
17 clicks
14 clicks
10.2 bar (148 psi)
950 mm (37.4 in)
Fork oil (SAE 4) (48601166S1) ( p. 128)
Fork oil (SAE 4) (48601166S1) ( p. 128)
Multi-purpose grease (00062010051) ( p. 129)
Fork oil (SAE 4) (48601166S1) ( p. 128)
34.18.8Q.73
WP Performance Systems Upside down AER 48
15 clicks
12 clicks
10 clicks
15 clicks
12 clicks
10 clicks
9.6 bar (139 psi)
950 mm (37.4 in)
Fork oil (SAE 4) (48601166S1) ( p. 128)
Fork oil (SAE 4) (48601166S1) ( p. 128)
Multi-purpose grease (00062010051) ( p. 129)
Fork oil (SAE 4) (48601166S1) ( p. 128)
18.18.7Q.01
WP Performance Systems 5018 DCC Link
17 clicks
15 clicks
13 clicks
2.5 turns
124
21 TECHNICAL DATA
Standard
Sport
Rebound damping
Comfort
Standard
Sport
Spring preload
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.)
Weight of rider: 75… 85 kg (165… 187 lb.)
Weight of rider: 85… 95 kg (187… 209 lb.)
Spring length
Gas pressure
Static sag
Riding sag
Fitted length
Shock absorber fluid ( p. 129)
21.9.2
TC 250
Shock absorber article number
Shock absorber
Compression damping, low-speed
Comfort
Standard
Sport
Compression damping, high-speed
Comfort
Standard
Sport
Rebound damping
Comfort
Standard
Sport
Spring preload
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.)
Weight of rider: 75… 85 kg (165… 187 lb.)
Weight of rider: 85… 95 kg (187… 209 lb.)
Spring length
Gas pressure
Static sag
Riding sag
Fitted length
Shock absorber fluid ( p. 129)
21.9.3
TX 300
Shock absorber article number
Shock absorber
Compression damping, low-speed
Comfort
Standard
2 turns
1.5 turns
17 clicks
15 clicks
13 clicks
6 mm (0.24 in)
36 N/mm (206 lb/in)
39 N/mm (223 lb/in)
42 N/mm (240 lb/in)
247 mm (9.72 in)
10 bar (145 psi)
35 mm (1.38 in)
105 mm (4.13 in)
477 mm (18.78 in)
SAE 2.5
18.18.7Q.53
WP Performance Systems 5018 DCC Link
17 clicks
15 clicks
13 clicks
2.5 turns
2 turns
1.5 turns
17 clicks
15 clicks
13 clicks
5 mm (0.2 in)
39 N/mm (223 lb/in)
42 N/mm (240 lb/in)
45 N/mm (257 lb/in)
247 mm (9.72 in)
10 bar (145 psi)
35 mm (1.38 in)
105 mm (4.13 in)
477 mm (18.78 in)
SAE 2.5
18.18.7Q.73
WP Performance Systems 5018 DCC Link
17 clicks
15 clicks
125
21 TECHNICAL DATA
Sport
Compression damping, high-speed
Comfort
Standard
Sport
Rebound damping
Comfort
Standard
Sport
Spring preload
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.)
Weight of rider: 75… 85 kg (165… 187 lb.)
Weight of rider: 85… 95 kg (187… 209 lb.)
Spring length
Gas pressure
Static sag
Riding sag
Fitted length
Shock absorber fluid ( p. 129)
21.10
Chassis tightening torques
Screw, fixed grip
Screw, service hour counter
Spoke nipple, front wheel
Spoke nipple, rear wheel
Remaining nuts, chassis
Remaining screws, chassis
M5
M5
Screw, battery terminal (TX 300) M5
Screw, shock absorber adjusting ring M5
Nut, cable on starter motor (TX 300) M6
Remaining nuts, chassis
Remaining screws, chassis
Screw, ball joint of push rod on foot brake cylinder
Screw, battery support bracket
(TX 300)
Screw, chain sliding guard
M4
M4
M4.5
M4.5
M6
M6
M6
M6
Screw, front brake disc
Screw, rear brake disc
Screw, throttle grip
Nut, foot brake lever stop
Nut, rear sprocket screw
Nut, rim lock
Remaining nuts, chassis
Remaining screws, chassis
Screw, bottom triple clamp
Screw, chain sliding piece
M8
M8
M8
M8
M6
M6
M6
M6
M8
M8
M8
Screw, engine brace
Screw, fork stub
Screw, front brake caliper
Screw, handlebar clamp
M8
M8
M8
M8
13 clicks
2.5 turns
2 turns
1.5 turns
17 clicks
15 clicks
13 clicks
7 mm (0.28 in)
39 N/mm (223 lb/in)
42 N/mm (240 lb/in)
45 N/mm (257 lb/in)
247 mm (9.72 in)
10 bar (145 psi)
35 mm (1.38 in)
105 mm (4.13 in)
477 mm (18.78 in)
SAE 2.5
5 Nm (3.7 lbf ft)
1 Nm (0.7 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
5 Nm (3.7 lbf ft)
5 Nm (3.7 lbf ft)
2.5 Nm (1.84 lbf ft)
5 Nm (3.7 lbf ft)
4 Nm (3 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
6 Nm (4.4 lbf ft)
14 Nm (10.3 lbf ft)
14 Nm (10.3 lbf ft)
5 Nm (3.7 lbf ft)
20 Nm (14.8 lbf ft)
35 Nm (25.8 lbf ft)
12 Nm (8.9 lbf ft)
25 Nm (18.4 lbf ft)
25 Nm (18.4 lbf ft)
12 Nm (8.9 lbf ft)
15 Nm (11.1 lbf ft)
25 Nm (18.4 lbf ft)
15 Nm (11.1 lbf ft)
25 Nm (18.4 lbf ft)
20 Nm (14.8 lbf ft)
–
–
–
Loctite
®
243™
–
–
–
–
–
–
–
Loctite
®
243™
–
–
–
Loctite ® 243™
Loctite
®
243™
Loctite
®
243™
–
–
–
–
Loctite
®
2701™
–
Loctite ® 2701™
–
Loctite
®
243™
–
126
21 TECHNICAL DATA
Screw, side stand attachment
(TX 300)
Screw, subframe
Screw, subframe
Screw, top steering stem
Screw, top triple clamp
Engine bracket screw
Remaining nuts, chassis
Remaining screws, chassis
Screw, bottom shock absorber
Screw, handlebar support
Screw, top shock absorber
Nut, frame on linkage lever
Nut, linkage lever on swingarm
Nut, linkage lever to angle lever
Nut, swingarm pivot
Screw, front wheel spindle
Screw, top steering head
Screw-in nozzles, cooling system
Nut, rear wheel spindle
M8
M8x20
M8x30
M8
M8
M10
M10
M10
M10
M10
M10
M14x1.5
M14x1.5
M14x1.5
M16x1.5
M20x1.5
M20x1.5
M20x1.5
M25x1.5
35 Nm (25.8 lbf ft)
30 Nm (22.1 lbf ft)
30 Nm (22.1 lbf ft)
20 Nm (14.8 lbf ft)
17 Nm (12.5 lbf ft)
60 Nm (44.3 lbf ft)
45 Nm (33.2 lbf ft)
45 Nm (33.2 lbf ft)
60 Nm (44.3 lbf ft)
40 Nm (29.5 lbf ft)
60 Nm (44.3 lbf ft)
80 Nm (59 lbf ft)
80 Nm (59 lbf ft)
80 Nm (59 lbf ft)
100 Nm (73.8 lbf ft)
35 Nm (25.8 lbf ft)
12 Nm (8.9 lbf ft)
12 Nm (8.9 lbf ft)
80 Nm (59 lbf ft)
Loctite
®
2701™
–
–
–
Loctite
®
2701™
Loctite ® 2701™
Loctite
®
243™
–
Loctite
®
2701™
Loctite ® 243™
Loctite
®
2701™
–
–
–
–
–
–
Loctite
®
243™
–
127
22 SUBSTANCES
128
Brake fluid DOT 4
Standard/classification
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties.
Recommended supplier
Bel‑Ray
®
– Super DOT 4 Brake Fluid
Coolant
Guideline
– Only use high quality coolant with corrosion inhibitor for aluminum motors (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming.
Mixture ratio
Antifreeze protection: −25… −45 °C (−13…
−49 °F) anti-corrosion/antifreeze distilled water
Recommended supplier
Bel‑Ray
®
– Moto Chill Racing Coolant
Engine oil (SAE 10W/40)
Standard/classification
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.
mineral engine oil
Recommended supplier
Bel‑Ray
®
– EXL Mineral 4T
Engine oil, 2-stroke
Standard/classification
Guideline
– Only use high grade 2-stroke engine oil of a reputable brand.
Synthetic engine oil
Recommended supplier
Bel‑Ray
®
– Si‑7 Synthetic 2T
Fork oil (SAE 4) (48601166S1)
Standard/classification
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.
22 SUBSTANCES
Multi-purpose grease (00062010051)
Recommended supplier
Klüber Lubrication
®
– CENTOPLEX 2 EP
Shock absorber fluid (SAE 2.5) (50180751S1)
Standard/classification
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.
Super unleaded (ROZ 98 / RON 98 / PON 94)
Standard/classification
– DIN EN 228 (ROZ 98 / RON 98 / PON 94)
Super unleaded (ROZ 95/RON 95/PON 91)
Standard/classification
– DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
– Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
– Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60)
Standard/classification
– DIN EN 228
Mixture ratio
1:60
Engine oil, 2-stroke ( p. 128)
Super unleaded (ROZ 95/RON 95/PON 91) ( p. 129)
Recommended supplier
Bel‑Ray
®
– Si‑7 Synthetic 2T
Super unleaded (98 octane) mixed with 2-stroke engine oil (1:40)
Standard/classification
– DIN EN 228
Mixture ratio
1:40
Engine oil, 2-stroke ( p. 128)
Super unleaded (ROZ 98 / RON 98 / PON 94) ( p. 129)
Recommended supplier
Bel‑Ray
®
– Si‑7 Synthetic 2T
129
23 AUXILIARY SUBSTANCES
Air filter cleaning agent
Recommended supplier
Bel‑Ray
®
– Foam Filter Cleaner & Degreaser
High viscosity grease
Recommended supplier
SKF
®
– LGHB 2
Long-life 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
130
24 STANDARDS
131
JASO T903 MA
Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard.
Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines. In most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. 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 for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions.
25 LIST OF ABBREVIATIONS
Art. no.
ca.
cf.
e.g.
etc.
i.a.
no.
poss.
Article number circa compare for example et cetera inter alia number possibly
132
INDEX
133
INDEX
A
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air filter
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Air filter box
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Air filter box cover
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Air suspension AER 48 . . . . . . . . . . . . . . . . . . . . . . . . 33
Antifreeze
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Auxiliary substances . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
B
Basic chassis setting
checking with rider's weight . . . . . . . . . . . . . . . . . . . 33
Battery
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Brake discs
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Brake fluid
front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 73
rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Brake fluid level
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 73
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 77
Brake linings
C
Capacity
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106, 122
Carburetor
float chamber, emptying . . . . . . . . . . . . . . . . . . . . . 100
Carburetor setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Chain
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Chain guide
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Chain tension
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Clutch
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 69
Compression damping
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Compression damping, high-speed
shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 34
Compression damping, low-speed
shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 34
Coolant
Coolant level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91-92
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
D
Difficult operating conditions
low temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
muddy surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
wet sand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
wet surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
E
Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine
running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine characteristic
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Filler cap
Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fork
air pressure, adjusting . . . . . . . . . . . . . . . . . . . . . . . 39
basic setting, checking . . . . . . . . . . . . . . . . . . . . . . . 38
INDEX
134
Fork legs
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fork part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fork protector
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Frame
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Front fender
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Front wheel
Fuel tank
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fuse
changing the main fuse . . . . . . . . . . . . . . . . . . . . . . . 88
G
Gear oil
adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Gear oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
H
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
I
Ignition timing map
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
plug-in connector . . . . . . . . . . . . . . . . . . . . . . . . . 101
Implied warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
K
Kick starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Kill switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
L
Lower triple clamp
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
M
Main fuse
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Main silencer
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Motorcycle
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
O
Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
P
Plug-in stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Preparing for use
advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . 20
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
checks and maintenance work when preparing for use . 26
Protective clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
R
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Rear sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Rear wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Rebound damping
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 35
Refueling
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Riding sag
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Right side cover
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Rubber grip
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
S
Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service hour counter . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Shock absorber
compression damping, general . . . . . . . . . . . . . . . . . 33
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
static sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 36
INDEX
Shock absorber article number . . . . . . . . . . . . . . . . . . 13
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Spoke tension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Start number plate
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Steering head bearing
greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Steering head bearing play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Swingarm
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
T
Technical data
capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
chassis tightening torques . . . . . . . . . . . . . . . . . . . 126
electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . 123
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
engine tightening torques . . . . . . . . . . . . . . . . . . . . 113
fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Throttle cable play
Throttle cable routing
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 110-111
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
U
Use definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
V
View of vehicle
front left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
rear right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
135
*3402094en*
3402094en
04/2016
Husqvarna Motorcycles GmbH
Stallhofnerstraße 3 | 5230 Mattighofen | Austria www.husqvarna-motorcycles.com
Photo: Mitterbauer,
Husqvarna Motorcycles GmbH
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Key Features
- Designed for competitive use
- Complies with international motorsport regulations
- State-of-the-art sports motorcycle
- Powerful engine
- Durable frame
- High-performance suspension