Husqvarna TE 250 (2008), TC 250 (2008), TE 510 (2008), TC 510 (2008), TE 450 (2008) Workshop Manual
...
Workshop Manual
TE 250-450-510/2008-I.E.,
TC 250-450-510/2008,
TXC 250-450-510/2008
(only USA),
SMR 450-510 2008-I.E.
SMR 450-R/2008
Part. N. 8000 B0148 (02-2008)
To the best knowledge of HUSQVARNA MOTORCYCLES S.R.L. - Varese, Inc. the material contained herein is accurate as of the
date this pubblication was approved for printing. Cagiva Motor S.p.a. - Varese, Inc. reserves the right to change specifications,
equipment, or designs at any time without notice and without incurring obligation. Illustrations in this manual are merely for
demonstration purposes and could not exactly match the detail described.No part of this manual can de reproduced without permission
in writing of the copyright holder.
1st Edition (02-2008)
a.1Part. N. 8000 B0148 (02-2008)
FOREWORD, SUMMARY
1st Edition (02-2008)
Printed in Italy
Print No. N° 8000 B0148
VALIDITY (from vehicle identification number)
Copyright by
HUSQVARNA MOTORCYCLES S.R.L.
BMW Group
Servizio Assistenza Tecnica
Via Nino Bixio, 8
21024 Biandronno
(Varese) - Italy
tel. ++39 0332 75.61.11
fax ++39 0332 756 558
www.husqvarna-motorcycles.com
Workshop Manual
TE 250-450-510/2008-I.E.,
TC 250-450-510/2008,
TXC 250-450-510/2008 (only USA),
SMR 450-510/2008-I.E.
SMR 450-R/2008
TE 250: ZKHA200AA8V000001
TE 450: ZKHA202AA8V000001
TE 510: ZKHA203AA8V000001
TE 250 (USA): ZKHECECA*8V100001
TE 450 (USA): ZKHECENB8V100001
TE 510 (USA): ZKHECEHB8V100001
TC 250: ZKHA200AA8V050001
TC 450: ZKHA202AA8V050001
TC 510: ZKHA203AA8V050001
TXC 250 (USA): ZKHTX250*8V000001
TXC 450 (USA): ZKHTX450*8V000001
TXC 510 (USA): ZKHTX510*8V000001
SMR 450: ZKHA202AB8V000001
SMR 510: ZKHA203AB8V000001
SMR 450-R: ZKHA222AB8V050001
1. Vehicle identification number
1
a.2 Part. N. 8000 B0148 (02-2008)
FOREWORD, SUMMARY
Foreword
This publication intended for HUSQVARNA Workshops has been prepared for the
purpose of helping the authorized personnel in the maintenance and repair work of the
motorcycles herewith dealt with. The perfect knowledge of the technical data contained
herein is essential for a more complete professional training of the operator.
The paragraphs have been completed with schematic illustrations evidencing the subject
concerned, in order to enable a more immediate understanding.
This manual contains information with particular meanings:
Accident prevention rules for the operator and for the personnel working near by.
Possibility of damaging the vehicle and/or its components.
Additional information concerning the operation under way.
Useful suggestions
HUSQVARNA suggests, in order to prevent troubles and in order to have an excellent final
result, to generically comply with the following instructions:
– in case of repair work, weigh the impressions of the Customer who complains about the
improper operation of the motorcycle, and formulate proper clearing questions about the
symptoms of the trouble.
– detect clearly the cause of the trouble. This manual gives the theoretical bases which
however shall be integrated by the personal experience and by the attendance to training
courses periodically organized by HUSQVARNA.
– rationally plan the repair work in order to prevent dead time as for instance procurement
of spare parts, tool preparation, etc.
– reach the component to be repaired and perform only the required operations.
In this connection, it will be useful to consult the disassembly sequence contained in this
manual.
General instructions for repair work
1 Always replace the seal rings and split pins with new components.
2 When loosening or tightening nuts or bolts, always start from the bigger ones or from the
center. Lock at the prescribed torque wrench setting following a crossed run.
3 Always earmark the components or positions which could be mistaken one for another
at the time of assembly.
4 Use original HUSQVARNA spare parts and the lubricants of the recommended brands.
5 Use special tools, where specified.
6 Consult the Service Bulletins as they may contain up-dated adjustment data and repair
methodologies.
a.3Part. N. 8000 B0148 (02-2008)
FOREWORD, SUMMARY
Summary
Chapter Section
Foreword, summary ...................................................... a
Important notices .......................................................... b
General ......................................................................... A
Maintenance ................................................................. B
Troubles and remedies ................................................. C
Settings and adjustments .............................................. D
General operations ....................................................... E
Engine disassembly ...................................................... F
Engine overhauling ....................................................... G
Engine re-assembly ...................................................... H
Front suspension .......................................................... I
Rear suspension ........................................................... J
Brakes .......................................................................... L
Electric system .............................................................. M
Engine cooling system .................................................. N
"KITS" assembling instructions ..................................... O
Hydraulic control clutch ................................................. P
Optional Parts List......................................................... Q
SMR 450-R ................................................................... R
Fuel injection system .................................................... S
Specific tools................................................................. W
Torque wrench settings ................................................. X
Frame, wheels ............................................................. Y
Notes for USA/CDN-AUS models ................................. Z
NOTES
1) Where not otherwise specified, data and instructions refer to all models.
2) Where not otherwise specified, data and instructions of SMR models are referred to the SMR 450-R model too.
a.4 Part. N. 8000 B0148 (02-2008)
FOREWORD, SUMMARY
b.1Part. N. 8000 B0148 (02-2008)
IMPORTANT NOTICES
Section
b
b.2 Part. N. 8000 B0148 (02-2008)
IMPORTANT NOTICES
1) The TC, TXC and SMR 450-R models are guaranteed COMPETITION motorcycles
exempt from functional defects, the suggested maintenance table for competition
use is shown on chapter B.
2) TE and SMR are STREET LEGAL motorcycles (with LIMITED POWER ENGINE);
they are guaranteed exempt from functional defects and covered with legal
guarantee, if the STANDARD CONFIGURATION is maintained and the suggested
maintenance table, shown on chapter B, is observed. If TE and SMR are
transformed in COMPETITION MOTORCYCLES (with FULL POWER ENGINE),
the suggested maintenance table for competition use is shown on chapter B.
IMPORTANT
The reference for recognition of the guarantee will be the MOTORCYCLE
CONFIGURATION, as shown below:
A) STANDARD MOTORCYCLE, STREET LEGAL: with LIMITED POWER ENGINE
B) COMPETITION MOTORCYCLE, RACING USE: with FULL POWER ENGINE
TC-TXC
TE
SMR
SMR 450-R
b.3Part. N. 8000 B0148 (02-2008)
IMPORTANT NOTICES
* This motorcycles was not designed for long trips with the engine
always at maximum rpm as can occur whilst travelling on roads
or highways. Long trips at full throttle can cause severe damage
to the engine.
* This motorcycles is setup for competition use and therefore guarantees maximum performance with the rider alone. It is thereby
not recommended to use the vehicle on circuits or off-road with a
passenger.
* ALWAYS keep in mind that these motorcycles have been designed strictly for competition use, that is, for conditions of usage
very different from those presented on the road.
* In order to maintain the vehicle’s “Guarantee of Functionality”,
the client must follow the maintenance program indicated in the
chapter B by carrying out maintenance checks at authorized
HUSQVARNA dealers. The cost for substituting parts and for the
labour necessary in order to respect the maintenance plan, is
charged to the client. The guarantee is EXTINGUISHED in the
case where the motorcycle is rented.
Notes
References to the “left” or “right” of the motorcycle are in the sense
of a person facing forwards.
Z: number of teeth
A: Austria
AUS: Australia
B: Belgium
BR: Brazil
CDN: Canada
CH: Switzerland
D: Germany
E: Spain
F: France
FIN: Finland
GB: Great Britain
I: Italy
J: Japan
USA: United States of America
Where not specified, alla the data and the instructions are referred to any and all the Countries.
b.4 Part. N. 8000 B0148 (02-2008)
IMPORTANT NOTICES
A.1Part. N. 8000 B0148 (02-2008)
GENERAL
Section
A
A.2 Part. N. 8000 B0148 (02-2008)
GENERAL
Engine ............................................................................. A.3
Timing system ................................................................. A.3
Fuel feeding .................................................................... A.3
Lubrication ...................................................................... A.3
Cooling ............................................................................ A.3
Ignition ............................................................................. A.3
Starting ............................................................................ A.3
Transmission ......................................................... A.4-A.5
Frame .............................................................................. A.6
Suspensions ................................................................... A.6
Brakes ............................................................................. A.6
Wheels ............................................................................ A.6
Tires ................................................................................ A.6
Ignition system- electric system ..................................... A.7
Weights ........................................................................... A.8
Overall dimensions ......................................................... A.8
Capacities ....................................................................... A.9
A.3Part. N. 8000 B0148 (02-2008)
GENERAL
ENGINE
4-stroke, single cylinder
Bore (250) ....................................................................................... 2.99 in.
Bore (450- 510) ............................................................................... 3.81 in.
Stroke (250) .................................................................................... 2.17 in.
Stroke (450) .................................................................................... 2.39 in.
Stroke (510) .................................................................................... 2.67 in.
Displacement (250) ................................................................. 15.22 cu. in.
Displacement (450) ................................................................. 27.39 cu. in.
Displacement (510) ................................................................. 30.56 cu. in.
Compression ratio ............................................................................. 12.9:1
TIMING SYSTEM
Double overhead camshaft; 4 valves
Valve angle in relation to cylinder:
INLET .................................................................................................... 12°
EXHAUST ............................................................................................. 13°
Valve clearance with cold engine
INLET.................................................................................. 0.004-0.006 in.
EXHAUST........................................................................... 0.006-0.008 in.
FUEL FEEDING
Type (TE-SMR) ......................................... to injection electronic, throttle body MIKUNI D42
Type (TC-TXC 250) .................................. carburetor “Keihin” FCR-MX 37 with acceleration pump and T.P.S. (Throttle Position Sensor)
Type (TC-TXC 450-510-SMR 450-R)....... carburetor “Keihin” FCR-MX 41 with acceleration pump and T.P.S. (Throttle Position Sensor)
Dry type air filter
LUBRICATION
Type .................................. Dry sump with two oil pump rotors and cartridge filter
COOLING
By fluid with double cooler (TC, TXC, SMR 450-R)
By fluid with double cooler and electric fan (TE-SMR)
IGNITION
CDI electronic (TC, TXC, SMR 450-R) inductive discharge (TE, SMR) with adjustable advance (digital control) (•)
Spark plug type ........................................................................ "NGK" CR8EB (excluded SMR 450-R); "NGK" CR9KB (SMR 450-R)
Spark plug gap ......................................................................... 0.7 mm (excluded SMR 450-R); 0.8 mm (SMR 450-R)
STARTING (TC) ................................. kick start (with automatic decompressor) *
STARTING (TE-TXC) ....... electric and kick start (with automatic decompressor)
STARTING (SMR) ............................... electric (with automatic decompressor) **
*: electric start upon request
**: kick start upon request (excluded SMR 450-R)
(•): Replace data on owner's manual no. 8000 B0147 page 8.
A.4 Part. N. 8000 B0148 (02-2008)
GENERAL
TRANSMISSION
Multi-plate clutch in oil bath, hydraulic control (the SMR 450-R model employs a "SLIPPER" clutch)
5-speed (TC) or 6-speed (TE-SMR-TXC) gearbox, constant mesh gear type
Drive between engine and gearbox main shaft by straight toothed
Primary drive
Drive pinion gear (TC 250) ............................................. z 20
Drive pinion gear (TE-TXC 250) .................................... z 24
Drive pinion gear (450-510) ........................................... z 23
Clutch ring gear (TC 250) .............................................. z 67
Clutch ring gear (TE-TXC 250) ...................................... z 88
Clutch ring gear (450-510) ............................................. z 63
Transmission ratio (TC 250) ......................................... 3.350
Transmission ratio (TE-TXC 250) ................................ 3.666
Transmission ratio (450-510) ....................................... 2.739
Gearbox ratios (TE-SMR-TXC)
1st gear .......................................................... 2.000 (z 28/14)
2nd gear ......................................................... 1.611 (z 29/18)
3rd gear ......................................................... 1.333 (z 24/18)
4th gear .......................................................... 1.086 (z 25/23)
5 th gear ........................................................ 0.920 (z 23/25)
6 th gear ........................................................ 0.814 (z 22/27)
Gearbox ratios (TC)
1st gear ....................................................... 1.866 (z 28/15)
2nd gear (250) .............................................. 1.529 (z 26/17)
2nd gear (450-510) ....................................... 1.444 (z 26/18)
3rd gear.......................................................... 1.263 (z 24/19)
4th gear ......................................................... 1.086 (z 25/23)
5 th gear ......................................................... 0.954 (z 21/22)
Final drive
Drive between gearbox and rear wheel by 5/8" x 1/4" chain (with OR for TE 250-450-510 and SMR 450-510 models; excluded SMR 450-R).
Transmission sprocket (TE 250-450-510; TXC 250-450-510; SMR 450-R) ... z 13
Transmission sprocket (TC 450) ...................................................................... z 14
Transmission sprocket (TC 250) ...................................................................... z 12
Transmission sprocket (TC 510) ...................................................................... z 14
Transmission sprocket (SMR 450-510) ........................................................... z 14
Rear wheel sprocket (TE 250 TXC 250) .......................................................... z 50
Rear wheel sprocket (TC 450) ......................................................................... z 50
Rear wheel sprocket (TC 250) ......................................................................... z 50
Rear wheel sprocket (TC 510 TE 450-510; TXC 450-510) ............................. z 47
Rear wheel sprocket (SMR 450-510) ............................................................... z 42
Transmission ratio (TE 250) ......................................... 3.846
Transmission ratio (TE 450-510) ................................. 3.615
Transmission ratio (TC 250) ........................................ 4.166
Transmission ratio (TC 450) ........................................ 3.571
Transmission ratio (TC 510) ........................................ 3.357
Transmission ratio (SMR 450-510) ............................. 3.000
Transmission ratio (SMR 450-R) ................................. 3.230
Rear chain size ........................................................ 5/8”x1/4”
A.5Part. N. 8000 B0148 (02-2008)
GENERAL
Total drive ratios
1st gear (TE-TXC 250) ............................................... 28.205
1st gear (TE-TXC 450-510) ........................................ 19.806
1st gear (TC 250) ........................................................ 26.055
1st gear (TC 450) ........................................................ 18.261
1st gear (TC 510) ........................................................ 17.159
1st gear (SMR 450-510) ............................................. 16.435
1st gear (SMR 450-R) ............................................. 17.699
2nd gear (TE-TXC 250) .............................................. 22.721
2nd gear (TE-TXC 450-510) ....................................... 15.955
2nd gear (TC 250) ....................................................... 21.348
2nd gear (TC 450) ....................................................... 14.130
2nd gear (TC 510) ....................................................... 13.283
2nd gear (SMR 450-510)............................................. 13.239
2nd gear (SMR 450-R)............................................. 14.257
3rd gear (TE-TXC 250) ............................................... 18.803
3rd gear (TE-TXC 450-510) ........................................ 13.204
3rd gear (TC 250) ....................................................... 17.631
3rd gear (TC 450) ....................................................... 12.357
3rd gear (TC 510) ....................................................... 11.616
3rd gear (SMR 450-510) ............................................ 10.956
3rd gear (SMR 450-R) ............................................ 11.799
4th gear (TE-TXC 250) ............................................... 15.329
4th gear (TE-TXC 450-510) ....................................... 10.764
4th gear (TC 250) ....................................................... 15.172
4th gear (TC 450) ....................................................... 10.633
4th gear (TC 510) ....................................................... 9.995
4th gear (SMR 450-510)............................................. 8.932
4th gear (SMR 450-R)............................................. 9.619
5th gear (TE-TXC 250) ............................................... 12.974
5th gear (TE-TXC 450-510) ....................................... 9.111
5th gear (TC 250) ....................................................... 13.324
5th gear (TC 450) ....................................................... 9.338
5th gear (TC 510) ....................................................... 8.778
5th gear (SMR 450-510)............................................. 7.560
5th gear (SMR 450-R)............................................. 8.141
6th gear (TE-TXC 250) ............................................... 11.491
6th gear (TE-TXC 450-510) ....................................... 8.069
6th gear (SMR 450-510).............................................. 6.696
6th gear (SMR 450-R).............................................. 7.211
A.6 Part. N. 8000 B0148 (02-2008)
GENERAL
FRAME
Steel single tube cradle (round, rectangular and ellipsoidal tubes, branching off into two parts approximately at the exhaust level), rear frame
in light alloy
Forward travel (in.) .............................................................. 4.17 (TE-TXC); 4.10 (TC); 3.27 (SMR); 3.23 (SMR 450-R)
SUSPENSIONS
Front
“MARZOCCHI” Overturned forkrod telehydraulic fork with advanced pin; forkrods 1.97 in. diameter; hydraulic brake adjustment both in
compression and extension
Axle travel on leg axis (in.) .................................................. 11.81 (TE, TC, TXC); 9.84 (SMR)
Rear
Swinging arm in light alloy with progressive damping, “SACHS” hydraulic mono-shock absorber with helical spring.
Hydraulic brake and spring preloading adjustment both in compression (DOUBLE) and in extension.
Wheel travel (in.) ................................................................. 11.65 (TC-TXC-TE); 11.41 (SMR)
BRAKES
Front
Drilled fixed disc 10.24 in. dia. with floating caliper (TE, TC, TXC); drilled floating disc 12.6 in. dia. (SMR) with radial fixed caliper
Pads area ........................................................................... 5.18 sq. in. (TE, TC); 6.48 sq. in. (SMR)
Independent hydraulic circuit and pump (type RACING on SMR 450-R) with control on the handlebar right side
Rear
Floating drilled disc 9.45 in. with floating caliper
Pads area ........................................................................... 3.64 sq. in.
Independent hydraulic circuit; controlled by pedal and pump on the motorcycle right side.
WHEELS
Rims
Front (TE, TC, TXC) ........................................................... "TAKASAGO“ Excel in light alloy: 1.6x21”
Front (SMR) ....................................................................... "SANREMO" in light alloy: 3.50x17”
Front (SMR 450-R) ............................................................ "EXCEL" in light alloy: 3.50x16,5”
Rear (TE, TXC) .................................................................. "TAKASAGO“ Excel in light alloy: 2.15x18”
Rear (TC) ........................................................................... "TAKASAGO“ Excel in light alloy: 1.85x19”(250); 2.15x19”(450-510)
Rear (SMR) ........................................................................ "SANREMO" in light alloy: 4.25x17”
Rear (SMR 450-R) ............................................................ "EXCEL" in light alloy: 3.50x16.5”
TIRES
Front
(TE-TXC) ........................................ "Michelin" ENDURO COMP. 3 - "Pirelli" MT 83 Scorpion - "Dunlop" 54R-D907; 90/90x21"
(TC) ................................................ "Pirelli" 51R-MT 32A; 80/100 x 21”
(SMR) ............................................. "Pirelli" MTR 21 DRAGON-EVO; 120/70-17”
(SMR 450-R)................................... "Dunlop" KR106 - Slick TUBELESS (465) - 125/80R420
Rear
(TE-TXC) .........
"Michelin" ENDURO COMP. 3 - "Pirelli" MT 83 Scorpion - "Dunlop" 70R-D907; 120/90x18” (250); 140/80x18” (450-510)
(TC) ................. "Pirelli" NHS (62) MT 32; 100/90x19” (250); 110/90x19” (450-510)
(SMR) .............. "Pirelli" MTR 22 DRAGON-EVO; 150/60x17”
(SMR 450-R) ... "Dunlop" KR108 - Slick TUBELESS (950) - 170/55R17
Cold tire pressure (front TE-TXC racing use, TC) .......................... 0.9÷1.0 Kg/cm2 (12.8-14.2 psi)
Cold tire pressure (rear TE-TXC racing use, TC) ........................... 0.8÷0.9 Kg/cm2 (11.4-12.8 psi)
Cold tire pressure (front TE-TXC road use) ................................... 1.1 Kg/cm2 (15.6 psi)
Cold tire pressure (rearTE-TXC road use) ..................................... 1.0 Kg/cm2 (14.2 psi)
Cold tire pressure
(front SMR) ............................................................. 1.4 kg/cm2 - 20 p.s.i.(Racing use); 1.8 kg/cm2 - 25.6 p.s.i. (Road use: rider only);
2.0 kg/cm2 - 28.4 p.s.i. (Road use: rider and passenger)
Pressione di gonfiaggio a freddo
(rear SMR) .............................................................. 1.6 kg/cm2 - 22.7 p.s.i. (Racing use); 2.0 kg/cm2 - 28.4 p.s.i. (Road use: rider only);
2.2 kg/cm2 - 31.3 p.s.i. (Road use: rider and passenger)
A.7Part. N. 8000 B0148 (02-2008)
GENERAL
ELECTRICAL COMPONENTS LOCATION (TE-SMR)
The ignition system includes the following elements:
- Generator, in oil bath, on the inner side of L.H. crankcase cover;
- Electronic ignition coil under the fuel tank;
- Electronic power unit under the fuel tank;
- Voltage regulator under the fuel tank;
- Spark plug on the R.H. side of cylinder head;
- Starting motor 12V-450W behind the cylinder;
- Electric start remote control switch on the L.H. side of the rear frame;
- M.A.Q.S. sensor (pressure, accelerator control position, air temperature) on the throttle body.
The electric system includes the following elements:
- Headlamp with two filaments bulb of 12V-35/35W and parking light bulb of 12V-3W;
- Rear tail-light with stop bulbs of 12V-21W and parking light bulb of 12V 5W;
- Turn signals bulb of 12V-10W;
- Two 15A fuses and one (13) 20A fuse on the right side of the rear frame;
- Battery 12V-6Ah under the saddle;
- Relay for the electric fan, on the R.H. side of the frame;
- Injection and lighting system relays on the left side of the frame;
- Coolant temperature sensor;
- Electric fan;
- Turn signal flash device on the left side of the rear frame;
- Lambda probe;
- Fall sensor (SMR) on the right side of the rear frame;
- Fuel pump in the tank.
ELECTRICAL COMPONENTS LOCATION (TC-TXC-SMR 450-R)
The ignition system includes the following elements:
- Generator on the inner side of L.H crankcase cover;
- Electronic coil and condenser (TC-TXC) under the fuel tank;
- Electronic central unit under the fuel tank;
- Voltage regulator under the fuel tank;
- Spark plug on the right side of the cylinder head;
- 12V- 450W starting motor behind the cylinder;
- Electric start remote control switch on the left side of the rear frame;
- Potentiometer on the carburettor.
The electric system includes the following elements:
- 12V-6Ah battery under the saddle;
- Two 20° fuses mounted on the electric start remote control switch (TXC-SMR 450-R).
A.9Part. N. 8000 B0148 (02-2008)
GENERAL
CAPACITIES TYPE QUANTITY
Fuel tank (reserve included) Unleaded gasoline (98 R.O.N.) 1.58 Imp. Gall./ 1.9 U.S. Gall.
Fuel reserve 1.58 Imp. Qt./ 1.9 U.S. Qt.
Change gear and main transmission oil AGIP RACING 4T (SAE 10W60) 1.5 Imp. Qt./ 1.8 U.S. Qt.
(oil and oil filter replacement)
Change gear and main transmission oil AGIP RACING 4T (SAE 10W60) 1.3 Imp. Qt./ 1.6 U.S. Qt.
(oil replacement)
Front fork oil AGIP FORK 7,5 (SAE 7,5; SAE for hard climatic conditions)
TC, SMR 450-R: 310 cm
3
TE: 775 cm
3
SMR: 740 cm
3
Oil for rear shock - absorber AGIP FORK 2,5 (SAE 2,5)
Fluid for cooling system AGIP COOL 2.0÷2.4 Imp. Pints; 2.3÷2.7 U.S. Pints
Front brake fluid AGIP BRAKE 4 (DOT 4)
Rear brake fluid AGIP BRAKE 4 (DOT 4)
Clutch fluid OLIO MINERALE SAE 10 PER CIRCUITI IDRAULICI
Drive chain lubrication AGIP CHAIN LUBE
Grease lubrication AGIP BIKE GREASE
Electric contact protection AGIP CONTACT CLEANER
Fillers for radiator AREXONS TURAFALLE LIQUIDO
Air filter oil AGIP FORMULA FILTER "Foam air filter protection oil"
Air filter detergent AGIP "Filter clean foam air detergent fluid"
WARNING! - Use of additives in fuel or lubricants is not allowed
A.10 Part. N. 8000 B0148 (02-2008)
GENERAL
B.1Part. N. 8000 B0148 (02-2008)
MAINTENANCE
Section
B
B.2
Part. N. 8000 B0148 (02-2008)
MAINTENANCE
PRE -DELIVERY INSPECTION
Description Operation Pre-delivery
Engine oil Check level #
Coolant Check / Restore level #
Cooling system Check for leakage #
Elettroventole (TE-SMR) Controllo funzionamento #
Spark plugs Check / Replace #
Throttle body / Carburettor Check and adjust #
Brakes / Clutch fluid Check level #
Brakes / Clutch Check operation #
Brakes / Clutch Check lines for leakage #
Throttle control Check operation #
Throttle control Check / Adjust play #
Choke control Check operation #
Flexible controls and transmissions Check / Adjust #
Drive chain Check / Adjust #
Tyres Check pressure #
Side stand Check operation #
Interruttore cavalletto laterale Check operation #
Electrical equipment Check operation #
Instrument panel Check operation #
Lights / Visual signals Check operation #
Horn Check operation #
Headlight Check operation #
Ignition switch Check operation #
Locks Check operation #
Screws and nuts Check / Tighten #
Hose clamps Check / Tighten #
General lubrication #
General test #
B.3Part. N. 8000 B0148 (02-2008)
MAINTENANCE
VALVE C (¥) C (¥) S
VALVE SPRING C X
VALVE CUP, VALVE HALF CONE C X
ROCKER ARM (INTAKE-EXHAUST) C X
CAMSHAFT C
VALVE TIMING CHAIN C S
VALVE TIMING CHAIN SLIDER S
VALVE TIMING DRIVEN GEAR C X
VALVE TIMING DRIVING GEAR C X
VALVE TIMING CHAIN TENSIONER C
STARTER DECOMPRESSOR SYSTEM C X
INTAKE MANIFOLD C S
CYLINDER ASSY. C X
PISTON ASSY. C S
CONNECTING ROD ASSY. S
CRANKCASE BEARINGS S
ENGINE OIL S S
OIL PUMP C
OIL FILTER CARTRIDGE/ NET OIL FILTER S, P S, P
CRANKCASE- CYLINDER HEAD HOSE C
SET OF MATCHED PRIMARY C
CLUTCH HUB C X
CLUTCH DISCS C S X
CLUTCH DISCS PRESSURE PLATE C
CLUTCH SPRING C X
CLUTCH DISCS HOUSING C
CLUTCH DISENGAGEMENT ROD C
DRIVE SPROCKET C S X
STARTING GEARS C X
PERIODIC MAINTENANCE SCHEDULE
(SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES)
AFTER FIRST
3 HOURS
4h MX/8h EN 8h MX/16h EN 16h MX/32h EN 32h MX/64h EN 40h MX/80h EN IF NECESSARY PAGE
ITEM
EVERY EVERY EVERY EVERY EVERY REPLACE SEE
COUPON COUPON COUPON COUPON COUPON
TE-TC-TXC 250, 450, 510 -2008
COMPETITION MOTORCYCLE, RACING USE:
with FULL POWER ENGINE
D.4 - F.8
G.6 - G.7
F.8 - G.7
F.8 - G.6
G.7
F.8 - G.8
F.4 - G.9
H.38 - H.39
F.11 - G.10
H.31 - H.44
F.8 - F.11
G.10
F.6 - G.10
H.38
F.11 - G.10
H.40
F.5 - G.10
H.38
D.8 - F.6
G.8 - H.39
H.44
F.10 - G.11
H.34
F.10 - G.11
H.34
F.27 - G.15
G.17 - H.14
F.27 - H.22
D.20
F.19 - G.20
H.24
D.21
F.5 - H.44
F.22 - G.19
H.24 - H.27
F.14 - G.19
H.27 - H.28
D.11 - F.13
G.8 - H.27
F.13 - G.19
H.27 - H.28
F.13 - G.18
H.27 - H.28
F.14 - G.19
H.27 - H.28
F.14 - G.19
H.27 - H.28
F.23 - H.17
Y.15
F.17
H.24 - H.26
B.4
Part. N. 8000 B0148 (02-2008)
MAINTENANCE
STARTING PEDAL L
GEAR CONTROL PEDAL C
SPARK PLUG P S
SPARK PLUG CAP C
CARBURETOR P R
CARBURETOR THROTTLE VALVE C
AIR FILTER P, L
RADIATORS C
COOLANT HOSES AND CLAMPS C
RADIATORS HOSES /WATER PUMP C
COOLANT C X
FOOTRESTS, FOOTREST PINS AND SPRINGS C X
SADDLE FRAME FASTENING BOLTS, ENGINE FASTENING BOLTS C C
SIDE STAND C
CHAIN GUIDE ROLLER, BEARINGS C
STEERING HEAD, STEM AND STEERING BRACKET L
FRONT FORK R
HANDLEBAR HOLDERS AND FASTENING SET C C
REAR SWING ARM BUSHINGS C
REAR CHAIN SLIDER C X
REAR SUSPENSION LINKS BUSHINGS C
REAR CHAIN GUIDE/ REAR CHAIN GUARD C X
REAR SWING ARM PIVOT NEEDLE BEARINGS L
REAR SHOCK ABSORBER R
REAR SUSPENSION LINKS NEEDLE BEARINGS AND GUDGEON PIN L
THROTTLE CONTROL ASSY. C, L
CLUTCH CONTROL ASSY. C (¥) R
PERIODIC MAINTENANCE SCHEDULE
(SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES)
AFTER FIRST
3 HOURS
4h MX/8h EN 8h MX/16h EN 16h MX/32h EN 32h MX/64h EN 40h MX/80h EN IF NECESSARY PAGE
ITEM
TE-TC-TXC 250, 450, 510 -2008
COMPETITION MOTORCYCLE, RACING USE:
with FULL POWER ENGINE
COUPON COUPON COUPON COUPON COUPON
EVERY EVERY EVERY EVERY EVERY REPLACE SEE
F.12 - H.43
F.20 - H.43
M. 26
M. 26
D.10 - E.9
G.21
G.21 - G.22
G.24
D.23
N.3
N.5
N.5
D.22 - N.3
Y.4
Y.4
Y.4
Y.4
I.48
I.4 - I.48
D.34 - D.35
J.15
J.17
J.16
J.17
J.15
J.5
J.16
D.9
D.16 - P.5
B.5Part. N. 8000 B0148 (02-2008)
MAINTENANCE
THROTTLE AND STARTING DECOMPRESSOR CABLES C L X
FRONT BRAKE DISC C X
FRONT BRAKE SYSTEM FLUID C S
REAR BRAKE DISC C (*) X
REAR BRAKE SYSTEM FLUID C S
BRAKE PADS C X
BRAKE SYSTEM PUMP/CALIPER HOSES C
FUEL HOSES C S X
EXHAUST SILENCER PACKING S
EXHAUST PIPE AND SILENCER C X
WHEEL SPOKES TENSION C C
WHEEL HUB BEARINGS S
REAR DRIVE SPROCKET S
REAR DRIVEN SPROCKET SCREWS TIGHTENING C C
REAR TRANSMISSION CHAIN C, L S
BOLTS AND NUTS TIGHTNESS GENERAL CHECK C C
PERIODIC MAINTENANCE SCHEDULE
(SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES)
AFTER FIRST
3 HOURS
4h MX/8h EN 8h MX/16h EN 16h MX/32h EN 32h MX/64h EN 40h MX/80h EN IF NECESSARY PAGE
ITEM
KEY FOR MAINTENANCE SCHEDULE
h: HOURS
S: REPLACEMENT
C: CHECK
C(¥): CLEARANCE CHECK
P: CLEANING
R: OVERHAUL
L: GREASING/LUBRICATION
MX: MOTOCROSS
EN: ENDURO
(*) ROTATE 45¡ THE FASTENING BUSHES
NOTE:
- EVERY REMOVAL REPLACE ALL GASKETS
- REPLACE SCREWS AND NUTS IF WORN
- GENERAL CHECK AFTER RACING USE ON MUDDY OR SANDY GROUNDS
TE-TC-TXC 250, 450, 510 -2008
COMPETITION MOTORCYCLE, RACING USE:
with FULL POWER ENGINE
COUPON COUPON COUPON COUPON COUPON
EVERY EVERY EVERY EVERY EVERY REPLACE SEE
D.8 - D.9
L.4
D.17 - L.6
L.9
L.4
D.19 - L.8
L.9
L.5
L.11
D.36
D.37
D.39
Y.13
Y.12
Y.14
X.5
D.24
Capitolo X
B.6
Part. N. 8000 B0148 (02-2008)
MAINTENANCE
VALVE C (¥) C (¥) S
VALVE SPRING C X
VALVE CUP, VALVE HALF CONE C X
ROCKER ARM (INTAKE-EXHAUST) C X
CAMSHAFT C
VALVE TIMING CHAIN S
VALVE TIMING CHAIN SLIDER C S
VALVE TIMING DRIVEN GEAR C X
VALVE TIMING DRIVING GEAR C
VALVE TIMING CHAIN TENSIONER C
STARTER DECOMPRESSOR SYSTEM C X
INTAKE MANIFOLD C S X
CYLINDER ASSY. C X
PISTON ASSY. S
CONNECTING ROD ASSY. S
CRANKCASE BEARINGS S
ENGINE OIL /OIL FILTER CARTRIDGE S S S
OIL PUMP C
CRANKCASE / CYLINDER HEAD HOSE C
SET OF MATCHED PRIMARY C X
CLUTCH HUB C X
CLUTCH DISCS C S X
CLUTCH DISCS PRESSURE PLATE C
CLUTCH SPRING C X
CLUTCH DISCS HOUSING C X
CLUTCH DISENGAGEMENT ROD C
DRIVE SPROCKET C S
STARTING GEARS C X
PERIODIC MAINTENANCE SCHEDULE
(SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES)
ITEM
AFTER FIRST
3 HOURS
EVERY
5 HOURS
EVERY
15 HOURS
REPLACE
IF
NECESSARY
AFTER FIRST
1000 KM
EVERY
5000 KM
EVERY
10000 KM
SEE
PAGE
COUPON COUPON COUPON
SMR 450, 510 - TE 250, 450, 510 / 2008
- STANDARD MOTORCYCLE, STREET LEGAL (with LIMITED
POWER ENGINE):
SMR 450, 510 / 2008 - SMR 450-R / 2008
- COMPETITION MOTORCYCLE, RACING USE (with FULL
POWER ENGINE)
D.4 - F.8
G.6 - G.7
F.8 - G.7
F.8 - G.6
G.7
F.8 - G.8
F.4 - G.9
H.38 - H.39
F.11 - G.10
H.31 - H.44
F.8 - F.11
G.10
F.6 - G.10
H.38
F.11 - G.10
H.40
F.5 - G.10
H.38
D.8 - F.6
G.8 - H.39
H.44
F.10 - G.11
H.34
F.10 - G.11
H.34
F.27 - G.15
G.17 - H.14
F.27 - H.22
D.20
F.19 - G.20
H.24
F.5 - H.44
F.22 - G.19
H.24 - H.27
F.14 - G.19
H.27 - H.28
D.11 - F.13
G.8 - H.27
F.13 - G.19
H.27 - H.28
F.13 - G.18
H.27 - H.28
F.14 - G.19
H.27 - H.28
F.14 - G.19
H.27 - H.28
F.23 - H.17
Y.15
F.17
H.24 - H.26
B.7Part. N. 8000 B0148 (02-2008)
MAINTENANCE
STARTING PEDAL L
GEAR CONTROL PEDAL X
SPARK PLUG P S
SPARK PLUG CAP C C X
CARBURETOR P
CARBURETOR THROTTLE VALVE C X
AIR FILTER (**) P, L P, L X
RADIATORS C
COOLANT HOSES AND CLAMPS C C
RADIATORS HOSES/WATER PUMP C C
FOOTRESTS, FOOTREST PINS AND SPRINGS X
SADDLE FRAME FASTENING BOLTS, ENGINE FASTENING BOLTS CC
SIDE STAND C
CHAIN GUIDE ROLLER, BEARINGS C C X
STEERING HEAD, STEM AND STEERING BRACKET L
FRONT FORK R
HANDLEBAR HOLDERS AND FASTENING SET C C
REAR SWING ARM BUSHINGS C
REAR CHAIN SLIDER S
REAR SUSPENSION LINKS BUSHINGS C X
REAR CHAIN GUIDE/ REAR CHAIN GUARD C C X
REAR SUSPENSION LINKS NEEDLE BEARINGS AND GUDGEON PIN L
REAR SHOCK ABSORBER C
THROTTLE CONTROL ASSY. C, L
CLUTCH CONTROL ASSY. C (¥) R
THROTTLE AND STARTING DECOMPRESSOR CABLES C L X
FRONT BRAKE DISC C X
FRONT BRAKE SYSTEM FLUID C S
PERIODIC MAINTENANCE SCHEDULE
(SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES)
AFTER FIRST
1000 KM
EVERY
5000 KM
EVERY
10000 KM
AFTER FIRST
3 HOURS
EVERY
5 HOURS
EVERY
15 HOURS
REPLACE
IF
NECESSARY
SEE
PAGE
ITEM COUPON COUPON COUPON
SMR 450, 510 - TE 250, 450, 510 / 2008
- STANDARD MOTORCYCLE, STREET LEGAL (with LIMITED
POWER ENGINE):
SMR 450, 510 / 2008 - SMR 450-R / 2008
- COMPETITION MOTORCYCLE, RACING USE (with FULL
POWER ENGINE)
F.12 - H.43
F.20 - H.43
M. 26
M. 26
D.10 - E.9
G.21
G.21 - G.22
G.24
D.23
N.3
N.5
N.5
Y.4
Y.4
Y.4
I.48
I.4 - I.48
D.34 - D.35
J.15
J.17
J.16
J.17
J.15
J.5
J.16
D.9
D.16 - P.5
D.8 - D.9
L.4
D.17 - L.6
L.9
B.8
Part. N. 8000 B0148 (02-2008)
MAINTENANCE
REAR BRAKE DISC C X
REAR BRAKE SYSTEM FLUID C S
BRAKE PADS C C C X
BRAKE SYSTEM PUMP/CALIPER HOSES C X
FUEL HOSES C X
EXHAUST SILENCER PACKING X
EXHAUST PIPE AND SILENCER C X
WHEEL SPOKES TENSION C C
WHEEL HUB BEARINGS C X
REAR DRIVE SPROCKET S
REAR DRIVEN SPROCKET SCREWS TIGHTENING C C C
REAR TRANSMISSION CHAIN C, L C, L S
BOLTS AND NUTS TIGHTNESS GENERAL CHECK C C
PERIODIC MAINTENANCE SCHEDULE
(SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES)
ITEM
AFTER FIRST
1000 KM
AFTER FIRST
3 HOURS
COUPON COUPON COUPON
EVERY
5000 KM
EVERY
5 HOURS
EVERY
10000 KM
EVERY
15 HOURS
REPLACE
IF
NECESSARY
SEE
PAGE
KEY FOR MAINTENANCE SCHEDULE
h: HOURS
S: REPLACEMENT
C: CHECK
C(¥): CLEARANCE CHECKP: CLEANING
R: OVERHAUL
L: GREASING/LUBRICATION
MX: MOTOCROSS
EN: ENDURO
(*) ROTATE 45¡ THE FASTENING BUSHES
NOTE:
- EVERY REMOVAL REPLACE ALL GASKETS
- REPLACE SCREWS AND NUTS IF WORN
- GENERAL CHECK AFTER RACING USE ON MUDDY OR SANDY GROUNDS
(**): + SOLENOID VALVE HOSE FILTER (STANDARD MOTORCYCLE)
SMR 450, 510 - TE 250, 450, 510 / 2008
- STANDARD MOTORCYCLE, STREET LEGAL (with LIMITED
POWER ENGINE):
SMR 450, 510 / 2008 - SMR 450-R / 2008
- COMPETITION MOTORCYCLE, RACING USE (with FULL
POWER ENGINE)
L.4
D.19 - L.8
L.9
L.5
L.11
D.36
D.37
D.39
Y.13
Y.12
Y.14
X.5
D.24
Section X
C.1Part. N. 8000 B0148 (02-2008)
TROUBLES AND REMEDIES
Section
C
C.2 Part. N. 8000 B0148 (02-2008)
TROUBLES AND REMEDIES
ENGINE
Trouble Cause Remedy
Engine don’t start or starts Inadequate compression
with difficulty 1. Piston seizure Replace
2. Con-rod small or big end seized Replace
3. Piston rings worn Replace
4. Cylinder worn Replace
5. Low torque cylinder head nuts Tighten
6. Head gasket blowing Replace
7. Spark plug loose Tighten
8. Incorrect valve play Adjust
9. Valve springs weak or seized Replace
10. Valves seized Replace
11. Incorrect decompressor adjustment Adjust
No or weak spark
1. Spark plug faulty Replace
2. Spark plug dirty or wet Clean or dry
3. Spark plug gap too large Adjust
4. Ignition coil faulty Replace
5. H.T. leads damaged or short circuiting Check
6. Electronic device faulty Replace
7. R.H. switch faulty Replace
Fuel not reaching carburettor (TC, TXC)
1. Fuel tank cap breather blocked Clean
2. Fuel cock blocked Clean
3. Fuel feed hose blocked Clean
4. Carburettor fuel filter dirty Clean
5. Worn out float valve or worn out floats Replace
6. Rocker blocking float valve Free
Carburettor flooding (TC, TXC)
1. High fuel level in float bowls Adjust
2. Worn out float valve or worn out floats in open position Replace or free
Engine cuts out easily 1. Spark plug dirty Clean
2. Electronic control unit faulty Replace
3. Carburettor jets blocked Clean
4. Idling low Adjust
Engine noisy Piston noise
1. Excessive play between cylinder liner and piston Replace
2. Piston rings or piston rings seats worn Replace
3. Excessive carbon layers inside the combustion chamber,
or on the piston top Clean
4. Worn rocker arm Replace
5. Excessive valve play Adjust
6. Valve springs weak or seized Replace
7. Cam chain worn Replace
8. Incorrect timing chain adjustment Adjust
Crankshaft noise
1. Main bearings worn Replace
2. High radial and axial play at con-rod big end Replace
3. Crankshaft gear damaged Replace
4. Crankshaft nut loose Tighten
C.3Part. N. 8000 B0148 (02-2008)
TROUBLES AND REMEDIES
Trouble Cause Remedy
Clutch noise
1. Discs worn Replace
2. Excesive free play between clutch drum and driving discs Replace
Gearbox noise
1. Gears worn Replace
2. Gear splines worn Replace
Rear transmission chain noise 1. Chain stretched or badly adjusted Replace or adjust
2. Engine sprocket and rear wheel sprocket worn Replace
Clutch slip 1. Clutch springs weak Replace
2. Clutch discs worn Replace
Clutch drag 1. Spring tension uneven Replace
2. Clutch discs bent Replace
Gears not engaging 1. Gearshift forks bent or seized Replace
2. Gearchange pawls worn Replace
3. Gearshift forks’ control pins damaged Replace
Gearchange lever doesn’t
return 1. Selector return spring weak or broken Replace
2. Gearshift forks worn Replace
Slips out of gear 1. Sliding dogs worn Replace
2. Gear splines worn Replace
3. Sliding dog seats on gears worn Replace
4. Splines gearshift forks’ control shaft worn Replace
5. Gearshift forks control pins worn Replace
Engine lacks power 1. Air filter dirty Clean
2. Carburettor main jet blocked or wrong size (TC, TXC) Clean or replace
3. Poor quality fuel Replace
4. Intake manifold loose Tighten
5. Spark plug gap too large Adjust
6. Inadequate compression Find cause
7. Incorrect valve play Adjust
8. Faulty valve guides or seats Replace
9. Valve springs weak or seized Replace
Engine overheating 1. Excessive coke on combustion chamber and/or
piston crown Clean
2. Insufficient engine oil, or wrong oil used Top up or replace
3. Radiator air flow blocked Clean
4. Poor seal at cylinder head gasket Replace
5. Clutch slipping Adjust
6. Faulty cooling fan (TE, SMR) Replace the thermoswitch
C.4 Part. N. 8000 B0148 (02-2008)
TROUBLES AND REMEDIES
FRAME, WHEELS AND SUSPENSION
Trouble Cause Remedy
Difficult to turn handlebars 1. Low tire pressure Inflate
2.
Steering head bearings’ adjustment ring nut or steering stem nut too tight Adjust
3. Bent steering head stem Replace steering bracket
4. Stearing head bearings worn or seized Replace
Handlebar vibrates 1. Front fork legs bent Replace
2. Front wheel axle bent Replace
3. Frame bent Replace
4. Front wheel rim bent Replace
5. Front wheel bearings worn Replace
Suspension too hard 1. Too much oil in front fork stanchions Drain excess
2. Too high viscosity of front fork stanchion oil Replace
3. Inflating pressure too high Deflate
4. Rear shock absorber incorrectly set Adjust
Suspension too soft 1. Insufficient oil in front fork stanchions Top up
2. Too low viscosity of front fork stanchion oil Replace
3. Weak front fork spring Replace
4. Weak rear shock absorber spring Replace
5. Rear shock absorber badly adjusted Adjust
Wheel (front and rear) 1. Wheel rim bent Replace
vibrates 2. Wheel hub bearings worn Replace
3. Wheel spokes loose Tighten
4. Wheel axle nut loose Tighten
5. Rear swinging arm bearings worn Replace
6. Chain tensioner incorrectly set Adjust
7. Wheel not balanced correctly Balance
Rear suspension noisy 1. Link rod bearings or spacers worn Replace
2. Shock absorber ball joints worn Replace
3. Shock absorber faulty Replace
Poor (front and rear) 1. Air in the brake system Bleed
braking 2. Insufficient fluid in reservoir Top up
3. Pads and/or disc worn Replace
4. Disc damaged Replace
5. Brake lever- pedal incorrectly adjusted Adjust
6. Water inside the braking system Replace the fluid
C.5Part. N. 8000 B0148 (02-2008)
TROUBLES AND REMEDIES
ELECTRICS (see also chapter M)
Trouble Cause Remedy
Spark plug becomes dirty 1. Mixture too rich Adjust carburettor
too frequently 2. Air filter dirty Clean
3. Piston rings worn Replace
4. Piston or cylinder worn Replace
Spark plug overheats 1. Mixture too lean Adjust carburettor
2. Spark plug gap too small Adjust
3. Too high heat rating Replace the spark plug
Generator charging too low 1. Wires to voltage regulator connected incorrectly
or not at all or short circuiting Connect correctly or replace
2. Faulty voltage regulator Replace
3. Generator coil faulty Replace
Generator charging too high 1. Voltage regulator faulty Replace
The battery is discharged fast 1. Battery terminals dirty Clean
Start motor won't start or slips 1. Battery flat Recharge
(TE, SMR, TXC) 2. Control button on right hand switch Replace
unit faulty
3. Starter relay faulty Replace
4. Starter motor faulty Repair or replace
5. Starter gears worn Replace
6. Free wheeel rollers worn or damaged Replace free wheeel
FUEL INJECTION SYSTEM (see chapter S)
C.6 Part. N. 8000 B0148 (02-2008)
TROUBLES AND REMEDIES
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.1
Section
D
D.2 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
Adjustment of valves play ......................................... D.4
Adjustment of starter decompression device ............. D.8
Throttle cable adjustment ................................. ......... D.9
Carburettor adjustment (TC, TXC, SMR 450-R) .... ... D.10
Idle adjustment (TC, TXC, SMR 450-R) ........... ......... D.10
Idle adjustment (TE, SMR) ............................... ......... D.10
Clutch discs replacement (TC, TE, TXC, SMR) ......... D.11
Clutch discs replacement (SMR 450-R) .................... D.12
Adjustment of the control lever and check of
the clutch fluid level ................................................... D.16
Adjustment of front brake control lever
and fluid level control (TE, TC, TXC, SMR) ............... D.17
Adjustment of front brake control lever
and fluid level control (SMR 450-R) ........................... D.18
Rear brake pedal position adjustment ....................... D.18
Rear brake idle stroke adjustment ............................. D.19
Checking the rear brake fluid level ............................ D.19
Checking the engine oil level ..................................... D.20
Engine oil replacement and bag filters-cartridge filter
cleaning or replacement
...................................... D.21
Coolant level check ................................................... D.22
Replacement of coolant ............................................ D.22
Air filter check ........................................................... D.23
Air filter cleaning ....................................................... D.23
Secondary transmission chain adjustment ................ D.24
Lubricating the transmission chain ............................ D.25
Adjusting the suspensions according to particular
track conditions ......................................................... D.26
Adjusting the shock absorber .................................... D.27
Adjusting the shock absorber spring preload ............. D.28
Shock absorber hydraulic brake adjustment .............. D.29
Shock absorber springs ............................................ D.30
Adjusting the front fork .............................................. D.31
Front fork springs ...................................................... D.32
Steering bearings play adjustment ............................ D.33
Handlebar position and height change
(TE, TC, TXC, SMR) ................................................. D.34
Handlebar position change (SMR 450-R) .................. D.35
Checking the fuel hose ............................................. D.36
Replacing the muffler deadening material
(TC, TE, TXC, SMR) ................................................. D.37
Replacing the muffler deadening material
(SMR 450-R) ............................................................ D.38
Checking the exhaust system ................................... D.39
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.3
TC-TXC
TE
SMR
SMR 450-R
D.4 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
Adjusting the valve play
To check the valve clearance, proceed as follows , WITH COLD ENGINE:
First turn counterclockwise fastening rear pin (1) then remove the saddle.
HOW TO REMOVE THE TANK (TC)
Close the fuel tap (2) and loosen the strap (3) on the connecting pipe to the
carburettor, pull the pipe out of the carburettor.
Remove the screws (4) and the side panels.
Remove the locking screw (A) and pull out the tank with its conveyors.
2
4
3
A
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.5
HOW TO REMOVE THE TANK (TE-SMR)
Remove the screws (1) and the side panels.
Remove the locking screw (A) of the tank.
Lift the tank, then disconnect the connector of the fuel pump from the main
cabling.
Disconnect the feeding pump (B) from the outlet coupling (C) on the fuel pump
in the lower back section of the tank.
Pull out the tank with its conveyors.
1
A
C
B
D.6 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
HOW TO REMOVE THE SADDLE AND THE TANK (SMR 450-R)
First turn counterclockwise fastening rear pin (1) then remove the saddle.
Close the fuel tap (2) and loosen the strap (3) on the connecting pipe to the
carburettor, pull the pipe out of the carburettor.
Remove the screws (4) and the side panels.
Remove the locking screw (A) and pull out the tank with (B) its conveyors.
1
2
3
4
4
B
B
A
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.7
PROCEDURE APPLYING TO ALL THE MODELS
Remove the spark plug (5), the four cylinder head cover fastening screws (6)
and the cylinder head cover.
Engage second gear and, moving the vehicle forwards and backwards, bring
the piston to Top Dead Center (in this condition , the mark on the cylinder head
is aligned with the two marks on the idle gear of the camshafts, as illustrated in
the figure).
Check, by means of a feeler gauge, that the valve clearance is 0,10÷0,15 mm
for INTAKE and 0,15÷0,20 mm for EXHAUST;
Otherwise, lift the retaining clip (7) using a hook, let the rocker arm slide to one
side, extract the pad with a pair of pliers and check the thickness;
Depending on the result, fit a new pad (as spare parts, pads are supplied ranging from 1.60 mm to 2.60 mm in steps of 0.05 mm) and return the clip and rocker
arm;
Check the valve clearance again and, if it’s correct, reassembly the removed
parts using the reverse procedure.
D.8 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
SMR 450-R
7
Adjustment of starter decompression device
In order to adjust the lever decompressor free play (approximately 3 mm - 0.12
in.): should the clearance be incorrect, unblock the counter ring-nut and turn the
adjusting screw (by unscrewing it, the clearance is reduced, while by screwing
screw it is increased); the lever holder (5) is provided with the adjuster (6); the
adjustment can be also effected with the tightener (7) on the R.H. side of the
engine (use this tightener if it is not possible to obtain the correct free play with
the adjuster on the handlebar).
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.9
Throttle cable adjustment
To check the correct adjustment of the throttle operate as follows:
- remove the upper rubber cap (1);
- by moving cable (2) back and forth check for 2 mm (0.08 in.) clearance;
- should the clearance be incorrect, unblock the counter ring-nut (3) and turn the
adjusting screw (4) (by unscrewing it, the clearance is reduced, while by screwing screw (4) it is increased);
- tighten the counter ring-nut again (3).
: Operation with damaged throttle cable could result in an unsafe riding
condition
: Exhaust gas contains poisonous carbon monoxide gas. Never run the
engine in a closed area or in a confined area.
SMR 450-R
1
3
4
2
SMR 450-R
3
B
In case of throttle control cables (1) and (2) replacement it is necessary to respect,
during reassembly, the measure Á (10mm/0.4 in.), as shown in the picture. Then
reassemble guard cover (B) using screw (3) and adjust throttle control cables on
handlebar. To replace throttle control cables, first remove tha fuel tank as shown
on page E.23.
D.10 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
Carburettor adjustment (TC, TXC, SMR 450-R)
Adjust the carburettor with warm engine and with the throttle in closed position.
Work as follows:
- turn slow running adjusting screw (1) on the left side of the bike, , until the engine
is turning over at fairly high rpm (turn the screw clockwise to increase the rpm, and
anticlockwise to descrease the rpm).
- turn adjusting screw (2) clockwise until the fully closed position is reached then
turn back 1,5 turns (250) or 2 turns (450-510).
- progressively loosen adjusting screw (1) to obtain the slow running required.
Idle adjustment (TC, TXC, SMR 450-R)
Adjust the carburetor with warm engine and with the throttle control in closed
position.
Proceed as follows:
- turn slow running adjusting screw (1) on the left side of the bike, near the fuel
cock (turn the screw clockwise to increase the rpm, and anticlockwise to
descrease the rpm).
3
TC-TXC
SMR 450-R
SMR 450-R
TE-SMR
Idle adjustment (TE, SMR)
Adjust the carburetor with warm engine and with the throttle control in closed
position.
- turn slow running adjusting screw (3) on the right side of the bike, on the throttle body, until you reach the minimum of 1.600 rpm (turn the screw clockwise to
increase the rpm, and anticlockwise to descrease the rpm).
1
2
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.11
1
Clutch discs replacement (TC-TE-TXC-SMR)
This operation can be carried out by laying the motorcycle on the left side without draining the engine oil. Remove the five fastening screws (1) and the
clutch cover (if necessary, lower the rear brake control pedal). Use a 5 mm allen
wrench to loosen the six screws (2) that fasten clutch springs. Remove springs,
pressure plate (3) complete with bearing and clutch control rod (4). Extract the
discs (5), lubricate the new discs with engine oil then assemble the new discs (first
always mount a lined disc). Reassemble pressure plate and springs. Tighten the
clutch springs bolts whilst following a cross-over pattern and in steps (8 Nm-0,8
Kgm- 5.8 ft/lb). Reassemble the clutch cover (8 Nm-0,8 Kgm- 5.8 ft/lb).
D.12 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
Clutch discs replacement (SMR 450-R)
Tilt the motorcycle to the left side without draining the engine oil. Remove the
five locking screws (A) and remove the clutch cover (lower the rear brake pedal
if necessary).
Use a 4 mm Allen wrench to loosen the six screws (9) and their notched washers
(8) and remove the support (30) along with the fifth wheel (33) and the thrust
bearing (32). Remove the clutch control pin (31), the nut (11) and the washer (12).
Insert the tool provided (a) in the seat on the hub (29). Use a 27 mm wrench (c)
and the tool (b) no. 8000 A8190 to remove the hub (29). Remove the thrust
bearing (28), the spring retainer plate (27) and the spring (26).
Remove the plate (6) along with the shim (25), the clutch spring (7), the toothed
washer (23) and the drum stop hub (22). Use a M6x15mm screw (A) to fix the
clutch drum (1) on the hub (4) in order to prevent balls (14) from escaping and
extract the disc assembly (5).
Lubricate the new discs (D) with engine oil and mount them on the drum (1)
(always insert a lined plates first).
Remove the M6x15mm screw (A) previously mounted.
TOOLS
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.13
D.14 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
Put the drum stop hub (22) on the clutch hub (1) with a small quantity of grease;
- insert the toothed washer (23) with the convex side facing upward;
- mount the spring (7) in its seat inside the drum (1) with a small quantity of grease;
- insert the plate (6) on the drum (1);
- arrange the shim (25) in the plate (6) and insert the spring (26);
- insert the spring retainer plate (27) into the spring (26) with the splined side
facing upward so that the 9 tabs match the 9 spokes of the spring (26). Insert the
thrust bearing (28) and the spring stop hub (29);
- insert the tool provided (a) in the seat on the hub (29) and use the 27 mm wrench
(c) and the tool (b) no. 8000 A8190 to screw the spring stop hub (29) onto the main
shaft (75 Nm- 7.6 Kgm- 55 ft/lb);
- mount the washer (12), the nut (11) and the pin (31) and place the support (30)
along with the fifth wheel (33) and the thrust bearing (32) into their seat in the
pressure plate (6), making sure it is properly inserted in the appropriate splines
and fix it with the 6 screws (9) and their notched washers (8);
- tighten the screws (9) crosswise and gradually with a 4 mm Allen wrench (6 Nm0,6 Kgm- 4.4 ft/lb).
- mount the clutch cover and tighten its screws (A) (11 Nm-1,1 Kgm- 8.1 ft/lb).
Check screw tightening (1) every 2 hours.
TOOLS
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.15
D.16 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
Adjustment of the control lever and check of the clutch fluid level
Free play (A) must be at least 3 mm (0.1 in.).
The lever position can be adjusted for any driver hand size. To decrease the lever
distance from the handle grip, rotate the adjuster (B) CLOCKWISE. To increase
the lever distance from the handle grip, rotate the adjuster (B)
COUNTERCLOCKWISE. To check the fluid level, proceed as follows:
- remove screws (1), cover (2) and rubber pump diaphragm on the handlebar
clutch control;
- by keeping the master cylinder (3) in horizontal position, check the fluid level is
NOT BELOW 4 mm (0.16 in.) from the upper surface (D) of the pump body;
- if necessary, add fluid until the correct level is reached (see page A.9: TABLE
FOR LUBRICATION and SUPPLIES for the fluid type)
: NEVER use brake fluid.
Reassembly the removed parts using the reverse procedure.
Periodically check the connecting hose (see “Periodical maintenance card”): if
the hose (C) is bent or cracked, replace it.
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.17
Adjustment of front brake control lever and fluid level control (TE-TC-TXCSMR)
On the SMR model the lever position can be adjusted (4 adjustments) for any driver
hand size. To decrease the lever distance from the handle grip, turn the adjuster (B)
CLOCKWISE. To increase the lever distance from the handle grip, turn the adjuster
(B) COUNTERCLOCKWISE. On the TE, TC and TXC models the adjuster (2),
located on the control lever, allows adjusting of the free play (a).
Free play (a) must be at least 3 mm (0.1 in.). The level of the fluid in pump
reservoir must never be below the minimum value (1), which can be checked from
the window on the rear side of the pump body (TE, TC and TXC). For SMR model,
check the level on the fluid reservoir. A decrease of the fuel level will let
air into the sustem, hence an extension of the level stroke.
: If the brake lever feels mushy when it is applied, there may be air in the
brake lines or the brake may be defective: CHECK THE BRAKING
SYSTEM (page L.2).
: If the lever free play is excessive, the brake action can decrease: CHECK
THE PADS THICKNESS (page L.5).
Do not spill brake fluid on to any painted surface or lenses (e.g. headlamp).
Do not mix two brands of fluid. Change the brake fluid in the brake line if
you wish to switch to another fluid brand.
Brake fluid may cause irritation. Avoid contact with skin or eyes. In case of
contact, flush thoroughly with water and call a doctor if your eyes were
exposed.
SMR
TE-TC-TXC
TE-TC-TXC
SMR
A: to encrease clearance
B: to decrease clearance
TE-TC-TXC
D.18 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
Rear brake pedal position adjustment
The position of the rear foot brake pedal as to the footrest may be adjusted
according to the individual needs. For the adjusting proceed as follows:
- loosen the screw (1);
- turn the cam (2) in order to adjust the brake pedal idle stroke (A);
- the operation done, tighten the screw (1).
The adjusting operation carried out, adjust the idle stroke of the pedal as shown
on page D.19.
Adjustment of front brake control lever and fluid level control (SMR 450-R)
The handlebar lever can be adjusted to the rider’s hand size. Turn the adjuster
(1) ANTICLOCKWISE to reduce the distance between the lever and the grip or
turn the adjuster (1) CLOCKWISE to increase the distance between the lever and
the grip.
The level of the fluid in the pump tank must never be below the minimum level (2)
(check the level on the transparent reservoir).
Any decrease in the fluid level may let air into the system, thus increasing the lever
stroke.
: If the brake lever feels mushy when it is applied, there may be air in the
brake lines or the brake may be defective: CHECK THE BRAKING
SYSTEM (page L.6).
: If the lever free play is excessive, the brake action can decrease: CHECK
THE PADS THICKNESS (page L.5).
Do not spill brake fluid on to any painted surface or lenses (e.g. headlamp).
Do not mix two brands of fluid. Change the brake fluid in the brake line if
you wish to switch to another fluid brand.
Brake fluid may cause irritation. Avoid contact with skin or eyes. In case of
contact, flush thoroughly with water and call a doctor if your eyes were
exposed.
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.19
C: to encrease clearance
D: to decrease clearance
Checking the rear brake fluid level
The level (A) must be set between the pump tank notches of MIN and MAX.
Rear brake idle stroke adjustment
The rear brake foot pedal should have a (B) 5 mm (0.2 in.) idle stroke before
starting the true braking action. Should this not happen proceed as follows:
- loosen nut (3);
- operate the pump rod (4) to increase or decrease the idle stroke;
- tighten nut (3) at the end of the operation.
: When the idle stroke figures are not met, the brake pads will be subjected
to a fast wear that may bring to the TOTAL BRAKE INEFFICIENCY.
: If the brake pedal feels mushy when it is applied, there may be air in the
brake lines or the brake may be defective: CHECK THE BRAKING SYSTEM
(pag. L.8).
D.20 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
Checking the engine oil level
By keeping the motorcycle on a flat surface, in vertical position, remove the
control screw (1) and check the oil should just barely escape from the hole on
the R.H. cover. To fill up, remove the filler cap (2).
: Have this operation made with warmed-up engine.
: Be careful not to touch hot engine oil.
MAX
MIN
1
2
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.21
A
4
2
3
Engine oil replacement and bag filters-cartridge filter cleaning or replacement
Drain the oil with WARM ENGINE; proceed as follows:
- remove oil filler cap (2);
- even if not necessary, remove the engine guard (A);
- place an oil drain pan under the engine block;
- remove the oil drain cap (3), drain the used oil completely then clean the magnet on the cap;
- remove the three filters (5), (6) and (7) on the L.H. side of the engine, check ORings for wear then clean filters with fuel.
Reassemble using the reverse procedure.
In order to replace the filter cartridge (4), unscrew the three fastening screws
then the filter cartridge cover;
- after filters replacement, reassemble the drain cap (3), the engine guard (A)
then pour the recommended oil quantity.
Reassemble, on engine L.H. side, filter (5-4) (8 Nm-0,8 Kgm-5.8 ft/lb) e (6) (25
Nm-2,55 Kgm-18.4 ft/lb) ed inferiormente il tappo (2) scarico olio (25 Nm-2,55
Kgm-18.4 ft/lb).
Be careful not to touch hot engine oil.
D.22 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
Coolant level check
Check level (1) in right-hand radiator when engine is cold (place the motorcycle
so that it is perpendicular to the ground). The coolant should be approximately
10 mm above cells and besides, on TE and SMR models, it doesn’t exceed the
middle of the expansion tank (2) located in front of the rear shock absorber.
The radiator cap (3) is provided of two unlocking positions, the first being for the
previous pressure discharge in the cooling system.
: Avoid removing radiator cap when engine is hot, as coolant may spout
out and cause scalding.
TE-SMR: Since the cooling fan (A) can be activated even when the start
switch is in OFF position, always keep a safe distance from the fane vanes.
: Difficulties may arise in eliminating coolant from varnished surfaces.
If this occurs, wash off with water.
Replacement of coolant
Place a vessel on the R.H. side of the cylinder, under the coolant drain screw
(3).
FIRST remove the screw (3) then SLOWLY open the R.H. radiator cap (4); slope
the motorcycle on the right side to drain the coolant easily in the vessel.
Reassemble the screw (3).
Pour the necessary quantity of coolant in the radiator then warm up the engine
in order to eliminate any possible air bubble. Periodically check the connecting
hoses (see “Periodical maintenance card” page B.4-B.7); this will avoid coolant
leakages and consequent engine seizure. If hoses (B) show cracks, swelling or
hardenings due to sheats desiccation, their replacement shall be advisable.
Check the correct tightening of the clamps (C).
1
2
3
B
C
C
4
B
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.23
1
Air filter check
Turn rear pin (1) counterclockwise, remove it and release the saddle from the
front fastening screw.
To gain access to the air filter, lift a little the electronic power unit (2). Remove
screw (3) and the filter (4). Separate filter (5) from frame (6).
AIR FILTER AND CLEANING
Wash filter with a specific detergent (AGIP” Filter clean foam air detergent fluid”
or similar) then dry it fully (wash filter with gasoline only in case of necessity).
Plunge filter in special oil for filters (AGIP "Foam air filter protection oil" or similar), then wring it to drain superfluous oil.
: Do not use gasoline or a low flash-point solvent to clean the element. A
fire or explosion could result.
: Clean the element in a well ventilated area, and do not allow sparks or
flames anywhere near the working area.
ASSEMBLY
To ensure tight fit, slightly (C) grease filter edge on side facing filter housing.
While re-inserting the filter into its housing, make surs that piece (A) is turned
upwards and edge (B) is on the left lower side of the filter case. Reassemble the
parts previously removed (battery: connect the positive cable first).
: If the element assembly is not installed correctly, dirt and dust may enter
and the engine resulting in rapid wear of the piston rings and cylinder.
D.24 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
Secondary transmission chain adjustment
Chain should be checked, adjusted and lubricated as shown on the Maintenance Chart (page B.5-B.8) to ensure security and prevent excessive wear. If
the chains becomes badly worn or is poorly adjusted (i.e., if it is too loose or too
taught), it could escape from sprocket or break.
To adjust the rear chain, it is necessary to lower the rear part of motorcycle so to
line up the drive sprocket axle, the rear swing arm axle and the rear wheel axle
as shown on drawing. Then let turn three times the rear wheel. Now the chain
should not be tight. (Fig. A).
Fast adjustment (Fig. B)
Insert a bushing (a) with a 35 mm diameter (or with the same thickness) as shown
in the image and make sure the lower section (C) of the chain is slightly taut.
If this is not the case, proceed as follows:
- loosen the nut (1) of the wheel axle on the right side with a 27 mm Allen wrench;
- loosen the check nuts (2) on both chain adjusters with a 12 mm wrench and act
on the screws (3) until the proper tension level is restored;
- once tension has been adjusted, tighten the check nuts (2) and the wheel axle
nut (1).
After the adjustment, always check the wheel alignment and tighten the wheel
axle fully (142.1 Nm- 14.5 kgm- 104.8 ft/lb).
Fig. B
a
C
1
2
3
Rear sprocket axle
Rear swing arm axle
Rear wheel axle
Fig. A
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.25
1- Chain tension roller
2- Chain driving roller
3- Chain guide
4- Chain slider
a- Joint spring
2
4
SMR 450-R
3
SMR 450-R
1
1
1
SMR 450-R
4
3
2
Lubricating the chain
Lubricate the chain following these instructions.
: Never use grease to lubricate the chain. Grease helps to accumulate dust
and mud, which act as abrasive and hepl to rapidly wear out the chain, the
sprocket, and the crown.
Disassembling and cleaning
When particularly dirty, remove and clean the chain before lubrication. Work as
follows:
- set a stand or a block under the engine and see that the rear wheel is lifted from
the ground;
- remove: screws (1), transmission sprocket guard (2), clip (3), master link (4) and
transmission chain (5). To reassemble, reverse the above procedure.
Check that the chain is neither worn out nor damaged. If the rollers or the links are
damaged, replace the chain by following the instructions given in the Periodical
Maintenance Table. Check that neither the sprocket nor the crown are damaged.
Wash and clean the chain as described hereunder.
Washing the chain without OR (TC-TXC-SMR 450-R)
Wash using either oil or diesel oil. When using gasoline or tricloroetilene, clean
and lubricate the chain to prevent oxidation.
Washing the chain with OR (TE-SMR)
Wash using oil, diesel oil, or paraffin oil. Never use gasoline, tricloroetilene, or
solvents, as the OR may suffer damages. Use instead special sprays for chains
with OR.
Lubricating the chain without OR (TC-TXC-SMR 450-R)
First dry, then plunge the chain in a bisulphide molybdenum lubricant, or in high
viscosity engine oil. Warm up the oil before use.
Lubricating the chain with OR (TE-SMR)
Lubricate all metallic and rubber (OR) elements using a brush, and use engine oil
with SAE 80-90 viscosity for the internal and external parts.
If the chain has been cut, reassemble using a joint. Assemble the joint spring (a)
by turning the closed side to the chain direction of rotation as shown in figure.
: Even if all the joints are reusable when in good conditions, for safety
purposes we advise using new joints when reassembling the chain.
Accurately adjust the chain as shown on page D.24.
: The chain oil has NEVER to get in contact with the tires or the rear brake
disk.
: Chain tension rollers, chain driving roller, chain guide, chain runner
Check the wear of the above mentioned elements and replace them when
necessary.
: Check the chain guide alignement, and remember that a bent element can
cause a rapid wear of the chain. In this case, a chain fleeting from the sprocket
may ensue.
D.26 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
Adjusting the suspensions according to particular track conditions
The following information is a useful guide for setting up the suspensions according
to the road conditions.
Always start from the standard calibration before making any change on the
suspensions. Afterwards, increase or decrease the adjusting clicks one at a time.
HARD GROUND
Fork: softer compression adjustment.
Shock absorber: softer compression adjustment.
The softer adjustment for the two suspensions is also used both in compression and
in extension when driving at top speed, in order to have better grip of the tires.
SANDY GROUND
Fork: have a harder compression adjustment, or replace the standard spring with
a harder one, and make a softer compression adjustment and a harder extension
adjustment at the same time.
Shock absorber: have a harder compression, and expecially a harder extension
adjustment. Work on the spring preload to lower the motorcycle rear side.
MUDDY GROUND
Fork: have a harder compression adjustment, or replace the standard spring with
a harder one.
Shock absorber: have a harder compression and extension adjustments, or replace
the standard spring with a harder one. Work on the spring preload to lift the
motorcycle rear side.
We advise replacing the springs of both suspensions to compensate the weight
increase due to the piling of the mud.
NOTE:
When the fork results as either too soft or too hard for any adjustment conditions,
check the oil level inside the forkrod.
The level can either be too low or too high. Remember that too much oil inside the
fork will involve a more frequent air drainage. When the suspensions do not react
to the changes of calibration, check that the adjusting units are not blocked.
The standard calibrations, the available springs and the adjustment procedures are
shown on the next pages.
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.27
B: axis of the panel screw
C: axis of rear wheel pin
C
A
B
Adjusting the shock absorber
The rear shock absorber must be adjusted according to the rider weight and track conditions.
Proceed as follows:
1. With motorcycle on the stand, measure distance (A).
2. Take the normal riding position on the motorcycle with all your riding apparel.
3. With somebody’s help, take the new distance (A).
4. The difference between these two measurements constitutes the “SAG” of the motorcycle’s rear end.
Suggested SAG: 4 in. with cold shock absorber. 3.7 in. with warmed up shock absorber.
5. To get the right SAG according to your weight, adjust the shock absorber spring preload (D.28).
D.28 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
The standard length of the preloaded spring is as follows:
TE: 243,5÷246,5 mm
SMR: 236,5÷239,5 mm
TC-TXC: 245,5÷248,5 mm
Adjusting the shock absorber spring preload
Follow the instructions below to perform the operation:
1. First turn the fastening rear pin (1) anticlockwise, then remove the saddle,
loosen the screws (2) and remove the right side panel (3).
2. TC-TE-TXC-SMR: Clean the ring nut (4) and the adjusting ring nut (5) of the
spring (6).
2. SMR 450-R: Clean the adjusting ring nut (5) of the spring (6).
3. TC-TE-TXC-SMR: Loosen the check ring nut with a hook wrench or with an
aluminium punch.
3. SMR 450-R: Loosen the screw (a) of the ring nut (5) with a 4 mm T-wrench.
4. Turn the adjusting ring nut as required.
5. TC-TE-TXC-SMR: after adjusting according to the weight or riding style of the
rider, tighten the check ring nut (tightening torque 5 Kgm).
5. SMR 450-R: after adjusting according to the weight or riding style of the rider,
tighten the screw
6. Mount the right side panel and the saddle.
: Be careful not to touch the hot exhaust pipe while adjusting the shock
absorber.
5
6
1
TC-TE-TXC-SMR
4
SMR 450-R
3
5
a
6
2
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.29
Shock absorber hydraulic brake adjustment
Adjustment of the compression stroke is independent from the rebound stroke.
A) COMPRESSION - Standard calibration:
1) Low damping speed:
-15 clicks (± 2 clicks)
(adjuster 1)
2) High damping speed:
-15 clicks (± 2 clicks)
(adjuster 3)
To reset the standard calibration, turn upper adjusters (1) and (3) clockwise
until reaching fully closed position. Return then back for the mentioned clicks.
In order to obtain a smooth braking action, turn the adjusters anticlockwise.
Reverse the operation in order to obtain a harder braking action.
B) EXTENSION - Standard calibration:
-18 clicks (± 2 clicks)
To reset the standard calibration, turn lower adjuster (2) clockwise until reaching fully closed position. Return then back for the mentioned clicks. In order to
obtain a smooth braking action, turn the adjuster anticlockwise. Reverse the
operation in order to obtain a harder braking action.
2
TC-TE-TXC-SMR
TC-TE-TXC-SMR
SMR 450-R
SMR 450-R
1
3
1
3
2
D.30 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
Shock absorber springs
STANDARD
K=5.4 kg/mm (TE-TXC 250; code 8000 98504)
K=5.6 kg/mm (TE-TXC 450/510; code 8000 H0076)
K=6.4 kg/mm (SMR; code 8000 98520)
TC-TE-TXC-SMR
SMR 450-R
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.31
Adjusting the front fork
a) COMPRESSION (LOWER REGISTER)
Standard calibration: -12 clicks (TE-SMR); -15 clicks (TC-TXC-SMR 450-R).
Remove plug (B) and turn register (A) clockwise until the position of fully closed
is reached then, turn back by the mentioned clicks.To obtain a smoother braking
action, turn the register anticlockwise. Reverse the operation in order to obtain a
harder action.
b) EXTENSION (UPPER REGISTER)
Standard calibration: -15 clicks (TC-TXC-SMR 450-R); -12 clicks (TE-SMR).
To reset standard calibration turn register (C) clockwise to reach the position of
fully closed; then, turn back by the mentioned clicks. To obtain a smoother braking action, turn the register anticlockwise. Reverse the operation in order to
obtain a harder action.
c) AIR VENT (to carry out after each competition, or monthly).
TE-SMR: Set the motorcycle on its central stand, fully extend the fork and loosen
the valve (D). Tighten the valve after this operation.
TC-TXC-SMR 450-R: Set the motorcycle on its central stand, fully extend the fork,
remove the cap (E) and press the valve with pointed object. Reassemble the cap.
: NEVER loosen screw (F).
WARNING: Never force the adjusting screws beyond the maximum opening
and closure positions.
TC-TXC-SMR 450-R
C
E
D
D
TE-SMR
C
TE-SMR
TC-TXC-SMR 450-R
C
F
A
B
A
B
a)
C
C
b)
D.32 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
Front fork springs
STANDARD
K=4.5 N/mm (TE; A: spring + spacer code 8000 B1713)
K=4.8 N/mm (TC-TXC 250; A: spring + spacer code 8000 B1690)
K=5.0 N/mm (TC-TXC 450/510; A: spring + spacer code 8000 B1716)
K=5.0 N/mm (SMR; A: spring + spacer code 8000 A7608)
TC-TXC
TE-SMR
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.33
Steering bearings play adjustment
To ensure maximum safety, the steering should always be adjusted so that the
handlebars rotate freely without play. To check steering adjustment, place kick
stand or other support under the engine so that the front wheel is raised from
ground. Place slight pressure on the tips of the handlebars to rotate steering;
the handlebars should also rotate without effort. Stand in front of the motorcycle
and grasp the lower end of the fork rods sliders moving them in the perpendicular direction to their axis.
If play is noticed, proceed with adjustment as follows:
- loosen steering sleeve nut (1);
- loosen four screws that fix steering head to fork rods (3);
- turn the steering ring nut (2) clockwise of the steering sleeve using a proper
tool, to adjust play properly;
- tighten steering sleeve nut (1) to a torque setting of 57,9÷65,1 Lb/ft; (78,4÷88,3
Nm)
- tighten four screws on the steering head (3) to a torque of 22,5÷26,5 Nm
(16.6÷19.5 Lb/ft).
D.34 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
Handlebar position and height change (TE-TC-TXC-SMR)
The handlebar position (a) and height (b) can be changed for better suiting Your
driving requirements. To effect these operations, remove the upper screw (3),
upper clamp (1), lower screw (4) then lower clamp (2).
a) Handlebar position change
Turn the lower clamp (2) 180° to move forward or backward (10 mm- 0.04in.) the
handlebar position with respect to the original setup.
b) Handlebar height change
Remove the lower spacer (A) then replace the screw (4) with a new one of L=65
mm (2.56 in.) height.
Once these operations are completed, tighten the screws (3) to 2,75-3,05 kgm
(27-30 Nm; 19.9-22 Lb/fts) and the screws (4) to 2,0-2,2 kgm (19,6-21,6 Nm; 14.5-
15.9 Lb/fts).
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.35
Handlebar position change (SMR 450-R)
The handlebar can be moved to suit your driving style. To effect these operations,
remove the upper screw (3), upper clamp (1), lower screw (4) then lower clamp
(2).
Turn the lower clamp (2) 180° to move forward or backward (10mm- 0.04in.) the
handlebar position with respect to the original setup.
Once these operations are completed, tighten the screws (3) to 2,75-3,05 kgm
(27-30 Nm; 19.9-22 Lb/fts) and the screws (4) to 2,0-2,2 kgm (19,6-21,6 Nm; 14.5-
15.9 Lb/fts).
1
2
3
D.36 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
Checking the fuel hose
Check the hose (1) for leaks and replace it, if necessary.
Remove the fuel hose as shown on page E.23-E.24.
1
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.37
Replacing the muffler deadening material (TC-TE-TXC-SMR)
First turn counterclockwise fastening rear pin (1) then remove saddle, screws (2)
and L.H. side panel (3). Using an 8 mm T-shaped spanner on the outside and a
10 mm T-shaped spanner on the inside, remove the locking screw (4) of the
muffler. Remove the spring (5) and with an 8 mm T-shaped spanner remove the
screw (8); then pull out the muffler.
Remove the six rear rivets (6), clamp and the exhaust terminal (7).
Remove innner pipe and replace the deadening material.
Reassemble L.H. side panel and saddle.
When diffuculties are found in removing the muffler, lightly beat with
a rubber or plastic hammer.
2
3
6
7
4
5
8
1
D.38 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
Replacing the muffler deadening material (SMR 450-R)
Remove the saddle after turning the locking back pin (1) anticlockwise, loosen the
screws (2) with an 8-mm T-shaped spanner and remove the side panel (3) (do the
same on the right side). Using an 8 mm T-shaped spanner on the outside and a
10 mm T-shaped spanner on the inside, remove the locking screw (4) of the
muffler. Remove the spring (5) and pull out the muffler (A) o (B). Remove the four
rear rivets (6), clamp and the exhaust terminal (7). Remove innner pipe and
replace the deadening material. Reassemble L.H. side panel and saddle.
: When diffuculties are found in removing the muffler, lightly beat with
a rubber or plastic hammer.
1
2
2
3
7
6
4
7
A
6
4
B
B
A
5
SETTINGS AND ADJUSTMENTS
Part. N. 8000 B0148 (02-2008) D.39
1
2
3
4
5
5
5
4
3
2
SMR 450-R
SMR 450-R
1
Checking the exhaust system
Remove the exhaust system components as shown on page E.20.
Check the exhaust pipe (1), (2), (3), (4) and silencer (5) for wear or damages.
Replace the component, if necessary.
D.40 Part. N. 8000 B0148 (02-2008)
SETTINGS AND ADJUSTMENTS
E.1Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
Section
E
E.2 Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
FOREWORD ............................................................ E. 3
REMOVAL OF ENGINE FROM MOTORCYCLE ...... E. 4
PARTIAL DISMALTEMENTS
Removal of saddle and battery .................................. E. 15
Removal of side panels ............................................. E. 16
Removal of rear frame with fender
(TE- SMR: with tail light) and air filter box assy .......... E. 17
Removal of exhaust system ...................................... E. 20
Removal of fuel tank, conveyors and spoiler ............. E. 23
Removal of cooling fan (TE-SMR), radiators and
coolant expansion tank (TE-SMR) ............................ E. 25
Removal of electronic power unit C.D.I.,
electronic coil, voltage regulator and clutch hose ....... E. 26
Removal of secondary drive chain ............................ E. 26
E.3Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
TE
RIGHT SIDE
LEFT SIDE
SMR 450-R
FOREWORD
The operations described in this section are referred to the removal of the engine from the motorcycle.
Nevertheless, in the case is had to effect operations on some parts of the motorcycle (as the access to the rear shock absorber, to the
electric parts, to the wiring harness etc.), it can be necessary to effect some partial dismantlements. The descriptions that refer to these
operations are listed beginning from the page E.15.
E.4 Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
Removal of engine from motorcycle
1) Pages E.4-E.5: turn counterclockwise the rear fastening pin (1) and remove
the saddle. Loosen the screws (2) and remove the side panels (3) and (4).
TE-SMR-TXC: first remove the BLACK negative cable, then the RED positive
cable (when reassembling, first connect the RED positive cable, then the BLACK
negative cable); release the elastic (5) and remove the battery (6) from its housing.
TXC: After battery removal, push ONCE THE ENGINE START BUTTON in order to discharge the condenser (7) fastened near the H.T. coil (8).
: After battery disassembly, DO NOT remove the condenser from the
frame: in case of engine starting in this condition, the voltage
regulator will be damaged.
8 7
1
2
2
3
4
6
5
E.5Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
TC-TXC-SMR 450-R
2) Remove the breather hose (1) from the steering axle. Turn the ring nut of the
fuel tap (2) anticlockwise to stop fuel flowing and loosen the clamp (3) on the
carburettor fuel pipe; remove this pipe from the carburettor and pour the remaining fuel into a container.
Remove the fuel tank fastening screw (4) and, pushing upward slightly in the
front zone of the conveyors, release them from the spoilers on the radiators.
Remove the fuel tank assy. with conveyors.
1
2
3
4
E.6 Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
TE-SMR
2) Remove the vent pipe (1) from the steering pin. Remove the fastening screw
(2) from the fuel tank by slightly pressing upward in the front area of conveyors
and release the conveyors from spoilers on radiators. Disconnect the fuel pump
connector from the main cable. Disconnect the feed line (B) from the outlet fitting (C) on the fuel pump on the lower rear part of the tank. Extract the tank with
the conveyors.
1
2
C
B
E.7Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
3) TE, TC, TXC, SMR: using an 8 mm T-shaped spanner on the outside and a
10 mm T-shaped spanner on the inside, remove the locking screw (1) of the
muffler (4). Remove the spring (2) and with an 8 mm T-shaped spanner remove
the screw (3); then pull out the muffler (4).
1
4
2
3
4
E.8 Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
3) SMR 450-R: use an 8 mm T-wrench outside and a 10 mm T-wrench inside to
remove the fastening screw (1) of silencers (3) and (4). Remove the spring (2)
and extract silencers (3) and (4). Remove the springs (5) that retain front pipes
(6) and (7) to intermediate pipe (8).
3) TE-SMR: remove the LAMBDA probe (A). Remove the intermediate pipe (8).
Remove the springs (9) and remove pipes (6) and (7) from the cylinder head by
gently hitting outward.
1
3
1
4
3
2
4
2
A
5
5
8
9
6
7
8
5
9
7
5
6
E.9Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
4) TC-TXC: Loosen the clamps (3) and (4) that fasten the carburetor to the
intake manifold and air filter box manifold. Pull back the carburetor to free it from
the intake manifold and extract the carburetor from the right side of the motorcycle. Remove the carburetor floater chamber lower screw (5), the floater chamber then eliminate the remaining gasoline.
4
Remove the fastening pin (8) and the rear brake pedal.
4) TE-SMR: loosen the left clamp (1) of the sleeve on the throttle body and the
front clamp (2) on the cylinder head. Disconnect the connector from the M.A.Q.S.
(6) on the throttle body of the main cable. Remove the throttle body (7); when
reassembly the throttle body, adjust the T.P.S. again (see chapter S).
1
2
3
7
6
5
8
E.10 Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
5) Place a vessel on the right side of the motorcycle, under the coolant draining
screw (1). Using a 8 mm wrench, FIRST remove the screw (1) then SLOWLY
open the R.H. radiator cap (2); slope the motorcycle on the right side to drain the
coolant easily in the vessel. Loosen lower clamps (3) of the hoses that connect
the radiators to the engine. Loosen the clamp (4) of the upper hose that connects the L.H. radiator to the water pump.
1
3
4
E.11Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
6) Even if not essential, it is advisable to remove the engine lower guard (A) then
place a vessel under the engine and remove the oil filler cap (1); using a 8 mm
Allen wrench, remove the oil draining plug (2) and eliminate the used oil; on the
L.H. side of the engine, using a 8 mm wrench, remove the rear filter cover screws
(3) and extract the steel filter (4) and the net filter (5).
Still operating on the L.H. side of the engine, using a 6 mm Allen wrench, unscrew the plug (6) then remove the net filter (7) and the O-Ring; on the R.H. side
of the engine, unscrew the three fastening screws (8) and remove the cover and
the filter cartridge (9).
2
9
1
6
7 4
5
3
8
A
E.12 Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
7) Remove the cap (1) from the spark plug. Remove the clamp (2) and detach
the hose (3) from the cylinder head cover. On the L.H. side, using a 6 mm wrench,
remove the rear transmission sprocket cover screws (4) and, using a 6 mm
Allen wrench, remove the screws (5) that fasten guide-chain plate.
Using a 8 mm wrench, remove the three screws (6) that fasten the clutch control
on the engine and eliminate the remaining fluid from the hose.
TE-SMR-TXC: detach the electrical connections from the starting motor [use a 8
mm wrench to remove the ground cable (8) and a 10 mm wrench to remove the
nut under the rubber cap (9)].
Remove the clutch hose-alternator cable connecting clamps (10). Detach the
alternator connector (11) (alternator cable-main wiring harness).
3
2
4
5
10
10
1
9
6
11
11
8
6
E.13Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
8) TE-SMR: disconnect the cooling fan (1) from the main wiring harness.
Detach the thermoswitch (2) from the main wiring harness.
Remove the two screws (3) and the coolant expansion tank (4).
1
1
3
4
2
E.14 Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
3
4
5
9) For the rear chain disassembling (both of the chain type without O-Rings
that with rings O-Rings), remove the clip (1), the master link (2) then the chain.
Using a 12 mm wrench on the L.H. side and a 10 mm wrench on the R.H. side,
remove fastening bolts (3) (engine-frame).
Remove the upper clamp (5) of the shock absorber.
Remove the guards (4) by removing the clamp to the frame; use a 22 mm wrench
on the left side, unscrew the nut from the fork pin, extract the axle from the R.H.
side then pull back the rear swing arm in order to facilitate the engine disassembly from the frame.
Lift the engine, slope it on the L.H. side and remove it from the motorcycle.
Place the engine on a turning stand in order to operate as shown on chapters FG-H.
E.15Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
Removal of saddle and battery
Turn counterclockwise the rear fastening pin (1) and remove the saddle.
TE-SMR-TXC: First remove the BLACK negative cable, then the RED positive
cable (when reassembling, first connect the RED positive cable and then the
BLACK negative cable); release the elastic (2) and remove the battery (3) from
its housing.
TXC: After battery removal, push ONCE THE ENGINE START BUTTON in order to discharge the condenser (4) fastened near the H.T. coil (5).
: After battery disassembly, DO NOT remove the condenser from the fra-
me: in case of engine starting in this condition, the voltage regulator will be
damaged.
TXC
1
3
2
E.16 Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
Removal of side panels
Turn rear pin (A) counterclockwise and remove the saddle from the front fastening screw. Loosen the screws (2) and remove the side panels (3) and (4).
1
2
2
3
4
E.17Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
Removal of rear frame with fender (TE- SMR: with tail light) and air filter
box assy.
Remove the saddle and disconnect the battery (A) from the electric system as
shown on page E.14.
Remove the side panels as shown on page E.15.
Remove the fuel tank as shown on page E.23.
TE-TC-TXC-SMR: use an 8 mm T-wrench and a 10 mm T-wrench inside to
remove the fastening screw (1) of silencers (4). Remove the spring (2) and use
an 8 mm T-wrench to remove also the screw (3); then extract the silencer (4).
1
4
2
3
4
E.18 Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
1
3
SMR 450-R: use an 8 mm T-wrench and a 10 mm T-wrench inside to remove
the fastening screw (1) of silencers (3) and (4). Remove the spring (2) and extract silencers (3) and (4).
On the left side disconnect the electric connections from the starting motor [use
an 8 mm wrench to remove the earth cable (5) and a 10 mm wrench for the nut
under the rubber cap (6)], remove the clamps (A) that hold the clutch pipe and
the alternator cable.
3
2
4
4
1
5
2
A
6
E.19Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
On the right side, remove the clamp (B) from the vent pipe from the filter box;
remove the pipe (C) from the cylinder head cover.
Disconnect the start remote control switch (7) and the connector of the rear light
from the cabling system (TE-SMR).
Without disconnecting them from the cabling system, remove the voltage regulator (9), the electronic CDI central unit (8) with the elastic support of the frame.
Loosen the clamp (10) that holds the rubber fitting from the filter box on the
carburettor or on the throttle body.
9
8
B
C
7
10
10
Use a 12 mm box wrench to remove the upper (11) and lower (12) fasteners
from the rear frame.
Pull the rear frame back, along with the mudguard and the air filter box, and
remove it from the main frame.
11
12
E.20 Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
Removal of exhaust system
Remove the saddle as shown on page E.15.
Remove the R.H. side panel as shown on page E.16.
E.21Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
TE, TC, TXC, SMR: use an 8 mm T-wrench outside and a 10 mm T-wrench
inside to remove the fastening screw (1) of silencer (4). Remove the spring (2)
and use an 8 mm T-wrench to remove also the screw (3); then extract the silencer (4).
1
4
2
3
4
E.22 Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
3) SMR 450-R: use an 8 mm T-wrench outside and a 10 mm T-wrench inside to
remove the fastening screw (1) of silencers (3) and (4). Remove the spring (2)
and extract silencers (3) and (4). Remove the clamps (A) that the hold front
pipes (6) and (7) to the intermediate pipe (8).
3) TE-SMR: remove the LAMBDA probe (A). Remove the intermediate pipe (8).
Remove the springs (9) and remove pipes (6) and (7) from the cylinder head by
gently hitting outward.
1
3
1
4
3
2
4
2
A
5
5
8
9
6
7
8
5
9
7
5
6
E.23Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
Removal of fuel tank, conveyors and spoiler
Remove the saddle as described on page E.15.
TC-TXC-SMR 450 R
Remove the vent pipe (1) from the steering pin. Turn the ring nut of the fuel tap
(2) anticlockwise to stop fuel flowing and loosen the clamp (3) on the carburettor
fuel pipe; remove this pipe from the carburettor and pour the remaining fuel into
a container.
Loosen the fastening screws (6) of the fuel tank. Remove the screws (4) holding
conveyors to the tank; remove the conveyors (7), the screws (5) holding spoilers
(8) to radiators. Remove the spoilers and extract the tank.
2
3
1
6
4
7
4
4
5
8
E.24 Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
TE-SMR
Remove the vent pipe (1) from the fuel tank cap. Unscrew the fastening screw
(6) of the fuel tank. Remove the screws (4) holding the conveyors to the tank;
remove the conveyors (7), the screws (5) holding spoilers (8) to radiators. Remove the spoilers. Disconnect the connector of the fuel pump from the main
cable. Disconnect the feed line (B) from the outlet fitting (C) on the fuel pump on
the lower rear part of the tank the feed line. Extract the tank.
C
B
E.25Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
Removal of cooling fan (TE-SMR), radiators and coolant expansion tank
(TE-SMR)
TE-SMR: disconnect the cooling fan (1) from the main wiring harness; remove the
fan from its holding plate. Detach the thermoswitch (2) from the main wiring
harness.
Remove the grid (3), detach the breather hose (4), the other hoses (A) from the
radiators, remove the three screws (5) and the R.H. radiator. Repeat the same
operations to remove the L.H. radiator:
TE-SMR: remove the two screws (6) and the coolant expansion tank (7).
2
1
5
4
A
7
A
6
A
3
A
E.26 Part. N. 8000 B0148 (02-2008)
GENERAL OPERATIONS
Removal of electronic power unit CDI, ignition coil, voltage regulator and
clutch hose
Remove: saddle, battery, side panels and fuel tank as shown on pages E.15,
E.16, E.23.
Remove the connector from electronic power unit CDI (1) and the electronic
power unit complete with elastic holder from the frame. Remove the cap (2)
from the spark plug. Detach the voltage regulator electrical (3) connection from
the main wiring harness, the screw and voltage regulator.
Remove the fastening screw and the ignition coil (4).
Unscrew the clutch hose union (5) on the L.H. side of the engine. Drain the fluid
from the hose. When reassembling, bleed the clutch system as shown on page
P.7.
2
1
3
4
Removal of secondary drive chain
To remove the transmission chain (without O-Rings type and with O-Rings type),
proceed as follows:
Remove: screws (1), transmission sprocket guard (2), clip (3), master link (4)
and transmission chain (5).
2
1
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