Husqvarna TC449 2012, TE449 2012, TE511 2012, TXC511 2012 Owner's manual

TXC

TC - TE 449 2013 I.E.

TE - TXC 511 2013 I. E.

Ed. 03-2012 - Rev. 00 Unless specified, data and prescription are referred to all the models.

SPECIFICATIONS - OPERATION - MAINTENANCE

EN - 1

EN - 2

SPECIFICATIONS - OPERATION - MAINTENANCE

SUMMARY Page

PRESENTATION ............................................................3

IMPORTANT NOTICES....................................................3

INTENDED USE .............................................................4

IDENTIFICATION DATA ..................................................5

TECHNICAL DATA ..........................................................6

TABLE FOR LUBRICATION, SUPPLIES ..............................7

MOTORCYCLE OVERALL VIEW - TE ..................................8

MOTORCYCLE OVERALL VIEW - TC - TXC ........................10

CONTROLS .................................................................12

RIDING

.......................................................................19

APPENDIX ..................................................................51

PRE-DELIVERY INSPECTION .........................................52

ALPHABETICAL INDEX ................................................. 53

SCHEDULED MAINTENANCE ..........................APPENDIX A

Note

lReferences to the “left” or “right” of the motorcycle are

considered from the point of view of a person facing forward.

lZ: number of teeth

l 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

lUnless otherwise specified, all the data and the instructions

are referred to any and all Countries.

EN - 3

SPECIFICATIONS - OPERATION - MAINTENANCE

PRESENTATION

Welcome to the Husqvarna motorcycling Family! Your new Husqvarna motorcycle is designed and manufactured to be the best in its field. The instructions in this book have been prepared to provide a simple and

understandable guide for your motorcycle’s operation

and care. Follow the instructions carefully to obtain maximum performance and your personal motorcycling pleasure. Your owner’s manual contains instructions for owner care and maintenance. The main repair or maintenance work requires the attention of a skilled mechanic and the use of special tools and equipment. Your Husqvarna Dealer has the facilities, experience and original parts necessary to properly render this valuable service.

This “Owner’s Manual” is part and parcel of the motorcycle, hence, it shall remain with the motorcycle even when sold to another user.

This motorcycle uses components designed thanks to systems and state-of-the-art technologies which are thereafter tested in competitions. In racing motorcycles, every detail is verified after each race in order to always guarantee better performance. To ensure trouble-free operation of the vehicle, it is necessary to follow the maintenance and inspection table found under Appendix A.

IMPORTANT NOTICES

1) TC - TXC models are designed for RACING use, and guar-

anteed free from operating faults; the recommended maintenance table for racing use can be found in Appendix A.

2) TE models are designed for ROAD use, guaranteed free from faults, and covered by legal warranty provided that NO CHANGE IS MADE TO THE STANDARD SETTING and that the intervals specified on maintenance table of Appendix A are complied with.

TXC

3) All the motorcycles and any of their parts used in competitions of any type are excluded from the warranty.

EN - 4

SPECIFICATIONS - OPERATION - MAINTENANCE

IMPORTANT

In order to maintain the vehicle’s “Guarantee of Functionality”, the client must follow the maintenance programme indicated in the user’s manual by carrying out maintenance inspections at authorised HUSQVARNA dealers. The cost for changing parts and for the labour necessary in order to comply with the maintenance plan is charged to the Client. NOTE: the warranty is NULL AND VOID if the motorcycle is rented.

Important Notice

Read this manual carefully and pay special attention to statements preceded by the following words:

WARNING*: Indicates the possibility of severe personal injury or death if instructions are not followed. CAUTION*: Indicates the possibility of personal injury or vehicle damage if instructions are not followed. Note*: Gives helpful information.

WARNING*: Never attempt to start or operate your motorcycle unless you are wearing appropriate protective clothing. Always wear a motorcycle helmet, boots, gloves, goggles and other appropriate protective clothing.

PRECAUTIONS FOR CHILDREN WARNING

l Park the vehicle where it is unlikely to be

bumped into or damaged.

Even slight or involuntary bumps can cause

the vehicle to tip over, with subsequent risk of serious harm to people or children.

l To prevent the vehicle from tipping over, nev-

er park it on soft or uneven ground, nor on asphalt strongly heated by the sun.

l Engine and exhaust pipes become very hot

during riding. Always park your motorcycle where people or children can not easily reach these parts, in order to avoid serious scalds.

INTENDED USE

This motorcycle has been manufactured so as to withstand the standard Offroad stresses.

Nevertheless, it is not suitable for use under the following conditions:

- prolonged use at a steady speed;

- prolonged use with fully-opened throttles;

- use with luggage;

WARNING* riding the motorcycle for

more than two consecutive minutes with fully-opened throttles could cause engine damage, with consequent faults storage inside memory. Any warranty claim for engine damage caused by too high engine revs will be rejected

HUSQVARNA MOTORCYCLES S.R.L.

When parts replacement is required, use only Husqvarna

Parts Replacement

ORIGINAL parts.

WARNING*: After a crash, inspect the motorcycle carefully. Make sure that the throttle, brake, clutch and all other systems are undamaged. Riding with a damaged motorcycle can lead to a serious accident.

EN - 5

SPECIFICATIONS - OPERATION - MAINTENANCE

IDENTIFICATION DATA

The engine identification number is stamped at the top of the crankcase, while vehicle serial number is stamped on the frame steering tube. Always quote the number stamped on the frame when ordering spare parts or requesting further details about your vehicle and note it on this booklet.

CHASSIS NUMBER

VEHICLE IDENTIFICATION NUMBER (V.I.N.)

The full 17-digit serial, or Vehicle Identification Number, is stamped on the steering tube (R.H. side).

(

) = Model designation

(▲) = Model Year (2013) (♦) = Progressive no.

TE 449

ZKHA600AADV000001

(l) (▲)

TE 511

ZKHA601AADV000001

(l) (▲)

TE 449 USA

ZKHKEEFM#DV000001

(l) (▲) (♦)

(

♦

)

(

♦

)

TC 449

ZKHA600AADV050001

(l) (▲)

TC 449 USA

ZKHTC443#DV000001

(l) (▲) (♦)

TE 511 USA

1. Chassis serial number

2. Engine serial number

ZKHKEEGM#DV000001

(

♦

)

(l) (▲) (♦)

TXC 511 USA

ZKHTX510#DV000001

(l) (▲) (♦)

EN - 6

SPECIFICATIONS - OPERATION - MAINTENANCE

TECHNICAL DATA

ENGINE

Type . . . . . . . . . . . . . . . . . . . . single cylinder, 4 stroke

(TE - TXC) Liquid cooling with double radiator and electric fan (TC) Liquid cooling with double radiator

TC-TE 449

Bore . . . . . . . . . . . . . . . . . . . . . . . . . .3.86 in (98 mm)

Stroke .......................2.35 in (59,6 mm)

Displacement . . . . . . . . . . . . .27.44 cu. in (449,6 cm3)

(TC) Compression ratio . . . . . . . . . . . . . . . . . . . . . 13:1

(TE-TXC) Compression ratio . . . . . . . . . . . . . . . . . . 12:1

TE-TXC 511

Bore . . . . . . . . . . . . . . . . . . . . . . . . .3.98 in (101 mm)

Stroke .......................2.35 in (59,6 mm)

Displacement . . . . . . . . . . . . . 29.14 cu.in (477,5 cm3)

Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . 12:1

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . electric

Type of fuel .............unleaded fuel 95ROZ/RON

TIMING SYSTEM Type . . .

double overhead camshaft chain operated; 4 valve Valve clearance (with engine cold)

Intake ...........0.008 ÷ 0.01 in (0,20 ÷ 0,25 mm)

Exhaust .........0.011 ÷ 0.013 in (0,30 ÷ 0,35 mm)

LUBRICATION

Type . . . . . . . . . . . . . . . wet sump with two lobe pumps

and cartridge filter

IGNITION

Type . . . . . . . . . .Capacitive discharge electronic system

with adjustable advance (digital control)

Spark plug type . . . . . . . . . . . . . . . . . .“NGK” CR 9EKB

Spark plug electrode gap . . . . . . . . 0.028 in (0,7 mm)

FUEL SYSTEM

Type . . . . . . . . . . . . . . . . . . . . .Electronic injection feed

PRIMARY DRIVE

Drive pinion gear . . . . . . . . . . . . . . . . . . . . . . . . . Z 32

Clutch ring gear ..........................Z 22

Transmission ratio . . . . . . . . . . . . . . . . . . . . . . . 2.618

CLUTCH

Type . . . . oil bath multiple disc clutch, hydraulic control

TRANSMISSION

Type . . . . . . . . . . . . . . . . . . . . constant mesh gear type

Transmission ratio (TC)

1st gear . . . . . . . . . . . . . . . . . . . . . . . . 2.286 (32/14)

2nd gear ........................1.875 (30/16)

3rd gear ........................1.533 (23/15)

4th gear . . . . . . . . . . . . . . . . . . . . . . . . 1.260 (29/23)

5th gear . . . . . . . . . . . . . . . . . . . . . . . . 1.043 (24/23)

(TE - TXC)

1st gear . . . . . . . . . . . . . . . . . . . . . . . . 2.286 (32/14)

2nd gear ........................1.875 (30/16)

3rd gear ........................1.533 (23/15)

4th gear . . . . . . . . . . . . . . . . . . . . . . . . 1.250 (25/20)

5th gear . . . . . . . . . . . . . . . . . . . . . . . . 1.043 (24/23)

6th gear . . . . . . . . . . . . . . . . . . . . . . . . 0.917 (22/24)

SECONDARY DRIVE

Transmission sprocket . . . . . . . . . . . . . . . . . . . . . Z 15

Wheel sprocket (TC) . . . . . . . . . . . . . . . . . . . . . . . Z 53

Wheel sprocket (TE - TXC) . . . . . . . . . . . . . . . . . . . Z 51

Transmission ratio (TC) . . . . . . . . . . . . . . . . . . . . 3.530

Transmission ratio (TE - TXC) . . . . . . . . . . . . . . . . . 3.40

Transmission chain dimensions . . . . . . . . . .5/8”x1/4”

FINAL RATIOS (TC)

1st gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.126

2nd gear ..............................17.327

3rd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.167

4th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.644

5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.639

(TE - TXC)

1st gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.348

2nd gear ..............................16.689

3rd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.645

4th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.126

5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.283

6th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.162

CHASSIS

Type . . . . . . . . . . . . . . . . . . . . . . . twin beam and twin

cradle steel chassis with round and elliptic cross-section, rear subframe in aluminium alloy.

FRONT SUSPENSION Fork type . . .Upside-down hydraulic fork and advanced stanchion (adjustable compression and rebound); tubes ø 1.89 in (ø 48 mm)

Travel .......................11.81 in (300 mm)

REAR SUSPENSION Type . .progressive with hydraulic single shock absorber (preload regulation of spring and hydraulic brake in compression and extension)

Wheel travel . . . . . . . . . . . . . . . . . .11.81 in (300 mm)

EN - 7

SPECIFICATIONS - OPERATION - MAINTENANCE

FRONT BRAKE

Fixed disc type . . . . . “WAVE” Ø 10.23 in (Ø 260 mm)

with hydraulic control and floating calliper. REAR BRAKE

Fixed disc type . . . . . . . “WAVE” Ø 9.45 in (Ø240 mm)

with hydraulic control and floating calliper RIMS

Front .....................in light alloy: 1.6”x21”

(TC) Rear . . . . . . . . . . . . . . . .in light alloy: 2.15”x19”

(TE-TXC) Rear . . . . . . . . . . . . .in light alloy: 2.15”x18”

TYRES (TC)

Front ............................ 80/100x21”

Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110/90x19”

(TXC)

Front ............................ 80/100x21”

Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . 110/100x18”

(TE)

Front ............................. 90/90x21”

Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140/80x18”

Cold tyre pressure Front

TC ............12.8 ÷ 14.22 psi (0,9 ÷ 1,0 Kg/cm

TE - TXC (*) ......12.8 ÷ 14.22 psi (0,9 ÷ 1,0 Kg/cm2)

TE (%) . . . . . . . . . . . . . . . . . 15.64 psi () 1,1 Kg/cm

Rear

TC .............11.37 ÷ 12.8 psi (0,8 ÷ 0,9 Kg/cm

TE - TXC (*) ......11.37 ÷ 12.8 psi (0,8 ÷ 0,9 Kg/cm2)

TE (%) ....................14.22 psi (1,0 Kg/cm

(*) - In case of racing use (%) - Road use

DIMENSION, WEIGHT, CAPACITY (TC-TXC)

Wheelbase ..................58.66 in (1490 mm)

Overall length ................86.92 in (2208 mm)

Overall width .................32.28 in (820 mm)

Max. height . . . . . . . . . . . . . . . . .49.60 in (1260 mm)

Saddle height . . . . . . . . . . . . . . . . .37.71 in (958 mm)

Min. ground clearance ...........13.19 in (335 mm)

(TE)

Wheelbase ..................58.66 in (1490 mm)

Overall length ................86.92 in (2280 mm)

Overall width .................32.28 in (820 mm)

Max. height . . . . . . . . . . . . . . . . .49.60 in (1260 mm)

Saddle height . . . . . . . . . . . . . . . . .37.91 in (963 mm)

Min. ground clearance ...........13.19 in (335 mm)

Kerb weight, without fuel.

(TE) . . . . . . . . . . . . . . . . . . . . . . . .249.12 lb (113 kg)

(TC) . . . . . . . . . . . . . . . . . . . . . . . .238.10 lb (108 kg)

(TXC) . . . . . . . . . . . . . . . . . . . . . . .242.50 lb (110 kg)

Fuel tank capacity, reserve included

(TC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.87 Imp. Gall

2.25 U.S. Gall 8,5 l

)

(TE 499/511) .................... 1.87 Imp. Gall

2.25 U.S. Gall

)

8,5 l

)

(TE 499/511 USA) . . . . . . . . . . . . . . . . 2.09 Imp. Gall

2.51 U.S. Gall

)

9,5 l

(TXC) . . . . . . . . . . . . . . . . . . . . . . . . . . .2.09 Imp. Gall

2.51 U.S. Gall 9,5 l

Fuel reserve (warning light coming on - TE)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.44 Imp. Gall

0.53 U.S. Gall 2 l

Coolant capacity . . . . . . . . . . . . . . . . . . . .0.2 Imp. Gall

0.24 U.S. Gall 0,9 l

Transmission oil

Oil and filter replacement . . . . . . . .Max 0.25 Imp. Gall

0.3 U.S. Gall Max. 1,15 l

Oil replacement ....................0.22 Imp. Gall

0.26 U.S. Gall 1 l

TABLE FOR LUBRICATION, SUPPLIES

Engine, gearbox and primary drive lubricating oil .......

. . . . . . . . . . . . . . . . . . . . . . . . .

CASTROL GPS SAE 10W-40

Engine coolant . . . . . . . . .CASTROL MOTORCYCLE COOLANT

Brake system fluid . . . . .CASTROL RESPONSE SUPER DOT 4

Clutch fluid ...........CASTROL RESPONSE SUPER DOT 4

Grease lubrication ...........

Final drive chain lubrication

CASTROL PASTE TA GREASE

. . CASTROL CHAIN LUBE RACING

Front fork oil ...........CASTROL SYNTHETIC FORK OIL 5W

Oil for rear shock absorber . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

CASTROL SYNTHETIC FORK OIL 5W

Electric contact protection . CASTROL METAL PARTS CLEANER

Fillers for radiator ........AREXONS TURAFALLE LIQUIDO

EN - 8

SPECIFICATIONS - OPERATION - MAINTENANCE

MOTORCYCLE OVERALL VIEW - TE

EN - 9

SPECIFICATIONS - OPERATION - MAINTENANCE

LEGEND

1. Front wheel

2. Front brake disc

3. Front brake calliper

4. Front fork

5. Gear shift pedal (the first gear is engaged by

pushing lever downwards; for other gears push it upwards. The neutral gear is between the first and second gear)

6. Front sprocket

7. Side stand

8. Rear sprocket

9. Rear wheel

10. Number plate holder

11. Rear turning indicators

12. Tail light

13. Fuel tank filler cap

14. Saddle

15. Handlebar controls

16. Front turning indicators

17. Headlight

18. Rear brake control pedal

19. Rear brake master cylinder

20. Rear brake disc

21. Rear brake calliper

22. Instrument

23. L.H. switch

24. ENGINE STOP button

25. R.H. switch

26. Front brake control lever

27. Throttle control twistgrip

28. Clutch control lever

EN - 10

SPECIFICATIONS - OPERATION - MAINTENANCE

MOTORCYCLE OVERALL VIEW - TC - TXC

TXC

EN - 11

SPECIFICATIONS - OPERATION - MAINTENANCE

LEGEND

1. Front wheel

2. Front brake disc

3. Front brake calliper

4. Front fork

5. Gear shift pedal (the first gear is engaged by

pushing lever downwards; for other gears push it upwards. The neutral gear is between the first and second gear)

6. Front sprocket

7. Side stand (TXC)

8. Rear sprocket

9. Rear wheel

10. Fuel tank filler cap

11. Saddle

12. Handlebar controls

13. Rear brake control pedal

14. Rear brake master cylinder

15. Rear brake disc

16. Rear brake calliper

17. DOUBLE MAP push-button (TC)

18. R.H. switch

19. Front brake control lever

20. Throttle control twistgrip

21. Clutch control lever

22. ENGINE STOP button (TXC)

23. Starter device (TC)

TXC

EN - 12

SPECIFICATIONS - OPERATION - MAINTENANCE

CONTROLS

FUEL TAPS

The two screw taps (1) positioned on tanks left rear side, shall always be left in fully OPEN position.

TE: The reserve warning is indicated on the digital instrument panel by the relevant warning light (See paragraph “Digital instrument, warning lights”).

FUEL Recommended fuel: premium grade UNLEADED petrol with octane rating of 95 or higher.

WARNING*: Do not overfill the tank. Refer to the lower mark on filler. After refuelling, make sure the tank cap (2) is closed securely.

Note*: If the engine "knocks", change fuel brand or use a higher octane rating fuel.

WARNING*: Do not continue operation if the engine pings or knocks. The engine will be damaged and could seize.

WARNING*: Fuel is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke or allow flames or sparks in the area where the motorcycle is refuelled or fuel is stored.

TC TE - TXC

EN - 13

SPECIFICATIONS - OPERATION - MAINTENANCE

SIDE STAND A side stand (1) is supplied with every motorcycle.

WARNING*: The stand is designed to support the WEIGHT of the MOTORCYCLE ONLY. Do not sit astride the motorcycle using the stand for support this could cause structural failure to the stand resulting in serious injury.

WARNING*: The motorcycle MUST be set on the side stand ONLY AFTER the rider has got off the vehicle. Stand AUTOMATICALLY folds back to rest position once the vehicle is vertical, no longer resting on the ground.

TE-TXC: Periodically check the side stand (see “Scheduled Maintenance Chart”); make sure that the springs are not damaged and the side stand freely moves. If the side stand is noisy, lubricate the fastening pivot (A).

COLD START

TE-TXC: These models feature an automatic starter positioned onto throttle body that is automatically enabled based on external temperature and engine temperature.

TC: For cold start, motorcycle is equipped with a knob (1) positioned on throttle body left side. Pull knob to enable starter, push it to close it.

TE-TXC

EN - 14

SPECIFICATIONS - OPERATION - MAINTENANCE

DIGITAL DASHBOARD, WARNING LIGHTS (TE) The motorcycle is fitted with a digital dashboard on which 3 warning lights are also available: high beam, turning indicators and fuel reserve.

1- BLUE warning light “High beam” 2- GREEN warning light “Turning indicators” 3- ORANGE warning light “Fuel reserve” When the ignition key is turned to the IGNITION position, the dashboard display lights up (amber colour).

NOTES

- At every connection with the battery, the dashboard shows the version of the test SW for the first 2 seconds; after the check routine, the dashboard shows the last planned function.

- When the engine is turned off, the dashboard does not show any functions.

- To select dashboard functions and reset functions, use the SCROLL button (A).

- The functions, which can be selected in this sequence, are as follows:

1- SPEED / ODO (figure 1) 2- SPEED / CLOCK (figure 2) 3- SPEED / TRIP (figure 3) 4- SPEED / LAP TIMER (figure 4) 5- SPEED (figure 5) 1- SPEED / ODO (figure 1)

.................

IMPORTANT: In the event of a FUEL INJECTION SYSTEM MALFUNCTION, the word FAIL appears on the right side of the dashboard display: When this is the

case, contact your HUSQVARNA dealer.

1- SPEED (Km/h or mph) / ODO (figure 1)

- SPEED: vehicle speed - maximum value: 299 Km/h or 299 mph;

- ODO: odometer- maximum value: 99999 km or

62136.50 mi;

To change unit from kilometres to miles or miles to kilometres, proceed as follows:

1) set to figure 1, turn the key to OFF and push SCROLL (A).

2) place the ignition key in the IGNITION position and

hold down the SCROLL button (A) until the word “Km/h” is displayed.

3) the display will now alternate between “Km/h” and

“Mph Miles”, push the SCROLL button (A) again while the desired unit is displayed.

EN - 15

SPECIFICATIONS - OPERATION - MAINTENANCE

2- SPEED / CLOCK (figure 2)

- SPEED: speed - maximum value: 299 Km/h or 299 mph;

- CLOCK: clock - reading from 0:00 to 23:59:59. To reset the clock, push the SCROLL button (A) and hold for more than 3 seconds in order to increase the hour value; release the button then, after 3 seconds, it is possible to increase the minutes value;

4- SPEED / LAP TIMER (STP) (figure 4)

- SPEED: speed - maximum value: 299 Km/h or 299 mph;

- STP 1: miles/kilometres covered time

- Reading from 0:00 to 99:59:59 (data will be lost after disconnecting the battery).

To activate the function STP, push the SCROLL button (A) and hold for more than 3 seconds.

5- SPEED (figure 5)

- SPEED: speed - maximum value: 299 Km/h or 299 mph

3- SPEED / TRIP 1 (figure 3)

- SPEED: speed - maximum value: 299 Km/h or 299 mph

- TRIP 1: distance- maximum value: 999.9 Km or 621.31 mi (data will be lost after disconnecting the battery).

To reset TRIP, push the SCROLL button (A) and hold for more than 3 seconds.

- 1st step: activate function;

- 2nd step: stop counters

- 3rd step: reset STP;

- 4th step: activate function;

- 5th step: stop counters;

.............................

and so on

The display also provides a Neutral” and a fuel injection system “Malfunction” indication; the latter takes

priority over any other indication.

MALFUNCTION: a "FUEL INJECTION SYSTEM MALFUNCTION" indicated by the word "FAIL" appearing in the right-hand portion of the dashboard display.

EN - 16

SPECIFICATIONS - OPERATION - MAINTENANCE

THROTTLE CONTROL The throttle twistgrip (1) is located on the right-hand side of the handlebar. The position of the throttle control can be adjusted by loosening the two retaining screws.

CAUTION*

Do not forget to tighten the screws (A) after the adjustment.

FRONT BRAKE CONTROL The brake control lever (2) is located on the right-hand

side of the handlebar. The position of the control on handlebar can be adjusted by loosening the two retaining screws (B).

CAUTION*

Do not forget to tighten the screws (B) after the adjustment.

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