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TC 50 Mini (2018)
Owner's Manual
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Husqvarna TC 50 (2018), TC 50 Mini (2018) Owner's Manual

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Page 1
OWNER'S MANUAL 2018
TC 50 TC 50 Mini
Art. no. 3402161en
Page 2
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DEAR HUSQVARNA MOTORCYCLES CUSTOMER
Congratulations on your decision to purchase a Husqvarna motorcycle. You are now the owner of a state-of­the-art sports motorcycle that will give you and your child enormous pleasure if you service and maintain it accordingly.
We hope you enjoy your new vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 13) Dealer's stamp
Engine number ( p. 13)
The Owner's Manual contained the latest information for this model series at the time of going to print. How­ever, minor differences due to further developments in design cannot be ruled out completely.
All specifications are non-binding. Husqvarna Motorcycles GmbH specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. Husqvarna Motorcycles accepts no liability for delivery options, devi­ations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.
© 2017 Husqvarna Motorcycles GmbH, Mattighofen Austria All rights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061) Husqvarna Motorcycles applies quality assurance processes that lead to the highest possible product quality as defined in the ISO 9001 international quality management standard. Issued by: TÜV Management Service
Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen, Austria
This document is valid for the following models: TC 50 (F2001R4) TC 50 Mini (F2001R5)
*3402161en*
3402161en
05/2017
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TABLE OF CONTENTS
TABLEOF CONTENTS
1 MEANS OF REPRESENTATION........................ 5
1.1 Symbols used ....................................... 5
1.2 Formats used ........................................ 5
2 SAFETY ADVICE ............................................... 6
2.1 Use definition – intended use ............... 6
2.2 Misuse................................................... 6
2.3 Safety advice ........................................ 6
2.4 Degrees of risk and symbols ................ 6
2.5 Tampering warning ............................... 7
2.6 Safe operation....................................... 7
2.7 Protective clothing ................................ 8
2.8 Work rules............................................. 8
2.9 Environment.......................................... 8
2.10 Owner's Manual.................................... 8
3 IMPORTANT NOTES ......................................... 9
3.1 Manufacturer and implied warranty ...... 9
3.2 Operating and auxiliary substances ..... 9
3.3 Spare parts, accessories ...................... 9
3.4 Service .................................................. 9
3.5 Figures .................................................. 9
3.6 Customer service................................ 10
4 VIEW OF VEHICLE .......................................... 11
4.1 View of vehicle, front left (example) .... 11
4.2 View of vehicle, rear right
(example)............................................. 12
5 SERIAL NUMBERS.......................................... 13
5.1 Chassis number .................................. 13
5.2 Type label............................................ 13
5.3 Engine number.................................... 13
5.4 Fork part number ................................ 13
5.5 Shock absorber article number .......... 14
6 CONTROLS..................................................... 15
6.1 Hand brake lever................................. 15
6.2 Throttle grip......................................... 15
6.3 Kill switch............................................ 15
6.4 Opening filler cap................................ 15
6.5 Closing the filler cap ........................... 16
6.6 Opening oil tank cap (TC 50 Mini)....... 16
6.7 Closing oil tank cap (TC 50 Mini) ........ 17
6.8 Fuel tap ............................................... 17
6.9 Choke (TC 50) ..................................... 17
6.10 Choke (TC 50 Mini) ............................. 17
6.11 Kick starter.......................................... 18
6.12 Foot brake lever .................................. 18
6.13 Plug-in stand....................................... 18
6.14 Service hour counter........................... 19
7 PREPARING FOR USE.................................... 20
7.1 Advice on first use .............................. 20
7.2 Running in the engine ......................... 22
8 RIDING INSTRUCTIONS ................................. 23
8.1 Checks and maintenance measures
when preparing for use ....................... 23
8.2 Starting the vehicle ............................. 23
8.3 Starting off .......................................... 24
8.4 Riding.................................................. 24
8.5 Applying the brakes ............................ 25
8.6 Stopping, parking ............................... 25
8.7 Transporting........................................ 26
8.8 Refueling............................................. 26
8.9 Filling up with oil (TC 50 Mini) ............. 27
9 SERVICE SCHEDULE...................................... 28
9.1 Additional information......................... 28
9.2 Required work..................................... 28
9.3 Recommended work........................... 29
10 TUNING THE CHASSIS................................... 30
10.1 Checking the basic chassis setting
with the rider's weight......................... 30
10.2 Air suspension AER 35 (TC 50) ........... 30
10.3 Compression damping of the shock
absorber (TC 50) ................................. 31
10.4 Adjusting the low-speed compression damping of the shock
absorber (TC 50) ................................. 31
10.5 Adjusting the high-speed compression damping of the shock
absorber (TC 50) ................................. 32
10.6 Adjusting the rebound damping of
the shock absorber............................. 32
10.7 Measuring rear wheel sag
unloaded............................................. 34
10.8 Checking the static sag of the
shock absorber ................................... 34
10.9 Checking the riding sag of the
shock absorber ................................... 35
10.10 Adjusting the spring pretension of
the shock absorber ......................... 35
10.11 Adjusting the riding sag .................. 37
10.12 Checking the basic setting of the
fork...................................................... 38
10.13 Adjusting the fork air pressure
(TC 50)................................................. 38
10.14 Adjusting the rebound damping of
the fork (TC 50) ................................... 39
10.15 Handlebar position.............................. 40
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TABLE OF CONTENTS
10.16 Adjusting the handlebar position .... 40
10.17 Adjusting the seat height ................ 41
11 SERVICE WORK ON THE CHASSIS ............... 43
11.1 Raising the motorcycle with a lift
stand ................................................... 43
11.2 Removing the motorcycle from the
lift stand .............................................. 43
11.3 Bleeding the fork legs ......................... 43
11.4 Cleaning the dust boots of the fork
legs ..................................................... 44
11.5 Removing the fork protector............... 45
11.6 Installing the fork protector................. 45
11.7 Removing the fork legs ................... 46
11.8 Installing the fork legs ..................... 46
11.9 Removing the lower triple clamp .... 48
11.10 Installing the lower triple clamp ...... 48
11.11 Checking play of steering head
bearing................................................ 51
11.12 Adjusting the steering head bearing
play .................................................. 52
11.13 Greasing the steering head
bearing ............................................ 53
11.14 Removing the fuel tank ................... 53
11.15 Installing the fuel tank ..................... 54
11.16 Removing the start number plate ....... 55
11.17 Installing the start number plate ......... 56
11.18 Removing front fender ........................ 56
11.19 Installing front fender .......................... 56
11.20 Removing the right side cover ............ 57
11.21 Installing the right side cover.............. 58
11.22 Securing right side cover ................ 59
11.23 Removing the left side cover .............. 59
11.24 Installing the left side cover ................ 60
11.25 Securing left side cover .................. 61
11.26 Removing the shock absorber ........ 61
11.27 Installing the shock absorber .......... 62
11.28 Removing the seat.............................. 63
11.29 Mounting the seat............................... 63
11.30 Removing the air filter ..................... 64
11.31 Installing the air filter ....................... 64
11.32 Cleaning the air filter and air filter
box .................................................. 65
11.33 Removing the main silencer................ 65
11.34 Installing the main silencer.................. 66
11.35 Changing the glass fiber yarn filling
of the main silencer ......................... 66
11.36 Removing the engine sprocket
cover ............................................... 67
11.37 Installing the engine sprocket
cover ................................................... 68
11.38 Checking the chain for dirt.................. 68
11.39 Cleaning the chain .............................. 69
11.40 Checking the chain tension ................ 69
11.41 Adjusting the chain tension................. 70
11.42 Checking the chain, rear sprocket,
engine sprocket and chain guide........ 71
11.43 Adjusting the chain guide ............... 73
11.44 Checking the frame ......................... 74
11.45 Checking the swingarm .................. 74
11.46 Checking the routing of the throttle
cable ................................................... 74
11.47 Checking the rubber grip .................... 75
11.48 Additionally securing the rubber
grip...................................................... 75
12 BRAKE SYSTEM ............................................. 76
12.1 Checking play of handbrake lever ...... 76
12.2 Adjusting the play of the hand brake
lever .................................................... 76
12.3 Adjusting the basic position of the
hand brake lever ................................. 76
12.4 Checking the brake discs ................... 77
12.5 Checking the front brake fluid level .... 78
12.6 Adding front brake fluid .................. 79
12.7 Checking the front brake linings ......... 80
12.8 Changing the front brake linings ..... 80
12.9 Checking the free travel of the foot
brake lever .......................................... 83
12.10 Adjusting the free travel of the foot
brake lever ...................................... 84
12.11 Adjusting the basic position of the
foot brake lever ............................... 84
12.12 Checking the rear brake fluid level ..... 85
12.13 Adding rear brake fluid .................... 85
12.14 Checking the rear brake linings .......... 87
12.15 Changing the rear brake linings ...... 87
13 WHEELS, TIRES.............................................. 90
13.1 Removing the front wheel ............... 90
13.2 Installing the front wheel ................. 90
13.3 Removing the rear wheel ................ 91
13.4 Installing the rear wheel .................. 92
13.5 Checking the tire condition................. 93
13.6 Checking tire air pressure ................... 94
13.7 Checking spoke tension ..................... 94
14 COOLING SYSTEM......................................... 96
14.1 Cooling system ................................... 96
14.2 Checking the antifreeze and coolant
level..................................................... 96
14.3 Checking the coolant level.................. 97
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14.4 Draining the coolant ........................ 98
14.5 Refilling with coolant ....................... 98
15 TUNING THE ENGINE................................... 100
15.1 Checking the installation position
of the throttle grip ............................. 100
15.2 Checking the play in the throttle
cable ................................................. 100
15.3 Adjusting the play in the throttle
cable ............................................. 101
15.4 Carburetor - idle (TC 50) ................... 101
15.5 Carburetor - idle (TC 50 Mini) ........... 102
15.6 Carburetor – adjusting the idle
speed (TC 50)................................ 102
15.7 Carburetor – adjusting the idle
speed (TC 50 Mini) ........................ 103
15.8 Checking the clutch setting .......... 104
15.9 Removing the clutch cover ........... 105
15.10 Adjusting the clutch ...................... 105
15.11 Installing the clutch cover ............. 107
16 SERVICE WORK ON THE ENGINE ............... 108
16.1 Checking oil level (TC 50 Mini).......... 108
16.2 Bleeding the oil pump (TC 50
Mini) .................................................. 108
16.3 Checking the gear oil level................ 109
16.4 Changing the gear oil .................... 110
16.5 Adding gear oil .............................. 111
20.7.2 TC 50 Mini .................................... 123
20.8 Shock absorber ................................ 124
20.8.1 TC 50............................................ 124
20.8.2 TC 50 Mini .................................... 124
20.9 Chassis tightening torques ............... 125
21 SUBSTANCES............................................... 127
22 AUXILIARY SUBSTANCES............................ 129
23 STANDARDS................................................. 130
24 LIST OF ABBREVIATIONS ............................ 131
INDEX .................................................................... 132
17 CLEANING, CARE ......................................... 113
17.1 Cleaning the motorcycle................... 113
18 STORAGE...................................................... 115
18.1 Storage ............................................. 115
18.2 Preparing for use after storage ......... 116
19 TROUBLESHOOTING ................................... 117
20 TECHNICAL DATA ........................................ 120
20.1 Engine ............................................... 120
20.2 Engine tightening torques................. 120
20.3 Carburetor with carburetor tuning .... 121
20.3.1 TC 50............................................ 121
20.3.2 TC 50 Mini .................................... 121
20.4 Capacities......................................... 122
20.4.1 Gear oil ......................................... 122
20.4.2 Coolant......................................... 122
20.4.3 Fuel............................................... 122
20.5 Chassis ............................................. 122
20.6 Tires .................................................. 123
20.7 Fork................................................... 123
20.7.1 TC 50............................................ 123
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1.1 Symbols used

The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of the safety of your child, have these jobs performed in an authorized Husq­varna Motorcycles workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.

1 MEANS OF REPRESENTATION

Indicates the result of a testing step.
Indicates the end of an activity, including potential rework.

1.2 Formats used

The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
®
Name
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
Indicates a protected name.
are explained in the glossary.
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2 SAFETY ADVICE

2.1 Use definition – intended use

This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the currently valid regulations and categories of the top international motorsport organizations.
Info
Only operate this vehicle in closed-off areas remote from public road traffic.

2.2 Misuse

The vehicle must only be used as intended. Dangers can arise for people, property and the environment through use not as intended. Any use of the vehicle beyond the intended and defined use constitutes misuse. Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respective use.

2.3 Safety advice

A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove informa­tion/warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.

2.4 Degrees of risk and symbols

Danger
Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.
Warning
Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
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2 SAFETY ADVICE

2.5 Tampering warning

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or
replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below:
1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct
exhaust gases. 2 Removal or puncturing of parts of the intake system. 3 Lack of proper maintenance. 4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those
specified by the manufacturer.

2.6 Safe operation

Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication. – Do not operate the vehicle if you are physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and
death.
– Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed
space.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake sys-
tem before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. Have malfunctions that impair safety promptly eliminated by an authorized Husqvarna Motorcycles workshop. Adhere to the information and warning labels on the vehicle.
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2 SAFETY ADVICE

2.7 Protective clothing

Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Ensure your child wears appropriate protective clothing such as helmet, boots, gloves as well as
trousers and a jacket with protectors on all rides.
– Alway use protective clothing for your child that is in good condition and meets the legal require-
ments.
– When you ride a motorcycle, set an example for your child and wear suitable protective clothing.
In the interest of your child’s safety, Husqvarna Motorcycles recommends that only operating the vehicle while wearing protective clothing.

2.8 Work rules

Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the number in parentheses. Example: bearing puller (15112017000) During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, seals, sealing rings, O-rings, pins, and lock washers). In the case of certain screws, a thread locker (e.g. Loctite®) is required. Apply according to the manufacturer's instructions. After disassembly, clean the parts that are to be reused and check them for damage and wear. Change dam­aged or worn parts. After completing a repair or service work, check the operating safety of the vehicle.

2.9 Environment

If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle sport, make sure that you use your motorcycle legally, be environmentally aware, and respect the rights of others. When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the respective country. Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized Husqvarna Motor­cycles dealer will be glad to advise you.

2.10 Owner's Manual

It is important that you read this Owner's Manual carefully and completely before your child makes his or her first trip. The Owner's Manual contains useful information and many tips for you and your child on how to oper­ate, handle, and maintain your motorcycle. This is the only way for you to find out how to ideally customize the vehicle and how to protect your child from injury. Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized Husqvarna Motorcycles dealer. The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold.
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3 IMPORTANT NOTES

3.1 Manufacturer and implied warranty

The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles workshop only and confirmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motor- cycles Dealer.net; otherwise, all warranty claims will be void. Damage or secondary damage caused by tam­pering with and/or conversions on the vehicle are not covered by the warranty. Additional information on the manufacturer or implied warranty and the procedures involved can be found in the Service & Warranty Booklet.

3.2 Operating and auxiliary substances

Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.

3.3 Spare parts, accessories

For the safety of your child, only use spare parts and accessory products that are approved and/or recom­mended by Husqvarna Motorcycles and have them installed by an authorized Husqvarna Motorcycles work­shop. Husqvarna Motorcycles accepts no liability for other products and any resulting damage or loss. Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized Husqvarna Motorcycles dealer will be glad to advise you.
The current Husqvarna Motorcycles accessories for your vehicle can be found on the Husqvarna Motorcycles website. International Husqvarna Motorcycles website: www.husqvarna-motorcycles.com

3.4 Service

A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and chassis is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis can lead to damage and breakage of components. Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to con­siderably more rapid wear of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service. It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.

3.5 Figures

The figures contained in the manual may depict special equipment. In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instruc­tions in the text.
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3 IMPORTANT NOTES

3.6 Customer service

Your authorized Husqvarna Motorcycles dealer will be happy to answer any questions you may have regarding your vehicle and Husqvarna Motorcycles.
A list of authorized Husqvarna Motorcycles dealers can be found on the Husqvarna Motorcycles website. International Husqvarna Motorcycles website: www.husqvarna-motorcycles.com
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4.1 View of vehicle, front left (example)

4 VIEW OF VEHICLE

Filler cap
1
Quick release of seat
2
Chain guide
3
Plug-in stand ( p. 18)
4
Choke
5
Fuel tap ( p. 17)
6
A00076-10
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4 VIEW OF VEHICLE

4.2 View of vehicle, rear right (example)

Kill switch ( p. 15)
1
Throttle grip ( p. 15)
2
Hand brake lever ( p. 15)
3
Chassis number ( p. 13)
4
Kick starter ( p. 18)
5
Foot brake lever ( p. 18)
6
Level viewer for brake fluid, rear
7
A00077-10
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5.1 Chassis number

5.2 Type label

5 SERIAL NUMBERS

The chassis number1is stamped on the right side of the steer­ing head.
401945-10
The type label1is located on the front frame tube.

5.3 Engine number

5.4 Fork part number

402154-10
The engine number1is located on the left side of the engine under the engine sprocket.
401949-11
The fork part number1is stamped on the outside of the axle clamp.
401947-10
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5 SERIAL NUMBERS
0011

5.5 Shock absorber article number

(TC 50)
The shock absorber article number1is stamped on the bottom of the shock absorber toward the right-hand side.
H01186-10
(TC 50 Mini)
The shock absorber article number1is stamped on the top of the shock absorber toward the rear.
401948-11
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6.1 Hand brake lever

6.2 Throttle grip

6 CONTROLS

Hand brake lever1is fitted on the right side of the handlebar. The hand brake lever is used to activate the front brake.
K00657-10
Throttle grip1is fitted on the right side of the handlebar.
K00657-11

6.3 Kill switch

Kill switch1is fitted on the left side of the handlebar.
Possible states
• Kill switch in basic position – In this position, the ignition circuit is closed, and the engine can be started.
• Kill switch pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.
K00647-10

6.4 Opening filler cap

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling. – Make sure that no fuel is spilled; particularly not on hot parts of the vehicle. – If any fuel is spilled, wipe it off immediately. – Observe the specifications for refueling.
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6 CONTROLS
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. – Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes. – Change your clothing in case of fuel spills on them. – Keep fuels correctly in a suitable canister, and out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
–
Turn the tank cap1counterclockwise and pull it up.
K00648-10

6.5 Closing the filler cap

– Mount the filler cap and turn it clockwise until the fuel tank is
firmly closed.
K00648-11

6.6 Opening oil tank cap (TC 50 Mini)

–
Turn the oil tank cap1counterclockwise and pull it up.
Info
Route fuel tank breather hose1without kinks.
16
A00092-10
Page 19

6.7 Closing oil tank cap (TC 50 Mini)

– Put the oil tank cap on and turn it clockwise.
A00092-11

6.8 Fuel tap

Fuel tap1is on the left of the fuel tank.
Possible states
• Fuel tap is closed – The knurled screw is turned all the way clockwise. Fuel cannot flow out of the fuel tank.
• Fuel tap is open – The knurled screw is turned all the way counterclockwise. Fuel can flow out of the fuel tank.
6 CONTROLS
Info
Run the oil tank breather hose1without kinks.

6.9 Choke (TC 50)

6.10 Choke (TC 50 Mini)

K00649-10
F00633-10
Choke1is fitted on the left side of the carburetor. Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel. This results in a richer fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deacti­vated.
Possible states
• Choke function activated – The choke lever is pulled out to the stop.
• Choke function deactivated – The choke lever is pushed in to the stop.
The choke lever1is fitted on the right of the carburetor. Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel. This results in a richer fuel-air mixture, which is needed for a cold start.
A00093-10
Info
If the engine is warm, the choke function must be deacti­vated.
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6 CONTROLS

6.11 Kick starter

6.12 Foot brake lever

Possible states
• Choke function activated – The choke lever is pushed up all the way to the stop.
• Choke function deactivated – The choke lever is pushed down all the way to the stop.
Kick starter1is fitted on the right side of the engine. The kick starter can be swiveled.
Info
Before riding, swing the kick starter inwards towards the engine.
H01184-10

6.13 Plug-in stand

Foot brake lever1is located in front of the right footrest. The rear brake is engaged with the foot brake lever.
401956-10
The fixture for plug-in stand1is located on the frame on the left side of the vehicle. The plug-in stand is used to park the motorcycle.
Info
Remove the plug-in stand before riding.
402581-10
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6.14 Service hour counter

F00634-10
6 CONTROLS
Service hour counter1is attached to the tail section under the left-hand side cover. It shows the total number of service hours of the engine. The service hour counter begins counting when the engine is started and stops when the engine is switched off.
Info
The value indicated by the service hour counter cannot be cleared or adjusted.
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7 PREPARING FOR USE

7.1 Advice on first use

Warning
Danger of accidents A lack of physical and mental readiness on the part of the child poses a major
risk. Children often underestimate or fail to recognize dangerous situations.
– Your child must already be able to ride a bicycle. – Your child must be able to put the vehicle upright independently after a fall. – Your child must understand that regulations and instructions from you or from other guardians must
be followed.
– Make it clear to your child that he or she should not, under any circumstances, operate the vehicle
without supervision.
– Make it clear to your child that he or she may only drive at speeds commensurate with the child's
riding abilities and the road conditions.
– Do not ask too much of your child.
Do not consider participation in competitive activities until your child's stamina, riding techniques and motivation are at the necessary levels.
– Only let your child ride on the vehicle if he or she is physically and mentally ready.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Ensure your child wears appropriate protective clothing such as helmet, boots, gloves as well as
trousers and a jacket with protectors on all rides.
– Alway use protective clothing for your child that is in good condition and meets the legal require-
ments.
– When you ride a motorcycle, set an example for your child and wear suitable protective clothing.
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling char-
acteristic. Different tire tread patterns can make the vehicle significantly more difficult to control.
– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidents An unadapted riding style constitutes a major risk.
– Ensure that your child adapts the riding speed to the road conditions and to his or her riding abili-
ties.
Warning
Danger of accidents The vehicle is not designed to carry passengers.
– Make it clear to your child that he or she must not carry passengers.
Warning
Danger of accidents The brake system fails in the event of overheating.
If the foot brake lever is not released, the brake linings drag continuously.
– Ensure that your child raises his or her foot from the foot brake lever if he or she does not want to
brake.
20
Page 23
7 PREPARING FOR USE
Warning
Danger of accidents The suspension components will become damaged or destroyed if overloaded.
– Do not exceed the maximum permissible weight of the rider.
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running. – Protect the vehicle against access by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-delivery inspection work has been carried out by an authorized Husqvarna Motorcy-
cles workshop.
You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.
– Carefully read the entire Owner's Manual together with your child before going for the first ride.
Info
Pay special attention to the safety warnings and injury risks. Explain to your child the techniques of riding and falling, e.g. how shifting weight can influence han­dling characteristics.
– Familiarize your child with the controls. – Adjust the basic position of the hand brake lever. ( p. 76) – Adjust the basic position of the foot brake lever. ( p. 84) – Before using the vehicle for the first time, ensure that the basic settings of the chassis are suitable for the
weight of your child.
– Accustom your child to the handling of the motorcycle on suitable terrain, preferably on a large, open
meadow.
Info
To give your child a feeling for the brake system, you should push your child at first. Do not start the engine until your child is able to apply the necessary front brake pressure. Initially, let your child ride to another person who can help your child stop and turn.
– Erect obstacles for your child to navigate around to accustom your child to handling the vehicle. – Your child should also try to ride as slowly as possible and in a standing position to get a better feeling for
the vehicle.
– Do not let your child ride on terrain that exceeds your child's capabilities and experience. – Your child should hold the handlebar firmly with both hands and keep his or her feet on the footrests when
riding.
– Make sure the maximum permissible weight of the rider is not exceeded.
Guideline
Maximum rider weight ≤ 45 kg (≤ 99 lb.) Maximum rider size < 130 cm (< 51.2 in)
– Check the spoke tension. ( p. 94)
Info
The spoke tension must be checked after half an hour of operation.
– Run the engine in. ( p. 22)
21
Page 24
7 PREPARING FOR USE

7.2 Running in the engine

– During the running-in phase, do not exceed the specified engine performance.
Guideline
Maximum engine performance
During the first 3 operating hours < 70 % During the first 5 operating hours < 100 %
– Avoid fully opening the throttle!
22
Page 25

8 RIDING INSTRUCTIONS

8.1 Checks and maintenance measures when preparing for use

Info
Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated.
– Check the gear oil level. ( p. 109) – Check the front brake fluid level. ( p. 78) – Check the rear brake fluid level. ( p. 85) – Check the front brake linings. ( p. 80) – Check the rear brake linings. ( p. 87) – Check that the brake system is functioning properly. – Check the coolant level. ( p. 97) – Check the chain for dirt. ( p. 68) – Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 71) – Check the chain tension. ( p. 69) – Check the tire condition. ( p. 93) – Check the tire air pressure. ( p. 94) – Check the spoke tension. ( p. 94)
Info
The spoke tension must be checked regularly as incorrect spoke tension will strongly impair riding safety.
– Clean the dust boots of the fork legs. ( p. 44) – Bleed the fork legs. ( p. 43) – Check the air filter. – Check the settings of all controls and ensure that they can be operated smoothly. – Check all screws, nuts, and hose clamps regularly for tightness. – Check the fuel level.

8.2 Starting the vehicle

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and
death.
– Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed
space.
Note
Engine failure High rpm with a cold engine negatively impacts the lifespan of the engine.
– Ensure that the engine is always warmed up at low engine speeds.
23
Page 26
8 RIDING INSTRUCTIONS
Info
If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable ele­ments of the fuel evaporate after a long time of standing. If the float chamber is filled with fresh fuel, the engine starts immediately.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
The motorcycle has been out of use for more than 1 week
– Empty the carburetor float chamber.
– Turn the knurled screw on the fuel tap all the way counterclockwise.
Fuel can flow from the fuel tank to the carburetor.
The engine is cold
(TC 50)
– Pull the choke knob fully out and turn it by max. ¼ turn.
(TC 50 Mini)
– Push the choke lever up all the way to the stop.
– Forcefully step on the kick starter, pushing it all the way forward.
Info
Do not open the throttle.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)

8.3 Starting off

Info
The plug-in stand must be removed before riding.
– Open the throttle carefully.

8.4 Riding

Info
If unusual noises occur while riding, stop immediately, switch off the engine, and contact an authorized Husqvarna Motorcycles workshop.
– If the choke function was activated, deactivate it after the engine has warmed up. – After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This
will barely reduce the speed but fuel consumption will be considerably lower.
– Your child should always open the throttle only as much as the engine can handle – abruptly opening the
throttle increases fuel consumption.
– Your child should switch off the engine if longer periods of engine idling or standing still are expected.
Guideline
≥ 2 min
24
Page 27
8 RIDING INSTRUCTIONS

8.5 Applying the brakes

Warning
Danger of accidents Excessively forceful application of the brakes blocks the wheels.
– Explain to your child that he or she must adapt the braking to the traffic situation and the road con-
ditions.
Warning
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.
– Check the brake system and do not allow your child to continue riding until the problem is elimi-
nated. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
Warning
Danger of accidents Moisture and dirt impair the brake system.
– Explain to your child that he or she must brake carefully several times to dry out and remove dirt
from the brake linings and the brake discs.
– On sandy, wet, or slippery surfaces, use the rear brake. – Always finish braking before you go into a bend.

8.6 Stopping, parking

Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running. – Protect the vehicle against access by unauthorized persons.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake sys-
tem before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface. – Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it.
– Apply the brakes on the motorcycle. – Press and hold the kill switch while the engine is idling until the engine stops. – Turn the knurled screw on the fuel tap all the way clockwise. – Park the motorcycle on firm ground.
25
Page 28
8 RIDING INSTRUCTIONS

8.7 Transporting

Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it.
– Switch off the engine. – Use tension belts or other suitable devices to secure the
motorcycle against falling over or rolling away.
401475-01

8.8 Refueling

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling. – Make sure that no fuel is spilled; particularly not on hot parts of the vehicle. – If any fuel is spilled, wipe it off immediately. – Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. – Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes. – Change your clothing in case of fuel spills on them.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
– Switch off the engine. – Open the filler cap. ( p. 15)
26
Page 29
8 RIDING INSTRUCTIONS
00
0
AA
–
Fill the fuel tank with fuel up to levelA. Guideline
Level
A
35 mm (1.38 in)
400214-10
Fuel tank capacity, approx. (TC 50 Mini)
Fuel tank capacity, approx. (TC 50)
– Close the filler cap. ( p. 16)
2.1 l (2.2 qt.) Super unleaded
2.3 l (2.4 qt.) Super unleaded

8.9 Filling up with oil (TC 50 Mini)

Warning
Engine damage The engine will not be lubricated unless there is 2-stroke oil in the oil tank.
– For a full fuel tank, fill the oil tank at least up to the MINmark.
– Switch off the engine. – Open the oil tank cap. ( p. 16)
–
Fill the oil tank at least up to the MINmarkA. Guideline
MIN mark Sufficient for a single tank
filling
(ROZ 95/RON 95/PON 91) ( p. 128)
(95 octane) mixed with 2-stroke engine oil (1:60) ( p. 128)
A00094-10
Oil tank contents ca. 0.2 l (0.2 qt.) Engine oil, 2-stroke
( p. 127)
– Close the oil tank cap. ( p. 17)
27
Page 30

9 SERVICE SCHEDULE

9.1 Additional information

Any further work that results from the required work or from the recommended work must be ordered sepa­rately and can be invoiced separately. Different service intervals may apply in your country, depending on the local operating conditions.

9.2 Required work

Check the front brake linings. ( p. 80) ○ ● ● ● Check the rear brake linings. ( p. 87) ○ ● ● ● Check the brake discs. ( p. 77) ○ ● ● ● Check the brake lines for damage and leakage. ○ ● ● ● Change the foot brake cylinder sealing cup. ● ● ● Check the rear brake fluid level. ( p. 85) ○ ● ● ● Check the free travel of the foot brake lever. ( p. 83) ○ ● ● ● Check the frame. ( p. 74) ● ● ● Check the swingarm. ( p. 74) ● ● ● Check the swingarm bearing for play. ● ● ● Check the heim joint for play. ● ● ● Check the tire condition. ( p. 93) ○ ● ● ● Check the tire air pressure. ( p. 94) ○ ● ● ● Check the wheel bearing for play. ● ● ● Check the wheel hubs. ● ● ● Check the rim run-out. ○ ● ● ● Check the spoke tension. ( p. 94) ○ ● ● ● Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 71) ○ ● ● ● Check the chain tension. ( p. 69) ○ ● ● ● Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. ○ ● ● ● Check the front brake fluid level. ( p. 78) ○ ● ● ● Check the play of the handbrake lever. ( p. 76) ○ ● ● ● Check play of steering head bearing. ( p. 51) ○ ● ● ● Change the spark plug and spark plug connector. ● ● ● Change the gear oil. ( p. 110) ○ ● ● Check the gear oil level. ( p. 109) ● Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks,
and incorrect routing. Check the antifreeze and coolant level. ( p. 96) ○ ● ● ● Check the cables for damage and routing without sharp bends. ○ ● ● ● Check that the throttle cables are undamaged, routed without sharp bends, and set cor-
rectly. Clean the air filter and air filter box. ( p. 65) ○ ● ● ● Change the glass fiber yarn filling of the main silencer. ( p. 66) ● ● ●
Every 80 operating hours
Every 40 operating hours
Every 20 operating hours
Once after 10 operating hours
○ ● ● ●
○ ● ● ●
28
Page 31
9 SERVICE SCHEDULE
Every 80 operating hours
Every 40 operating hours
Every 20 operating hours
Once after 10 operating hours
Service the fork. ● ● Service the shock absorber. ● Check the screws and nuts for tightness. ○ ● ● ● Check idle. ○ ● ● ● Check the clutch setting. ( p. 104) ● ● ● Final check: Check the vehicle for safe operation and take a test ride. ○ ● ● ● Make the service entry in Husqvarna Motorcycles Dealer.net and in the Service and War-
ranty Booklet.
○ One-time interval
● Periodic interval

9.3 Recommended work

Every 80 operating hours
Once after 20 operating hours / Every 20 operating hours
Once after 10 operating hours
Change the front brake fluid. ● Change the rear brake fluid. ● Service the fork. ○ Service the shock absorber. ○ Grease the steering head bearing. ( p. 53) ● Check/adjust the carburetor components. ● Perform minor engine service. Check the cylinder and piston. Check the inlet
membrane.) Perform major engine service including removing and installing engine. (Check the clutch.
Change the piston. Change the connecting rod, conrod bearing, and crank pin. Check the transmission. Change the crankshaft bearing. Change all engine bearings.)
○ ● ● ●
Annually
● ●
●
○ One-time interval
● Periodic interval
29
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10 TUNING THE CHASSIS

10.1 Checking the basic chassis setting with the rider's weight

Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
– For optimal motorcycle riding characteristics and to avoid
damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspension components must match the rider's weight.
– On delivery, Husqvarna offroad motorcycles are adjusted for
an average rider's weight (with full protective clothing). Guideline
Standard rider weight 25 … 35 kg (55 … 77 lb.)
– If the rider's weight is above or below this range, the basic
setting of the suspension components must be adjusted accordingly.
– Small weight differences can be compensated by adjust-
ing the spring preload, but in the case of large weight differ­ences, the springs must be replaced.
401030-01

10.2 Air suspension AER 35 (TC 50)

Air suspension WP Performance Systems AER 35 is used in the fork. In this system, suspension is located in the left fork leg and damping in the right fork leg. As fork springs are no longer required, a significant weight advantage is achieved when compared to conven­tional forks. The response on slightly uneven surfaces is significantly improved. In normal driving mode, suspension is provided exclusively by an air cushion. A steel spring is located in the left fork leg as an end stop.
Info
If the fork is frequently overloaded, then the air pressure in the fork must be increased to avoid damage to the fork and frame.
The air pressure in the fork can be quickly adjusted for the rider's weight, surface conditions and the rider's preference using a fork pump. The fork does not have to be detached. The time consuming mounting of harder or softer fork springs is not required. If the air chamber loses air due to a damaged seal, the fork will still not sag. In this case the air is retained in the fork. The suspension travel is maintained as far as possible. The damping becomes harder and the riding comfort reduces. The rebound damping can be adjusted. The rebound adjustment is located at the upper end of the right fork leg.
30
Page 33
10 TUNING THE CHASSIS

10.3 Compression damping of the shock absorber (TC 50)

The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed. High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed. The high-speed setting, for example, has an effect on the landing after a jump: the rear wheel suspension com­presses quickly. The low-speed setting, for example, has an effect when riding over long ground swells: the rear wheel suspen­sion compresses slowly. These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in the high-speed range affect the compression damping in the low-speed range and vice versa.

10.4 Adjusting the low-speed compression damping of the shock absorber (TC 50)

Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor-
rectly. The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be
glad to help.)
Info
The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.
–
Turn adjusting screw1clockwise with a screwdriver up to the last perceptible click.
Info
Do not loosen fitting2!
– Turn counterclockwise by the number of clicks correspond-
ing to the shock absorber type.
K00658-10
Guideline
Compression damping, low-speed
Comfort 18 clicks Standard 15 clicks Sport 12 clicks
Info
Turn clockwise to increase damping; turn counter­clockwise to reduce damping.
31
Page 34
10 TUNING THE CHASSIS

10.5 Adjusting the high-speed compression damping of the shock absorber (TC 50)

Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor-
rectly. The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be
glad to help.)
Info
The effect of the high-speed setting can be seen in fast compression of the shock absorber.
– Push splash protector to the side.
–
Using an open end wrench, turn adjusting screw1clock­wise all the way.
Info
Do not loosen fitting2!
– Turn counterclockwise by the number of turns corresponding
F00635-10
to the shock absorber type. Guideline
Compression damping, high-speed
Comfort 2.5 turns Standard 2 turns Sport 1.5 turns
Info
Turn clockwise to increase damping; turn counter­clockwise to reduce damping.
– Position the splash protector.

10.6 Adjusting the rebound damping of the shock absorber

Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor-
rectly. The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be
glad to help.)
32
Page 35
K00659-10
10 TUNING THE CHASSIS
(TC 50)
–
Turn adjusting screw1clockwise up to the last percep­tible click.
– Turn counterclockwise by the number of clicks corre-
sponding to the shock absorber type. Guideline
Rebound damping
Comfort 17 clicks Standard 15 clicks Sport 13 clicks
Info
Turn clockwise to increase damping; turn counter­clockwise to reduce damping.
(TC 50 Mini)
– Raise the motorcycle with a lift stand. ( p. 43)
–
Remove nut1.
V00257-10
V00258-10
V00259-10
–
Remove screw2.
– Pull the shock absorber out of the support and push the
rear wheel upwards.
–
Turn adjusting screw3clockwise up to the last percep­tible click.
– Turn counterclockwise by the number of clicks corre-
sponding to the shock absorber type. Guideline
Rebound damping
Standard 12 clicks
Info
Turn clockwise to increase damping; turn counter­clockwise to reduce damping.
33
Page 36
10 TUNING THE CHASSIS
00AA
00AA
0
0
BB

10.7 Measuring rear wheel sag unloaded

V00260-10
– Position the shock absorber and rear wheel.
–
Mount and tighten screw2and nut1. Guideline
Screw, bot­tom shock absorber
– Remove the motorcycle from the lift stand. ( p. 43)
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work
– Measure the distance – as vertical as possible – between the
rear axle and a fixed point, for example, a mark on the side cover.
–
Make a note of the value as measurementA.
M10 45 Nm (33.2 lbf ft)
Loctite®243™
400988-10
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)

10.8 Checking the static sag of the shock absorber

–
Measure distanceAof rear wheel unloaded. ( p. 34)
– Hold the motorcycle upright with the aid of an assistant. – Measure the distance between the rear axle and the fixed
point again.
–
Note down the value as dimensionB.
Info
The static sag is the difference between measure­mentsAandB.
– Check the static sag.
Static sag (TC 50) 12 mm (0.47 in)
Static sag (TC 50 Mini) 10 mm (0.39 in)
» If the static sag is less or more than the specified value:
– Adjust the spring pretension of the shock absorber.
( p. 35)
34
400989-10
Page 37

10.9 Checking the riding sag of the shock absorber

00AA
0
0
CC
–
Measure distanceAof rear wheel unloaded. ( p. 34)
– With another person holding the motorcycle, the rider, wear-
ing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.
The rear wheel suspension levels out.
– Another person now measures the distance between the rear
axle and the fixed point.
–
Note down the value as dimensionC.
Info
The riding sag is the difference between measure­mentsAandC.
– Check the riding sag.
Riding sag (TC 50) 80 mm (3.15 in)
Riding sag (TC 50 Mini) 65 mm (2.56 in)
400990-10
» If the riding sag differs from the specified measurement:
– Adjust the riding sag. ( p. 37)
10 TUNING THE CHASSIS

10.10 Adjusting the spring pretension of the shock absorber

Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor-
rectly. The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be
glad to help.)
Preparatory work (TC 50)
– Raise the motorcycle with a lift stand. ( p. 43)
(TC 50 Mini)
– Raise the motorcycle with a lift stand. ( p. 43)
– Remove the rear wheel. ( p. 91) – Remove the shock absorber. ( p. 61) – After removing the shock absorber, clean it thoroughly.
35
Page 38
10 TUNING THE CHASSIS
Main work (TC 50)
– Measure the full spring length while it is under tension
and note down the value.
–
Loosen retaining ring1.
–
Turn adjusting ring2until the spring is no longer under tension.
Hook wrench (T304) Hook wrench (T1533)
– Measure the overall spring length while the spring is not
under tension.
–
Tighten the spring by turning adjusting ring2to mea­surementA.
Guideline
Spring preload
Standard 3 mm (0.12 in)
402746-10
V00262-10
Info
The spring preload is the difference between the relaxed spring length and the tensioned spring length. Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring pretension.
–
Tighten retaining ring1.
(TC 50 Mini)
– Measure the full spring length while it is under tension
and note down the value.
–
Loosen retaining ring1.
–
Turn adjusting ring2until the spring is no longer under tension.
Hook wrench (T304) Hook wrench (T1533)
– Measure the overall spring length while the spring is not
under tension.
–
Tighten the spring by turning adjusting ring2to the specified measurement.
Guideline
Spring preload
Standard 5 mm (0.2 in)
36
Page 39

10.11 Adjusting the riding sag

B00292-10
10 TUNING THE CHASSIS
Info
The spring preload is the difference between the relaxed spring length and the tensioned spring length. Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring pretension.
–
Tighten retaining ring1.
Finishing work
– Install the shock absorber. ( p. 62) – Remove the motorcycle from the lift stand. ( p. 43)
Preparatory work (TC 50)
– Raise the motorcycle with a lift stand. ( p. 43)
(TC 50 Mini)
– Raise the motorcycle with a lift stand. ( p. 43)
– Remove the rear wheel. ( p. 91) – Remove the shock absorber. ( p. 61) – After removing the shock absorber, clean it thoroughly.
Main work
– Choose and mount a suitable spring.
Guideline
Spring rate (TC 50)
Weight of rider: 15 … 25 kg (33 … 55 lb.)
Weight of rider (stan­dard): 25 … 35 kg (55 … 77 lb.)
Weight of rider: 35 … 45 kg (77 … 99 lb.)
Spring rate (TC 50 Mini)
Weight of rider: 15 … 25 kg (33 … 55 lb.)
Weight of rider (stan­dard): 25 … 35 kg (55 … 77 lb.)
Weight of rider: 35 … 45 kg (77 … 99 lb.)
30 N/mm (171 lb/in)
35 N/mm (200 lb/in)
40 N/mm (228 lb/in)
65 N/mm (371 lb/in)
75 N/mm (428 lb/in)
85 N/mm (485 lb/in)
Info
The spring rate is shown on the outside of the spring. Smaller weight differences can be compensated by changing the spring preload.
37
Page 40
10 TUNING THE CHASSIS

10.12 Checking the basic setting of the fork

Info
For various reasons, no exact riding sag can be determined for the fork.
401000-01
Finishing work
– Install the shock absorber. ( p. 62) – Remove the motorcycle from the lift stand. ( p. 43) – Check the static sag of the shock absorber. ( p. 34) – Check the riding sag of the shock absorber. ( p. 35) – Adjust the rebound damping of the shock absorber. ( p. 32)
(TC 50)
– Smaller differences in the rider's weight can be compen-
sated for by the fork air pressure.
– However, if the fork frequently bottoms out (hard end
stop on compression), the fork air pressure must be increased, within the specified values, to avoid damage to the fork and frame.
(TC 50 Mini)
– As with the shock absorber, smaller differences in the
rider's weight can be compensated by the spring preload.
– However, if the fork frequently bottoms out (hard end
stop on compression), harder springs must be fitted to avoid damage to the fork and frame.

10.13 Adjusting the fork air pressure (TC 50)

Warning
Danger of accidents Modifications to the suspension setting may seriously alter the handling charac-
teristic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling
characteristic and overload components.
– Only make adjustments within the recommended range. – Make sure your child rides slowly to start with after making adjustments in order that he or she can
assess the new handling characteristic.
Info
Check or adjust the air pressure under the same conditions at the earliest 5 minutes after switching off the engine. The air suspension is located in the left fork leg. The rebound damping is located in the right fork leg.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
38
Page 41
S01478-10
10 TUNING THE CHASSIS
Main work
–
Remove protection cap1.
–
Push fork pump2together fully.
Fork pump (79412966000)
Info
The fork pump is included as part of the motorcycle's separate enclosure.
– Connect the fork pump to the left fork leg.
The fork pump indicator switches on automatically. A little air escapes from the fork leg when connecting.
Info
This is due to the volume of the hose and not due to a defect in the fork pump or the fork. Read the accompanying instructions for Husqvarna Motorcycles accessories.
– Adjust the air pressure as specified.
Guideline
Air pressure 2 bar (29 psi) Changing of the air pressure
in steps of Minimum air pressure 1.4 bar (20 psi) Maximum air pressure 4 bar (58 psi)
0.2 bar (3 psi)
Info
Never set the air pressure to a value outside the stated range.
– Disconnect the fork pump from the left fork leg.
When disconnecting, excess pressure will escape from the hose – the fork leg itself does not lose any air.
The fork pump indicator switches off automatically after 80 seconds.
– Mount the protection cap.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)

10.14 Adjusting the rebound damping of the fork (TC 50)

Info
The hydraulic rebound damping determines the fork suspension behavior.
39
Page 42
10 TUNING THE CHASSIS
S01479-10
–
Turn adjusting screw1clockwise all the way.
Info
Adjusting screw1is located at the upper end of the right fork leg.
– Turn counterclockwise by the number of clicks correspond-
ing to the fork type. Guideline
Rebound damping
Comfort 15 clicks Standard 12 clicks Sport 10 clicks
Info
Turn clockwise to increase damping; turn counter­clockwise to reduce damping.

10.15 Handlebar position

On the upper triple clamp, there are 2 holes at a distance of to each other.
15 mm (0.59 in)
3.5 mm (0.138 in)
H01850-10
Hole distance
The holes on the handlebar support are placed at a distance ofBfrom the center.
Hole distance
The handlebar holder can be mounted in four different positions. This allows the handlebar to be mounted in the most comfortable position for the rider.
A
B

10.16 Adjusting the handlebar position

Warning
Danger of accidents A repaired handlebar poses a safety risk.
If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result.
– Change the handlebar if the handlebar is damaged or bent.
–
Remove screws1. Take off the handlebar clamps. Remove the handlebar and lay it to one side.
A
40
H01851-10
Info
Protect the motorcycle and its attachments against damage by covering them. Do not kink the cables and lines.
–
Remove screws2. Remove the handlebar support.
Page 43
10 TUNING THE CHASSIS
– Place the handlebar support in the required position. Mount
and tighten screws2.
Guideline
Screw, handle­bar support
– Position the handlebar.
Info
Make sure the cables and wiring are positioned cor­rectly.
–
Position the handlebar clamps. Mount screws1and tighten
evenly.
Guideline
Screw, handlebar clamp
Info
Make sure the gap widths are even.
M10 40 Nm (29.5 lbf ft)
Loctite®243™
M8 20 Nm (14.8 lbf ft)

10.17 Adjusting the seat height

Warning
Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride
behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work
–
Remove nut1.
A00095-10
– Hold the rear wheel with the swingarm and remove
screw2. – Position the shock absorber according to the required seat
height.
Guideline
K00651-10
Low seat position (standard) High seat position
–
Position screw2.
A B
41
Page 44
10 TUNING THE CHASSIS
A00095-10
–
Mount nut1and tighten fitting. Guideline
Screw, top shock absorber
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)
M10 45 Nm (33.2 lbf ft)
Loctite®243™
42
Page 45

11 SERVICE WORK ON THE CHASSIS

11.1 Raising the motorcycle with a lift stand

Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
– Raise the motorcycle at the frame underneath the engine.
Lift stand (80329955100)
Neither wheel is in contact with the ground.
– Secure the motorcycle against falling over.
401942-01

11.2 Removing the motorcycle from the lift stand

Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
– Remove the motorcycle from the lift stand. – Remove the lift stand.
–
To park the motorcycle, insert plug-in stand1into the plug-
in stand bracket on the left side of the vehicle.
Info
Remove the plug-in stand before riding.
402581-10

11.3 Bleeding the fork legs

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work (TC 50)
–
Release bleeder screws1.
Any excess pressure escapes from the interior of the fork.
– Tighten the bleeder screws.
S01480-10
43
Page 46
11 SERVICE WORK ON THE CHASSIS
(TC 50 Mini)
–
Release bleeder screws1.
Any excess pressure escapes from the interior of the fork.
– Tighten the bleeder screws.
H01183-11
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)

11.4 Cleaning the dust boots of the fork legs

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43) – Remove the fork protector. ( p. 45)
Main work
–
Push dust boots1of both fork legs downward.
S00886-10
Info
The dust boots remove dust and coarse dirt parti­cles from the inside fork tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.
Warning
Danger of accidents Oil or grease on the brake
discs reduces the braking effect. – Always keep the brake discs free of oil and
grease.
– Clean the brake discs with brake cleaner when
necessary.
– Clean and oil the dust boots and inner fork tubes of both fork
legs.
Universal oil spray ( p. 129)
– Press the dust boots back into their installation position. – Remove excess oil.
Finishing work
– Install the fork protector. ( p. 45) – Remove the motorcycle from the lift stand. ( p. 43)
44
Page 47

11.5 Removing the fork protector

–
–
A00079-10
–
11 SERVICE WORK ON THE CHASSIS
Remove screws1and take off the clamp.
Remove screws2on the left fork leg. Take off the fork pro-
tector.
Remove screws3on the right fork leg. Take off the fork
protector.
A00078-10

11.6 Installing the fork protector

A00078-11
A00079-11
– Position the fork protector on the right fork leg. Mount and
tighten screws1.
Guideline
Remaining screws, chassis
– Position the fork protector on the left fork leg. Mount and
tighten screws2.
Guideline
Remaining screws, chassis
– Position the brake line and clamp. Mount and tighten
screws3.
M6 10 Nm (7.4 lbf ft)
M6 10 Nm (7.4 lbf ft)
45
Page 48
11 SERVICE WORK ON THE CHASSIS

11.7 Removing the fork legs

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43) – Remove the front wheel. ( p. 90)
Main work
–
Remove screws1and take off the clamp.
–
Remove screws2and take off the brake caliper.
– Allow the brake caliper and brake line to hang loosely to the
side.
Info
Do not kink the brake line.
A00084-10
(TC 50)
–
Loosen screws3. Remove the left fork leg.
–
Loosen screws4. Remove the right fork leg.
H01853-10
A00096-10

11.8 Installing the fork legs

S01480-10
(TC 50 Mini)
–
Loosen screws3. Remove the left fork leg.
–
Loosen screws4. Remove the right fork leg.
Main work (TC 50)
– Position the fork legs.
Bleeder screws1are positioned toward the front.
Info
The second milled groove in the fork leg must be flush with the upper edge of the upper triple clamp.
46
Page 49
H01853-11
H01183-11
11 SERVICE WORK ON THE CHASSIS
–
Tighten screws2. Guideline
Screw, top triple clamp
–
Tighten screws3. Guideline
Screw, bottom triple clamp
(TC 50 Mini)
– Position the fork legs.
Bleeder screws1are positioned toward the front.
Info
The second milled groove (from the top) must be flush with the top edge of the upper triple clamp.
M8 20 Nm (14.8 lbf ft)
M8 15 Nm (11.1 lbf ft)
A00096-11
A00085-10
–
Tighten screws2. Guideline
Screw, top triple
M8 20 Nm (14.8 lbf ft)
clamp
–
Tighten screws3. Guideline
Screw, bottom
M8 15 Nm (11.1 lbf ft)
triple clamp
–
Position the brake caliper, and mount and tighten screws4.
Guideline
Screw, front brake caliper
–
Mount and tighten screw5.
M8x60 20 Nm (14.8 lbf ft)
Loctite®243™
Finishing work
– Install the front wheel. ( p. 90)
47
Page 50
11 SERVICE WORK ON THE CHASSIS

11.9 Removing the lower triple clamp

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43) – Remove the front wheel. ( p. 90) – Remove the fork legs. ( p. 46) – Remove the start number plate. ( p. 55) – Remove front fender. ( p. 56)
Main work
–
Pull fuel tank breather1out of the steering stem.
–
Remove nut2, loosen screw3, take off the upper triple clamp with the handlebar, and place it to one side.
Info
Cover the components to protect them against dam­age.
H01855-10
– – Remove the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.
Do not kink the cables and lines.
Remove protective ring4.
H01856-10

11.10 Installing the lower triple clamp

Main work
– Clean the bearing and sealing elements, check for damage,
and grease.
– Insert the lower triple clamp with the steering stem. Mount
upper steering head bearing1.
–
Check whether upper steering head seal2is correctly posi­tioned.
–
Push on protective ring3.
601602-10
High viscosity grease ( p. 129)
48
Page 51
H01857-10
000550055
S01480-11
11 SERVICE WORK ON THE CHASSIS
– Position the upper triple clamp with the handlebar.
–
Mount nut4, but do not tighten it yet.
(TC 50)
– Position the fork legs.
Bleeder screws5are positioned toward the rear.
Info
The second milled groove (from the top) must be flush with the top edge of the upper triple clamp.
H01858-10
H01859-10
–
Tighten screws6. Guideline
Screw, bottom triple clamp
–
Tighten nut4. Guideline
Nut, steering head
Nut, steering head
–
Position the fuel tank breather7in the steering stem.
–
Tighten screw8. Guideline
Screw, top triple clamp
M8 15 Nm (11.1 lbf ft)
M20x1.5 10 Nm (7.4 lbf ft)
M20x1.5 9 Nm (6.6 lbf ft)
Only applies when using: Holding wrench for steering head bearing (45229050000)
M8 20 Nm (14.8 lbf ft)
– Using a plastic hammer, tap lightly on the upper triple
clamp to avoid stresses.
–
Tighten screws9.
H01859-11
49
Page 52
11 SERVICE WORK ON THE CHASSIS
Guideline
Screw, top triple clamp
(TC 50 Mini)
– Position the fork legs.
Bleeder screws5are positioned toward the front.
H01183-10
–
Tighten screws6. Guideline
Screw, bottom triple clamp
M8 20 Nm (14.8 lbf ft)
Info
The second milled groove (from the top) must be flush with the top edge of the upper triple clamp.
M8 15 Nm (11.1 lbf ft)
H01858-10
A00097-11
A00097-12
–
Tighten nut4. Guideline
Nut, steering
M20x1.5 10 Nm (7.4 lbf ft)
head Nut, steering
head
M20x1.5 9 Nm (6.6 lbf ft)
Only applies when using: Holding wrench for steering head bearing (45229050000)
–
Position the fuel tank breather7in the steering stem.
–
Tighten screw8. Guideline
Screw, top triple
M8 20 Nm (14.8 lbf ft)
clamp
– Using a plastic hammer, tap lightly on the upper triple
clamp to avoid stresses.
–
Tighten screws9. Guideline
Screw, top triple
M8 20 Nm (14.8 lbf ft)
clamp
50
Page 53
A00085-11
11 SERVICE WORK ON THE CHASSIS
–
Position the brake caliper, and mount and tighten screwsbk.
Guideline
Screw, front brake caliper
– Position the brake line and clamp. Mount and tighten
screwsbl.
Finishing work
– Install front fender. ( p. 56) – Install the start number plate. ( p. 56) – Check that the wiring harness, throttle cables, and brake and
clutch lines can move freely and are routed correctly.
– Install the front wheel. ( p. 90) – Check play of steering head bearing. ( p. 51) – Remove the motorcycle from the lift stand. ( p. 43)
M8x60 20 Nm (14.8 lbf ft)
Loctite®243™

11.11 Checking play of steering head bearing

Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and
damages components. – Correct incorrect steering head bearing play immediately. (Your authorized Husqvarna Motorcycles
workshop will be glad to help.)
Info
If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become damaged over time.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work
– Move the handlebar to the straight-ahead position. Move the
fork legs to and fro in the direction of travel.
No play should be noticeable in the steering head bear­ing.
» If there is noticeable play present:
– Adjust the steering head bearing play. ( p. 52)
H01167-01
– Move the handlebar to and fro over the entire steering range.
The handlebar must be able to move easily over the entire steering range. No resting locations should be noticeable.
» If click positions are noticeable:
– Adjust the steering head bearing play. ( p. 52)
51
Page 54
11 SERVICE WORK ON THE CHASSIS
– Check the steering head bearing and replace if
required.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)

11.12 Adjusting the steering head bearing play

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work (TC 50)
–
Pull fuel tank breather1out of the steering stem.
–
Loosen screws2.
–
Loosen screw3.
–
Loosen and retighten nut4. Guideline
H01859-12
Nut, steering head
Nut, steering head
M20x1.5 10 Nm (7.4 lbf ft)
M20x1.5 9 Nm (6.6 lbf ft)
Only applies when using: Holding wrench for steering head bearing (45229050000)
A00097-10
– Using a plastic hammer, tap lightly on the upper triple
clamp to avoid stresses.
–
Tighten screw3. Guideline
Screw, top triple clamp
–
Tighten screws2. Guideline
Screw, top triple clamp
–
Position the fuel tank breather1in the steering stem.
(TC 50 Mini)
–
Pull fuel tank breather1out of the steering stem.
–
Loosen screws2.
–
Loosen screw3.
–
Loosen and retighten nut4.
M8 20 Nm (14.8 lbf ft)
M8 20 Nm (14.8 lbf ft)
52
Page 55
11 SERVICE WORK ON THE CHASSIS
Guideline
Nut, steering head
Nut, steering head
– Using a plastic hammer, tap lightly on the upper triple
clamp to avoid stresses.
–
Tighten screw3. Guideline
Screw, top triple clamp
–
Tighten screws2. Guideline
Screw, top triple clamp
M20x1.5 10 Nm (7.4 lbf ft)
M20x1.5 9 Nm (6.6 lbf ft)
Only applies when using: Holding wrench for steering head bearing (45229050000)
M8 20 Nm (14.8 lbf ft)
M8 20 Nm (14.8 lbf ft)
–
Position the fuel tank breather1in the steering stem.
Finishing work
– Check play of steering head bearing. ( p. 51) – Remove the motorcycle from the lift stand. ( p. 43)

11.13 Greasing the steering head bearing

– Remove the lower triple clamp. ( p. 48) – Install the lower triple clamp. ( p. 48)
H02387-01

11.14 Removing the fuel tank

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling. – Make sure that no fuel is spilled; particularly not on hot parts of the vehicle. – If any fuel is spilled, wipe it off immediately. – Observe the specifications for refueling.
53
Page 56
11 SERVICE WORK ON THE CHASSIS
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. – Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes. – Change your clothing in case of fuel spills on them. – Keep fuels correctly in a suitable canister, and out of the reach of children.
Preparatory work
– Remove the seat. ( p. 63) – Remove the left side cover. ( p. 59) – Remove the right side cover. ( p. 57) – Turn the knurled screw on the fuel tap all the way clockwise.
Main work
–
Remove screw1.
K00663-10
– Raise the fuel tank.
–
Pull off fuel hose2.
Info
Remaining fuel may flow out of the fuel hose.
– Pull fuel tank breather out of the steering stem. – Take off the fuel tank.
K00664-10

11.15 Installing the fuel tank

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling. – Make sure that no fuel is spilled; particularly not on hot parts of the vehicle. – If any fuel is spilled, wipe it off immediately. – Observe the specifications for refueling.
54
Page 57
11 SERVICE WORK ON THE CHASSIS
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. – Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes. – Change your clothing in case of fuel spills on them. – Keep fuels correctly in a suitable canister, and out of the reach of children.
Main work
– Check the throttle cable routing. ( p. 74)
–
Mount fuel hose1.
K00664-11
– Position the fuel tank. – Make sure that no cables or throttle cables are trapped or
damaged.
–
Mount and tighten screw2.
Guideline
Remaining screws, chassis
K00663-11
– Position the fuel tank breather in the steering stem.
Finishing work
– Install the left side cover. ( p. 60) – Install the right side cover. ( p. 58) – Mount the seat. ( p. 63)

11.16 Removing the start number plate

–
Remove screw1. – Unhook the start number plate from the brake line and
remove it.
M6 10 Nm (7.4 lbf ft)
A00103-10
55
Page 58
11 SERVICE WORK ON THE CHASSIS

11.17 Installing the start number plate

– Attach the start number plate to the brake line. – Position the start number plate.
Holding lugs1engage in the fender.
A00104-10
–
Mount and tighten screw2. Guideline
Screw, start number plate
M6 4 Nm (3 lbf ft)
A00105-10

11.18 Removing front fender

K00665-10

11.19 Installing front fender

–
Remove screws1. Take off the front fender.
–
Position the fender with drill holes1in the holding lugs on the start number plate.
56
K00675-10
Page 59
–
K00665-11

11.20 Removing the right side cover

Preparatory work
– Remove the seat. ( p. 63)
Condition
11 SERVICE WORK ON THE CHASSIS
Position front fender. Mount and tighten screws2.
Guideline
Screw, fender M6 6 Nm (4.4 lbf ft)
Right side cover secured.
–
Remove screw1.
S01546-10
K00685-10
–
Pull off the side cover sideways in areasAandB, and
remove toward the front.
57
Page 60
11 SERVICE WORK ON THE CHASSIS

11.21 Installing the right side cover

Main work
–
Position the side cover on collar bushings1and2, and push toward the rear.
–
Engage the side cover in areasAandB.
K00684-10
S01546-11
Condition
Right side cover secured.
–
Mount and tighten screw3. Guideline
Screw, side cover EJOT PT
Finishing work
– Mount the seat. ( p. 63)
K60x20-Z
®
2 Nm (1.5 lbf ft)
58
Page 61

11.22 Securing right side cover

S01545-10
11 SERVICE WORK ON THE CHASSIS
Preparatory work
– Remove the seat. ( p. 63) – Remove the right side cover. ( p. 57)
Main work
–
Drill a hole at markingA.
Guideline
Diameter 6.5 mm (0.256 in)
Finishing work
– Install the right side cover. ( p. 58) – Mount the seat. ( p. 63)

11.23 Removing the left side cover

Preparatory work
– Remove the seat. ( p. 63)
Condition
S01547-10
Left side cover secured.
–
Remove screw1.
59
Page 62
11 SERVICE WORK ON THE CHASSIS
–
Pull off the side cover sideways in areasAandB, and remove toward the front.
K00682-10

11.24 Installing the left side cover

Main work
–
Position the side cover on collar bushings1and2, and push toward the rear.
–
Engage the side cover in areasAandB.
K00683-10
S01547-11
Condition
Left side cover secured.
–
Mount and tighten screw3. Guideline
Screw, side cover EJOT PT
K60x20-Z
®
2 Nm (1.5 lbf ft)
60
Page 63

11.25 Securing left side cover

S01548-10
11 SERVICE WORK ON THE CHASSIS
Finishing work
– Mount the seat. ( p. 63)
Preparatory work
– Remove the seat. ( p. 63) – Remove the left side cover. ( p. 59)
Main work
–
Drill a hole at markingA.
Guideline
Diameter 6.5 mm (0.256 in)
Finishing work
– Install the left side cover. ( p. 60) – Mount the seat. ( p. 63)

11.26 Removing the shock absorber

Preparatory work (TC 50)
(TC 50 Mini)
Main work (TC 50)
K00676-10
– Raise the motorcycle with a lift stand. ( p. 43)
– Raise the motorcycle with a lift stand. ( p. 43)
– Remove the rear wheel. ( p. 91)
–
Remove nut1and2.
–
Remove screw3and lower the rear wheel with the swingarm as far as possible without blocking the rear wheel. Secure the rear wheel in this position.
–
Remove screw4, push splash protector5to the side, and remove the shock absorber.
K00670-11
61
Page 64
11 SERVICE WORK ON THE CHASSIS
(TC 50 Mini)
–
Remove nut1and2.
A00098-10
–
Remove screw3and lower the swingarm carefully.
–
Remove screw4, push splash protector5to the side, and remove the shock absorber.
A00099-10

11.27 Installing the shock absorber

Warning
Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride
behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior.
Main work (TC 50)
–
Push splash protector1to the side.
–
Position the shock absorber with screw2, depending on the desired seating height.
– Raise the swingarm; position the shock absorber with
screw3.
K00670-10
–
Mount nut4and tighten fitting. Guideline
K00676-11
Screw, top shock absorber
–
Mount nut5and tighten fitting. Guideline
Screw, bot­tom shock absorber
M10 45 Nm (33.2 lbf ft)
M10 45 Nm (33.2 lbf ft)
Loctite®243™
Loctite®243™
62
Page 65
A00099-11
A00098-11
11 SERVICE WORK ON THE CHASSIS
(TC 50 Mini)
–
Push splash protector1to the side.
–
Position the shock absorber with screw2, depending on the desired seating height.
– Raise the swingarm; position the shock absorber with
screw3.
–
Mount nut4and tighten fitting. Guideline
Screw, top shock absorber
–
Mount nut5and tighten fitting. Guideline
Screw, bot­tom shock absorber
M10 45 Nm (33.2 lbf ft)
Loctite®243™
M10 45 Nm (33.2 lbf ft)
Loctite®243™

11.28 Removing the seat

11.29 Mounting the seat

K00654-10
– Install the rear wheel. ( p. 92)
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)
–
Open quick release1and raise the rear of the seat.
– Pull back the seat and remove it.
–
Hook the seat onto screw1, lower the seat at the rear, and
push it forward.
Catch2hooks into the fuel tank.
K00655-10
63
Page 66
11 SERVICE WORK ON THE CHASSIS
–
Close quick release3.
K00654-11

11.30 Removing the air filter

Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
– Never start to use the vehicle without an air filter.
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance
with the applicable regulations.
K00671-10

11.31 Installing the air filter

K00672-10
Preparatory work
– Remove the seat. ( p. 63)
Main work
–
Press the rear holding lugs1together slightly and swing the air filter box cover upward. Pull out the front holding lug and take off the air filter box cover.
– Take off the air filter.
Main work
– Position the clean air filter. – Position the rear holding lug. Lower the air filter box cover
and allow the front holding lug1to snap in.
Info
If the air filter is not correctly mounted, dust and dirt can enter the engine and cause damage.
64
Finishing work
– Mount the seat. ( p. 63)
Page 67
11 SERVICE WORK ON THE CHASSIS

11.32 Cleaning the air filter and air filter box

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance
with the applicable regulations.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Preparatory work
– Remove the seat. ( p. 63) – Remove the air filter. ( p. 64)
Main work
– Wash the air filter thoroughly in special cleaning liquid and
allow it to dry properly.
Air filter cleaning agent ( p. 129)
Info
Only press the air filter to dry it, never wring it out.
M01514-01
– Oil the dry air filter with a high quality filter oil.
Oil for foam air filter ( p. 129)
– Clean the air filter box. – Check the intake flange for damage and looseness.
Finishing work
– Install the air filter. ( p. 64) – Mount the seat. ( p. 63)

11.33 Removing the main silencer

Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.
Preparatory work
– Remove the seat. ( p. 63) – Remove the right side cover. ( p. 57)
65
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11 SERVICE WORK ON THE CHASSIS
Main work
–
Remove screw1.
–
Remove screw2.
– Pull off the main silencer from the manifold at rubber
sleeve3.
K00673-10

11.34 Installing the main silencer

Main work
–
Mount the main silencer with rubber sleeve1.
–
Mount the silent block with screw2. Guideline
Remaining screws, chassis
– Position the collar bushings.
–
K00673-11
Mount and tighten screw3. Guideline
Remaining screws, chassis
M6 10 Nm (7.4 lbf ft)
M6 10 Nm (7.4 lbf ft)
Finishing work
– Install the right side cover. ( p. 58) – Mount the seat. ( p. 63)

11.35 Changing the glass fiber yarn filling of the main silencer

Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.
Info
Over time, the fibers of the glass fiber yarn escape and the damper "burns" out. Not only is the noise level higher, the performance characteristic changes.
Preparatory work
– Remove the seat. ( p. 63) – Remove the right side cover. ( p. 57) – Remove the main silencer. ( p. 65)
66
Page 69
700514-01
11 SERVICE WORK ON THE CHASSIS
Main work
–
Remove screws with toothed washers1from the silencer
cap2.
–
Remove end cap and outer tube3.
–
Remove glass fiber yarn filling4from the inner tube. – Clean the parts that need to be reinstalled and check for
damage.
– Mount the new glass fiber yarn filling on the inner tube. – Slide the outer tube over the glass fiber yarn filling. – Insert the end cap into the outer tube. – Mount and tighten the screws with the toothed washers.
Guideline
Remaining screws, chassis
Finishing work
– Install the main silencer. ( p. 66) – Install the right side cover. ( p. 58) – Mount the seat. ( p. 63)
M6 10 Nm (7.4 lbf ft)

11.36 Removing the engine sprocket cover

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work (TC 50)
–
Remove screws1.
–
Remove screw2.
– Take off the engine sprocket cover.
A00080-10
(TC 50 Mini)
–
Remove screws1.
–
Remove screw2.
– Take off the engine sprocket cover.
A00100-10
67
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11 SERVICE WORK ON THE CHASSIS

11.37 Installing the engine sprocket cover

Main work (TC 50)
–
Position the engine sprocket cover. Mount screws1but do not tighten yet.
–
Mount and tighten screw2. Guideline
Screw, engine sprocket cover
A00080-10
–
Tighten screws1. Guideline
Screw, engine sprocket cover
(TC 50 Mini)
–
Position the engine sprocket cover. Mount screws1but do not tighten yet.
–
Mount and tighten screw2. Guideline
Screw, engine sprocket cover
M8 12 Nm (8.9 lbf ft)
M8 12 Nm (8.9 lbf ft)
M8 12 Nm (8.9 lbf ft)
A00100-10

11.38 Checking the chain for dirt

400678-01
–
Tighten screws1. Guideline
Screw, engine sprocket cover
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)
– Check the chain for coarse dirt accumulation.
» If the chain is very dirty:
– Clean the chain. ( p. 69)
M8 12 Nm (8.9 lbf ft)
68
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11 SERVICE WORK ON THE CHASSIS

11.39 Cleaning the chain

Warning
Danger of accidents Oil or grease on the tires reduces the road grip.
– Remove the lubricant from the tires using a suitable cleaning agent.
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary.
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance
with the applicable regulations.
Info
The service life of the chain depends largely on its maintenance.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work
– Rinse off loose dirt with a soft jet of water. – Clean chain and apply chain spray.
Offroad chain spray ( p. 129)
400725-01
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)

11.40 Checking the chain tension

Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or the engine will be damaged.
– Check the chain tension regularly. – Set the chain tension in accordance with the specification.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
69
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11 SERVICE WORK ON THE CHASSIS
Main work (TC 50)
– Press the chain upward at the end of the chain sliding
piece and determine chain tensionA.
K00674-10
Chain tension 5 … 8 mm (0.2 …
» If the chain tension does not meet the specification:
– Adjust the chain tension. ( p. 70)
(TC 50 Mini)
– Press the chain upward at the end of the chain sliding
piece and determine chain tensionA.
H01439-10
Chain tension 5 … 8 mm (0.2 …
Info
The upper part of the chain1must be taut. Chain wear is not always even, so you should repeat this measurement at different chain posi­tions.
0.31 in)
Info
The upper part of the chain1must be taut. Chain wear is not always even, so you should repeat this measurement at different chain posi­tions.
0.31 in)
» If the chain tension does not meet the specification:
– Adjust the chain tension. ( p. 70)
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)

11.41 Adjusting the chain tension

Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or the engine will be damaged.
– Check the chain tension regularly. – Set the chain tension in accordance with the specification.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43) – Check the chain tension. ( p. 69)
70
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11 SERVICE WORK ON THE CHASSIS
Main work
–
Loosen nut1.
–
Adjust the chain tension by turning adjusting nuts2left and
right.
Guideline
Chain tension 5 … 8 mm (0.2 … 0.31 in) Turn adjusting nuts2equally on the left and right. The
101947-10

11.42 Checking the chain, rear sprocket, engine sprocket and chain guide

rear wheel must be aligned with the front wheel.
–
Make sure that the chain adjuster support plates3are in
contact with adjusting nuts2.
–
Tighten nut1.
Guideline
Nut, rear wheel spin­dle
M12x1 40 Nm (29.5 lbf ft)
H01863-10
400227-01
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43) – Remove the engine sprocket cover. ( p. 67)
Main work
– Check the engine sprocket cover for wear.
» If the engine sprocket cover is worn through in the
marked areaA:
– Change the engine sprocket cover.
– Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket or engine sprocket is worn:
– Change the drivetrain kit.
Info
The engine sprocket, rear sprocket, and chain should always be replaced together. When fitting the chain joint, always make sure that the closed side of the joint faces forward (riding direction).
– Check the chain for wear.
» If the chain is worn:
– Change the drivetrain kit.
71
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11 SERVICE WORK ON THE CHASSIS
– Check the chain sliding guard for wear.
» If the ridge is worn down to the level of the main corpus:
– Change the chain sliding guard.
– Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
– Tighten the screw of the chain sliding guard.
Guideline
Screw, chain slid­ing piece
Info
When a new chain is mounted, the rear sprocket and engine sprocket should also be changed. New chains wear out faster on old, worn sprockets.
M6 3 Nm (2.2 lbf ft)
K00677-10
K00678-10
– Check the chain sliding piece for wear.
» If the lower edge of the chain pins is in line with or below
the chain sliding piece:
– Change the chain sliding piece.
– Check that the chain sliding piece is firmly seated.
» If the chain sliding piece is loose:
– Tighten the screw on the chain sliding piece.
Guideline
Screw, chain slid­ing piece
M8 15 Nm
(11.1 lbf ft)
72
Page 75
400985-01
H00095-01
11 SERVICE WORK ON THE CHASSIS
– Check the chain guide for wear.
Info
Wear can be seen on the front of the chain guide.
» If the light part of the chain guide is worn:
– Change the chain guide.
– Check that the chain guide is firmly seated.
» If the chain guide is loose:
– Tighten the screws on the chain guide.
Guideline
Remaining screws, chassis
M6 10 Nm (7.4 lbf ft)
Finishing work
– Install the engine sprocket cover. ( p. 68) – Remove the motorcycle from the lift stand. ( p. 43)

11.43 Adjusting the chain guide

Info
The size of the chain wheel varies with the number of teeth. The chain guide can be adjusted on small sprockets.
–
Loosen screw1.
– Position the chain guide. – Tighten the screw.
Guideline
Remaining screws, chassis
H00096-10
M6 10 Nm (7.4 lbf ft)
73
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11 SERVICE WORK ON THE CHASSIS

11.44 Checking the frame

– Check the frame for cracks and deformation.
» If the frame exhibits cracks or deformation due to a
mechanical impact: – Change the frame.
S00876-01

11.45 Checking the swingarm

– Check the swingarm for damage, cracking, and deformation.
» If the swingarm shows signs of damage, cracking, or
deformation: – Change the swingarm.
Info
Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by Husqvarna Motorcycles.
Info
Always change a damaged swingarm. Repair of the swingarm is not authorized by Husq-
S00877-01
varna Motorcycles.

11.46 Checking the routing of the throttle cable

Warning
Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.
The throttle slide will then no longer be closed and the speed can no longer be controlled.
– Make sure that the throttle cable routing and the play in throttle cable complies with the specifica-
tion.
Preparatory work
– Remove the seat. ( p. 63) – Remove the left side cover. ( p. 59) – Remove the right side cover. ( p. 57) – Turn the knurled screw on the fuel tap all the way clockwise. – Remove the fuel tank. ( p. 53)
74
Page 77
V00551-01

11.47 Checking the rubber grip

11 SERVICE WORK ON THE CHASSIS
Main work
– Check the throttle cable routing.
The throttle cable must be routed to the carburetor behind the handlebars and underneath the fuel tank bracket. The throttle cable must be fixed on the fuel tank bracket with a rubber band.
» If the throttle cable is not routed as specified:
– Correct the throttle cable routing.
Finishing work
– Install the fuel tank. ( p. 54) – Install the left side cover. ( p. 60) – Install the right side cover. ( p. 58) – Mount the seat. ( p. 63)
– Check the rubber grips on the handlebar for damage, wear,
and looseness.
» If a rubber grip is damaged, worn, or loose:
– Change the rubber grip.
– Additionally secure the rubber grip. ( p. 75)
401197-01

11.48 Additionally securing the rubber grip

Preparatory work
– Check the rubber grip. ( p. 75)
Main work
– Secure the rubber grip at two locations with the retaining
wire.
Securing wire (54812016000) Wire twister forceps (U6907854)
The twisted wire ends face away from the palms and are bent in toward the rubber grip.
401198-01
Grip adhesive (00062030051) ( p. 129)
75
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12 BRAKE SYSTEM

12.1 Checking play of handbrake lever

Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.
– Set the free travel on the hand brake lever in accordance with the specification.

12.2 Adjusting the play of the hand brake lever

K00679-10
–
Push the handbrake lever forwards and check playA.
Play of hand brake lever 3 … 5 mm (0.12 … 0.2 in)
» If the play does not meet specifications:
– Adjust the play of the hand brake lever. ( p. 76)
– Check the play of the handbrake lever. ( p. 76) – Adjust the play of the hand brake lever using adjusting
screw1. Guideline
Play of hand brake lever 3 … 5 mm (0.12 … 0.2 in)
K00680-10

12.3 Adjusting the basic position of the hand brake lever

–
Remove screw1. Take off cover2.
K00680-11
– Check the play of the handbrake lever. ( p. 76) – Adjust the basic position of the hand brake lever with adjust-
ing screw3to the rider's hand size.
76
K00681-10
Page 79
K00680-11
A
A
12 BRAKE SYSTEM
Info
Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the han­dlebar. Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar. The range of adjustment is limited.
–
Position cover2. Mount and tighten screw1.

12.4 Checking the brake discs

Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
– Make sure that worn-out brake discs are replaced immediately. (Your authorized Husqvarna Motor-
cycles workshop will be glad to help.)
– Check the front and rear brake disc thickness at multiple
points for the dimensionA.
Info
Wear reduces the thickness of the brake disc around the contact surface of the brake linings.
Brake discs - wear limits
400257-10
» If the brake disc thickness is less than the specified value:
– Check the front and rear brake discs for damage, cracking,
and deformation.
» If the brake disc exhibits damage, cracking, or deforma-
front 2.2 mm (0.087 in) rear 2.2 mm (0.087 in)
– Change the front brake disc. – Change the rear brake disc.
tion:
– Change the front brake disc. – Change the rear brake disc.
77
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12 BRAKE SYSTEM

12.5 Checking the front brake fluid level

Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
Husqvarna Motorcycles workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. – Consult a doctor immediately if brake fluid has been swallowed. – Rinse the affected area with plenty of water in the event of contact with the skin. – Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance
with the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.
– Move the brake fluid reservoir mounted on the handlebar to a
horizontal position.
–
Remove screws1.
–
Remove cover2with membrane3.
– Check the brake fluid level.
Brake fluid level under top level of container
5 mm (0.2 in)
78
V00549-10
» If the brake fluid level does not meet specifications:
– Add front brake fluid. ( p. 79)
– Position the cover with the membrane. Mount and tighten the
screws.
Page 81
12 BRAKE SYSTEM
Info
Clean up overflowed or spilled brake fluid immediately with water.

12.6 Adding front brake fluid

Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
Husqvarna Motorcycles workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. – Consult a doctor immediately if brake fluid has been swallowed. – Rinse the affected area with plenty of water in the event of contact with the skin. – Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance
with the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.
Preparatory work
– Check the front brake linings. ( p. 80)
79
Page 82
12 BRAKE SYSTEM
V00549-10
Main work
– Move the brake fluid reservoir mounted on the handlebar to a
horizontal position.
–
Remove screws1.
–
Remove cover2with membrane3.
– Correct the brake fluid level.
Guideline
Brake fluid level under top level of container
Brake fluid DOT 4 ( p. 127)
– Position the cover with the membrane. Mount and tighten the
screws.
5 mm (0.2 in)
Info
Clean up overflowed or spilled brake fluid immediately with water.

12.7 Checking the front brake linings

Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy-
cles workshop will be glad to help.)
–
Check the brake linings for minimum thicknessA.
≥ 1 mm (≥ 0.04 in)
A00088-10
Minimum thickness
» If the minimum thickness is less than specified:
– Change the front brake linings. ( p. 80)
– Check the brake linings for damage and cracking.
» If damage or wear is encountered:
– Change the front brake linings. ( p. 80)
A

12.8 Changing the front brake linings

Warning
Danger of accidents Incorrect maintenance will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized Husqvarna
Motorcycles workshop will be glad to help.)
80
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12 BRAKE SYSTEM
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. – Consult a doctor immediately if brake fluid has been swallowed. – Rinse the affected area with plenty of water in the event of contact with the skin. – Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings. If brake linings are used that differ from the original equipment, compliance with the original homolo­gation is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the warranty shall be void.
– Only use brake linings approved and recommended by Husqvarna motorcycles.
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance
with the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work
– Move the brake fluid reservoir mounted on the handlebar to a
horizontal position.
–
Remove screws1.
–
Remove cover2with membrane3.
V00549-10
81
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12 BRAKE SYSTEM
A00089-10
–
Remove lock washer4.
–
Loosen screw5.
–
Remove screws6.
– Carefully pull the brake caliper backward from the brake disc.
–
Remove screw5.
Warning
Danger of accidents Oil or grease on the brake
discs reduces the braking effect. – Always keep the brake discs free of oil and
grease.
– Clean the brake discs with brake cleaner when
necessary.
– Check the brake discs. ( p. 77)
– Remove the brake linings. – Clean the brake caliper and brake caliper support. – Press the brake piston back into the basic position and
ensure that brake fluid does not flow out of the brake fluid reservoir, sucking it away if necessary.
V00553-10
V00553-11
Warning
Danger of accidents Brake linings which have not
been approved alter the braking efficiency. Not all brake linings are tested and approved for
Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings. If brake linings are used that differ from the original equipment, compliance with the original homologa­tion is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the warranty shall be void.
– Only use brake linings approved and
recommended by Husqvarna motorcycles.
– Position the new brake linings.
Info
Always change the brake linings in pairs. Ensure that the brake linings are correctly positioned in the holding spring.
82
Page 85
A00089-10
12 BRAKE SYSTEM
– Position the brake caliper.
–
Mount and tighten screw5.
Guideline
Screw, brake linings M5 8 Nm (5.9 lbf ft)
–
Mount lock washer4.
–
Mount and tighten screws6.
Guideline
Screw, front brake caliper
– Operate the hand brake lever repeatedly until the brake lin-
ings lie on the brake disc and there is a pressure point. – Correct the brake fluid level.
Guideline
Brake fluid level under top level of container
Brake fluid DOT 4 ( p. 127)
– Position the cover with the membrane. Mount and tighten the
screws.
M8x60 20 Nm (14.8 lbf ft)
Loctite®243™
5 mm (0.2 in)
Info
Clean up overflowed or spilled brake fluid immediately with water.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)

12.9 Checking the free travel of the foot brake lever

Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
– Set the free travel on the foot brake lever in accordance with the specification.
–
Disconnect spring1. – Move the foot brake lever back and forth between the end
stop and the foot brake cylinder piston bracket and check
free travelA.
Guideline
Free travel of foot brake lever
3 … 5 mm (0.12 … 0.2 in)
V00547-10
» If the free travel does not meet specifications:
– Adjust the free travel of the foot brake lever.
( p. 84)
–
Attach spring1.
83
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12 BRAKE SYSTEM

12.10 Adjusting the free travel of the foot brake lever

Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
– Set the free travel on the foot brake lever in accordance with the specification.
V00548-10
– Detach foot brake lever spring.
–
Loosen nut1.
–
Turn push rod2accordingly until you have free travelA. Guideline
Free travel of foot brake lever
–
Hold push rod2and tighten nut1.
– Attach foot brake lever spring. – Check whether the basic position of the foot brake lever is
suitable for the rider. » When the basic position of the foot brake lever needs to
be adjusted: – Adjust the basic position of the foot brake lever.
( p. 84)
3 … 5 mm (0.12 … 0.2 in)

12.11 Adjusting the basic position of the foot brake lever

Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
– Set the free travel on the foot brake lever in accordance with the specification.
– Detach the spring.
–
Loosen nut1.
–
Turn back push rod2until free travel is at a maximum.
– For an individual adjustment of the basic position of the foot
brake lever, loosen the screw3and turn the eccentric brake lever stop4accordingly.
–
Tighten screw3.
V00548-11
Guideline
Remaining screws, chassis
–
Turn push rod2accordingly until you have free travelA. Guideline
Free travel of foot brake lever
M6 10 Nm (7.4 lbf ft)
3 … 5 mm (0.12 … 0.2 in)
84
–
Hold push rod2and tighten nut1.
– Attach spring.
Page 87
12 BRAKE SYSTEM
– Check whether the basic position of the foot brake lever is
suitable for the rider.

12.12 Checking the rear brake fluid level

Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
– Check the brake system and ensure that nobody drives the vehicle before the problem is elimi-
nated. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
– Stand the vehicle upright.
–
Check the brake fluid level in level viewer1.
»
If an air bubble is visible in viewer1: – Add rear brake fluid. ( p. 85)
H01654-11

12.13 Adding rear brake fluid

Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
– Check the brake system and ensure that nobody drives the vehicle before the problem is elimi-
nated. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. – Consult a doctor immediately if brake fluid has been swallowed. – Rinse the affected area with plenty of water in the event of contact with the skin. – Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
85
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12 BRAKE SYSTEM
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance
with the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43) – Check the rear brake linings. ( p. 87)
Main work
–
Remove screws1.
–
Take off cover2with washer3and membrane4.
H01448-10
H01654-10
–
Add brake fluid up to levelA. Guideline
LevelA(brake fluid level below reservoir rim)
Brake fluid DOT 4 ( p. 127)
– Position the cover with the washer and membrane. – Mount and tighten the screws.
10 mm (0.39 in)
Info
Clean up overflowed or spilled brake fluid immediately with water.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)
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12 BRAKE SYSTEM

12.14 Checking the rear brake linings

Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy-
cles workshop will be glad to help.)
–
Check the brake linings for minimum thicknessA.
≥ 1 mm (≥ 0.04 in)
700491-01
Minimum thickness
» If the minimum thickness is less than specified:
– Change the rear brake linings. ( p. 87)
– Check the brake linings for damage and cracking.
» If damage or wear is encountered:
– Change the rear brake linings. ( p. 87)
A

12.15 Changing the rear brake linings

Warning
Danger of accidents Incorrect maintenance will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized Husqvarna
Motorcycles workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. – Consult a doctor immediately if brake fluid has been swallowed. – Rinse the affected area with plenty of water in the event of contact with the skin. – Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary.
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12 BRAKE SYSTEM
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings. If brake linings are used that differ from the original equipment, compliance with the original homolo­gation is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the warranty shall be void.
– Only use brake linings approved and recommended by Husqvarna motorcycles.
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance
with the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.
S00868-10
H01449-10
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work
–
Remove lock washer1.
–
Remove screw2.
–
Remove screws3.
– Take off the brake caliper and pull the brake line out of
holder4.
Info
Do not kink or damage the brake line.
– Remove the brake linings. – Clean the brake caliper and brake caliper support. – Allow the brake caliper and brake line to hang loosely to the
side.
88
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H01448-11
H01450-10
12 BRAKE SYSTEM
–
Remove screws5.
–
Take off cover6with washer7and membrane8. – Press the brake piston back into the basic position and
ensure that brake fluid does not flow out of the brake fluid
reservoir, sucking it away if necessary.
– Position the new brake linings.
Info
Always change the brake linings in pairs. Ensure that the brake linings are correctly positioned in the holding spring.
– Position the brake caliper on the brake disc.
The brake linings are correctly positioned.
–
Attach the brake line to holder4.
S00880-10
H01654-10
–
Mount and tighten screws3.
Guideline
Rear brake caliper screw
–
Mount screw2.
M6 10 Nm (7.4 lbf ft)
Loctite®243™
Guideline
Screw, brake linings M5 8 Nm (5.9 lbf ft)
–
Mount lock washer1.
– Check the brake discs. ( p. 77)
– Operate the foot brake lever repeatedly until the brake lin-
ings are in contact with the brake disc and there is a pressure
point.
–
Add brake fluid up to levelA.
Guideline
LevelA(brake fluid level
10 mm (0.39 in)
below reservoir rim)
Brake fluid DOT 4 ( p. 127)
– Position the cover with the washer and membrane. – Mount and tighten the screws.
Info
Clean up overflowed or spilled brake fluid immediately with water.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)
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13 WHEELS, TIRES

13.1 Removing the front wheel

A00086-10
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work
–
Remove screw1.
–
Loosen screws2.
Warning
Danger of accidents Damaged brake discs reduce
the braking effect. – Always lay the wheel down in such a way that the
brake disc is not damaged.
– Holding the front wheel, withdraw the wheel spindle. Take the
A00087-10
front wheel out of the fork.
Info
Do not pull the hand brake lever when the front wheel is removed.
–
Remove spacers3.
H00934-10

13.2 Installing the front wheel

Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary.
90
Page 93
H01198-10
A00087-11
13 WHEELS, TIRES
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change front wheel bearing.
–
Clean and grease the contact surfacesAof the spacers.
Long-life grease ( p. 129)
– Insert the spacers.
– Clean and grease the wheel spindle.
Long-life grease ( p. 129)
– Position the front wheel.
The brake linings are correctly positioned.
– Insert the wheel spindle.
V00545-10

13.3 Removing the rear wheel

–
Mount and tighten screw1.
Guideline
Screw, front wheel spindle
– Operate the hand brake lever several times until the brake
linings are seated correctly against the brake disc.
– Remove the motorcycle from the lift stand. ( p. 43) – Operate the front brake and compress the fork a few times
firmly.
The fork legs straighten.
–
Tighten screws2.
Guideline
Screw, fork stub M6 10 Nm (7.4 lbf ft)
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 43)
Main work
–
Remove nut1with washer2.
M10 40 Nm (29.5 lbf ft)
Loctite®243™
V00281-10
Info
Cover the components to protect them against dam­age.
–
Pull out wheel spindle3with washer4. – Remove the chain from the rear sprocket.
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13 WHEELS, TIRES
Warning
Danger of accidents Damaged brake discs reduce
the braking effect. – Always lay the wheel down in such a way that the
brake disc is not damaged.
– Take the rear wheel out of the swingarm.
Info
Do not operate the foot brake lever when the rear wheel is removed.
–
Remove spacers5.
H00936-12

13.4 Installing the rear wheel

Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary.
Main work
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change the rear wheel bearing.
–
Clean and grease the contact surfacesAof the spacers.
Long-life grease ( p. 129)
– Insert the spacers.
H01199-10
Info
Insert the wide spacer on the left in the direction of travel.
92
Page 95
V00281-12
13 WHEELS, TIRES
–
Clean and grease wheel spindle1.
Long-life grease ( p. 129)
– Position rear wheel and mount the chain.
The brake linings are correctly positioned.
–
Insert wheel spindle1with washer2.
–
Position washer3. Mount nut4, but do not tighten it yet. – Make sure that the chain adjuster support plates are in con-
tact with the adjusting nuts.
– Check the chain tension. ( p. 69)
–
Tighten nut4.
Guideline
Nut, rear wheel spin­dle
– Operate the foot brake lever repeatedly until the brake lin-
ings are in contact with the brake disc and there is a pressure
point.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 43)
M12x1 40 Nm (29.5 lbf ft)

13.5 Checking the tire condition

Info
Only mount tires approved and/or recommended by Husqvarna Motorcycles. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcy­cle. The tires mounted on the front and rear wheels must have a similar profile. Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
– Check the front and rear tires for cuts, run-in objects, and
other damage.
» If the tires have cuts, run-in objects, or other damage:
– Change the tires.
– Check the tread depth.
Info
Adhere to the legally required minimum tread depth.
400602-10
Minimum tread depth ≥ 2 mm (≥ 0.08 in)
» If the tread depth is less than the minimum tread depth:
– Change the tires.
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13 WHEELS, TIRES

13.6 Checking tire air pressure

Info
Low tire air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
H01144-10
– Check the tire age.
Info
The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. Husqvarna Motorcycles recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear.
» If the tires are more than 5 years old:
– Change the tires.
– Remove the protection cap. – Check the tire air pressure when the tires are cold.
Tire air pressure off road
front 1.0 bar (15 psi) rear 1.0 bar (15 psi)
» If the tire pressure does not meet specifications:
– Correct the tire pressure.
400695-01
– Mount the protection cap.

13.7 Checking spoke tension

Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in
secondary damage. The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes
is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a result.
– Check spoke tension regularly, and in particular on a new vehicle. (Your authorized Husqvarna
Motorcycles workshop will be glad to help.)
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13 WHEELS, TIRES
– Strike each spoke briefly using a screwdriver blade.
Info
The frequency of the sound depends on the spoke length and spoke diameter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indica­tion of different spoke tensions.
400694-01
You should hear a high note.
» If the spoke tension differs:
– Correct the spoke tension.
– Check the spoke torque.
Guideline
Spoke nipple M3.5 3 Nm (2.2 lbf ft)
Torque wrench with various accessories in set (58429094000)
95
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14 COOLING SYSTEM

14.1 Cooling system

14.2 Checking the antifreeze and coolant level

Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or
the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator
hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
V00542-10
The water pump1in the engine forces the coolant to flow. The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap2. This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. – Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes. – Change clothing if coolant spills onto your clothing.
– Stand the motorcycle upright on a horizontal surface.
–
Take off radiator cap1.
– Check the antifreeze in the coolant.
−25 … −45 °C (−13 … −49 °F)
» If the antifreeze in the coolant does not match the speci-
fied value: – Correct the antifreeze in the coolant.
K00666-10
96
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14 COOLING SYSTEM
– Check the coolant level in the radiator.
Coolant levelAabove the radiator fins
» If the coolant level does not match the specified value:
– Correct the coolant level.
Coolant ( p. 127)
– Mount the radiator cap.
400243-10
10 mm (0.39 in)

14.3 Checking the coolant level

Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or
the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator
hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. – Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes. – Change clothing if coolant spills onto your clothing.
400243-10
– Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator.
Coolant levelAabove the radiator fins
» If the coolant level does not match the specified value:
– Correct the coolant level.
Coolant ( p. 127)
– Mount the radiator cap.
10 mm (0.39 in)
97
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14 COOLING SYSTEM

14.4 Draining the coolant

Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or
the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator
hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. – Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes. – Change clothing if coolant spills onto your clothing.
Info
Carry out this work with a cold engine.
– Position the motorcycle upright. – Place a suitable container under the water pump cover.
–
Remove screw1. Remove the radiator cap.
– Completely drain the coolant.
–
Mount and tighten screw1with a new seal ring. Guideline
K00660-10
Drain plug, water pump cover
M6 6 Nm (4.4 lbf ft)

14.5 Refilling with coolant

Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. – Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes. – Change clothing if coolant spills onto your clothing.
98
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