Husqvarna TC 250 (2010), TC 250 (2009), TE 250 (2010), TXC 250 (2010) Workshop Manual

Workshop Manual

TC 250 / 2009
TC 250 / 2010

TE 250 / 2010

TXC 250 / 2010 (USA only)

Part. N. 8000 H1489 (10-2009)

HUSQVARNA MOTORCYCLES S.R.L. - Varese disclaims all liabilities
for any errors or omissions in this manual and reserves the right to make
changes to reect on-going product development. Illustrations in the ma­nual may differ from actual components. No reproduction in full or in part
without written authorisation.
1st edition (10-2009)

a.1Part. N. 8000 H1489 (10-2009)

FOREWORD, TABLE OF CONTENTS

1st edition (10-2009)
Printed in Italy
Print no. 8000 H1489

MODELS COVERED (from serial number onwards)

Copyright by

HUSQVARNA MOTORCYCLES S.R.L.
BMW Group

Technical Service
Via Nino Bixio, 8
21024
(Varese) - Italy
tel. ++39 0332 75.61.11
tel. ++39 0332 756 558
www.husqvarna-motorcycles.com

Workshop Manual

TC 250: ZKHA300AAAV050001

TC 250 (USA): ZKHTC250#AV000001

TE 250: ZKHA300AAAV050001

TE 250 (USA): ZKHTE250#AV000001

TXC 250: ZKHTX250#AV000001

1. Chassis serial number

TC 250 / 2009
TC 250 / 2010

250:2010;

TXC 250 / 2010 (USA only)

a.2 Part. N. 8000 H1489 (10-2009)

FOREWORD, TABLE OF CONTENTS

Foreword

This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance
and repair of the models covered in this manual. The technical information provided in this manual is a critical comple­ment to operator training and operators should become thoroughly familiar with it.
For ease of understanding, diagrams and photographs are provided next to the text.

Notes with special signicance are identied as follows throughout the manual:

Accident-prevention rules for operator and persons working nearby.

Damage to vehicle and/or its components may result from incompliance with relevant instructions.

Additional information concerning the operation covered in the text.

Useful tips

To prevent problems and ensure effective service work, observe the following HUSQVARNA recommendations:
– before repair, evaluate the customer's description of the problem and ask the appropriate questions to clearly identify

problem symptoms;

– diagnose the problem and identify the causes clearly. This manual provides basic background information that must

be supplemented with the operator's expertise and specic training available through HUSQVARNA held at regular

periods;
– plan ahead before starting work: gather any spare parts and tools to avoid unnecessary delays;
– avoid unnecessary disassembly work to get to the part that needs repairing.
Always read the relevant instructions and follow the disassembly sequence outlined in this manual.

Recommended shop practices

1 Always replace gaskets, sealing rings and split pins with new ones.
2 When loosening or tightening nuts or bolts, always begin with the bigger ones or from the centre. Tighten to the speci-

ed torque and follow a cross pattern.

3 Always mark any parts or positions that might be confused upon assembly.
4 Use genuine HUSQVARNA parts and the recommended lubricant brands.

5 Use special tools where specied.

6 Technical Bulletins might contain more up-to-date setting data and procedures than this manual. Be sure to read

them.

a.3Part. N. 8000 H1489 (10-2009)

FOREWORD, TABLE OF CONTENTS

Table of Contents

Title Section

Foreword, Table of Contents ...............................................................................a

Important Notices ................................................................................................b

General Information .............................................................................................A

Maintenance ........................................................................................................B

Troubleshooting .................................................................................................. C

Settings and Adjustments ................................................................................... D

General Procedures ............................................................................................E

Engine Disassembly

............................................................................................F

Engine Overhaul

.................................................................................................G

Engine Reassembly............................................................................................ H

Front Suspension .................................................................................................I

Rear Suspension ................................................................................................. J

Brakes

.................................................................................................................L

Electrical System

................................................................................................M

Engine Cooling ................................................................................................... N

“KIT” Installation Instructions .............................................................................. O

Hydraulically Controlled Clutch............................................................................P

Optional Components

.........................................................................................Q

Fuel Injection System

..........................................................................................S

Special Tools

......................................................................................................W

Tightening Torque Figures

...................................................................................X

Chassis and Wheels

............................................................................................Y

NOTES

Unless otherwise specied, data and specications apply to all models.

b.1

b

Part. N. 8000 H1489 (10-2009)

IMPORTANT NOTICES

Section

b.2 Part. N. 8000 H1489 (10-2009)

IMPORTANT NOTICES

1) TC and TXC models are RACING motorcycles and are warranted to be free
from operating defects; a scheduled maintenance chart for racing use is provided
in Section B.

2) The TE model is for ROAD USE (DERATED); it is warranted to free from
defects and covered by legal warranty, provided that the STANDARD CON­FIGURATION IS MAINTAINED and the maintenance chart provided in Section

B is observed. For TE models modied to RACING SPECIFICATIONS (FULL

POWER RATING), observe the scheduled maintenance chart for racing use
provided in Section B.

* This motorcycle has not been designed to travel over long distances with the

engine at top rpm, as in long-distance road or highway travel. Riding over long
distances at full throttle may result in severe engine damage.

* The geometry and setup of this motorcycle have been designed for racing

and to provide top performance when riding solo. We advise against riding
two-up, whether off-road or on the track.

* ALWAYS remember that these motorcycles are specically designed for

racing, i.e. for usage conditions signicantly different from those experienced

in regular road use.

IMPORTANT

VEHICLE CONFIGURATION as outlined below is a prerequisite for the war­ranty to remain valid:

A) STANDARD MOTORCYCLE, FOR ROAD USE: DERATED;
B) RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING.

* In order to maintain the vehicle’s “Guarantee of Functionality”, the client must

follow the maintenance programme indicated in Section B by having the required

maintenance inspections carried out at authorised HUSQVARNA dealers. The
cost for changing parts and for the labour necessary in order to comply with

the maintenance plan is charged to the Client. The warranty becomes NULL

AND VOID if the motorcycle is rented.
Notes

Left and right side is determined when seated on motorcycle.

Z: number of teeth
A: Austria

AUS: Australia
B: Belgium
BR: Brazil
CDN: Canada
CH: Switzerland
D: Germany
E: Spain
F: France
FIN: Finland
GB: Great Britain
I: Italy
J: Japan
USA: United States of America

Unless otherwise specied, data and instructions apply to all market variants.

A.1

A

Part. N. 8000 H1489 (10-2009)

GENERAL INFORMATION

Section

A.2 Part. N. 8000 H1489 (10-2009)

GENERAL INFORMATION

Engine ..........................................................................................................A.3

Timing system ..............................................................................................A.3

Fuel system ..................................................................................................A.3

Lubrication

....................................................................................................A.3

Cooling

.........................................................................................................A.3

Ignition system..............................................................................................A.3

Starter ..........................................................................................................A.3

Drive and Transmission ................................................................................A.3

Chassis

.........................................................................................................A.4

Suspension

...................................................................................................A.4

Brakes ..........................................................................................................A.4

Wheels..........................................................................................................A.4

Tyres .............................................................................................................A.5

Electrical components location

.....................................................................A.5

Overall dimensions - Weight

.........................................................................A.6

Capacities .....................................................................................................A.7

A.3Part. N. 8000 H1489 (10-2009)

GENERAL INFORMATION

Engine

Single cylinder, 4 stroke

Bore .........................................................................................................79 mm

Stroke ...................................................................................................50.9 mm

Displacement ...................................................................................249.5 cu.in.

Compression ratio ...................................................................................13.6:1

Timing system

Type .............................................................4 radially arranged titanium valves

.operated by two chain and gear driven overhead camshafts via valve buckets
Valve clearance ( cold with engine)

INTAKE .................................................................................................0.15 mm

EXHAUST .............................................................................................0.20 mm

Fuel system

Type (TC) ..............................................................“Keihin” FCR-MX 39 carburettor with accelerator pump and TPS

(Throttle Position Sensor) (Throttle valve position sensor)

Type (TE - TXC) ...................................................Electronic injection feed, MIKUNI D42 throttle body

Air cleaning: dry air lter

Lubrication

Type

......................................................................Wet sump with positive displacement pump and cartridge and mesh lters

Cooling

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

Ignition system

Electronic capacitive (TC) or inductive (TE - TXC) discharge ignition with adjustable advance (digital control)

Spark plug type....................................................."NGK" CR9EB

Spark plug electrode gap......................................0.7 ÷ 0.8 mm

Starter (TC). .........................................................Kick start (with automatic decompressor)

Starter (TE - TXC). ...............................................Electric starter and kick start (with automatic decompressor)

Drive and transmission

Clutch: oil bath multiple disc clutch, hydraulic control
Transmission: 5 (TC) or 6 (TE - TXC) gear ratios with constant-mesh gears
Motion is transmitted from engine to gearbox primary shaft through spur gears

Primary drive
Drive pinion gear

.........................................................................................z 17

Clutch ring gear

........................................................................................... z 54

Transmission ratio .....................................................................................3.176

Gear ratios (TC)

1st gear ........................................................................................2.142 (z 30/14)

2nd gear .......................................................................................1.750 (z 28/16)

3rd gear .......................................................................................1.450 (z 29/20)

4th gear ........................................................................................1.227 (z 27/22)

5th gear ........................................................................................1.041 (z 25/24)

Gear ratios (TE - TXC)

1st gear ........................................................................................2.142 (z 30/14)

2nd gear .......................................................................................1.750 (z 28/16)

3rd gear .......................................................................................1.450 (z 29/20)

4th gear ........................................................................................1.227 (z 27/22)

5th gear ........................................................................................1.041 (z 25/24)

6th gear ........................................................................................0.884 (z 22/27)

A.4 Part. N. 8000 H1489 (10-2009)

GENERAL INFORMATION

Secondary drive

Motion is transmitted from gearbox to rear wheel by 5/8" x 1/4" nal drive chain ("D.I.D." 520 DS or "REGINA" 135 RX3)

Transmission sprocket (TC) ........................................................................z 13

Transmission sprocket (TE - TXC) .............................................................. z 13

Rear wheel sprocket (TC)............................................................................ z 50

Rear wheel sprocket (TE - TXC) .................................................................z 40

Transmission ratio (TC)

.............................................................................3.846

Transmission ratio (TE - TXC) ...................................................................3.076

Total transmission ratios (TC)

1st gear....................................................................................................26.180

2nd gear ..................................................................................................21.380

3rd gear ...................................................................................................17.715

4th gear ...................................................................................................14.994

5th gear ...................................................................................................12.726

Total transmission ratios (TE - TXC )

1st gear....................................................................................................20.944

2nd gear ..................................................................................................17.104

3rd gear

...................................................................................................14.172

4th gear

...................................................................................................11.995

5th gear

...................................................................................................10.181

6th gear .....................................................................................................7.964

Chassis

Single frame, in steel tubes with circular, rectangular and ellipsoidal section; light alloy rear chassis

Trail (mm) ......................................................................................................111

Suspension

Front TC/2009:
"MARZOCCHI” upside-down telescopic hydraulic front fork with advanced axle; tube diameter 50 mm; rebound and compression
damping adjustment.

travel (mm) ......................300

Front TC-TE-TXC/2010:
"KAYABA” upside-down telescopic hydraulic front fork with advanced axle; tube diameter 48 mm;
rebound and compression damping adjustment.

Travel (mm) .................................................................................................300

Rear
Light alloy rising-rate swinging arm and “SACHS” hydraulic monoshock with coil spring.
(DUAL) adjustment for spring preload and compression damping and rebound damping adjustment.

Wheel travel (mm) .......................................................................................296

Brakes

Front

260 mm xed drilled wave disc with oating calliper

Brake pad surface area .....................................................................33.4 sq cm

Separate hydraulic circuit and master cylinder with control on right handlebar.
Rear

240 mm Ø oating wave disc with oating calliper

Brake pad surface area ....................................................................23.5 sq cm

Separate hydraulic circuit, pedal and master cylinder on right side of vehicle.

Wheels

Rims

Front ............................................... "TAKASAGO“ Excel light alloy rim: 1.6x21”

Rear (TC) ...................................... "TAKASAGO“ Excel light alloy rim: 1.85x19”

Rear (TE - TXC) ..........................."TAKASAGO“ Excel light alloy rim: 2.15x18”

A.5Part. N. 8000 H1489 (10-2009)

GENERAL INFORMATION

Tyres

Front (TC) ........................"Pirelli" 51R-MT 32A or "Dunlop" D756; 80/100 x 21”

Front (TE - TXC) ............................................. "Michelin" ENDURO COMP. 3 or

"Pirelli" MT 83 Scorpion; 90/90 x 21”

Front (TE USA) ................................................."Metzeler KAROO"; 90/90 x 21”

Rear (TC)

.................................................................."Pirelli" NHS (57) MT 32 or

"Dunlop" D756; 100/90x19”

Rear (TE - TXC) ............................................."Michelin" ENDURO COMP. 3 or

"Pirelli" MT 83 Scorpion 120/90x18”;

Rear (TE USA) ..............................................."Metzeler KAROO"; 140/80 x 18”

Cold tyre pressure - Front (TC)

...............................................0.9-1.0 Kg/sq cm

Cold tyre pressure - Front (TE - TXC) (*) ................................0.9-1.0 Kg/sq cm

Cold tyre pressure - Front (TE) (%)

............................................... 1.1 Kg/sq cm

Cold tyre pressure - Rear (TC)

................................................0.8-0.9 Kg/sq cm

Cold tyre pressure - Rear (TE - TXC) (*) .................................0.8-0.9 Kg/sq cm

Cold tyre pressure - Rear (TE) (%)................................................1.0 Kg/sq cm

(*) Racing use - (%) Road use

Electrical components location (TC)

The ignition system includes the following elements:

- Generator on the inner side of L.H. crankcase half cover;

- Electronic ignition coil under the fuel tank;

- Electronic control unit under the fuel tank;

- Spark plug on cylinder head;

- Throttle position sensor on carburettor.

Electrical components location (TXC)

The ignition system includes the following elements:

- Generator on the inner side of L.H. crankcase half cover;

- Electronic ignition coil under the fuel tank;

- Electronic control unit under the fuel tank;

- Voltage regulator under the fuel tank;

- Spark plug on cylinder head;

- 12V-450W starter motor behind the engine cylinder;

- Solenoid starter on the left of rear chassis;

- M.A.Q.S. sensor (pressure, throttle position, air temperature) on throttle body.
The electrical system includes the following elements:

- 12V-6Ah battery under the saddle;

- Electric fan relay on right side of chassis:

- Electric fan;

- Two 15A and 20A fuses on right side of rear chassis;

- Coolant temperature sensor;

- Lambda sensor;

- Fuel pump inside the fuel tank.

- Fuel and reserve indicator.

Electrical components location (TE)

The ignition system includes the following elements:

- Generator on the inner side of L.H. crankcase half cover;

- Electronic ignition coil under the fuel tank;

- Electronic control unit under the fuel tank;

- Voltage regulator under the fuel tank;

- Spark plug on cylinder head;

- 12V-450W starter motor behind the engine cylinder;

- Solenoid starter on the left of rear chassis;

- M.A.Q.S. sensor (pressure, throttle position, air temperature) on throttle body.

A.6 Part. N. 8000 H1489 (10-2009)

GENERAL INFORMATION

The electrical system includes the following elements:

- 12V-6Ah battery under the saddle;

- Turning indicator asher on left side of rear chassis;

- Relay for electric fan, fuel injection system and lights on right side of chassis:

- Electric fan;

- Two 15A fuses and one 20A fuse on right side of rear chassis;

- Coolant temperature sensor;

- Lambda sensor;

- Headlamp with 12V-35W twin halogen bulb and 12V-3W parking light bulb;

- LED tail light with stop light bulb;

- 12V-10W turning indicator bulbs;

- Fuel pump inside the fuel tank.

- Odometer.

Overall dimensions - Weight

Kerb weight, without fuel (TC): ..................................................95 Kg (209.4 lb)

Kerb weight, without fuel (TE): .............................................102.5 Kg (225.9 lb)

Kerb weight, without fuel (TXC): .............................................99.5 Kg (219.3 lb)

*: max. width

A.7Part. N. 8000 H1489 (10-2009)

GENERAL INFORMATION

Capacities Type Quantity

Fuel tank (TC) 98 octane unleaded fuel 7 litres
Fuel tank (TE - TXC) 98 octane unleaded fuel 6.5 litres
Gearbox/engine oil CASTROL POWER 1 RACING (SAE 10W50) 0.9 litres

(oil change and oil lter

replacement)

0.7 litres
(oil change)

Front fork oil (TC 2009) AGIP FORK 7,5 (SAE 7,5; SAE 5 for extremely cold weather)
TC: 300 cu cm

Front fork oil (MY 2010) KAYABA KHL15-11 (SAE 7,5; SAE 5 for extremely cold weather)
TC: 325 cu cm
TXC: 325 cu cm
TE: 100 mm

Rear shock absorber oil CASTROL SYNTHETIC FORK OIL (5W)
Coolant CASTROL MOTORCYCLE COOLANT 0.9 litres

Front brake uid CASTROL RESPONSE SUPER (DOT 4)
Rear brake uid CASTROL RESPONSE SUPER (DOT 4)
Clutch uid CASTROL RESPONSE SUPER (DOT 4)
Drive chain lubrication CASTROL CHAIN LUBE RACING

Grease lubrication CASTROL LM GREASE 2
Electric contact protection CASTROL METAL PARTS CLEANER

Fillers for radiator AREXONS LIQUID FILLER
Air lter oil AGIP FORMULA FILTER "Foam air lter protection oil"
Air lter detergent AGIP "Filter clean foam air detergent uid"

IMPORTANT - Do not add any additives to fuel or lubricants.

B.1

B

Part. N. 8000 H1489 (10-2009)

MAINTENANCE

Section

B.2

Part. N. 8000 H1489 (10-2009)

MAINTENANCE

SCHEDULED MAINTENANCE CHART

(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)

TC - TE - TXC

RACING MOTORCYCLE, FOR

RACING USE: FULL POWER RATING

SERVICE SERVICE SERVICE SERVICE SERVICE

COUPON COUPON COUPON COUPON COUPON

PART

AFTER FIRST EVERY EVERY EVERY EVERY EVERY REPLACE SEE

3 HOURS 4h MX/8h EN 8h MX/16h EN 16h MX/32h EN 32h MX/64h EN 40h MX/80h EN AS REQUIRED PAGE

VALVES C (•) C (•) S (#)

VALVE SPRINGS C X
VALVE SPRING RETAINERS, VALVE COLLETS C X
VALVE BUCKETS C X
CAMSHAFT C
TIMING CHAIN C S
TIMING CHAIN SLIDER C/S
TIMING DRIVEN GEAR C X
TIMING DRIVE GEAR

C X
TIMING CHAIN TENSIONER C
INTAKE COUPLING C S
COMPLETE CYLINDER C S C X
COMPLETE PISTON S C S
COMPLETE CONNECTING ROD S
CRANKCASE BEARINGS S
ENGINE OIL S C S
OIL PUMP C
OIL FILTER/MESH FILTER S, P S, P

OIL PUMP TO CRANKCASE OIL LUBRICATION
PIPE

C

PRIMARY DRIVE GEAR PAIR C
CLUTCH HUB C X
CLUTCH PLATES C S X
CLUTCH PRESSURE PLATE C
CLUTCH SPRINGS C X
CLUTCH HOUSING C
CLUTCH PUSHROD C
TRANSMISSION SPROCKET C S X
STARTER GEARS C X

B.3Part. N. 8000 H1489 (10-2009)

MAINTENANCE

SCHEDULED MAINTENANCE CHART

(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)

TC - TE - TXC

RACING MOTORCYCLE, FOR

RACING USE: FULL POWER RATING

SERVICE SERVICE SERVICE SERVICE SERVICE

COUPON COUPON COUPON COUPON COUPON

PART

AFTER FIRST EVERY EVERY EVERY EVERY EVERY REPLACE SEE

3 HOURS 4h MX/8h EN 8h MX/16h EN 16h MX/32h EN 32h MX/64h EN 40h MX/80h EN AS REQUIRED PAGE

KICK START PEDAL L
GEAR SHIFT PEDAL C
SPARK PLUG P S
SPARK PLUG CAP C
CARBURETTOR P R
CARBURETTOR THROTTLE VALVE C
AIR FILTER P, L
RADIATORS C
WATER HOSES AND CLAMPS C
RADIATORS TO WATER PUMP HOSE C
COOLANT C X
FOOTPEGS, PINS, SPRINGS C X
REAR CHASSIS MNTG BOLTS, ENGINE MNTG BOLTS

C C
SIDE STAND C
CHAIN GUIDE ROLLER, BEARINGS C
STEERING HEAD, BOTTOM YOKE WITH STEM

L
FRONT FORK R
HANDLEBAR MOUNTS AND FASTENERS C C
REAR SWINGING ARM BUSHING C
REAR CHAIN SLIDER C X
REAR SUSPENSION LINKAGE BUSHINGS C
CHAIN GUIDE/CHAIN GUARD C X
SWINGING ARM AXLE ROLLER CAGES L
REAR SHOCK ABSORBER R
ROLLER CAGES, LINKAGE PINS OF REAR SUSP.

L

COMPLETE THROTTLE CONTROL C, L

COMPLETE CLUTCH CONTROL C (•) R (#)

B.4

Part. N. 8000 H1489 (10-2009)

MAINTENANCE

SCHEDULED MAINTENANCE CHART

(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)

LEGEND

h: HOURS
S: REPLACE
C: CHECK

C (•): CHECK CLEARANCE

P: CLEAN
R: OVERHAUL
L: GREASE/LUBRICATE
MX: MOTOCROSS
EN: ENDURO
(#) SEE WORKSHOP MANUAL

NOTES:

- REPLACE GASKETS AND SEALS AFTER EACH REMOVAL;

- REPLACE SCREWS AND BOLTS IF DAMAGED;

- PERFORM A GENERAL INSPECTION AFTER RIDING ON MUDDY OR SANDY TERRAIN.

TC - TE - TXC

RACING MOTORCYCLE, FOR

RACING USE: FULL POWER RATING

SERVICE SERVICE SERVICE SERVICE SERVICE

COUPON COUPON COUPON COUPON COUPON

PART

AFTER FIRST EVERY EVERY EVERY EVERY EVERY REPLACE SEE

3 HOURS 4h MX/8h EN 8h MX/16h EN 16h MX/32h EN 32h MX/64h EN 40h MX/80h EN AS REQUIRED PAGE

THROTTLE CABLES C L X
FRONT BRAKE DISC C X
FRONT BRAKING SYSTEM FLUID C S
REAR BRAKE DISC C X
REAR BRAKING SYSTEM FLUID C S
BRAKE PADS C X
MASTER CYLINDER TO BRAKE CALLIPER HOSES

C
FUEL PIPES C S X
SILENCER SOUND DEADENING MATERIAL

S X
EXHAUST PIPE AND SILENCER C X
WHEEL SPOKE TENSION C C
WHEEL HUB BEARINGS S X
REAR CHAIN SPROCKET S X
SPROCKET BOLT TIGHTENING C C
SECONDARY DRIVE CHAIN C, L S X
TORQUE OF NUTS AND BOLTS C C

B.5Part. N. 8000 H1489 (10-2009)

MAINTENANCE

VALVES C (•) C (•) S (#)

VALVE SPRINGS C X

VALVE SPRING RETAINERS, VALVE COLLETS C X

VALVE BUCKETS C X

CAMSHAFT C

TIMING CHAIN S

TIMING CHAIN SLIDER C S

TIMING DRIVEN GEAR C X

TIMING DRIVE GEAR C

TIMING CHAIN TENSIONER C

INTAKE COUPLING C S X

COMPLETE CYLINDER C X

COMPLETE PISTON S

COMPLETE CONNECTING ROD S

CRANKCASE BEARINGS S

ENGINE OIL AND OIL FILTER S S S

OIL PUMP C

OIL FILTER/MESH FILTER S, P S, P

OIL PUMP TO CRANKCASE OIL FEED C

PRIMARY DRIVE GEAR PAIR C X

CLUTCH HUB C X

CLUTCH PLATES C S X

CLUTCH PRESSURE PLATE C

CLUTCH SPRINGS C X

CLUTCH PUSHROD C

TRANSMISSION SPROCKET C S

STARTER GEARS C X

SCHEDULED MAINTENANCE CHART

(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)

AFTER FIRST

1000 KM

EVERY

5000 KM

EVERY

10000 KM

TE

- STANDARD MOTORCYCLE, FOR ROAD USE
(DERATED)

SEE

PAGE

REPLACE

AS

REQUIRED

B.6

Part. N. 8000 H1489 (10-2009)

MAINTENANCE

KICK START PEDAL L
GEAR SHIFT PEDAL X
SPARK PLUG P S
SPARK PLUG CAP C C X
AIR FILTER P, L P, L X
RADIATORS
WATER HOSES AND CLAMPS C C
RADIATORS TO WATER PUMP HOSE C C
FOOTPEGS, PINS, SPRINGS X
REAR CHASSIS MNTG BOLTS, ENGINE MNTG BOLTS

C C
SIDE STAND C
CHAIN GUIDE ROLLER, BEARING C C X
STEERING HEAD, BOTTOM YOKE WITH STEM

L
FRONT FORK R
HANDLEBAR MOUNTS WITH FASTENERS C C
REAR SWINGING ARM BUSHING C
REAR CHAIN SLIDER C X
REAR SUSPENSION LINKAGE BUSHINGS C X
CHAIN GUIDE/CHAIN GUARD C C X
ROLLER CAGES, LINKAGE PINS OF REAR SUSP.

L
REAR SHOCK ABSORBER C
COMPLETE THROTTLE CONTROL C, L

COMPLETE CLUTCH CONTROL C (•) R (#)

THROTTLE CABLES C L X
FRONT BRAKE DISC C X
FRONT BRAKING SYSTEM FLUID C S

SCHEDULED MAINTENANCE CHART

(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)

PART

SERVICE SERVICE SERVICE
COUPON COUPON COUPON

SEE

PAGE

AFTER FIRST

1000 KM

EVERY

5000 KM

EVERY

10000 KM

TE - TXC

- STANDARD MOTORCYCLE, FOR ROAD USE
(DERATED)

REPLACE

AS

REQUIRED

B.7Part. N. 8000 H1489 (10-2009)

MAINTENANCE

SERVICE SERVICE SERVICE
COUPON COUPON COUPON

SEE

PAGE

TE

- STANDARD MOTORCYCLE, FOR ROAD USE
(DERATED)

REAR BRAKE DISC C X
REAR BRAKING SYSTEM FLUID C S
BRAKE PADS C C C X
MASTER CYLINDER TO BRAKE CALLIPER HOSES

C X
FUEL PIPES C X
SILENCER SOUND DEADENING MATERIAL X
EXHAUST PIPE AND SILENCER C X
WHEEL SPOKE TENSION C C
WHEEL HUB BEARINGS C X
REAR CHAIN SPROCKET S
SPROCKET BOLT TIGHTENING C C C
SECONDARY DRIVE CHAIN C, L C, L S
TORQUE OF NUTS AND BOLTS C C

SCHEDULED MAINTENANCE CHART

(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)

AFTER FIRST

1000 KM

PART

REPLACE

AS

REQUIRED

EVERY

5000 KM

EVERY

10000 KM

LEGEND

S: REPLACE
C: CHECK

C (•): CHECK CLEARANCE

P: CLEAN
R: OVERHAUL
L: GREASE/LUBRICATE

NOTES:

- REPLACE GASKETS AND SEALS AFTER EACH REMOVAL;

- REPLACE SCREWS AND BOLTS IF DAMAGED;

- PERFORM A GENERAL INSPECTION AFTER RIDING ON MUDDY OR SANDY TERRAIN.

C.1

C

Part. N. 8000 H1489 (10-2009)

TROUBLESHOOTING

Section

C.2 Part. N. 8000 H1489 (10-2009)

TROUBLESHOOTING

ENGINE

Trouble Cause Remedy

Engine does not start or Insufcient compression

has starting trouble 1. Piston seized Replace

2. Connecting rod small or big end seized Replace

3. Worn piston rings Replace

4. Worn cylinder Replace

5. Cylinder head loosely tightened Tighten

6. Head gasket leaking Replace

7. Spark plug loose Tighten

8. Incorrect valve clearances Adjust

9. Weak or seized valve springs Replace

10. Seized valves Replace
Weak or no spark

1. Spark plug faulty Replace

2. Fouled or wet spark plug Clean or dry

3. Spark plug electrode gap too wide Adjust

4. Ignition coil faulty Replace

5. High-tension cables open circuit or shorted Check

6. Electronic control unit faulty Replace

7. Right-hand switch faulty (TE - TXC) Replace

Carburettor is receiving no fuel (TC)

1. Tank cap breather clogged Clean

2. Fuel cock clogged Clean

3. Fuel feed pipe clogged Clean

 4. Filteroncarburettorttingdirty Clean
 5. Floatervalveoroatersfaulty Replace
 6. Linkageisblockingoatervalve Release

Carburettor oods (TC)

1. High fuel level in bowl Adjust

 2. Floatervalveoroaterswornorstuck

open Replace or release

Engine stalls 1. Fouled spark plug Clean
easily 2. Electronic control unit faulty Replace

3. Carburettor jets clogged Clean

4. Low idle Adjust

Engine is noisy Noise seems to come from piston

1. Too much piston-to-cylinder clearance Replace

2. Worn piston rings or piston grooves Replace

3. Too much carbon build-up in
combustion chamber or on piston crown Clean

4. Valve clearances too large Adjust

5. Weak or seized valve springs Replace

6. Worn timing chain Replace

7. Incorrect timing chain tension Adjust

Noise seems to come from crankshaft

1. Worn main bearings Replace

2.

Connectingrodbigendhastoomuchsideclearanceorendoat

Replace

3. Crankshaft gear damaged Replace

4. Crankshaft locknut loose Tighten

C.3Part. N. 8000 H1489 (10-2009)

TROUBLESHOOTING

Trouble Cause Remedy

Noise seems to come from the clutch

1. Worn plates Replace

2.

Too much clearance between clutch housing and friction plates

Replace

Noise seems to come from gearbox

1. Worn gears Replace

2. Worn gear grooves Replace

Noise seems to come 1. Chain stretched (worn) or improperly adjusted Replace or adjust
from secondary drive 2. Worn transmission sprocket and rear chain sprocket Replace

chain

Clutch slips 1. Weak clutch springs Replace

2. Worn clutch plates Replace
Clutch is hard to operate 1. Uneven spring load Replace

2. Bent clutch plates Replace
Gears do not engage 1. Bent or seized shifter forks Replace

2. Worn gear ratchets Replace

3. Damaged shifter fork shafts Replace

Gear shift pedal
does not return to original position

1. Weak or broken selector return spring Replace

2. Worn shifter forks Replace
Transmission jumps out of gear 1. Worn sliding gear dogs Replace

2. Worn gear grooves Replace

3. Worn dog slots in gears Replace

4. Worn selector shaft splines Replace

5. Damaged shifter fork shafts Replace

Engine has low power 1. Dirtyairlter Clean

2. Carburettor main jet clogged or
is the wrong size (TC) Clean or Replace

3. Poor fuel quality Replace

4. Intake coupling loose Tighten

5. Spark plug electrode gap too wide Adjust

 6. Insufcientcompression Identifycause

7. Incorrect valve clearances Adjust

8. Valve seats or guides faulty Replace

9. Weak or seized valve springs Replace
Engine overheats 1. Combustion chamber and/or piston crown fouled

with carbon deposits Clean

 2. Insufcientoilinengineor

wrong oil Top up or change

 3. Obstructionsblockingairowonradiator Clean

4. Cylinder head gasket leaking Replace

5. Clutch slips Adjust

6. Cooling fan faulty (TE-TXC) Replace thermal switch

C.4 Part. N. 8000 H1489 (10-2009)

TROUBLESHOOTING

CHASSIS

Trouble Cause Remedy
Handlebar turns hard 1. Insufcienttyrepressure Inate

2. Bearing adjuster ring nut or steering stem nut overtightened Adjust

3. Bent steering stem Replace bottom yoke

4. Worn or seized steering bearings Replace
Handlebar vibration 1. Bent fork legs Replace

2. Bent front wheel axle Replace

3. Warped chassis Replace

4. Bent front wheel rim Replace

5. Worn front wheel bearings Replace
Damping is 1. Too much oil in fork legs Remove excess oil

too hard 2. Fork oil viscosity too high Change

 3. Overinatedtyres Deate

4. Improperly set rear shock absorber Adjust

Damping is 1. Insufcientoilinforklegs Topup

too soft 2. Fork oil viscosity too low Change

3. Weak fork springs Replace

4. Weak rear shock absorber spring Replace

5. Improperly set rear shock absorber Adjust
(Front / rear) wheel 1. Bent wheel rim Replace

shakes 2. Worn wheel hub bearings Replace

3. Incorrect spoke tension Adjust

4. Wheel axle nut loose Tighten

5. Worn rear swinging arm bearings Replace

6. Improperly adjusted chain tensioners Adjust

7. Improperly balanced wheel Balance
Rear suspension is 1. Worn link rod spacers or bearings Replace

noisy 2. Worn shock absorber ball joints Replace

3. Shock absorber faulty Replace
Poor braking 1. Air in brake system Bleed

(front and rear) 2. Insufcientuidintank Topup

3. Worn brake pad and/or disc Replace

4. Damaged disc Replace

5. Improperly adjusted brake pedal Adjust

 6. Waterinbrakesystem Changeuid

C.5Part. N. 8000 H1489 (10-2009)

TROUBLESHOOTING

ELECTRICAL SYSTEM (see also Section M)

Trouble Cause Remedy

Spark plug fouls 1. Mixture too rich Adjust carburettor setting

easily 2. Dirtyairlter Clean

3. Worn piston rings Replace

4. Worn piston or cylinder liner Replace

Spark plug electrodes 1. Mixture too lean Adjust carburettor setting
overheat 2. Spark plug electrode gap too close Adjust

3. Heat rating too high Replace with recommended
spark plug

Generator does not charge or 1.

Cables running to voltage regulator improperly connected or

Connect correctly or

is not providing enough charge shorted replace

2. Voltage regulator faulty Replace

3. Generator coil faulty Replace

Generator overcharges battery 1. Voltage regulator faulty Replace
Battery does not hold charge 1. Battery terminals dirty Clean

(TE-TXC)

Starter motor 1. Batteryisat Charge

does not start or slips 2. Control on R.H. switch faulty Replace
(TE-TXC) 3. Starter relay faulty Replace

4. Starter motor faulty Repair or replace

5. Worn starter gears Replace

6. Worn or damaged freewheel rollers Replace freewheel

INJECTION FUEL FEEDING SYSTEM (TE-TXC) (See Section S)

D.1

D

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

Section

D.2 Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

Saddle removal.............................................................................................D.4

Tank removal (TC) ........................................................................................D.4

Tank removal (TE - TXC) ..............................................................................D.5

Valve clearance adjustment ..........................................................................D.6

Throttle cable adjustment (TC) .....................................................................D.7

Throttle cable adjustment (TE - TXC) ...........................................................D.8

Enrichener lever play adjustment (TE - TXC) ...............................................D.8

Carburettor adjustment (TC).........................................................................D.9

Idle adjustment (TC) .....................................................................................D.9

Idle adjustment (TE - TXC)

...........................................................................D.9

Clutch plate replacement

............................................................................D.10

Hydraulic clutch lever adjustment and uid level check ............................D.11

Front brake lever adjustment and uid level check ....................................D.12

Rear brake pedal adjustment .....................................................................D.13

Rear brake pedal free play adjustment.......................................................D.14

Rear brake uid level check .......................................................................D.14

Engine oil level check .................................................................................D.15

Engine oil replacement and mesh lters-lter cartridge cleaning

or replacement............................................................................................D.16

Coolant level check

....................................................................................D.17

Coolant replacement

..................................................................................D.17

Air lter check (TC)

.....................................................................................D.18

Air lter check (TE - TXC)

...........................................................................D.19

Air lter cleaning

.........................................................................................D.19

Installation ..................................................................................................D.20

Secondary drive chain adjustment .............................................................D.21

Chain lubrication .........................................................................................D.22

Removal and cleaning ................................................................................D.22

Washing a chain without O-rings ................................................................D.22

Lubricating a chain without O-rings ............................................................D.22

Lubricating an O-ring chain ........................................................................D.22

Suspension setup according to track condition ..........................................D.23

Rear shock absorber adjustment................................................................D.24

Shock absorber spring preload adjustment ................................................D.25

Shock absorber compression and rebound damping adjustment ..............D.26

Shock absorber springs ..............................................................................D.26

MARZOCCHI front fork adjustment (TC 2009) ...........................................D.27

KAYBA front fork adjustment (TC - TE - TXC / 2010) .................................D.28

KAYBA front fork springs ............................................................................D.29

MARZOCCHI front fork springs ..................................................................D.30

Steering bearing clearance adjustment ......................................................D.31

Steering angle adjustment ..........................................................................D.31

Changing handlebar position and height ....................................................D.32

Supply hose check (TC) .............................................................................D.33

Supply hose check (TE – TXC) ..................................................................D.33

Silencer sound deadening material replacement .......................................D.34

Exhaust system check ................................................................................D.35

D.3

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

D.4 Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

Saddle removal

Turn the rear xing (1) counter clockwise, remove it and extract the saddle.

Tank removal (TC)

Close the fuel cock (2) and loosen the clamp (3) on the hose running to the
carburettor. Detach hose (4) from carburettor making sure to drain any fuel in
the hose into a container.

Remove the screws (5) and the side panels.

Remove the retaining screw (6) and then the tank (7) together with the
scoops.

D.5

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

Tank removal (TE - TXC)

Remove the screws (1) and the side panels.

Remove the tank retaining screw (2).

Lift the tank and disconnect the fuel pump connector from the main wiring har­ness.

Disconnect the supply hose (3) from the outlet tting (4) on the fuel pump, located

in the rear bottom section of the tank.

Remove the tank (5) together with the scoops.

D.6 Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

Valve clearance adjustment

Remove saddle and tank as outlined in the relevant paragraphs.

Remove spark plug (1), both head cover screws (2) and head cover (3).

Engage the 2nd gear and push and pull the motorcycle back and forth to bring

the piston to Top Dead Centre. In this condition, the holes (4) in the camshaft

gears will be located at the positions shown.
Cover parting line "A" is visible through the holes (4).

Use a feeler gauge to make sure clearance is 0.15 mm on the INTAKE side and

0.20 mm on the EXHAUST side.
If not so, remove the shim from under the valve bucket and measure its thick-

ness.

Depending on what you nd, replace the shim with a new shim with the required

thickness to achieve correct clearance (replacement shims are available in a

1.60 mm to 2.60 mm thickness range, in 0.05 mm increments).

Check valve clearances again. If clearances are correct, ret the parts you have

removed reversing the disassembly procedure.

For camshaft disassembly and reassembly, see Section “F” Engine disassembly
and Section “H” Engine assembly.

D.7

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

Throttle cable adjustment (TC)

To check the correct adjustment of the throttle cable, operate as follows:

- remove the rubber gaiter (1) at cable end;

- push and pull cable (2) to make sure it has about 2 mm free play;

- if not so, loosen the lock ring nut (3) and suitably turn the adjuster screw (4)

(loosen to decrease play or tighten to increase it);

- tighten back the lock ring nut (3).

Operation with damaged throttle cable could result in an unsafe riding

condition.

Exhaust gas contains poisonous carbon monoxide. Never run the engine

indoors.

When replacing the throttle cables (1) and (2), make sure a 10-mm length of
each cable protrudes over the clip (length A) as shown in the picture. Ret the

protection cover (B) using the screw (3) and adjust the cables at handlebar end.

To replace the cables, you will need to remove the fuel tank as described in the

relevant paragraph.

D.8 Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

Throttle cable adjustment (TE - TXC)

To check the correct adjustment of the throttle cable, operate as follows:

- Loosen the screw and remove the cover (1).

- Make sure the cables protrude by 10 mm (length A). If they need adjusting,

loosen the check nuts (2) and turn the adjuster screws (3).

When nished, tighten the check nuts (2).

- Always check length "A" after replacing the cables (4) and (5).

- Ret the cover (1) and tighten the screw.

Operation with damaged throttle cable could result in an unsafe riding

condition.

Exhaust gas contains poisonous carbon monoxide. Never run the engine

indoors.

To replace the cables, you will need to remove the fuel tank as described in the

relevant paragraph.

Enrichener lever play adjustment (TE - TXC)

The lever (1) holder features an adjuster screw (2) to adjust free play. Free play

should be about 3 mm: if not so, loosen the check nut and turn the adjuster screw
as required (loosen to decrease play or tighten to increase it).

D.9

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

Carburettor adjustment (TC)

Adjust the carburettor with warm engine and with the throttle control in closed

position. Proceed as follows:

- turn the idle speed adjuster screw (1) located on the left-hand side of the

vehicle, until setting idle RPM quite high (turn clockwise to increase the speed

and counter clockwise to reduce the speed).

- Turn the adjuster screw (2) clockwise to fully closed position, and then turn

it back 1.5 turns.

- Gradually loosen the screw (1) until achieving suitable idle speed setting.

Idle adjustment (TC)

Adjust the carburettor with warm engine and with the throttle control in closed

position. Proceed as follows:

- Turn the idle speed adjuster screw (1) located on the left-hand side of the

vehicle, until setting idle RPM as required (turn clockwise to increase the

speed and counter clockwise to reduce it).

Idle adjustment (TE - TXC)

Adjust the carburettor with warm engine and with the throttle control in closed

position. Proceed as follows:

- Turn the idle speed adjuster screw (3) located on the throttle body on the right-

hand side of the vehicle, until setting idle speed to 1,600 RPM (turn clockwise

to increase the speed and counter clockwise to reduce it).

D.10 Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

Clutch plate replacement
This procedure can be performed with the motorcycle leaning to the left - there

is no need to drain engine oil.

- Remove the brake pedal (1).

- Remove the six retaining screws (2) and the clutch cover (3).

- Using an 8 mm wrench, unscrew the six screws (4) securing the clutch springs.

Remove springs, pressure plate (5) with bearing (6) and clutch actuator plate

(7).

D.11

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

- Remove the plates (8), lubricate the new plates with engine oil and install

them (always start with a friction plate).

Ret clutch actuator plate, bearing and pressure plate.

Tighten the spring screws gradually in a cross pattern (8 Nm - 0.8 Kgm - 5.8 ft/
lb).

When retting the clutch cover (8 Nm - 0.8 Kgm - 5.8 ft/lb), check gasket for
wear and replace as required.

For additional information on assembly procedures, see Section "H"

Engine assembly.

Hydraulic clutch lever adjustment and uid level check

Free play (A) must be at least 0.1 in.
The lever position can be adjusted to suit the rider hand size.

To decrease the lever distance from the handgrip, rotate the adjuster (B)

CLOCKWISE.
To increase the lever distance from the handgrip, rotate the adjuster (B) COUN­TER CLOCKWISE.

Fluid level is checked as follows:

- Remove screws (1), cover (2) and rubber diaphragm from the control;

- Keep the control cylinder (3) in a horizontal position and make sure that uid

level has not dropped lower than 4 mm (0.16 in.) below the upper edge (D)
of master cylinder body;

- If needed, top up with the uid specied in the LUBRICANT CHART included

in Section "A".

Ret any parts you have removed.
Periodically check the connecting hose (see “Scheduled Maintenance Chart”);
if hose (C) is worn or cracked, its replacement is advised.

D.12 Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

A: to increase clearance

B: to decrease clearance

Front brake lever adjustment and uid level check

The adjuster (1) located on the control lever, allows adjusting of the free play

(a). Free play (a) must be at least 3 mm.

The level of the uid in master cylinder reservoir must never be below the mini-

mum value (2), which can be checked from the inspection window on the rear of
the master cylinder body. A decrease of the uid level will let air into the system,

hence an extension of the lever stroke.

If the brake lever feels mushy when pulled, there may be air in the brake

line or the brake may be defective: CHECK THE BRAKING SYSTEM

(see Section "L").

Too much brake lever free play may reduce braking action: CHECK

BRAKE PAD THICKNESS (see Section "L").

Do not spill brake uid onto any painted surface or lens (for example

lights lens).

Do not mix two brands of uid. Completely change the brake uid in the

brake system if you wish to switch to another uid brand.

Brake uid may cause irritation. Avoid contact with skin or eyes. In case

of contact, ush thoroughly with water and call a doctor if your eyes were

exposed.

D.13

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

Rear brake pedal position adjustment

The position of the rear brake pedal with respect to the footrest may be adjusted
according to individual needs.

For adjusting, proceed as follows:

- Loosen the screw (1).

- Turn the cam (2) in order to raise or lower the brake pedal within the range
available (A).

- When nished, tighten the screw (1).

Once this adjustment is completed, adjust the free play of the pedal following the

instructions provided in paragraph "Rear brake pedal free play adjustment".

D.14 Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

C: to increase clearance
D: to decrease clearance

Rear brake pedal free play adjustment

The rear brake pedal should have 5 mm free play (B) before the brake begins

to bite. Should this not happen, operate as follows:

- Loosen the nut (3);

- Operate the master cylinder linkage (4) to increase or decrease free play;

- Tighten the nut (3) at the end of the operation.

When the free play requirement is not met, the brake pads will be subjected

to an early wear that may lead to TOTAL BRAKE INEFFECTIVENESS.

If the brake pedal feels mushy when pulled, there may be air in the brake

line or the brake may be defective. CHECK THE BRAKING SYSTEM (see
Section L).

Rear brake uid level check

Level (A) must be between the MIN and MAX notches visible on the master
cylinder reservoir.

D.15

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

Engine oil level check

Keeping the motorcycle level and upright, check the oil level through the inspec­tion window (1) on the right crankcase.
Make sure level is up to window midline (1).

To top up, remove the ller cap (2).

Have this operation made with warmed-up engine.

Be careful not to touch hot engine oil.

D.16

H00977-1

A

7

8

6

Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

Engine oil replacement and mesh lters-lter cartridge cleaning or replace­ment

Drain the oil with WARM ENGINE; proceed as follows:

- Remove the oil ller cap (2).

- The oil sump guard (A) may be left in place. However, the procedure will be

easier with the guard removed.

- Place an oil drain pan under the engine.

- Remove oil drain plug (3) and lter (4), drain the oil and clean the plug mag­net.

- Wash the lter (4) with petrol and ret it into its seat.

- Unscrew the screws (5) and remove cover (6) together with lter (7).

- Change the lter (7) and ret the assembly making sure to t the Belleville

washer (8) in the correct position.

- Ret the drain plug (3) (25 Nm - 2.5 Kgm - 33.89 ft/lb) and the oil sump guard

(A).

- Fill with the specied quantity of oil.

For recommended oil type and quantity, see "Capacities" table in Section

"A".

Be careful not to touch hot engine oil.

WARNING When assembling lter to cover, make sure to t the lter

oil seal (A) rst onto the cover (6).

D.17



















SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

Coolant level check

Check level (1) in right-hand radiator when engine is cold (place the motorcycle
so that it is perpendicular to the ground). The coolant should be approximately

0.39 in. above the cells.

The radiator cap features two locking positions: the rst one is for prior discharge

of pressure from the cooling system.

Avoid removing radiator cap when engine is hot, as coolant may spout

out and cause scalding.

TE-TXC: Because the cooling fan (V) can be activated even when the

start switch is in OFF position, always keep at a safe distance from the

fan blades.

Difculties may arise in eliminating coolant from painted surfaces. If this

occurs, wash off with water.

Coolant replacement

Place a vessel on the L.H. side of the cylinder, under the hose (1).
Remove the drain hose (A) as follows:

- Unscrew the two screws (C);

- Release the spring (D).
Loosen the clamp (2) on the hose (1) and detach the hose from the engine.
SLOWLY open the cap (3) of the right-hand radiator and lean the motorcycle to
the left to let the coolant drain into the vessel.

When nished, ret the hose (1) and secure it with the clamp (2). Ret the drain

hose.

Pour the necessary quantity of coolant in the radiator then warm up the engine

in order to eliminate any possible air bubbles.

Periodically check the connecting hoses (see “Scheduled Maintenance Chart”):
this will avoid coolant leakage and consequent engine seizure. If hoses (A) show
cracks, swelling or hardening due to sheaths desiccation, their replacement

shall be advisable.
Check the correct tightening of the clamps (B).

D.18 Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

Air lter check (TC)

Turn the rear xing (1) counter clockwise, remove it and extract the saddle re­leasing it from the front retaining screw.

Remove the screw (3), remove the complete air lter (4) and separate lter (5)

from rear chassis (6).

D.19

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

Air lter check (TE - TXC)

Turn the rear xing (1) counter clockwise, remove it and extract the saddle releasing

it from the front retaining screw.
Take out the battery (A) and leave it hanging on the side of the motorcycle.

Remove the screw (3), remove the complete air lter (4) and separate lter (5) from

intake silencer (6).

Air lter cleaning

Wash the lter with a specic detergent (see "Capacities" table in Section A)
then dry it fully (wash lter with gasoline only in case of need). Plunge the lter
in special oil for lters (see "Capacities" table in Section A), then wring it to drain
superuous oil.

Do not use fuel or a low ash-point solvent to clean the ltering element.

A re or explosion could result.

Clean the ltering element in a well ventilated area and do not allow

sparks or ames anywhere near the working area.

D.20 Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

Assembly

Grease the edge (C) of the lter face that goes into the housing to ensure proper
sealing. When retting the lter into its housing, make sure to position it with
the tab (A) pointing upwards and edge (B) at the left bottom corner of the lter
housing. Ret any parts you have removed.

An improperly positioned lter might let dirt or dust into the engine, leading

to early wear of piston rings and cylinder.

A = Upper side
B = Left-hand side

D.21

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

Fig. A

Fig. B

Secondary drive chain adjustment

Chain should be checked, adjusted and lubricated as per the "Maintenance
Chart" (see Section B) to ensure safety and prevent excessive wear. If the chain
becomes badly worn or is poorly adjusted (i.e., if it is too loose or too taut), it
could escape from sprocket or break. To adjust chain tension, you need to lower
the rear end of the motorcycle so as to bring the axes of rotation of sprocket,

swinging arm and rear wheel into alignment as shown in gure "A", and then

turn the rear wheel three turns. In this condition, the chain should be neither
taut nor slack. (Fig. A).

Quick adjustment (Fig. B)
Insert a 35 mm socket (a) (or a shim of the same size) at the position shown in

the gure and check that the lower section (C) of the chain is slightly taut.

If it is not, proceed as follows:

- Loosen the wheel axle nut (1) on the right-hand side using a 27 mm socket
wrench;

- Loosen the check nuts (2) on both chain tensioners with a 12 mm wrench
and work the screws (3) until achieving the correct tension;

- When the adjustment is completed, tighten the check nuts (2) and the wheel
axle nut (1).

After any adjustment, always check wheel alignment and tighten wheel axle
securely (142.1 Nm - 14.5 Kgm - 104.8 ft/lb).

Asse pignone = Sprocket axis
Asse forcellone = Swinging arm axis
Asse ruota = Wheel axis

D.22

H01042

5

4

3

Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

Chain lubrication

Lubricate the chain following these instructions.

Never use grease to lubricate the chain. Grease helps to accumulate dust

and mud, which act as abrasive and help to rapidly wear out the chain,

the front and rear sprockets.

Disassembling and cleaning

When particularly dirty, remove and clean the chain before lubrication. Proceed
as follows:

- Set a stand or a block under the engine and see that the rear wheel is lifted
from the ground.

- Remove: screws (1), sprocket guard (2), clip (3), master link (4) and chain
(5). To reassemble, reverse the above procedure.

Make sure that the chain is neither worn out nor damaged. If the rollers or the

links are damaged, replace the chain by following the instructions given in the

Scheduled Maintenance Chart. Ensure that the sprockets are not damaged.
Wash and clean the chain as described hereunder.

Washing a chain without O-rings

Wash using petroleum or naphtha. If you use fuel or especially trichloroethylene,

dry and lubricate the chain to avoid oxidisation.

Lubricating a chain without O-rings

After drying, dip the chain in Molybdenum Disulphide chain lubricant, if possible,
or in warm high-viscosity engine oil (if warmed up, oil will be more uid).

Lubricating an O-ring chain

Lubricate all metallic and rubber (O-ring) elements using a brush and engine oil

with SAE 80-90 viscosity, inside and outside parts.

Assemble the master link clip (3) by setting the closed side facing the chain

direction of rotation, as shown in the gure.

The master link is the most critical safety part in the drive chain. Even if

the master links are reusable when in good conditions, for safety purposes

we advise using a new master link when reassembling the chain.

Accurately adjust the chain as described on page D.18.

The chain lubricant shall NEVER get in contact with the tyres or the rear

brake disc.

Chain guide roller, chain guide roller, chain guide, chain slider

Check the wear of the above-mentioned elements and replace them when

necessary.

Check the chain guide alignment, and remember that a bent element

can cause chain early wear. In this case, chain might unwrap from the

sprocket.

D.23

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

Suspension setup according to track condition

Following are a few guidelines to nd the right suspension setup

for different types of terrain. Always start from the suspensions standard set-

ting before making any change. Afterwards, increase or decrease the adjusting
clicks, one at a time.

HARD GROUND

Front fork: softer compression setting.
Shock absorber: softer compression setting.
For fast tracks, a softer compression and rebound setting both front and rear

will give more grip.

SANDY GROUND

Front fork: set compression harder, or replace the standard spring with a harder

spring and set the compression softer and the rebound harder.

Shock absorber: harder compression, and especially harder rebound settings.

Work on the spring preload to lower the motorcycle riding height (rear end).

MUDDY GROUND

Front fork: set compression harder, or replace the standard spring with a harder

spring.

Shock absorber: harder compression and rebound settings

or replace the standard spring with a harder spring. Work on the spring preload
to lift the motorcycle riding height (rear end). Changing the springs front and
rear is advised in order to compensate for increased motorcycle weight due to
caked-on mud.

NOTES

If the fork remains too soft or too hard no matter what setting you choose,
check oil level in the fork tubes, as it might be too low
or too high. Remember that the more oil you add, the more frequently you will
need to bleed the forks. If changes to suspension settings take no effect, check
the adjuster assemblies, as they might be stuck.
Standard settings, available replacement springs and adjusting procedures are

outlined in the following pages.

D.24 Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

B: panel retaining screw axis
C: rear wheel axle height

Shock absorber adjustment

The rear shock absorber must be adjusted to suit rider weight and terrain condi­tions.

Proceed as follows:

1. Place the motorcycle on the stand and measure distance (A).

2. Sit on the motorcycle in normal riding position with full riding gear on.

3. Have someone else measure distance (A) again.

4. The difference between these two measurements is the distance the rear end
settles when the rider sits on the motorcycle (RIDER SAG). Recommended
rider sag is 100 mm with a cold shock absorber and 95 mm with a warm
shock absorber.

5. To achieve correct rider sag for your weight, adjust the spring preload of the

shock absorber (see relevant paragraph).

D.25

H01043

2

2

3

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

The standard length of the preloaded spring is

as follows:

TC: A= 250 ± 1.5 mm
TE: A= 247 ± 1.5 mm

TXC: A= 250 ± 1.5 mm

Shock absorber spring preload adjustment

Proceed as follows:

1. Turn the rear xing (1) counter clockwise and remove the saddle, unscrew

the retaining screws (2) and remove the right-hand side panel (3).

2. Clean lock ring nut (4) and adjuster ring nut (5) of the spring (6).

3. Either with a hook wrench or an aluminium punch, loosen the lock ring nut.

4. Turn the adjuster ring nut as required.

5. Adjust preload to suit your weight or riding style and tighten the lock ring nut

rmly (tightening torque 50 Nm - 5 Kgm - 67.8 ft/lb).

6. Reassemble the R.H. side panel and the saddle.

Be careful not to touch hot exhaust pipe while adjusting the shock ab-

sorber.

D.26 Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

Shock absorber compression and rebound damping adjustment

Adjustment of the compression stroke is independent from the rebound
stroke.

A) COMPRESSION - Standard setting:

1) Low damping speed:

-15 clicks (± 2 clicks)

(adjuster 1)

2) High damping speed:

-15 clicks (± 2 clicks)

(adjuster 3)

To reset the standard setting, turn upper adjusters (1) and (3) clockwise until

reaching fully closed position. Then turn them back the number of clicks speci-

ed above.

In order to obtain a smooth braking efciency, turn the adjusters counter clock-

wise. Vice versa to obtain a harder braking action.

B) REBOUND - Standard setting:

-18 clicks (± 2 clicks)

To reset the standard setting, turn lower adjuster (2) clockwise until reaching

fully closed position. Then turn it back by the mentioned clicks.

In order to obtain a smooth braking action, turn the adjuster counter clockwise.

Vice versa to obtain a harder braking action.

Shock absorber springs (4)

STANDARD

K=5.4 kg/mm (part no. 8000 98504) (TC + TXC)
K=5.2 kg/mm (part no. 8000 98569) (TE)

D.27

b)

a)

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

MARZOCCHI front fork adjustment (TC 2009)

a) COMPRESSION (LOWER ADJUSTER)

Standard setting: -20 clicks.
To reset the standard setting, remove cap (B) and turn the adjuster (A) clockwise

until reaching fully closed position. Then turn it back by the mentioned clicks.

In order to obtain a smooth braking action, turn the adjuster counter clockwise.

Vice versa to obtain a harder braking action.
b) REBOUND (TOP ADJUSTER)

Standard setting: -20 clicks.
To reset standard setting, turn adjuster (C) clockwise to reach the fully closed
position; then, turn it back by the mentioned clicks. In order to obtain a smooth
braking action, turn the adjuster counter clockwise. Vice versa to obtain a harder

braking action.

c) BLEEDING (to carry out after each competition, or monthly).
Set the motorcycle on a central stand, release the fork fully extended, remove cap
(E) and push the bleed valve (D) in with the tip of a pointed tool. Ret the cap.

NEVER loosen the screw (F).

NOTE: Never force the adjuster screws beyond the maximum open and closed

positions.

D.28 Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

KAYABA front fork adjustment (TC - TE - TXC / 2010)

- COMPRESSION (Fig. a)

(TC - TXC: TOP ADJUSTER; TE: LOWER ADJUSTER)
KAYABA: -13 clicks (TC - TXC / 2010);

KAYABA: -10 clicks (TE / 2010);
To reset the standard setting, turn cap nut (A) clockwise to reach the fully closed

position; then, turn it back by the mentioned clicks. In order to obtain a smooth
braking action, turn the adjuster counter clockwise. Vice versa to obtain a harder
braking action.

- REBOUND (Fig. b)

(TC - TXC: LOWER ADJUSTER; TE: TOP ADJUSTER)
KAYABA: -9 clicks (TC - TXC / 2010);

KAYABA: -10 clicks (TE / 2010).
To reset standard setting, turn adjuster (C) clockwise to reach the fully closed

position; then, turn it back by the mentioned clicks. In order to obtain a smooth
braking action, turn the adjuster counter clockwise. Vice versa to obtain a harder
braking action.

- BLEEDING (Fig. a/b) (to carry out after each competition, or monthly).

Set the motorcycle on a central stand, release the fork fully extended and loosen
the bleed valve (D). Once this operation is over, tighten the valve.

NOTE: Never force the adjuster screws beyond the maximum open and closed
positions.

D.29

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

KAYABA front fork springs

STANDARD
(TC - TXC / 2010): K=4.4 N/mm (spring part no. 8000 H2669)

(TE / 2010): K=4.2 N/mm (spring part no. 8000 H2690)

D.30 Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

MARZOCCHI front fork springs

STANDARD

K=4.8 N/mm (spring + spacer part no. 8000 H1994)

D.31

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

Steering bearing clearance adjustment

For safety reasons, the steering should always be adjusted so that the handlebar
turns freely and without play. To check steering adjustment, set a stand or a block

under the engine and see that the front wheel is lifted from the ground. Press
lightly on the handlebar grips to cause the front end to rotate; the handlebar should
turn smoothly. Sit on the ground in front of the front wheel and hold the lower
ends of the fork legs. Push and pull in a front to rear motion to feel for play.

If any play is detected, adjust as follows:

- Loosen the steering head tube nut (1);

- Loosen the four bolts (3) that secure the fork legs to the steering head; ­Turn the steering head tube ring nut (2) clockwise using the special key until
achieving correct play adjustment;

- Tighten the steering head tube nut (1) to 8÷9 Kgm. (78.4÷88.3 Nm);

- Tighten the four bolts (3) on the steering head to 22.5-26.5 Nm (2.3-2.7
Kgm).

Steering angle adjustment

Steering angle can be modied by means of the adjuster assemblies located on
either side of the steering head tube as follows: loosen the check nut (1), turn

the adjuster screw (2) until setting the desired steering angle and then re-tighten
the check nut (1). Make the same changes on both sides.

D.32 Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

Changing handlebar position and height

Handlebar position (a) and height (b) can be modied to better suit your personal
preferences. To perform these adjustments, remove the handlebar clamp bolts
(3) and (4), and then remove the handlebar upper (1) and lower (2) clamps.

a) Changing handlebar position
Rotate the lower clamp by 180° to move handlebar position forward or back-

ward (10 mm - 0.04 in.).
b) Changing handlebar height
Remove the lower spacer (A) and replace the screw (4) with a 65 mm long

screw.

When nished, tighten the bolts (3) to 2.75-3.05 kgm (27 -30 Nm; 19.9-22 lb/ft)

and the bolts (4) to 2.0-2.2 kgm (19.6 -21.6 Nm; 14.5-15.9 lb/ft).

D.33

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

Supply hose check (TC)

Check the hose (1) for leaks and replace it as required.

Remove the supply hose as described in Section "E".

Supply hose check (TE – TXC)

Remove saddle and side panels as described in Section "E".
Remove the tank (1) retaining screw (2).
Lift the tank (2) and check the hose (3) running from the pump (4) to the throttle
body (5).

To replace the hose, squeeze the two retainer tabs (6) at one end of the hose

and detach hose. Repeat at the other end of the hose.

D.34 Part. N. 8000 H1489 (10-2009)

SETTINGS AND ADJUSTMENTS

Silencer sound deadening material replacement

Turn the rear xing (1) counter clockwise and remove the saddle.

Loosen the screws (2) and remove the left-hand side panel (3).

Using an 8 mm T-wrench on the outside and a 10 mm T-wrench on the inside,

remove the silencer retaining screw (4). Remove the spring (5) and then the
screw (8) using an 8 mm T-wrench; remove the silencer. Remove the six rear

rivets (6), the clamp and the exhaust end cap (7).

Remove the inner pipe and replace the sound deadening material. Reassemble
the L.H. side panel and the saddle.

If the silencer proves hard to remove, tap lightly with a rubber or

plastic hammer to aid removal.

D.35

SETTINGS AND ADJUSTMENTS

Part. N. 8000 H1489 (10-2009)

Exhaust system check

Remove exhaust system components as described in Section "E". Check pipes

(1) and (2) silencer (3) for cracks or damage: replace if cracked or damaged.

E.1

E

Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

Section

E.2 Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

Foreword ......................................................................................................E.3

Saddle removal.............................................................................................E.4

Side panel removal .......................................................................................E.4

Removing the rear chassis complete with mudguard and

air box (TC) ...................................................................................................E.5

Removing the rear chassis complete with mudguard and

air box (TE–TXC)..........................................................................................E.5

Battery removal ............................................................................................E.7

Exhaust system removal ..............................................................................E.8

Fuel tank, scoop and spoiler removal (TC).................................................E.10

Fuel tank, scoop and spoiler removal (TE–TXC)........................................E.13

Fuel pump removal (TE–TXC)....................................................................E.16

Solenoid starter removal (TE–TXC) ...........................................................E.17

CDI electronic control unit removal.............................................................E.18

Voltage regulator removal (TE–TXC)

.........................................................E.18

Ignition coil removal

....................................................................................E.19

Clutch hose removal ...................................................................................E.20

Horn removal (TE) ......................................................................................E.20

Electric cooling fan removal (TE–TXC) ......................................................E.21

Secondary drive chain removal

..................................................................E.22

Engine removal...........................................................................................E.22

Radiator removal ........................................................................................E.30

Thermostat removal (TE–TXC)

..................................................................E.31

E.3Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

Foreword

This section describes the operations preliminary to engine removal.
Please note that, in order to gain access to certain motorcycle components (rear
shock absorber, electrical parts, wiring, etc.), it may be necessary to partially
remove some parts.

RIGHT-HAND SIDE LEFT-HAND SIDE

E.4 Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

Saddle removal

- Turntherearxing(1)counterclockwiseandremovethesaddle.

Side panel removal

- Remove the saddle as described in the relevant paragraph.

- Loosen the retaining screws (1) and remove the side panels (2) and (3).

Battery removal (TE - TCX)

- Remove the saddle as described in the relevant paragraph.

- First remove the BLACK negative cable (8 mm Allen wrench), then the RED

positivecable(whenreassembling,rstconnecttheREDpositivecable,then

the BLACK negative cable); remove the battery (1) from its housing.

E.5

H00633

2

1

Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

Removing the rear chassis complete with mudguard and air box (TC)

- Remove the saddle as described in the relevant paragraph.

- Remove the side panels as described in the relevant paragraph.

- Lift the tank at the rear end.

- Remove the exhaust silencer as described in the relevant paragraph.

- Slacken the clamp (1) that secures the rubber coupling (2) of the air box (3)
at the carburettor end.

- Removetheupperxing(4)andlowerxings(5)onbothsidesoftherear

chassis using a 10 mm ring wrench.

- Pull the rear chassis (6) rearwards together with mudguard and air box, and
detach it from the main chassis.

Removing the rear chassis complete with mudguard and air box
(TE – TXC)

- Remove the following parts in the order given: saddle, side panels, fuel tank,
silencer and battery (see relevant paragraphs for instructions).

- Shear the plastic clips securing wiring to rear chassis.

- Disconnect the connector (1) of the turning indicator relay (2) (TE).

- Remove the solenoid starter (3) from its mount.

E.6

H00621

8

7

Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

- Disconnect the connector (4) of the tail light unit (TE).

- Detach relays (5) and fuses (6) on the right-hand side of the motorcycle.

- Detachthebreatherhose(7)fromtheairlter(8).

E.7Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

- Unscrewtheclamp(9)connectingairlter(8)tothrottlebody(10).

- Remove the four screws (11) of the rear chassis (12) using a 10 mm ring
wrench.

- Pull the rear chassis (12) rearwards together with mudguard and air box ,
and detach it from the main chassis.

E.8

H00625

TC

TE-TXC

Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

Exhaust system removal

- Remove the saddle as described in the relevant paragraph.

- Remove the left-hand side panel as described in the relevant paragraph.

- Using an 8 mm T-wrench on the outside and a 10 mm T-wrench on the inside,
remove the silencer (4) retaining screw (1).

E.9Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

- Remove the spring (2) and the screw (3) using an 8 mm T-wrench; slide out
the silencer (4).

- Disconnect the Lambda sensor connector (7) and shear the wiring clips (TE­TXC).

E.10 Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

- Loosen the two bolts (5) and remove the exhaust pipe (6).

Fuel tank, scoop and spoiler removal (TC)

E.11Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

- Remove the saddle as described in the relevant paragraph.

- Remove the side panels as described in the relevant paragraph.

- Remove the breather hose (1) from the steering stem.

- Turn the ring nut of the fuel cock (2) counter clockwise to shut off fuel supply
and loosen the clamp (3) on the hose running to the carburettor. Detach the
hose at carburettor end and let fuel drain into a pan.

- Loosen the fuel tank retaining screw (6).

E.12 Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

- Remove the screws (4) retaining the scoops to the fuel tank. Remove the
scoops (7) and the screws (5) retaining the spoilers (8) to the radiators.
Remove the spoilers and slide out the tank.

E.13

H00630

Husqvarna

3

4

3

3

4

1

2

14

10

6

7

9

8

3

4

3

5

6

Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

Fuel tank, scoops and spoiler removal (TE – TXC)

- Remove the saddle as described in the relevant paragraph.

- Remove the side panels as described in the relevant paragraph.

- Remove the breather hose (1).

- Loosen the fuel tank retaining screw (2).

E.14 Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

- Remove the screws (3) retaining the scoops to the fuel tank. Remove the
scoops (4) and the screws (5) retaining the spoilers (6) to the radiators and
then remove the spoilers.

E.15

H00645

8

9

Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

- Disconnect the fuel pump connector (7) from the main wiring harness.

- Liftthetankanddisconnectthehose(8)fromthefuelpumpoutlettting(9)

in the bottom section of the tank.

- Slide out the tank (10).

E.16

H00648

2

Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

Fuel pump removal (TE – TXC)

- Remove the fuel tank as described in the relevant paragraph.

- Removethetankllercapandpourthefuelcontainedinthetankintoaves­sel of adequate capacity.

- Use an Allen wrench to loosen the 6 screws (1) and remove the pump (2).

WARNING

On assembly, make sure that the pump O-ring (3) is correctly po-

sitioned in its seat.

E.17Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

Solenoid starter removal (TE – TXC)

- Remove saddle and left-hand side panel (in this order) as outlined in the
relevant paragraphs.

- Disconnect the negative and positive cables of the battery.

- Disconnect the starter motor positive cable (1) from the solenoid starter.

- Disconnect the connector (2) and remove the solenoid starter (3) from its
mount.

E.18 Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

CDI electronic control unit removal

Remove: saddle and fuel tank as described in the relevant paragraphs.
Detach the connector (1) from the CDI electronic control unit (2) and take the
control unit together with its vibration mount out of the chassis.

Voltage regulator removal (TE – TXC)

- Remove the electronic control unit as described in the relevant paragraph.

- Disconnect the connector (1).

E.19

H00658

2

3

TE-TXC

H00660

2

3

1

TE-TXC

Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

- Loosen the two retaining screws (2) and remove the regulator (3).

Ignition coil removal

- Remove: saddle and fuel tank as described in the relevant paragraphs.

- Remove the spark plug cap (1).

- Remove the retaining screws (2) and then the coil (3).

E.20 Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

Clutch hose removal

- Loosenthetting(1)oftheclutchhose(2)ontheleft-handoftheengine.

- Drain any oil left in the hose. On assembly, bleed the clutch system as de­scribed in Section "P".

Horn removal (TE)

- Remove saddle and fuel tank (in this order) as outlined in the relevant para­graphs.

- Loosen the screw (1) securing the spoiler to the right-hand radiator.

- Disconnect the two connectors (2) and remove the horn (3) with its bracket.

E.21Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

Electric cooling fan removal (TE – TXC)

- Remove saddle, fuel tank and scoops (in this order) as outlined in the relevant
paragraphs.

- Disconnect the connector (1).

- Loosen the screw (2) and remove the electric fan (3).

E.22 Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

Secondary drive chain removal

The following procedure applies to both O-ring chains and chains without O­rings:

- Remove: screws (1), sprocket guard (2), clip (3), master link (4) and chain
(5).

Engine removal

- Remove the saddle as described in the relevant paragraph.

- Remove the side panels as described in the relevant paragraph.

- Remove the fuel tank as described in the relevant paragraph.

- Remove the exhaust system as described in the relevant paragraph.

- Slacken the drain screw (1) and drain fuel into a vessel (TC).

E.23

H00665

4

7

5

8

6

9

Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

(TC)

- Slacken the clamps (2) and (3) securing the carburettor to the intake coupling
and to the hose coupling on the air box. Pull the carburettor rearwards to
release it from the intake coupling and extract it from the right-hand side of
the motorcycle.

(TE – TXC)

- Disconnect the connectors (4 ) and (5) from the throttle body (6).

- Loosen the clamps (7) and (8).

- Push the intake coupling (9) towards the rear end of the motorcycle to re­lease the throttle body (6) and then extract it from the right-hand side of the
motorcycle.

- Place a vessel on the left-hand side of the cylinder, under the engine.

- Slacken the radiator cap (10).

E.24 Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

- Slacken the clamp (11) and disconnect the hose (12) connecting the radiators

totheengine.Drainalluid.

- Slacken the clamp (13) and disconnect the hose (14) connecting the radiator
to the water pump.

- Remove the oil sump guard, place a pan under the engine and remove the

oilllercap(15);removetheoildrainplug(16)witha12mmwrenchand

drain the oil.

E.25Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

- Remove the spark plug cap (17).

- Remove the clamp (18) and disconnect the hose (19) from the cylinder head
cover.

- Remove the chain as described in the relevant paragraph.

- Remove the chain guide plate (20) unscrewing the screw (21) with an 8 mm
wrench.

E.26

H00674

27

28

TE-TXC

Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

- Loosen the three screws (22) and remove the clutch actuator (23).

(TC)

- Remove the clip (24) that holds clutch hose and wiring harness together.

- Disconnect the connector (25) that connects wiring harness (26) to control
unit.

(TE-TXC)

- Remove the water temperature sensor connector (27).

- Remove the ground cables (28).

E.27

H00676

30

31

TE-TXC

H00675

29

TE-TXC

Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

- Remove the positive power supply cable (29) of the starter motor.

- Disconnect the gear sensor connector (30) and the ignition connectors
(31).

- Shear the clips securing engine wiring to chassis to release the wiring har­nesses.

- To remove the brake lever (32), use an 8 mm wrench to loosen the master
cylinder linkage (33) and a 6 mm Allen wrench to loosen the central screw
(34). Remove the lever.

E.28 Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

- Loosen the upper retaining screw (35) of the shock absorber (36) with a 14
mm wrench.

- Remove the guards (37) on both sides shearing the clips (38).

E.29Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

- Remove the engine mounting bolts (39) using a 12 mm wrench on the left­hand side and a 10 mm wrench on the right-hand side.

- Loosen the swinging arm axle nut (40) using a 22 mm wrench; pull out the axle
from the right-hand side of the engine and pull the swinging arm rearwards
to facilitate engine removal.

- Lift the engine, tilt it to the left and remove it from the motorcycle.

- Place the engine on a rotating stand to perform the procedures described in
Sections F-G-H.

E.30

H00685

13

7

6

8

H00683

2

4

3

1

5

H00687

9

10

11

12

Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

Radiator removal

- Remove the fuel tank together with scoops and spoilers as outlined in the
relevant paragraphs.

- Remove the electric cooling fan (TE – TXC) as described in the relevant
paragraph.

- Place a pan under the hose (1) to collect coolant, then loosen the clamp (2),
detach the hose (1) and drain all coolant.

- Loosen the clamp (3) and disconnect the hose (4) from the left-hand radiator
(5).

- Loosen the clamp (6) and disconnect the hose (7) from the right-hand radiator
(8).

- Remove the plastic grids (9) from the radiators.

- Remove the clamp (10) and disconnect the radiator connecting hose (11).

E.31

H00690

3

3

2

1

1

Part. N. 8000 H1489 (10-2009)

GENERAL PROCEDURES

- Loosen the screws (12) and remove the left-hand radiator (5).

- Loosen the screws (13) and remove the right-hand radiator (8).

Thermostat removal (TE – TXC)

- Remove the fuel tank and the left-hand spoiler as outlined in the relevant
paragraph.

- Loosen the three clamps (1) securing the thermostat (2).

- Disconnect the hoses (3) and remove the thermostat (2).

F.1

F

Part. no. 8000 H1489 (10-2009)

ENGINE DISASSEMBLY

Section

F.2 Part. no. 8000 H1489 (10-2009)

ENGINE DISASSEMBLY

Layout of engine components ......................................................................F.3

Cylinder head cover removal ........................................................................F.4

Camshaft removal ........................................................................................F.4

Water pump body removal ...........................................................................F.8

Water pump disassembly ............................................................................. F.8

Cylinder head removal................................................................................F.10

Valve removal .............................................................................................F.12

Cylinder removal.........................................................................................F.14

Piston removal ...........................................................................................F.14

Flywheel removal .......................................................................................F.15

Kick start pedal removal ............................................................................. F.16

Sprocket removal .......................................................................................F.16

Oil lter removal .........................................................................................F.18

Clutch cover removal ..................................................................................F.19

Clutch disassembly.....................................................................................F.20

Slider removal.............................................................................................F.23

Kick start disassembly ................................................................................ F.23

Starter motor removal (TE–TXC)................................................................F.25

Starter motor disassembly (TE–TXC).........................................................F.27

Starter drive disassembly (TE – TXC)

........................................................ F.27

Oil pump disassembly

................................................................................F.30

Gear shift pedal and selector assembly removal........................................F.31

Primary drive gear removal ........................................................................F.33

Crankcase disassembly..............................................................................F.34

Gearbox disassembly

................................................................................. F.35

Crankshaft disassembly .............................................................................F.37