Husqvarna TR 650 TERRA (2013), TR 650 STRADA (2013) Workshop Manual

TR 650 TERRA 2013

TR 650 STRADA 2013

Workshop Manual Ed. 09-2012

Rev 01

Revision Record

Rev. No. Date Page Description

01 30/11/2012 a.1 Change revision.

01 30/11/2012 X.4 Tightening torque figures have been revised.

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.

st

edition (09-2012) - Rev. 01

1

simbolo

FOREWORD, TABLE OF CONTENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Workshop Manual

TR 650 TERRA 2013

TR 650 STRADA 2013

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

1st edition (09-2012) - Rev. 01
Printed in Italy

MODELS COVERED (from serial number onwards)

1

TR 650 TERRA (43 kW): ZKH0H11A#DV000001
TR 650 TERRA (43 kW - ABS): ZKH0H11C#DV000001
TR 650 TERRA (35 kW - ABS): ZKH0H11D#DV000001
TR 650 STRADA (43 kW - ABS): ZKH0H11E#DV000001
TR 650 STRADA (35 kW - ABS): ZKH0H11F#DV000001

1. Chassis serial number

H11657

Workshop Manual Ed. 09-2012

a.1

FOREWORD, TABLE OF CONTENTS

simbolo

TR 650 TERRA 2013 - TR 650 STRADA 2013

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.

This publication is for the exclusive use of those HUSQVARNA technicians who have an adequate basic mechanical
preparation and a good knowledge of the vehicles repair procedures. Thus much information has been intentionally

omitted as it was considered superuous. The technicians must adopt special safety procedures that they will deem

necessary in order to prevent damages to the motorbike, to its components, and to people.

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.

Workshop Manual Ed. 09-2012

a.2

FOREWORD, TABLE OF CONTENTS

simbolo

TR 650 TERRA 2013 - TR 650 STRADA 2013

Table of Contents

Title Section

Foreword, table of contents ................................................................................. a

Important notices ................................................................................................. b

General information

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

Troubleshooting

Settings and adjustments ................................................................................... D

General procedures .............................................................................................E

Engine settings and adjustments.........................................................................F

General engine procedures ............................................................................... F1

Cylinder head removal/disassembly .................................................................. F2

Crankcase disassembly.....................................................................................F3

Engine torque gures ........................................................................................F4

Engine parts wear limits ....................................................................................F5

Front suspension .................................................................................................. I

Rear suspension.................................................................................................. J

Brakes ................................................................................................................. L

Electrical system................................................................................................. M

Engine cooling .................................................................................................... N

Tightening torque gures .....................................................................................X

Chassis and wheels.............................................................................................Y

............................................................................................. A

.................................................................................................. C

NOTES

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

a.3

Workshop Manual Ed. 09-2012

IMPORTANT NOTICES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Section

b

b.1

Workshop Manual Ed. 09-2012

IMPORTANT NOTICES

TR 650 TERRA 2013 - TR 650 STRADA 2013

GENERAL SAFETY WARNINGS

Read these general recommendations carefully before using the vehicle.

Carbon monoxide

Only run the engine in an open or very well ventilated area. If you do work in an enclosed area, make sure you use a fume extraction
system.

Exhaust emissions contain carbon monoxide, a poisonous gas which can cause loss of consciousness and even

death if inhaled.

Parts of the vehicle that become hot

Before working on the engine and the exhaust unit, wait for them to cool down; while the vehicle is running, these parts become very
hot and remain hot for some time after turning off the engine.

Risk of burns - work with caution and wear suitable PPE if necessary.

Fuel

The fuel used to power internal combustion engines is highly ammable and explosive.

Do all fuelling and maintenance operations with the engine switched off and in ventilated areas; do not

smoke and avoid contact between the fuel and naked ames, sparks, etc. that may cause an explosion.

Do not dispose of fuel in the environment.

Keep out of reach of children.

Do not tilt the vehicle excessively since this may cause fuel to leak.

Engine

In some cases, coolant may become inammable and if burnt, produce invisible ames which cause burns.

Do not spill coolant onto hot components like the engine or exhaust pipe, etc. since it may ignite.

During maintenance work, wear latex gloves.
Never leave the coolant in open containers in areas accessible to children and animals since it is toxic.

DO NOT remove the radiator cap when the engine is hot; the coolant is pressurised and may cause scalding.

Engine oil

Do not dispose of oil in the environment since it is highly polluting.

Keep out of reach of children.
Wear latex gloves since prolonged contact with the skin can cause serious damage.
Send used oil to special authorised recyclers in accordance with the legal requirements in force in the country where

the vehicle will be used.

Brake uid

Brake uid is highly corrosive and may damage the rubber and painted parts of the vehicle.

While performing maintenance work, protect your eyes by wearing special goggles and wear protective gloves.
In the event of accidental contact with the eyes, rinse them with plenty of clean, running water and seek medical advice

immediately.

Keep out of reach of children.

Workshop Manual Ed. 09-2012

b.2

IMPORTANT NOTICES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Battery

Recharge the battery in well ventilated areas since the battery produces toxic, highly inammable gases when being

recharged; do not smoke or use naked ames or sparks.

The liquid in the battery is highly corrosive. If it comes into contact with the skin, rinse thoroughly with running water.

It is extremely important to protect your eyes because even a small amount of liquid can cause irreversible damage
to the eyes.

If it comes into contact with the eyes, rinse thoroughly with clean, running water and if swallowed accidentally, drink

plenty of water or milk.

In all cases, seek medical advice immediately.

The battery liquid is corrosive and should not be poured onto the painted or rubber parts.

The battery liquid is highly polluting. DO NOT dispose in the environment; at the end of its service life, take the battery

to the special authorised recycling centres in accordance with the legal requirements in force in the country where
the vehicle will be used.

Keep out of reach of children.

H11658

TR 650 TERRA and TR 650 STRADA models are
STREET LEGAL motorcycles; they are guaranteed
exempt from functional defects and covered with
legal guarantee, as far as the STANDARD CON­FIGURATION IS MAINTAINED and the suggested
maintenance table shown in Section "B" is observed.

* 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

Unless otherwise specied, data and instructions

apply to all market variants.

b.3

Workshop Manual Ed. 09-2012

IMPORTANT NOTICES

TR 650 TERRA 2013 - TR 650 STRADA 2013

RECOMMENDED SHOP PRACTICES

Before disassembling components or before performing repair operations, clean the motorbike removing possible mud, dust, or
foreign bodies.

- Put the vehicle in a well lit area;

- Fasten the vehicle in a steady position so that it cannot overturn; use suitable stands and belts.

- Use suitable equipment for lifting/removing heavy parts.

- Use appropriate keys (not pliers) to loosen/tighten nuts and screws.

- 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 or a dedicated pattern as outlined in the relevant section.

- Always mark any parts or positions that might be confused upon assembly.

- Use special tools where specied.

- Clean thoroughly the removed components before retting them

- During the reassembly, make sure that the bearings turn freely without obstruction or without getting stuck, otherwise replace

them

- Always replace the seals, the sealing rings, the split pins, the screws with damaged thread, and the self-locking nuts with new

parts.

- Use genuine HUSQVARNA parts and the recommended lubricant brands.

- At the end of a repair or periodic maintenance, test the vehicle before delivering it to the customer.

Electrical parts

- Disconnect the electrical component connectors by pressing the special safety hooks.

- Make sure that inside the connector there is no dirt or rust; if need be, clean them with an air jet or suitable products.

- Make sure that the cables are correctly seamed to the connector terminals.

- When you reconnect the connectors, ensure the correct coupling.

Do not disconnect the connectors by pulling the electrical cables.

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

Where not specied, ret the previously removed components following the procedures in the reverse order with

respect to the removal.

Workshop Manual Ed. 09-2012

b.4

GENERAL INFORMATION

TR 650 TERRA 2013 - TR 650 STRADA 2013

Section

A

A.1

Workshop Manual Ed. 09-2012

GENERAL INFORMATION

TR 650 TERRA 2013 - TR 650 STRADA 2013

Sommario

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

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

Lubrication ....................................................................................................A.3

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

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

Primary drive ................................................................................................A.3

Clutch ...........................................................................................................A.3

Transmission ................................................................................................A.3

Transmission ratio ........................................................................................A.3

Secondary drive............................................................................................A.3

Final ratios ....................................................................................................A.4

Chassis .........................................................................................................A.4

Front suspension

Rear suspension...........................................................................................A.4

Front brake ...................................................................................................A.4

Rear brake

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

Tyres

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

Table for lubrication, supplies .......................................................................A.5

Electrical components location .....................................................................A.5

Dimensions, weight, capacity

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

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

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

Workshop Manual Ed. 09-2012

A.2

GENERAL INFORMATION

TR 650 TERRA 2013 - TR 650 STRADA 2013

Engine

Single cylinder, 4 stroke engine with four valves

Cooling .............................................................................liquid and electric fan

Bore ...................................................................................... 3,937 in (100 mm)

Stroke ..................................................................................... 3,268 in (83 mm)

Displacement ..................................................................... 39,787 in3 (652 cm3)

Compression ratio ..................................................................................12,3:1

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

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

Timing system

Double overhead camshaft chain operated; 4 valves

Valve clearance (with engine cold)

Intake ............................................................0,009 ÷ 0,011 in (0,23 ÷ 0,28 mm)

Exhaust........................................................ 0,015 ÷ 0,017 in (0,38 ÷ 0,43 mm)

Lubrication

Dry sump with tank integrated in the chassis and cartridge oil lter.

Ignition

Electronic with adjustable advance (digital control)

Spark plug type................................................................ “NGK” MAR9A-J-G06

Spark plug electrode gap....................................................0,024 in (± 0,004 in)

0,6 mm (± 0,1 mm)

Fuel system

Electronic injection feed

Primary drive

Drive gear on crankshaft ............................................................................ Z 37

Driven gear on clutch housing .................................................................... Z 72

Transmission ratio ....................................................................................1.946

Clutch

Multidisc in oil bath with mechanical control

Transmission

With front couplings always engaged

Transmission ratio

1st gear......................................................................................... 2.750 (33/12)

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

3rd gear ........................................................................................ 1.313 (21/16)

4th gear ........................................................................................ 1.045 (23/22)

5th gear ........................................................................................ 0.875 (21/24)

Secondary drive

Transmission sprocket ............................................................................... Z 16

Rear wheel sprocket ................................................................................... Z 47

Transmission ratio ....................................................................................2.938

Drive chain dimensions ..........................................................520KR0 112 links

A.3

Workshop Manual Ed. 09-2012

GENERAL INFORMATION

TR 650 TERRA 2013 - TR 650 STRADA 2013

Final ratios

1st gear....................................................................................................15.722

2nd gear ..................................................................................................10.005

3rd gear ....................................................................................................7.506

4th gear .....................................................................................................5.974

5th gear .....................................................................................................2.898

Chassis

Single frame, in round, rectangular and ellipsoidal steel pipes; rear steel chassis

Front suspension

Upside down type hydraulic fork..............................ø 1.81 in (46 mm) fork legs

Wheel travel ........................................................................... 7.48 in (190 mm)

Rear suspension

Hydraulic monoshock (adjustment of spring preload and rebound hydraulic
damping)

Wheel travel ........................................................................... 7.48 in (190 mm)

Front brake

Ø 11,811 in (300 mm) xed disc with hydraulic control and oating calliper

Rear brake

Ø 9,449 in (240 mm) oating wave disc with hydraulic control and oating calliper

Wheels

TR 650 STRADA
Front

.................................................................................in light alloy: 2.5”x19”

.....................................................................................in light alloy: 3”x17”

Rear

TR 650 TERRA

Front ................................................ with spokes and aluminium rim: 1.85”x21”

Rear

....................................... with spokes and aluminium rim: 3”x18” (no ABS)

with spokes and aluminium rim: 3”x17” ( ABS)

Tyres

TR 650 STRADA

Front ............................................................................... 110/80 R19” M/C 59 V

................................................................................ 140/80 R17” M/C 59 V

Rear
Cold tyre pressure (Rider only)
Front

................................................................................2.2 kg/cm2 (31.29 psi)

................................................................................. 2.0 kg/cm2 (28.45 psi)

Rear
Cold tyre pressure (Rider and passenger)

Front ................................................................................2.2 kg/cm2 (31.29 psi)

Rear

................................................................................. 2,5 kg/cm2 (35.56 psi)

TR 650 TERRA

....................................................................90/90 21” M/C 54 H TL (ABS)

Front
90/90 21” M/C 54 S (no ABS)

Rear ........................................................................140/80 17” M/C 59 H (ABS)

140/80 18” M/C 70 S (no ABS)
Cold tyre pressure (Rider only)

Front ................................................................................2.0 kg/cm2 (28.45 psi)

Rear

................................................................................. 2.5 kg/cm2 (35.56 psi)

Cold tyre pressure (Rider and passenger)

Front ................................................................................2,0 kg/cm2 (28.45 psi)

................................................................................. 2,8 kg/cm2 (39.82 psi)

Rear

Workshop Manual Ed. 09-2012

A.4

GENERAL INFORMATION

TR 650 TERRA 2013 - TR 650 STRADA 2013

Table for lubrication, supplies

Engine, gearbox and primary drive

lubricating oil................................ CASTROL POWER1 RACING SAE 10W-50

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

Brake uid ...........................................CASTROL RESPONSE SUPER DOT 4

Grease lubrication ....................................................CASTROL LM GREASE 2

Secondary drive chain lubrication................ CASTROL CHAIN LUBE RACING

Electric contact protection ......................CASTROL METAL PARTS CLEANER

Electrical components location

The ignition system includes the following elements:

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

- Electronic ignition coil with integrated spark plug cap positioned on cylinder head;

- Electronic control unit on rear chassis under saddle;

- Spark plug on cylinder head;

- Starter motor in front of cylinder block;

- Solenoid starter on rear chassis under saddle;

- Potentiometer on throttle body;

- Voltage regulator on right-hand side of engine;

- Neutral position sensor on right-hand side of engine.

The electrical system includes the following elements:

- 12V - 10Ah battery in the central part;

- Turning indicator asher integrated in the digital instrument;

- Fuel pump relay, main relay and fan on rear chassis under saddle;

- Electric fan;

- Auxiliary fuses on rear chassis under saddle; two 30A main fuses on solenoid starter;

- Coolant temperature sensor on cylinder head;

- Lambda sensor;

- Headlamp with H4-12V-55/60W HD halogen bulb and 12V-5W LL parking light bulb;

- LED tail light with stop light bulb;

- 12V-RY10W turning indicator bulbs;

- Fuel pump inside the tank.

- Multifunction digital instrument.

A.5

Workshop Manual Ed. 09-2012

GENERAL INFORMATION

TR 650 TERRA 2013 - TR 650 STRADA 2013

Dimensions, weight, capacity

Wheelbase ............................................................................................................................55,055 in (1500 mm)

Total length (STRADA) ........................................................................................................ 88,504 in (2248 mm)

Total length (TERRA)............................................................................................................ 89,252 in (2267 mm)

Overall width ...........................................................................................................................34,843 in (885 mm)

Max. height (STRADA) ......................................................................................................... 47,441 in (1205 mm)

Max. height (TERRA) ............................................................................................................. 48,15 in (1223 mm)

Saddle height (STRADA).........................................................................................................33,858 in (860 mm)

Saddle height (TERRA) ..............................34,449 in (875 mm) (no ABS - 18”) / 34,055 in (865 mm) (ABS - 17”)

Minimum height off ground (STRADA) .....................................................................................9,843 in (250 mm)

Minimum height off ground (TERRA) ............. 10,472 in (mm 266) (no ABS 18”) / 10,118 in (257 mm) (ABS 17”)

Weight, without fuel (STRADA). ..............................................................................................390,218 lb (177 kg)

Weight without fuel. (TERRA) ......................................................................................................383,604 (174 kg)

Fuel tank capacity including reserve

Fuel reserve................................................................................... approx. 0,55 Imp. Gall. / 0,66 U.S. Gall. / 2.5 l

Coolant tank capacity ........................................................................... 0,255 Imp. Gall. / 0,306 U.S. Gall. / 1.16 l

Oil and oil lter replacement

Topping up oil between minimum and max. level ................................. 0,055 Imp. Gall. / 0,066 U.S. Gall. / l 0.25

.................................................................... 0,44 Imp. Gall. / 0,528 U.S. Gall. / 2.0 l

......................................................... 3,08 Imp. Gall. / 3,698 U.S. Gall. / l 14

Workshop Manual Ed. 09-2012

C

D

1500 mm

A

B

885 mm

H11659

A.6

MAINTENANCE

TR 650 TERRA 2013 - TR 650 STRADA 2013

Section

B

All tightening indicated with the letter "S" (Safety) in section X "Tightening Torques" must be checked at each service

or whenever other maintenance/repair work is carried out.

Workshop Manual Ed. 09-2012

B.1

MAINTENANCE

TR 650 TERRA 2013 - TR 650 STRADA 2013

TR 650 STRADA

TR 650 TERRA

SERVICE
COUPON

AFTER

THE FIRST

1.000 Km

Check engine oil level

Replace engine oil together with oil lter,

clean magnetic plug

Check / adjust valve play C/R C/R C/R C/R

Replace spark plugs

Oil lter (on oil return pipe from chassis) P/S P/S

Replace coolant EVERY 2 YEARS

Check / adjust clutch play C/R C/R C/R C/R C/R

C S S S S

S S S S S

(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)

10.000 Km

SCHEDULED MAINTENANCE CHART

ENGINE

SERVICE
COUPON

EVERY

SERVICE
COUPON

EVERY

20.000 Km

S S

SERVICE
COUPON

EVERY

30.000 Km

SERVICE
COUPON

EVERY

40.000 Km

EVERY

1.000 Km

EVERY

10.000 Km
or

ONCE A

YEAR

EVERY

20.000 Km

C: Check
S: Change
R: Reset

Workshop Manual Ed. 09-2012

B.2

MAINTENANCE

TR 650 TERRA 2013 - TR 650 STRADA 2013

TR 650 STRADA

TR 650 TERRA

(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)

SCHEDULED MAINTENANCE CHART

CHASSIS

SERVICE
COUPON

AFTER THE

FIRST

SERVICE
COUPON

EVERY

10.000 Km

SERVICE
COUPON

EVERY

20.000 Km

SERVICE
COUPON

EVERY

30.000 Km

SERVICE
COUPON

EVERY

40.000 Km

1.000 Km

Check and lubricate secondary chain

Lubricate the secondary drive chain at least once every 1,000 km.

If used on dusty or wet roads, do this more frequently

Second.Drive chain: check tension and
wear

C/L C/L/S C/L/S C/L/S C/L/S

Check front/rear sprockets for wear: if nec­essary, replace along with the secondary

C/L/S C/L/S C/L/S C/L/S

drive chain

Air lter S S

If the vehicle is used in very dusty conditions/on very dusty roads, reduce this service

to 10,000 km

Safety tightening check

C/R C/R C/R C/R C/R

Transmission cables and controls C/R/L C/R/L C/R/L C/R/L C/R/L

Steering bearings and steering clearance C/R C/R C/R C/R

Emptying the intake silencer hose C/P C/P C/P C/P

Brake discs C/S C/S C/S C/S

Brake pad wear C/S C/S C/S C/S

Front fork (oil change) S S

General vehicle operation C C C C C

Braking systems (check pipes) C/R C/R C/R C/R C/R

Cooling system (check level) C/S C/S

Lights / warnings C/R C/R C/R C/R C/R

Safety switches C/R C/R C/R C/R

Brake uid

Coolant

(1)

(3)

C/R C/R C/R C/R C/R

C/R C/R C/R C/R C/R

Checking battery charge level C/R C/R C/R C/R

Tyres: Pressure / Wear C/R C/R C/R C/R

Wheels (checking spoke tension - terra
version)

C/R C/R C/R C/R

Control unit diagnosis C/R C/R C/R C/R C/R

Side stand C/R/L C/R/L C/R/L C/R/L

Checking function and clearance of ac­celerator cable

Fuel hoses

(2)

C/R C/R C/R C/R

C/S

Check cooling-water tubes and water

pump for condition and leakage / replace

C C C C

if necessary

S: Change
L: Lubricate
P: Clean
R: Reset

B.3

C: Check

(1):

Replace every 2 years

(2):

Replace every 4 years

(3):

Replace every year

Workshop Manual Ed. 09-2012

TROUBLESHOOTING

TR 650 TERRA 2013 - TR 650 STRADA 2013

Section

C

C.1

Manuale d'officina Ed. 09-2012

TROUBLESHOOTING

TR 650 TERRA 2013 - TR 650 STRADA 2013

ENGINE

Trouble Possible causes Remedy

Ignition switch not in ON position Switch ignition switch to position ON

Engine-stop-switch on OFF position Switch to position ON

Starter motor does not operate or does not
turn engine over

Engine turns over but does not start engine
or starts hard

Engine runs irregularly at idle

Flat battery, loose or rusty connections

Ignition circuit in short-circuit Check ignition circuit

Starter motor defect Replace starter motor

Spark plugs loose Tighten spark plugs

Spark plugs not according to specications

or defective

Spark plugs fouled or wet Clean or exchange

Battery nearly discharged, starting rpm
too low

Fuel supply inadequate

Valve clearance below specication

Valve timing incorrect Adjust position of camshaft gears

Ignition coil or ignition cable defective Check / replace

Ignition unit defective, ignition timing incor­rect

Cylinder gasket defective Exchange cylinder head gasket

Valves and valve guides worn or imperfect
valve seat

Piston rings and/or cylinder bore worn Exchange piston rings and/or cylinder

Engine oil too heavy (winter operation) Exchange engine oil

Excessive spark plug electrode gap Exchange spark plug

Valve clearance below specication

Intake coupling not tightened or damaged

Ignition unit defective, ignition timing incor­rect

Valves leaking Rework valve seats

For other possible causes see also "Engine
starts over but does not start engine or
starts hard"

Check/replace battery and check connec­tions, check charging system

Replace spark plug

Check/replace battery and check con­nections, check if battery is charged by
generator

Check fuel tank if empty
Check / replace fuel supply pipes, fuel pump,
fuel pressure sensor and injectors

Adjust valve clearance according to speci-

cation

Check / replace crank position trigger and
ECU

Exchange valves, rework valve seats or
exchange cylinder head

Adjust valve clearance according to speci-

cation

Tighten intake socket or exchange if nec­essary

Check / replace crank position trigger and
ECU

Manuale d'officina Ed. 09-2012

C.2

TROUBLESHOOTING

TR 650 TERRA 2013 - TR 650 STRADA 2013

Trouble Possible causes Remedy

Check fuel pressure sensor, fuel pump and
fuel supply

Replace spark plug

Adjust valve clearance according to speci-

cation

Check / replace ignition coil

Check / replace crank position trigger and
ECU

Check fuel pressure sensor, fuel pump and
fuel supply

Exchange piston rings and/or cylinder

Use fuel of specied octane number (min.

ROZ 95)

Replace spark plug

Check / replace intake socket and intake
system

Check / replace crank position trigger and
ECU

Engine runs irregularly at higher speed

Engine has no or insufcient performance

Engine knocks or pings

Fuel pressure too low

Leak air Check / replace intake socket

Camshafts worn Check and replace if necessary

For other possible causes see also "Engine
starts over but does not start engine or
starts hard"

Leak air, intake system leaking Check / replace intake socket

Spark plugs not according to specications

or defective

Valve clearance not according specication

Valve timing incorrect Adjust position of camshaft gears

Ignition coil supplies insufcient ignition

voltage

Ignition unit defective, ignition timing incor­rect

Valves leaking Exchange valves, rework valve seats

Clutch slipping See remedies "clutch is slipping".

Fuel pressure too low

Air lter dirty Exchange

Exhaust system defective Exchange

Excessive Blow-by gases, Piston rings and/
or cylinder bore worn

Engine oil not according to specications Exchange engine oil

Fuel of too low octane number

Spark plugs not according to specications

or defective

Leak air, intake system leaking

Ignition unit defective, ignition timing incor­rect

C.3

Manuale d'officina Ed. 09-2012

TROUBLESHOOTING

TR 650 TERRA 2013 - TR 650 STRADA 2013

Trouble Possible causes Remedy

Not enough coolant in cooling system, cool­ing system leaking, air in cooling system

Cooling fan motor defective Replace cooling fan motor

Not enough engine oil in the engine Rell oil

Radiator dirty Clean radiator

Faulty thermostatic valve Replace

Engine overheats

Engine temperature is too low Faulty thermostatic valve Replace

Engine produces excessive blue smoke or
engine uses too much oil

Engine vibrates

Engine oil quantity increases

Low or no engine oil pressure

Ignition unit defective, ignition timing incor­rect

Water pump, water pump drive defective

Oil pump or oil pump drive defective, oil
circuit blocked

Cylinder head gasket defective Exchange cylinder head gasket

Leak air Check / replace intake socket

Too much oil in the engine (oil in the airbox) Drain engine oil

Cylinder head gasket leaking Exchange cylinder head gasket

Valve stem seals leaking Exchange valve stem seals

Oil diluted with fuel / Piston rings and/or
cylinder bore worn

Oil diluted with fuel / motocycle is only used
in short distances (cold engine)

Engine xation into frame loose Tighten engine xation

Bearing or bearing seat worn Replace bearing or worn component

Oil diluted with fuel / motocycle is only used
in short distances

Oil diluted with fuel / Piston rings and/or
cylinder bore worn

Not enough engine oil in the engine Rell oil

Pressure regulating piston blocked (bypass
valve stuck in opened position)

Oil pump and/or oil pump drive defective

Oil pump worn Replace oil pump

Oil diluted with fuel / Piston rings and/or
cylinder bore worn

Oil diluted with fuel / motocycle is only used
in short distances

Oil sieve / oil lter dirty/blocked Clean / replace oil sieve and replace oil lter

Rell coolant, check system under pressure

Check / replace crank position trigger, ECU
and sensors

Repair water pump, check and renew water
pump drive

Exchange oil pump or oil pump gears,
clean oil circuit

Exchange piston rings and/or cylinder

Use motorcycle at long distances in between

Use motorcycle at long distances in between

Exchange piston rings and/or cylinder

Check/replace pressure regulating piston

Check / replace oil pump and/or oil pump
drive

Exchange piston rings and/or cylinder

Use motorcycle at long distances in between

Manuale d'officina Ed. 09-2012

C.4

TROUBLESHOOTING

TR 650 TERRA 2013 - TR 650 STRADA 2013

Trouble Possible causes Remedy

High engine oil pressure

Pressure regulating piston blocked (bypass
valve stuck in closed position)

Oil circuit blocked Clean oil ducts

Check/replace pressure regulating piston

C.5

Manuale d'officina Ed. 09-2012

TROUBLESHOOTING

TR 650 TERRA 2013 - TR 650 STRADA 2013

Trouble Possible causes Remedy

Noise is heard when the engine is started:

Sprag clutch, sprag clutch housing or free­wheel gear worn

Teeth of starter motor and/or starter drive
gears worn

Chain tensioner does not work

Noise seems to come from the valve train:

Excessive valve clearance

Chain tensioner does not work Replace chain tensioner

Camshaft or brackets of camshaft worn Replace camshafts and/or cylinder head

Camshaft drive worn or loose Tighten or replace camshaft gears

Camshaft chain, chain guide or chain ten­sion guide worn

Noise seems to come from the piston:

Replace Sprag clutch, sprag clutch housing
or freewheel gear

Replace starter motor and/or starter drive
gears

Noise disappears after the engine is started
when oil pressure is available

Adjust valve clearance according to speci-

cation

Replace camshaft chain, chain guide or
chain tension guide

Engine excessively noisy

Piston or cylinder worn Replace piston or cylinder

Piston pin bore or piston pin worn Replace piston pin bore or piston pin

Piston rings broken or ring grooves worn

The noise seems to come from the
crankshaft, countershaft or crankcase:

Bearings of crankshaft or conrods worn Replace the crankshaft

Worn needle bushing and/or balancer shaft
bearings and/or balancing connecting rod

Noise seem to come from the clutch or
clutch side:

Friction plates (hammer heads) and/or
clutch drum worn

Excessive or insufcient backlash of the

teeth of the primary drive gears

Clutch drum, clutch hub or pressure plate
worn

Bearing of clutch gear worn Replace primary drive assy.

Disk springs of primary drive assy. worn Replace primary drive assy.

Springs and spring retainers of primary
drive assy. Worn

Noise with clutch engaged - ball bearing of
the pressure plate worn

Noise seem to come from the gearbox:

Tooth anks of the gearbox gears worn

Ball bearing of gearbox shafts and/or needle
bearings of gears worn

Replace piston rings broken or ring grooves

Replace the balancer shaft

Replace friction plates and /or clutch drum

Replace primary drive assy.

Replace clutch drum, clutch hub or pres­sure plate

Replace springs and spring retainers

Replace ball bearing

Check gears and gear shafts, replace if
necessary

Replace bearings

Manuale d'officina Ed. 09-2012

C.6

TROUBLESHOOTING

TR 650 TERRA 2013 - TR 650 STRADA 2013

Trouble Possible causes Remedy

Fatigue of clutch springs Replace clutch springs

Clutch slips

Clutch disengages unsatisfactorily

The clutch drags

Gears do not engage or gears jump out at
start or at abrupt acceleration

Clutch plates worn or warped Replace clutch plates

Engine oil not according to specications Exchange engine oil

Engine oil not according to specications Exchange engine oil

Clutch plates warped Exchange clutch plates

Clutch plates stuck together Clean or exchange

Clutch plates worn or warped Replace clutch plates

Guide slots for friction plates in clutch drum
are worn

Guide slots for steel plates in clutch hub
are worn

Gearshifting action incomplete Always actuate gearshift lever till stop

Gearshift lever incorrectly adjusted Correct position of gearshift lever

Fastener of gearshift lever loose Tighten fastener

Gearshift lever bent Replace gearshift lever

Function of index lever or index spring
imperfect

Adjustment of gearshift pawl incorrect

Engagement teeth and/or windows of gear­box gears badly worn

Gearshift forks are worn or bent Exchange gearshift forks

Replace clutch drum

Replace clutch hub

Check index lever and index spring and
exchange if necessary

Check and adjust pawl wich spring, ex­change if necessary

Exchange gears

Gearbox gears are worn or damaged Exchange gearshift gearbox gears

The clutch does not disengage See "Clutch disengages unsatisfactorily"

Gears can be shifted only noisily Clutch does not disengage See "Clutch disengages unsatisfactorily"

Spark plugs not according to specications Replace spark plug

Spark plugs loose Tighten spark plugs

Spark plugs overheated, burnt or dirty

The generator does not charge the battery

Intake socket not tight or leaking

Fuel supply system defective Check and replace if necessary

Battery faulty, loose or corroded connections

Rectier regluator defective Replace rectier regluator

Break in current, short circuit or earthing of
stator windings

Break in cables or short circuit, connec­tions loose

Tighten intake socket or exchange if nec­essary

Check/replace battery and check connec­tions

Replace stator

Check and replace if necessary

C.7

Manuale d'officina Ed. 09-2012

TROUBLESHOOTING

TR 650 TERRA 2013 - TR 650 STRADA 2013

CHASSIS

Trouble Cause Remedy

Insufcient tyre pressure Inate

Handlebar turns hard

Handlebar vibration

Damping is too hard

Damping is too soft

(Front / rear) wheel shakes

Rear suspension is noisy

Poor braking (front and rear)

Bearing adjuster ring nut or steering stem
nut overtightened

Bent steering stem Replace bottom yoke

Worn or seized steering bearings Replace

Bent fork legs Replace

Bent front wheel axle Replace

Warped chassis Replace

Bent front wheel rim Replace

Worn front wheel bearings Replace

Improperly balanced wheel Balance

Too much oil in fork legs Remove excess oil

Fork oil viscosity too high Change

Overinated tyres Deate

Improperly set rear shock absorber Adjust

Insufcient oil in fork legs Top up

Fork oil viscosity too low Change

Weak fork springs Replace

Weak rear shock absorber spring Replace

Improperly set rear shock absorber Adjust

Bent wheel rim Replace

Worn wheel hub bearings Replace

Wheel axle nut loose Tighten

Worn rear swinging arm bearings Replace

Improperly balanced wheel Balance

Worn shock absorber joints Replace

Shock absorber faulty Replace

Air in brake system Bleed

Insufcient uid in tank Top up

Worn brake pad and/or disc Replace

Damaged disc Replace

Adjust

Manuale d'officina Ed. 09-2012

C.8

TROUBLESHOOTING

TR 650 TERRA 2013 - TR 650 STRADA 2013

ELECTRICAL SYSTEM (see also Section M)

Trouble Cause Remedy

Dirty air lter Clean

Spark plug fouls easily

Spark plug electrodes overheat

Generator does not charge or is not
providing enough charge

Generator overcharges battery Voltage regulator faulty Replace

Battery does not hold charge

Starter motor does not start or slips

Worn piston rings Replace

Worn piston or cylinder liner Replace

Spark plug electrode gap too close Adjust

Wrong heat rating Replace with recommended spark plug

Cables running to voltage regulator im­properly connected or shorted

Voltage regulator faulty Replace

Faulty generator Replace

Battery terminals dirty Clean

Faulty generator Replace

Faulty battery Replace

Battery is at Charge

Control on R.H. switch faulty Replace

Starter relay faulty Replace

Starter motor faulty Repair or replace

Worn starter gears Replace

Worn or damaged freewheel rollers Replace freewheel

Ignition key not recognised Check control unit key immobiliser

Connect correctly or replace

C.9

Manuale d'officina Ed. 09-2012

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Section

D

D.1

Workshop Manual Ed. 09-2012

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Sommario

Saddle removal.............................................................................................D.3

Removal of central upper cover....................................................................D.4

Side panel removal .......................................................................................D.4

Throttle cable adjustment .............................................................................D.5

Throttle control..............................................................................................D.5

Throttle position adjustment .........................................................................D.5

Front brake control .......................................................................................D.5

Position adjustment ......................................................................................D.5

Front brake lever adjustment and uid level check ......................................D.6

Clutch control................................................................................................D.6

Position adjustment ......................................................................................D.6

Clutch control lever distance adjustment ......................................................D.7

Clutch free play adjustment

Rear brake pedal free play adjustment.........................................................D.8

Rear brake uid level check .........................................................................D.8

Oil level check

Engine oil replacement and cartridge lter replacement ..............................D.9

Replacement of cartridge lter....................................................................D.10

Filling

..........................................................................................................D.11

Coolant level check ....................................................................................D.11

Coolant replacement

Air lter check

Chain tension adjustment
Lubricating the chain

Suspension ................................................................................................D.15

Shock absorber spring preload adjustment

Rebound shock absorber hydraulic damping adjustment...........................D.16

Fork adjustment .........................................................................................D.16

Fuel supply hose inspection and replacement

Exhaust system check ................................................................................D.17

Idle speed adjustment
Checking and adjustment of valve clearance

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

.............................................................................................D.13

..........................................................................D.7

..................................................................................D.12

...........................................................................D.14

..................................................................................D.14

................................................D.15

...........................................D.16

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

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

Workshop Manual Ed. 09-2012

D.2

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Saddle removal

2

H11660

2

To remove the saddle proceed as follows:

- Insert the key in the lock (1) positioned in the rear part of the motorcycle;

- turn the key clockwise to release the saddle (2), and then lift it and pull it out
towards the rear, releasing it from the front fastener.

To t the saddle back on, fasten it at the front and then press the rear until the

1

fastening "Click" is heard.

H11661

D.3

Workshop Manual Ed. 09-2012

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Removal of central upper cover

1

1

2

H11662

1

- Unscrew the four screws (1) that fasten the cover (2) and remove it.

1

Side panel removal

- Remove the saddle as described in the relevant paragraph.

- Remove the upper cover as described in the relevant paragraph.

- Unscrew the ve screws (1) and remove the left-hand side panel (2) from

its ttings.

- Repeat to remove the right-hand side panel.

When retting, rst insert the rear and then the front ttings.

H11664

1

1

H11663

1

Workshop Manual Ed. 09-2012

H11665

2

H11666

D.4

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

4

2 mm

(0,8 in.)

1

2 mm

(0,8 in.)

4

3

2

H11667

H11668

Throttle cable adjustment

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

- remove the reservoir and the lter box as outlined in the relevant sections;

- turn throttle twistgrip (1) and make sure that there is a clearance of approx.

2 mm (0.08 in);

- if this does not work, unlock the check nut (2);

- work on the nut (3) until you have about 2 mm clearance (0.08 in.);

- tighten check nut (2).

- reassemble all parts, in the reverse order compared to disassembly.

Operation with damaged throttle cable could result in an unsafe

riding condition.

When throttle control cables (4) are replaced, adjust new cables as previously
explained.

Throttle control

2

1

The throttle twistgrip (1) is located on the right-hand side of the handlebar:

Throttle position adjustment

The position of the control on the handlebar can be adjusted by loosening the
two retaining screws (2).

Do not forget to tighten the screws (2) after adjusting.

2

H11669

Front brake control

The brake control lever (1) is located on the right-hand side of the handlebar.

Position adjustment

1

The position of the control on the handlebar can be adjusted by loosening the
two retaining screws (2).

After adjustment, turn the handlebar as far as possible to the right

and make sure that the lever does not touch the bodywork

A stop switch, during the braking action, causes the stop light on the tail light
to come on.

2

Do not forget to tighten the screws (2) after adjusting.

H11670

D.5

Workshop Manual Ed. 09-2012

2

MIN

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Front brake lever adjustment and uid level check

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

minimum level visible through the inspection sight glass (1) on the side of the
master cylinder (2) body.
A decrease of the fuel level will let air into the sustem, hence an extension of
the level stroke.

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

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

1

H11671

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.

Clutch control

The clutch control lever (1) is located on the left-hand side of the handlebar.

1

Position adjustment

The position of the clutch control on the handlebar can be adjusted by loosening
the retaining screws (2).

After adjustment, turn the handlebar as far as possible to the left

2

H11672

and make sure that the lever does not touch the bodywork.

Do not forget to tighten the screws (2) after adjusting.

Workshop Manual Ed. 09-2012

A "STOP" switch on the clutch lever support allows you to start the engine when
the motorcycle is in gear or the clutch lever is pulled (the stand must be off the
ground).

D.6

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Clutch control lever distance adjustment

The lever (1) can be adjusted (3 settings available) to suit the rider's hand size

To regulate the position of the lever (1) push it outwards and then select the
required position by means of the adjuster screw (2).

1

2

H11673

Clutch free play adjustment

Free play (A) must be 5 -10 mm (0.196 - 0.39 in).

- Move the rubber gaiter (1);

- regulate the adjuster screws (2) and the counter adjuster screw (3) to obtain

A

the indicated free play.

- after completing the operation, make sure the counter adjuster screw (3) is

properly tightened and then replace the rubber gaiter (1).

1

3

2

1

H11674

D.7

Workshop Manual Ed. 09-2012

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Rear brake pedal free play adjustment

Before staring the braking action, rear brake pedal (1) shall have a free play
(B) of 5-10 mm (0,196 ÷ 0,39 in.). Should this not happen, operate as follows:

1

H11675

3

2

- Loosen the nut (2);

- Operate the master cylinder linkage (3) to increase or decrease free play;

- Tighten the nut (2) at the end of the operation.

B

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).

C: to increase clearance
D: to decrease clearance

MIN

D

C

H11676

Rear brake uid level check

MAX

2

The uid level in the master cylinder tank shall never be below the minimum

level (1) shown on the transparent reservoir (2).

A decrease in the uid level will let air into the system and increase the lever

stroke.

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

brake lines or the brake may be defective.

1

Do not spill brake uid onto any painted surface or light lens.

H11677

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.

Workshop Manual Ed. 09-2012

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.8

MAX

MIN

MAX

MIN

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Oil level check

The oil level must be checked with the vehicle in vertical position on a flat sur­face.

1

3

2

H11678

1

- Start the motorcycle and heat the engine until the cooling fan starts; wait for
another 3 minutes and switch off the engine.

- Check the level as follows:

- Undo the cap (1) with the dipstick (2) and remove it from the frame.

- Clean the dipstick (2) with a cloth.

- Place the dipstick (2) in the hole (3) without screwing the cap on.

- Remove the dipstick (2) from the hole (3) and check that the level is be-

tween the two MIN and MAX marks.

- To top up, pour oil into the hole (3); for the type of oil, see the section

“Technical data”.

Never exceed max. level.

Engine oil replacement and cartridge lter replacement

Be careful not to touch hot engine oil.

Drain the oil with WARM ENGINE; proceed as follows:

- Place the motorcycle on its side stand

- Remove the cap (1) with the dipstick

Oil change must be performed in two stages:
Draining oil from tank;
Draining oil from engine

H11679

2

3

H11680

Draining oil from tank:

- Place a 2 litre container under the coupling (2) and then unscrew the screw
(3) and let the oil in the tank drain out completely.

- Once it has drained out, tighten the screw (3) with its corresponding washer.

Draining oil from engine:

- Place a container to collect the oil under the engine.

- Unscrew the screw (4) and let all the oil in the engine drain out completely.

- Once it has drained out, clean the magnetic screw (4), replace the gasket

and ret it on the engine by tightening it to torque.

Fill with oil as described in the relevant paragraph.

4

H11681

Workshop Manual Ed. 09-2012

D.9

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Replacement of cartridge lter

- Unscrew the screws (5) and remove the sprocket casing (6).

6

- Unscrew the screws (7) and remove the oil lter cover (8).

- Replace the lter (9) with a new one, then ret the cover (8) making sure that

the O-ring (10) is not damaged and positioned correctly on the cover.

- Ret the sprocket casing (6) making sure that the cable (11) of the rear stop

switch is positioned correctly as in the gure and that the cable guide (12) is

fastened externally onto the bottom screw.

5

H11682

8

7

H11683

9

11

Workshop Manual Ed. 09-2012

8

H11684

10

H11685

H11686

12

H11687

D.10

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Filling

- Remove the cap (1) with the dipstick.

- Pour 1.5 litres of oil into the chassis tank.

1

2

H11743

- Run the engine for 30 seconds and then switch it off.

- Pour another 0.5 litres of oil into the chassis tank.

- Check the oil level as described in the relevant paragraph.

Check the condition of the gasket (2) of the cap (1) with the dipstick

and if it is damaged, replace it.

For the type of oil to use, refer to the “Technical data”paragraph.

Coolant level check

When the engine is cold, check that the level of the coolant is between the MIN
and MAX marks on the expansion tank (1) on the left-hand side of the motorcycle.
If topping up is necessary, do the following:

MAX

MIN

3

1

H11689

Do not remove the radiator cap (2) since all the liquid in the expan-

sion tank (1) will ow out.

- Remove the cap (3) and add the uid needed to restore the level to the ex-

pansion tank (1).

(for the type of liquid to use, see the section “Technical data”).

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

If this occurs, wash off with water.

Never exceed max. level.

2

H11690

Workshop Manual Ed. 09-2012

D.11

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Coolant replacement

Drainage

- Place the motorcycle on its side stand.

- Remove the cap (1) of the expansion tank (2).

- Place a 2 litre container under the water pump and unscrew the screw (3).

- Let a small amount of coolant drain out and then turn the radiator cap (4) to

the rst click and wait for all the coolant to ow out of the water pump drain-

1

2

age hole.

Filling

- Re-tighten screw (2) on the water pump.

- Remove the radiator cap (4).

- Pour the coolant into the radiator (5) until it is full and gradually top up as the
level drops until it stays at maximum level.

- Put the radiator cap on again and pour the coolant into the expansion tank
(2) until it reaches maximum level.

- Put the cap (1) of the expansion tank on again.

- Start the engine, wait for the radiator cooling fan to start up and then wait
another 3 minutes.

- Switch off the engine and wait for it to cool, then check the level as described
in the relevant paragraph.

5

H11691

3

H11692

4

Workshop Manual Ed. 09-2012

5

H11693

D.12

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Air lter check
Note: Clean the lter area before removing the cover.

- Unscrew the screws (1) and remove the cover (2) together with the lter (3);

- remove the lter (3) and check that it is not clogged/dirty; replace if neces-

sary;

- when retting, check that the lter (3) is correctly placed in its housing (4).

2

1

Before retting the lter, check that the contact surfaces between

the lter, the lter box and the cover are completely clean.

H11694

2

3

H11695

4

3

3

H11696

D.13

H11697

Workshop Manual Ed. 09-2012

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

1

A

2

H11744

6

4

Chain tension adjustment

Chain should be checked, adjusted and lubricated as per the Maintenance
Chart to ensure safety and prevent excessive wear.
If the chain becomes badly worn or is adjusted incorrectly (i.e., it is too loose or
too tight), it could jump out of the sprocket or break.

- Position the motorcycle on the side stand so the chain is not stressed and
loaded;

- where the screw (1) is located, lift the chain (2) upwards and measure the
chain travel.

- the correct setting must be 45 mm (1.77 in).

If this is not the case, proceed as follows:

- make sure that the motorcycle is fully upright on the special rear support
stand (optional).

- on the right side, loosen the locking nut (3) of the wheel axle;

- loosen the check nuts (4) on both chain tensioners;

- turn the adjuster screws (5) to obtain the correct tension and check on both
sides that the wheel centring sliders (6) are in the same position as the mark­ings in the chain tensioner slider seats on the swinging arms;

- once adjusted, tighten the check nuts (4) and the wheel axle nut (3).

After adjusting, always check that distance "A" is 45 mm (1.77 in).

5

3

H11699

4

5

6

Lubricating the chain

Lubricate the chain following these instructions.

H11700

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.

Do not wash the chain with high-pressure water jets and do not use

harsh or highly ammable solvents.

- After washing the chain using special detergent, dry it and lubricate with suit­able spray grease.

Workshop Manual Ed. 09-2012

The chain lubricant must NOT come into contact with the tyres or

the rear brake disc.

D.14

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Suspension

The vehicle leaves the factory with standard settings for the front and rear sus­pension that meet most requirements.

Before making any change and afterwards, if the adjustment is not

satisfactory, always start from the standard suspension setting
and increase or decrease the adjusting clicks, one at a time.

Shock absorber spring preload adjustment

This is easier to do if you lift the motorcycle at the centre so that

the rear wheel is released.

- Adjust the ring nut (1) using the spanner provided; by turning left “A”, the
preload increases;

by turning right “B” the preload decreases.

1

H11701

H11702

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

absorber.

A: Wheelbase
B: Spring in its seat

A= 341 ± 1,5 mm (13,4252 ± 0,0591 in.)

B= 201 ± 1,5 mm (7,9134 ± 0,0591 in.)

A= 341 ± 1,5 mm (13,4252 ± 0,0591 in.)

TERRA

H11704

STRADA

1

B= 198 ± 1,5 mm (7,7953 ± 0,0591 in.)

A

B

H11703

H11705

Workshop Manual Ed. 09-2012

D.15

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Rebound shock absorber hydraulic damping adjustment

It is possible to adjust the rebound travel of the shock absorber.

B) REBOUND - Standard setting:

- 11 clicks

1

H11706

(adjuster 1)

To reset the standard setting, turn lower adjuster (1) clockwise until reaching fully

closed position. Then turn it back the number of clicks specied above.

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

Fork adjustment

On the fork installed on this motorbike version, it is not possible to perform any
type of adjustment.

1

Fuel supply hose inspection and replacement

- Remove the saddle as described in the relevant paragraph.

- Check fuel supply hose (1) conditions; if cracked, swollen, kinked, etc. it is
necessary to change it as follows:

- Press the ring nut (2) and unfasten the union (3).

- Open the clamps (4) and detach the pipe (1) from the unions (3) and (5).

H11707

During this operation, make sure that you do not damage the hose

holder coupling on the throttle body.

- Replace the pipe (1) and close the clamps (4) on unions (5) and (3).

2

H11708

- Ret the union (3) by pressing it down.

4

3

5

4

Workshop Manual Ed. 09-2012

H11709

H11710

D.16

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Exhaust system check

Perform a visual inspection of the exhaust system rst, in order to identify pos­sible gas leaks from the sealing elements (gaskets), and to ensure that the
Silent-Blocks are not damaged.

Subsequently, inspect the single components by disassembling the exhaust
system.

Also check the tightening of the ange nuts (1) fastening the manifold to the

cylinder head and the clamps (2) fastening the silencers to the manifolds as well
as the tightening of the screw (3) fastening the silencer to its support.

The damaged or broken parts must be replaced.

H11711

3

1

H11712

2

H11714

2

D.17

H11713

Workshop Manual Ed. 09-2012

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Idle speed adjustment

The idle speed is pre-set by the control unit (1550 rev/min.) and the stepper

motor ensures that this value is preserved.
No manual adjustment is possible, nor any adjustment through the diagnostic
tool.

Checking and adjustment of valve clearance

4

3

2

1

Remove the lter box and the throttle body as described in the relevant para­graphs.
Drain the oil from the tank on the chassis as described in the relevant paragraph.

- Disconnect the connectors (1) and (2) from the coils/tubes (3) and (4).

- Remove the coils/tubes (3) and (4).

- Remove the spark plugs.

When retting, do not invert the coils / tubes; the coil with the white

ring nut should be tted on the outer part of the cylinder head and
the connector with the white clamp connected to the cable.

H11715

- Loosen the clamps (5) and (6) and remove the two pipes (7) and (8). Place
them so that they do not drip oil.

7

5

8

When retting, do not invert the position of the two pipes;
Pipe 7 = oil return pipe to tank must go over the ABS pipes;
Pipe 8 = oil delivery pipe must go under the ABS pipes.

6

H11716

7

8

Workshop Manual Ed. 09-2012

8

H11717

D.18

SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

- Loosen the clamp (9) and remove the intake coupling (10) from the cylinder
head.

10

10

9

H11718

When retting the intake coupling (10) make sure you place the

prong (A) on the slot (B) of the intake manifold.

- Disconnect the cylinder head from the electrical system.

A

B

H11719

14

13

11

12

13

- Move the two pipes (11) of the ABS to unscrew the screw (12), then un­screw the screws (13) and remove them.

H11720

- Remove the head cover (14) at the back of the motorcycle; if this is difcult,
remove the intake manifold (15) by unscrewing the corresponding screws
without losing the corresponding gaskets.

- Adjust valve clearance as described in the relevant paragraph in Section F.

15

H11721

Workshop Manual Ed. 09-2012

D.19

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Section

E

E.1

Workshop Manual Ed. 09-2012

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Sommario

Stand removal / replacement........................................................................E.3

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

Removal of central upper cover....................................................................E.4

Side panel removal .......................................................................................E.5

Removal of luggage rack ..............................................................................E.5

Removal of tail cover ....................................................................................E.6

Removal of rear panels ................................................................................E.6

Removal of antitheft device compartment cover ..........................................E.7

Replacement of the saddle lock key lock ....................................................E.8

Removal of saddle lock ................................................................................E.9

Removal of number plate holder ..................................................................E.9

Removal of tail light ....................................................................................E.12

Removal of rear turning indicators..............................................................E.12

Removal of radiator guards ........................................................................E.13

Removal of lower tail cover ........................................................................E.14

Removal of tail chassis ...............................................................................E.16

Front fairing removal...................................................................................E.17

Front turning indicator removal ...................................................................E.18

Combined dashboard removal ...................................................................E.19

Removal of front mudguard ........................................................................E.20

Removal of fuel tank ...................................................................................E.21

Fuel pump removal .....................................................................................E.24

Fuel pump inspection .................................................................................E.26

Removal of lter box ...................................................................................E.27

Dismantling of lter box ..............................................................................E.29

Throttle body removal .................................................................................E.30

Exhaust system removal ............................................................................E.31

Exhaust system removal ............................................................................E.32

Lambda sensor removal .............................................................................E.34

Coil / Stick-Coil removal and spark plug test ..............................................E.34

Horn removal ..............................................................................................E.35

Radiator removal ........................................................................................E.35

Removal of electric fan ...............................................................................E.37

Gearbox lever removal ...............................................................................E.38

Removal of engine......................................................................................E.39

Reassembly of engine ................................................................................E.42

Workshop Manual Ed. 09-2012

E.2

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Stand removal / replacement

- Loosen the nut (1) and remove the rotary type switch (2).

2

1

H11790

2

H11791

- Release the spring (3).

- Loosen the screw (4) and remove the stand (5).

- When reassembling, grease the screw (4) and the stand fork and ret the

bushing (6) correctly with its bearing (7).

The screw (4) must be replaced at every disassembly.

3

NOTE: For the correct installation of the rotatory type switch (2), refer to

chapter "M".

5

4

H11792

4

6

1

7

2

5

3

H11793

Workshop Manual Ed. 09-2012

E.3

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Saddle removal

2

H11660

2

To remove the saddle proceed as follows:

- Insert the key in the lock (1) positioned in the rear part of the motorcycle;

- turn the key clockwise to release the saddle (2), and then lift it and pull it out
towards the rear, releasing it from the front fastener.

To t the saddle back on, fasten it at the front and then press the rear until the

1

fastening "Click" is heard.

H11661

1

Removal of central upper cover

- Unscrew the four screws (1) that fasten the cover (2) and remove it.

1

1

2

H11662

Workshop Manual Ed. 09-2012

E.4

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Side panel removal

- Remove the saddle as described in the relevant paragraph.

- Remove the upper cover as described in the relevant paragraph.

- Unscrew the ve screws (1) and remove the left side panel (2) by releasing

1

H11664

1

1

the xing tabs.

- Repeat to remove the right side panel.

When reassembling, rst insert the rear xing tabs and then the

front ones.

H11663

1

2

H11665

2

Removal of luggage rack

Remove the saddle as described in the relevant paragraph.

- Unscrew the screws (1) and remove the luggage rack (2).

H11666

1

When reassembling, tighten the screws to torque by placing the

longest ones at the rear and the shortest ones at the front of the
luggage rack.

1

H11794

Workshop Manual Ed. 09-2012

E.5

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Removal of tail cover

2

1

1

H11795

4

3

1

Remove the saddle and luggage rack as described in the relevant paragraphs.

- Unscrew the screws (1) and remove the tail (2).

Removal of rear panels

Remove the saddle, luggage rack, rear tail cover and the side panels as described
in the relevant paragraphs.

- Unscrew the upper screws (1).

- Unscrew the three lower screws (2) and remove the left rear panel (3).

Repeat the above steps to remove the right rear panel (4).

1

H11796

2

Workshop Manual Ed. 09-2012

H11797

E.6

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Removal of antitheft device compartment cover

Remove the saddle, the luggage rack and the rear tail cover as described in the
relevant paragraphs.

- Unscrew the two lower screws (1) and the two upper screws (2) and remove
the cover (3).

1

H11798

2

2

H11799

3

H11800

E.7

Workshop Manual Ed. 09-2012

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Replacement of the saddle lock key lock

Remove the saddle, the luggage rack, the rear tail cover and the antitheft device

2

1

H11801

compartment cover as described in the relevant paragraphs.

- Push up the end of the cable (1) and remove it from the support plate (2).

- Unscrew the screw (3) and remove the plate (2) from the plastic.

- Remove the key block (4) and detach it from the cable (5).

When retting the new key block, follow the same steps for removal

in reverse order and make sure that the reference guide (6) in the
block is correctly inserted into the seat (7) in the number plate
holder.

3

H11802

2

H11803

5

4

2

Workshop Manual Ed. 09-2012

H11804

7

6

H11805

E.8

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Removal of saddle lock

Remove the saddle, the luggage rack and the rear tail cover as described in the

2

1

3

1

H11806

1

3

relevant paragraphs.

Removal of number plate holder

Remove the saddle, the luggage rack, the rear tail cover and the antitheft device
compartment cover as described in the relevant paragraphs.

- Unscrew the upper screws (1) and the lower screws (2) of the rear panels
(3).

1

3

H11807

2

H11797

Workshop Manual Ed. 09-2012

E.9

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

- Disconnect the tail light connector (4) and the turning indicator connectors

4

H11808

5

(5).

H11809

- Remove the licence plate light bulb holder (6).

6

H11810

9

- Unscrew the two screws (7) of the lock (8) and remove the cable (9).

7

8

Workshop Manual Ed. 09-2012

7

H11811

E.10

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

10

3

10

11

3

11

H11812

- Pull the two rear panels (3) apart so that you can access the screws (10).

- Unscrew the screws (10) of the number plate holder (11) and remove it along
with the key block, tail light and turning indicators.

H11813

H11814

- Remove the various parts by unscrewing the relevant screws.

E.11

Workshop Manual Ed. 09-2012

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Removal of tail light

Remove the saddle, the luggage rack, the rear tail cover and the antitheft device
compartment cover as described in the relevant paragraphs.

- Unscrew the two screws (1), disconnect the connector (2) and remove the
tail light (3).

1

H11815

2

3

H11816

Removal of rear turning indicators

Remove the saddle, the luggage rack, the rear tail cover and the antitheft device
compartment cover as described in the relevant paragraphs.

DX

- Disconnect the two connectors (1).

- Unscrew the screws (2) and remove the turning indicators (3).

During the reassembly of the turning indicators, make sure that the

water discharge hole (4) faces downwards and that the connector
of the right-hand turning indicator is connected to the connector
marked with a white adhesive tape of the bike harness.

1

2

Workshop Manual Ed. 09-2012

H11817

3

H11818

4

H11819

E.12

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Removal of radiator guards

3

1

H11821

Remove the side panels as described in the relevant paragraph.

- Unscrew the screws (1).

- Put the guard (2) out and release it from the ttings (top tting with clip (3),
bottom tting with rubber ring (4)).

Use spray grease to make removal and reassembly easier.

- Retrieve the upper clip.

- When reassembling, rst insert the bottom pin (5) in the rubber ring (4), then
the upper clip (3) and nally the screws (1).

1

2

H11820

5

3

2

4

H11822

E.13

Workshop Manual Ed. 09-2012

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

5

4

6

Removal of lower tail cover

4

Remove the saddle, the luggage rack, the rear tail cover, the antitheft device
compartment cover, the side panels and the rear panels as described in the
relevant paragraphs.

- Remove the battery (1) as described in the relevant paragraph.

1

8

7

9

H11823

- Disconnect the tail light connector (2) and the turning indicator connectors
(3).

2

- Unscrew the screws (4) that secure the ECU (5).

- Remove the starter relay (6), the relays (7), the fuse box (8) and the diagnosis

socket (9) from their supports.

H11824

3

H11825

- Free the lower cover from the cable harness and the electrical components.

Workshop Manual Ed. 09-2012

H11826

E.14

10

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

- Unscrew the two front screws (10) in the battery compartment and the two
rear screws (11) and then remove the lower cover (12).

H11827

11

H11828

12

H11829

E.15

Workshop Manual Ed. 09-2012

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Removal of tail chassis

Remove the lower tail cover and the number plate holder as described in the

2

1

H11830

4

relevant paragraphs.

- Unfasten the two clips (1) of the shock absorber protection (2).

- Unscrew the screw (3) fastening the rear brake uid tank (4).

3

H11831

- Move the cable harness with the electrical components in the inner part of
the chassis and place them on the rear wheel.

- Unscrew the four screws (5) and slide the chassis out from the rear (6).

When reassembling, make sure that you put the cable harness back

H11832

in the same position it was before.

5

Workshop Manual Ed. 09-2012

5

H11833

6

H11834

E.16

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Front fairing removal

- Unscrew the screws (1) and remove the front fairing (2).

1

1

1

1

H11835

2

H11836

E.17

Workshop Manual Ed. 09-2012

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Front turning indicator removal

- Remove the front fairing as described in the relevant paragraph.

- Unscrew the screw (1) and remove the support (2).

1

2

H11898

- Disconnect the left turning indicator connector (3).

3

2

H11899

- Unscrew the screw (4) and remove the entire left turning indicator (5).

4

Retrieve the nut after unscrewing the screw (4).

Repeat the above steps to remove the right turning indicator.

5

H11900

6

During the reassembly of the turning indicators, make sure that the

water discharge hole (6) faces downwards and that the connector
of the right-hand turning indicator is connected to the connector
marked with a white adhesive tape of the bike harness.

H11901

Workshop Manual Ed. 09-2012

E.18

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Combined dashboard removal

- Remove the front fairing as described in the relevant paragraph.

- Remove the clips (1) and raise the dashboard (2).

1

1

2

1

H11902

2

- Disconnect the connector (3) and remove the dashboard (2).

During the reassembly, insert the pins in the special rubbers and

lock the dashboard with the special retaining clips.

After the replacement of the dashboard, it is necessary to connect

the diagnostic tool to the vehicle and follow the wizard.

3

H11903

E.19

Workshop Manual Ed. 09-2012

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

4

1

1

Removal of front mudguard

STRADA version:

- Unscrew the two screws (1) and release the front brake hose (2) from the
cable ring.

- Unscrew the screws (3) on both sides and remove the mudguard (4).

2

3

3

H11904

3

TERRA version:

- Unscrew screws (8) and screws (9) and then remove the front mudguard

H11905

(10).

- To disassemble the mudguard (10), unscrew the screws (11).

10

9

8

8

11

10

11

H11907

Removal of upper pushrod ON STRADA VERSION:

- Unscrew screws (5) and screws (6) and then remove the pushrod (7).

7

5

6

5

H11906

H11908

Workshop Manual Ed. 09-2012

E.20

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Removal of fuel tank

Remove the saddle, side panels and rear panels, the battery, silencers and the

central exhaust manifold.

1

While disassembling the tank, do not bend, force or pull the cable

harness too hard.

- Unscrew the screw (1) and remove the rear brake oil tank.

H11909

- Unscrew the screw (2) on the right side of the tank.

2

H11910

- Unscrew the two screws (3) on the battery compartment.

3

3

H11911

- Disconnect the breather hose (4).

4

H11912

Workshop Manual Ed. 09-2012

E.21

12

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

- Disconnect the fuel pipe (12) by pressing the ring nut (5) and lifting the union
(6).

5

H111028

- Disconnect the connector (7) from the fuel pump.

6

7

H11914

8

- Unscrew the two screws (8) on both sides that secure the upper part of the
rear chassis and loosen the lower screws (9).

9

H11915

- Lower the rear chassis with the tank and place it with a support on the rear
wheel and then unscrew the lower screws (9).

9

Workshop Manual Ed. 09-2012

When lowering the chassis, the tank interferes with the lter box

and the fuel delivery pipe; make sure you do not break the pipe

tting on the throttle body.

H11916

E.22

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

- Remove the central part of the cable harness (10) from the chassis.

10

H11917

- Turn the chassis to the right and remove the tank (11).

11

Follow the same steps in reverse order to reassemble the tank and

make sure you put the cable harness back in the same position it
was before.

H11918

E.23

Workshop Manual Ed. 09-2012

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Fuel pump removal

- This operation cannot be performed when the tank is completely full because
the fuel will leak out: we recommend emptying the tank by drawing the fuel

2

3

1

H11919

4

through suction using a special tool.

Fuel vapours are extremely harmful. Make sure you do not inhale

them and work in ventilated areas.

- Disassemble the saddle as described in the relevant paragraph.

- Disconnect the connector (1).

- Disconnect the fuel pipe (2) by pressing the ring nut (3) and lifting the union
(4).

H11920

5

- Undo screws (5) and remove the ring nut (6).

5

5

5

H11921

6

Workshop Manual Ed. 09-2012

H11922

E.24

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

- Remove the pump (7) from the tank.

- Check the seal (8) for wear, change it if dry or damaged.

7

8

H11923

10

- When reassembling the pump, align the tab (9), located under the connec­tor, with the seat (10) of the ring nut and the seat (11) of the ring nut with the
bump (12) on the tank.

- Tighten the screws (5) to torque and reconnect the union (4) and the con­nector (1).

12

9

11

H111023

E.25

Workshop Manual Ed. 09-2012

HYDRAULIC
DIAGRAM

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Fuel pump inspection

Remove the pump as described in the relevant paragraph.

- Connect the positive pole (12V) of the power supply to the pin of the red
cable in the pump connector;

Connect the negative pole of the power supply to the negative pin in the

pump connector.

Never keep the pump connected to the power supply unit for more

than 3 seconds in a row.

H111029

OUT

ELECTRIC
DIAGRAM

FUEL SYSTEM

GROUND

REGULATOR

FINE FILTER

PUMP

FUEL

PRE-FILTER

H10963

SIGNAL

GROUND

Workshop Manual Ed. 09-2012

H111030

E.26

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Removal of lter box

3

1

H11925

2

Remove the front panels, the radiator guards, the rear panels, the exhaust silenc­ers and the central exhaust manifold, as described in the relevant paragraphs.

- Unscrew the side screw (1) and the front screw (2), then remove the tank (3)
at the rear of the motorcycle and pour the coolant in a container.

H11926

3

H11927

- Disconnect the fuel pipe by pressing the ring nut (4) and lifting the union (5).

5

4

H11928

H11929

Workshop Manual Ed. 09-2012

E.27

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

- Unscrew the screw (6) on the right side of the tank.

6

H11930

- Unscrew the two upper screws (7) of the chassis and loosen the two lower

7

screws (8).

8

H11931

H11932

- Rock the rear chassis with the fuel tank towards the rear of the motorcycle
by placing a suitable support on the rear wheel so that the cable harness is
not too tight.

- Unscrew the screw (9) on the lower right-hand part of the lter box.

- Lift the lter box (10) by releasing it form the special ttings and from the

throttle body.

10

9

Workshop Manual Ed. 09-2012

H11933

H11934

E.28

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Check that the rubber seal element (11) is not worn/damaged; re-

place if necessary.

When reassembling, t the lter box onto the throttle body until the seal element

11

H11935

(11) is pushed all the way down. To make it easier to insert, use special lubricants

and slightly rock the lter box.

1

Dismantling of lter box

- Unscrew the three screws (1) and remove the air lter (2) with its support.

1

1

H11936

2

H11937

- Unscrew the screws (3) to remove the front cover (4) of the lter box.

3

3

3

4

H11938

Workshop Manual Ed. 09-2012

E.29

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Throttle body removal

1

- Remove the lter box as described in the relevant paragraph.

- Disconnect the injector connector (1), the throttle position sensor connector
(2) and the idle speed adjustment actuator connector (3).

2

3

H11939

- Disconnect the throttle cable (4).

4

H11940

- Loosen the clamp (5).

6

Workshop Manual Ed. 09-2012

5

H11941

- Remove the throttle body (6) with the fuel supply pipe.

NOTE: The electromechanical parts have a set position. If replaced, they

must be reassembled in exactly the same position.

H11942

E.30

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Exhaust system removal

2

1

3

4

3

4

7

5

8

6

Key:

1) Left silencer

2) Right silencer

3) Clamps

4) Gaskets

5) Central manifold

6) Manifold

7) Lambda sensor

8) Gasket

H11943

E.31

Workshop Manual Ed. 09-2012

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Exhaust system removal

Remove the saddle as described in the relevant paragraph.

- Unscrew the rear support (1) on both sides.

1

H11944

- Loosen the clamps (2) on both sides and remove both silencers (3) by sliding
them out of the support (4).

2

H11945

4

3

H11946

- Loosen the clamp (5) and remove the central manifold (6).

5

Workshop Manual Ed. 09-2012

H11947

6

H11948

E.32

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

- Disconnect the Lambda sensor connector (7).

7

H11949

8

- Undo the nuts (8) fastening the exhaust manifold (9) to the cylinder head,

remove the manifold and retrieve the steel gasket (10).

When reassembling, t the steel gasket (10) onto the manifold

making sure that the support tabs are inserted on the pipe.

8

9

H11951

7

9

H11950

10

9

H11952

Workshop Manual Ed. 09-2012

E.33

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Lambda sensor removal

- Disconnect the connector (1).

1

2

H11953

- Unscrew the Lambda sensor (2) from the exhaust manifold.

Coil / Stick-Coil removal and spark plug test

- Remove the lter box as described in the relevant paragraph.

- Disconnect the connectors (1) and (2) from the coils/stick coils (3) and (4).

- Lift the coils/stick coils (3) and (4) to remove them from the cylinder head.

0,6 mm (±0,1 mm)

0.024 in. (±0.004 in.)

4

3

Spark plug electrodes gap shall be 0,6 mm ± 0,1 mm (0,024 in. ± 0,004 in).

A wider gap may cause difculties in starting the engine and overload the coil.
A gap that is too narrow may cause difculties when accelerating, when idling

or poor performance at low speed.
Clean off any dirt around spark plug base before removing the spark plug.

H11954

2

1

H11955

- Unscrew the spark plugs using the special spanner to remove them from the
cylinder head.

It is very useful to examine the state of the spark plug just after it has been

removed from the engine since the scale deposits on the plug and the colour of
the insulator provide useful indications.

Correct heat rating: the tip of the insulator should be dry and the colour should
be light brown or grey.

High heat rating: in this case, the insulator tip is dry and covered with dark
deposits.

Low heat rating: in this case, the spark plug has overheated and insulator tip is

vitried (glazed), white or grey in colour.

When reassembling, place the coil/stick coil (4) with the white rim

on the external right-hand part of the engine and connect it using

the connector (2) with the white ring to the cable.

Workshop Manual Ed. 09-2012

4

If the position of the two coils/stick coils or the connectors is in-

verted, the engine will run erratically.

H11956

E.34

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Horn removal

- Undo the nut (1).

- Disconnect the connector (2) and remove the horn (3).

1

3

H11957

2

3

H11958

5

4

2

Radiator removal

- Remove the saddle and the radiator guards, as described in the relevant
paragraphs.

- Drain the coolant as indicated in the relevant paragraph.

- Use suitable pliers to open the clamps (1) that fasten the pipes (2) and (3)
that connect the radiator / engine.

- Remove the two pipes (2) and (3) from the radiator.

- Open the clamp (4) and remove the pipe (5) that connects the expansion

tank to the radiator.

1

3

H11959

Workshop Manual Ed. 09-2012

E.35

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

- Unscrew the two upper screws (6).

6

H11960

6

H11961

7

H11962

8

- Cut the clamp (7) that secures the electric fan cable harness.

- Disconnect the electric fan connector (8).

Workshop Manual Ed. 09-2012

H11963

E.36

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

- Slide the radiator (9) out from the left and remove it from its special support

9

H11964

(10).

- When reassembling, make sure that the support (10) is correctly inserted in
the retaining pin (11).

11

10

H11965

Removal of electric fan

1

H11966

2

3

- Remove the left radiator guard as described in the relevant paragraph.

- Cut the clamp (1) and remove the cable harness.

- Disconnect the connector (2).

- Unscrew the three screws (3) by locking the nut (4) on the other side.

- Remove the electric fan.

4

3

3

H11967

E.37

H11968

Workshop Manual Ed. 09-2012

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Gearbox lever removal

- Loosen the screw (1) and remove the lever (2).

1

2

H11969

Workshop Manual Ed. 09-2012

E.38

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

Removal of engine

Remove the following components in order as described in the relevant para­graphs/sections:

- exhaust;

- fuel tank;

- lter box;

- throttle body;

- sprocket casing;

- voltage regulator.

1

- Remove the voltage regulator support plate (1) by unscrewing the screws
(2).

2

H11970

1

- Disconnect the connectors (3) and remove the plate (1) with the horn.

3

H11971

4

H11972

- Disconnect the coolant temperature sensor connector (4).

Workshop Manual Ed. 09-2012

E.39

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

- Unscrew the screw (5) and disconnect the ground cable (6).

6

5

H11973

- Remove clutch cable (7).

7

11

10

H11974

- Unfasten the nut (8) of the starter motor power supply cable (9).

9

8

H11975

- Remove the clip (10) and remove the master cylinder (11) from the brake
lever (12).

Workshop Manual Ed. 09-2012

12

H11976

E.40

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

- Unfasten the nut (13) and remove the chain tensioner slider (14).

14

13

H11977

- Slightly ease the pin (15) in order to release the left slider (16).

15

16

17

26

H11978

- Move the wheel towards the engine to remove the chain (17) from the
sprocket.

H11979

- Remove the screw (26).

- Remove the connection cable (27).

- Place a hoister under the engine and raise slightly.

27

H111031

Workshop Manual Ed. 09-2012

E.41

GENERAL PROCEDURES

TR 650 TERRA 2013 - TR 650 STRADA 2013

- Remove the front support cross-member (18) by unscrewing the upper screws
(19) that connect it to the chassis and the lower screws (20) that connect it

19

to the engine.

When reassembling, insert the screws from the left and the nuts

from the right.

18

18

24

20

H11980

H11981

- Unscrew the lower screws (21) that fasten the engine to the chassis.

- Remove the swinging arm pin (22).

- Unscrew the two upper screws (23) that fasten the engine to the chassis.

When reassembling, align the spacer (24) with the right upper screw.

- Lower the hoister keeping the engine (25) balanced and then remove the
engine from the front.

Reassembly of engine

Reassemble by following the steps in reverse order and make sure you:

- reassemble the swinging arm by performing the steps in the relevant para-

graph for adjustment of axial clearance;

- position the cable harnesses correctly;

- tighten the screws (19), (20), (21), (23) and (24) correctly.

Workshop Manual Ed. 09-2012

H11984

21

H11982

23

25

22

H11983

E.42

ENGINE SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Refer to chapter F4 for all engine tightening torques.

Section

F

F.1

Workshop Manual Ed.09-2012

ENGINE SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Sommario

VALVE CLEARANCE CHECK ...................................................................... F. 3

Valve clearance check .................................................................................. F. 3

Valve clearance measurement ..................................................................... F.3

PAD REPLACEMENT ................................................................................. F.4

Locking the crankshaft.................................................................................. F.4

Chain tensioner disassembly........................................................................ F.5

Chain guide disassembly.............................................................................. F.5

Camshaft removal ........................................................................................ F.6

Pad replacement .......................................................................................... F.6

Camshaft assembly ...................................................................................... F.6

Chain tensioner installation .......................................................................... F.7

Chain guide installation ................................................................................ F.7

Removal of engine block screw .................................................................... F.7

TIMING CHECK .......................................................................................... F.8

ENGINE PHASING ...................................................................................... F.9

Workshop Manual Ed.09-2012

F.2

ENGINE SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

VALVE CLEARANCE CHECK

Remove the coil / spark plug cap, spark plugs and the head cover as described
in chapter "F1".

Valve clearance check

- Remove the screw plug (1).

- Place an Allen wrench into the hole (2) and turn the crankshaft in the normal
sense of rotation until the ignition TDC.

- the marks (3) placed on the crankshaft gears must be coplanar to the sealing

2

1

H11483

surfaces and the holes (4) must face upwards.

- In this position, both cams of the intake and exhaust camshafts must face
upwards and be at the same angle relative to the upper face of the head.

4

3 3 3 3

4

H11485

5

H11486

Valve clearance measurement

Measure valve clearance using a feeler between the cam and valve bucket both
for the intake (4) and exhaust (5) cams.

Note down the measurements on a measurement sheet.

H10182

Technical specications

Intake valve clearance with cold engine

max. 35 °C

Exhaust valve clea­rance

with cold engine
max. 35 °C

0.23 - 0.28 mm

0.0091 - 0.011 in.

0.38 - 0.43 mm

0.015 - 0.016 in.

H11484

If the valve clearance does not lie within the correct tolerance, correct clearance
must be restored by replacing the pads beneath the valve buckets.

- Reassemble the screw plug (1) and all other parts removed.

Workshop Manual Ed.09-2012

F.3

ENGINE SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

PAD REPLACEMENT

Bring the to the top dead centre as described in the previous paragraph and
lock the crankshaft.
.

H11487

Locking the crankshaft

Remove the screw (1) with the sealing ring.

Check that the notch on the crankshaft is visible through the hole.

1

H11751

Fully screw down the retaining screw (2) manually; the screw must perfectly
engage in the notch of the crankshaft.

2

Workshop Manual Ed.09-2012

H11752

F.4

ENGINE SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Chain tensioner disassembly

1

2

3

H11491

- Remove the screw (1) with the sealing ring (2) and chain tensioner (3).

H11490

2

Chain guide disassembly

- Remove the screws (1) and chain guide (2).

1

H11492

F.5

Workshop Manual Ed.09-2012

ENGINE SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

1

2

3

4

5

5

Camshaft removal

- Remove the screws (1) with the washers.(2).

- Remove the top part of the support (3).

- Removethechain(4)fromthegearsandxtoapointsafetoavoiditfrom

falling into the engine.

- Remove the camshafts (5) with the chain gears.

- Remove the bottom part of the support (6).

- Remove the chain slider (7).

6

7

H11493

1

2

Pad replacement

- Mark the valve bucket (1) with a marker (e.g. A= intake valve).

- Extract the valve bucket (1)

- According to the measurement of the valve clearance, replace the pads with
those of a size appropriate to restore the correct valve clearance.

- Replace adjustment pad (2) with one having a thickness adequate to restore

thecorrectvalue,makingsureitisrmlyseatedintheseat.

- Install the corresponding valve buckets as marked.

3a

1

H11494

5

4

6

3b

2

H11495

Camshaft assembly

- Install the chain slider (1) making sure that the top part of the slider is aligned
with the sealing surface.

- Mount the bottom part of the support (2).

- Lubricate all contact surfaces with engine oil.

- Fit the camshaft exhaust (3a), then the cam shaft intake (3b) with the timing
chain and positioning them in phase.

- Mount the top part of the support (4).

- Tighten the screws (5) with the washers (6).

Workshop Manual Ed.09-2012

F.6

ENGINE SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

Chain tensioner installation

2

3

1

H11496

- Insert the chain tensioner (1) and tighten the screw (2) replacing the gaskets
(3).

2

H11497

1

Chain guide installation

- Clean the threading and screws.

- Install the chain guide (1) and tighten the screws (2).

2

H11498

Removal of engine block screw

- Remove the locking screw (1) and re-tighten the screw (2) to torque, replac­ing the gasket.

2

1

H11499

F.7

H11646

Workshop Manual Ed.09-2012

ENGINE SETTINGS AND ADJUSTMENTS

TR 650 TERRA 2013 - TR 650 STRADA 2013

TIMING CHECK

- Remove the coil / spark plug cap, head cover, spark plugs and chain tensioner
and the head cover as described in chapter "F1".

- Remove the screw (1) with the sealing ring.

1

H11488

- Remove the plug (2).

3 3 3 3

2

H11500

- Check the position of the camshaft gears.

- The marks (dashes) (3) located on the camshaft gears must be coplanar with
the sealing surface.

- Make sure the notch on the crankshaft is visible through the hole (marks (3)
coplanar to the surface and notch (4) visible indicate a correct timing).

- If the notch cannot be seen through the hole, carefully turn the engine until it
can be seen through the hole, then fully tighten down the retaining screw (5)
manually, blocking the engine at TDC; it must perfectly engage in the notch
of the crankshaft.

H11501

If the marks on the camshaft gears are not opposed and parallel to

the sealing surface, a collision between pistons and valves is pos­sible.

Workshop Manual Ed.09-2012

4

H11502

5

H11503

F.8