Husqvarna TE 250i Owner's Manual
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Husqvarna TE 250i Owner's Manual

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OWNER'S MANUAL 2018
TE 250i
TE 300i
Art. no. 3402171en

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Summary of Contents for Husqvarna TE 250i

  • Page 1 OWNER'S MANUAL 2018 TE 250i TE 300i Art. no. 3402171en...
  • Page 3 DEAR HUSQVARNA MOTORCYCLES CUSTOMER Congratulations on your decision to purchase a Husqvarna motorcycle. You are now the owner of a state-of- DEAR HUSQVARNA MOTORCYCLES CUSTOMER the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly.

  • Page 4: Table Of Contents

    Throttle grip......... 17 Preparing vehicle for rides on dry Kill switch (All EU models) ....17 sand ............ 33 Kill switch (TE 250i US) ....... 18 Preparing vehicle for rides on wet Horn button (All EU models) ....18 sand ............ 34 Light switch (All EU models) ....
  • Page 5 TABLE OF CONTENTS RIDING INSTRUCTIONS ......... 37 SERVICE WORK ON THE CHASSIS ....56 Checks and maintenance measures 12.1 Raising the motorcycle with a lift when preparing for use ....... 37 stand ........... 56 Starting the vehicle ......37 12.2 Removing the motorcycle from the lift stand ..........
  • Page 6 Changing the headlight bulb..... 115 22.1 Engine ..........144 15.9 Changing the turn signal bulb 22.1.1 All TE 250i ........144 (All EU models)........116 22.1.2 TE 300i EU........144 15.10 Checking the headlight setting ..117 22.2 Engine tightening torques....145...
  • Page 7 TABLE OF CONTENTS 22.3 Capacities ......... 147 22.3.1 Gear oil ......... 147 22.3.2 Coolant ......... 147 22.3.3 Fuel..........147 22.4 Chassis ..........147 22.5 Electrical system....... 148 22.6 Tires ..........148 22.7 Fork........... 149 22.8 Shock absorber ........ 149 22.9 Chassis tightening torques ....

  • Page 8: Means Of Representation

    1 MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understand- ing.

  • Page 9: Safety Advice

    This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross. (TE 250i US) This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the currently valid regulations and categories of the top international motorsport organizations.

  • Page 10: Degrees Of Risk And Symbols

    2 SAFETY ADVICE Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

  • Page 11: Protective Clothing

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, Husqvarna Motorcycles recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks.

  • Page 12: Environment

    Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized Husqvarna Motor- cycles dealer will be glad to advise you.

  • Page 13: Important Notes

    3 IMPORTANT NOTES Manufacturer and implied warranty The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles workshop only and confirmed in the customer's Service & Warranty Booklet and in the Husqvarna Motorcy- cles Dealer.net; otherwise, all warranty claims will be void. Damage or secondary damage caused by tamper- ing with and/or conversions on the vehicle are not covered by the warranty.

  • Page 14: Customer Service

    3 IMPORTANT NOTES Customer service Your authorized Husqvarna Motorcycles dealer will be happy to answer any questions you may have regarding your vehicle and Husqvarna Motorcycles. A list of authorized Husqvarna Motorcycles dealers can be found on the Husqvarna Motorcycles website.

  • Page 15: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) V00922-10 Clutch lever ( p. 17) Filler cap Air filter box cover Side stand ( p. 23) Engine number ( p. 15) Shift lever ( p. 22)

  • Page 16: View Of Vehicle, Rear Right (Example)

    V00923-10 2-stroke oil tank cap Kill switch ( p. 17) (All EU models) Kill switch ( p. 18) (TE 250i US) p. 18) (All EU models) Horn button ( Light switch ( p. 18) (All EU models) p. 19) (All EU models)

  • Page 17: Serial Numbers

    5 SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steer- ing head. 401945-10 Type label (All EU models) Type label is fixed to the front of the steering head. 401946-10 Key number (All EU models) Key number for the steering lock is stamped onto the key connector.

  • Page 18: Fork Article Number

    5 SERIAL NUMBERS Fork article number Fork article number is stamped on the inside of the axle clamp. 401947-10 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. H02222-10...

  • Page 19: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. K00923-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever.

  • Page 20: Kill Switch (Te 250I Us)

    6 CONTROLS Kill switch (TE 250i US) The kill switch is fitted on the left side of the handlebar. Possible states in basic position – In this position, the ignition • Kill switch circuit is closed and the engine can be started.

  • Page 21: Turn Signal Switch (All Eu Models)

    The high beam indicator lamp lights up blue – The high beam is switched on. Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized Husqvarna Motorcycles workshop. V00924-01...

  • Page 22: Indicator Lamps Overview (Te 250I Us)

    MINmarking. Ride for no more than until the remaining fuel in the tank is depleted and at the next opportunity refuel with 2-stroke oil. 6.13 Indicator lamps overview (TE 250i US) Possible states High beam indicator lamp – inoperative Malfunction indicator lamp lights up/flashes yellow –...

  • Page 23: Closing The Filler Cap

    6 CONTROLS – Press release button , turn the filler cap counterclockwise, and lift it free. V00894-10 6.15 Closing the filler cap – Replace the filler cap and turn clockwise until release but- locks in place. Info Route fuel tank breather hose without kinks.

  • Page 24: Cold Start Button

    6 CONTROLS 6.18 Cold start button The cold start button is fitted on the side of the throttle valve body. The injection system extends the injection time if the engine is cold and the outside temperature is low. To help the engine burn the increased amount of fuel, it must be supplied with additional oxygen by pulling the cold start button.

  • Page 25: Kick Starter

    6 CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.21 Kick starter Kick starter is fitted on the right side of the engine. The top part of the kick starter pivots. Info 0 0 1 Before riding, swing the top part of the kick starter inward...

  • Page 26: Steering Lock (All Eu Models)

    6 CONTROLS The side stand is used to park the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber band 401944-10 6.24 Steering lock (All EU models) The steering lock is fitted on the left side of the steering head.

  • Page 27: Combination Instrument

    7 COMBINATION INSTRUMENT Overview Indicator lamps overview ( p. 19) (All EU models) p. 20) (TE 250i US) Indicator lamps overview ( Left button Display Right button 402819-10 Activation Activating combination instrument The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.

  • Page 28: Setting The Kilometers Or Miles

    7 COMBINATION INSTRUMENT – Wait for 5 seconds. The combination instrument changes to the next menu item. The symbol flashes. – Press one of the buttons to select the 24h or 12h display of the clock. 401911-01 – Wait for 5 seconds. The combination instrument changes to the next menu item.

  • Page 29: Setting The Clock

    7 COMBINATION INSTRUMENT – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. – Press one of the buttons to select UNIT for the speed in kilo- meters KM/H or miles M/H. 401909-01 Setting the clock Condition The motorcycle is stationary.

  • Page 30: Speed, Time, And Dst Distance 1

    7 COMBINATION INSTRUMENT Switching off the service interval display – Press and hold the left button. off appears on the display. 401914-01 Speed, time, and DST distance 1 – Press one of the buttons until DST appears on the combina- tion instrument.

  • Page 31: Avg Average Speed, Art Operating Hours, And Odo Total Distance Covered

    7 COMBINATION INSTRUMENT Press the left DST2 can be preset to a value between 0.0 button for 3 – and 39999.9 by pressing the buttons. 5 seconds. Press the Next display mode right button briefly. Press the DST2 is reset to 0.0. right button for 3 –...

  • Page 32: Preparing For Use

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized Husqvarna Motorcy- cles workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.

  • Page 33: Running In The Engine

    8 PREPARING FOR USE – Adjust the basic position of the hand brake lever. ( p. 89) – Adjust the basic position of the foot brake lever. p. 94) – Adjust the basic position of the shift lever. p. 129) –...

  • Page 34: Starting Power Of Lithium-Ion Batteries At Low Temperatures

    8 PREPARING FOR USE Starting power of lithium-ion batteries at low temperatures Lithium-ion batteries are far lighter than lead batteries, have a low self-discharge rate, and have more starting power at tem- peratures over 15 °C (60 °F). At low temperatures, however, the starting power of lithium-ion batteries drops to below that of lead batteries.

  • Page 35: Preparing Vehicle For Rides On Dry Sand

    Change the radiator cap. – Mount a dust cover on the air filter. Dust cover for air filter (79006920000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01104-01 – Mount a sand cover on the air filter. Sand cover for air filter (79006922000)

  • Page 36: Preparing Vehicle For Rides On Wet Sand

    In the event of scalding, rinse the area affected immediately with lukewarm water. – Change the radiator cap. – Fit a rain cover on the air filter. Waterproofing device for air filter (79006921000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01106-01...

  • Page 37: Preparing Vehicle For Rides On Wet And Muddy Circuits

    Preparing vehicle for rides on wet and muddy circuits – Fit a rain cover on the air filter. Waterproofing device for air filter (79006921000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01106-01 – Mount the steel sprocket.

  • Page 38: Preparing Vehicle For Low Temperatures Or Snow

    Check the coolant level. ( p. 120) Preparing vehicle for low temperatures or snow – Fit a rain cover on the air filter. Waterproofing device for air filter (79006921000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01106-01...

  • Page 39: Riding Instructions

    9 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 40: Starting Off

    9 RIDING INSTRUCTIONS Note Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine. – Always run the engine warm at a low speed. – Take the motorcycle off side stand and secure the side stand with rubber band –...

  • Page 41: Braking

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 42: Stopping, Parking

    Shift gear to neutral. (All EU models) – Press and hold the kill switch while the engine is idling until the engine stops. (TE 250i US) – Press and hold the kill switch while the engine is idling until the engine stops. –...

  • Page 43: Refueling

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Environmental hazard Improper handling of fuel is a danger to the environment.

  • Page 44: Adding 2-Stroke Oil

    9 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to level Guideline 35 mm (1.38 in) Level Total fuel tank Super unleaded capacity, approx. (2.4 US gal) (ROZ 95/RON 95/PON 91) p. 153) 401226-10 Info Do not refuel using pre-mixed fuel. –...

  • Page 45: Service Schedule

    Once after 5 operating hours Once after 1 operating hour ○ ○ ● ● ● Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. ○ ● ● ● Check that the electrical system is functioning properly. ● ●...

  • Page 46: Recommended Work

    ● Final check: Check the vehicle for operating safety and take a test ride. ○ ○ ● ● ● Read out the fault memory after the test ride using the Husqvarna Motorcycles diag- nostics tool. ○ ○ ● ● ●...
  • Page 47 10 SERVICE SCHEDULE Every 40 operating hours when used for motorsports Every 10 operating hours when used for motorsports Annually Every 80 operating hours Every 40 operating hours Once after 20 operating hours Once after 10 operating hours ● ● Change the fuel filter.

  • Page 48: Tuning The Chassis

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 49: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber.

  • Page 50: Adjusting The Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor- rectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 51: Checking The Static Sag Of The Shock Absorber

    11 TUNING THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 56) 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 48) – Hold the motorcycle upright with the aid of an assistant. –...

  • Page 52: Adjusting The Spring Preload Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

  • Page 53: Adjusting The Riding Sag

    11 TUNING THE CHASSIS 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 56) – Remove the shock absorber. p. 65) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 54: Adjusting The Compression Damping Of The Fork

    11 TUNING THE CHASSIS 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn white adjusting screw clockwise as far as it will go. Info Adjusting screw is located at the upper end of the left fork leg.

  • Page 55: Adjusting The Spring Preload Of The Fork

    11 TUNING THE CHASSIS Guideline Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping; turn counter- clockwise to reduce damping. 11.14 Adjusting the spring preload of the fork Preparatory work – Raise the motorcycle with a lift stand. ( p.

  • Page 56: Handlebar Position

    11 TUNING THE CHASSIS 11.15 Handlebar position On the upper triple clamp, there are 2 holes at a distance of to each other. Hole distance A 15 mm (0.59 in) The holes on the handlebar support are placed at a distance from the center.
  • Page 57 11 TUNING THE CHASSIS Info Make sure the gap widths are even.

  • Page 58: Service Work On The Chassis

    12 SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (81329955100) Neither wheel is in contact with the ground.

  • Page 59: Cleaning The Dust Boots Of The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 56) – Remove the fork protector. ( p. 59) Main work – Push dust boots of both fork legs downward.

  • Page 60: Installing The Fork Legs

    12 SERVICE WORK ON THE CHASSIS – Loosen screws . Take out the left fork leg. – Loosen screws . Take out the right fork leg. V00931-10 12.6 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front.

  • Page 61: Removing The Fork Protector

    12 SERVICE WORK ON THE CHASSIS 12.7 Removing the fork protector – Remove screws and take off the clamp. – Remove screws and take off the left fork protector. – Remove screws and take off the right fork protector. V00903-10 12.8 Installing the fork protector –...

  • Page 62: Installing The Lower Triple Clamp

    12 SERVICE WORK ON THE CHASSIS Info Cover the components to protect them against dam- age. Do not kink the cables and lines. – Remove O-ring . Remove protective ring – Take out the lower triple clamp with the steering stem. –...
  • Page 63 12 SERVICE WORK ON THE CHASSIS – Position the fork legs. Bleeder screws are positioned toward the front. Info The rebound damping is located in the right fork leg (red adjusting screw). The compression damping is located in the left fork leg (white adjusting screw). Grooves are milled into the side of the upper end of the fork legs.

  • Page 64: Checking The Play Of The Steering Head Bearing

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

  • Page 65: Adjusting The Play Of The Steering Head Bearing

    12 SERVICE WORK ON THE CHASSIS – Adjust the play of the steering head bearing. p. 63) – Check the steering head bearing and change if neces- sary. Finishing work – Remove the motorcycle from the lift stand. ( p. 56) 12.12 Adjusting the play of the steering head bearing Preparatory work...

  • Page 66: Removing Front Fender

    12 SERVICE WORK ON THE CHASSIS 12.14 Removing front fender Preparatory work – Remove the headlight mask with the headlight. ( p. 113) Main work – Remove screws – Remove screws . Take off the front fender. V00938-10 12.15 Installing front fender Main work –...

  • Page 67: Removing The Shock Absorber

    12 SERVICE WORK ON THE CHASSIS 12.16 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 56) Main work – Remove the cable ties. – Remove screws – Remove screws with the washers. –...

  • Page 68: Installing The Shock Absorber

    12 SERVICE WORK ON THE CHASSIS – Remove screws – Pull off foot brake cylinder from the push rod. V00941-10 – Remove the connecting link of the chain. – Take off the chain. V00942-01 – Remove nut and pull out the swingarm pivot. –...
  • Page 69 12 SERVICE WORK ON THE CHASSIS – Position the swingarm and mount the swingarm pivot. Info Pay attention to flat area – Mount and tighten nut Guideline Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) V00946-10 – Mount the chain. –...

  • Page 70: Removing The Seat

    12 SERVICE WORK ON THE CHASSIS Guideline Screw, bottom 60 Nm (44.3 lbf ft) ® Loctite 2701™ shock absorber Info Raise the wheel slightly to be able to mount the screw more easily. – Position the frame protectors on the left and right. –...

  • Page 71: Mounting The Seat

    12 SERVICE WORK ON THE CHASSIS 12.19 Mounting the seat Main work – Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear, and push the seat forward. – Make sure that the seat is locked in correctly. –...

  • Page 72: Installing The Air Filter Box Cover

    12 SERVICE WORK ON THE CHASSIS 12.21 Installing the air filter box cover – Position air filter box cover on collar bushings and push toward the rear. – Engage the air filter box cover in areas V00905-10 12.22 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine.

  • Page 73: Cleaning The Air Filter And Air Filter Box

    12 SERVICE WORK ON THE CHASSIS 12.23 Cleaning the air filter and air filter box Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam.

  • Page 74: Sealing The Air Filter Box

    12 SERVICE WORK ON THE CHASSIS – Insert air filter and position retaining pin in bushing The air filter is correctly positioned. – Insert retaining tab Retaining pin is secured with retaining tab Info If the air filter is not mounted correctly, dust and dirt may enter the engine and result in damage.

  • Page 75: Installing The Main Silencer

    12 SERVICE WORK ON THE CHASSIS 12.27 Installing the main silencer Main work – Mount the main silencer with the rubber sleeve spring ring. – Mount and tighten screws with the washers. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00909-10 Finishing work...

  • Page 76: Removing The Right Side Cover

    12 SERVICE WORK ON THE CHASSIS 12.29 Removing the right side cover – Remove screw – Pull off the side cover sideways in areas , and remove toward the front. V00910-10 12.30 Installing the right side cover – Position the side cover on collar bushings , and push toward the rear.
  • Page 77 12 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. –...

  • Page 78: Installing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS – Remove screw with the rubber bushing. V00927-10 – Pull both spoilers off laterally from the radiator bracket and lift off the fuel tank. V00928-10 12.32 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled.
  • Page 79 12 SERVICE WORK ON THE CHASSIS – Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracket. – Make sure that no cables or throttle cables are trapped or damaged. V00928-11 – Mount and tighten screw with the rubber bushing.

  • Page 80: Checking The Chain For Dirt

    12 SERVICE WORK ON THE CHASSIS – Attach fuel tank breather hose – Plug in connector for the fuel pump. V00949-10 Finishing work – Mount the seat. ( p. 69) – Install the air filter box cover. ( p. 70) –...

  • Page 81: Checking The Chain Tension

    12 SERVICE WORK ON THE CHASSIS Main work – Rinse off loose dirt with a soft jet of water. – Clean chain and apply chain spray. Offroad chain spray ( p. 154) 400725-01 Finishing work – Remove the motorcycle from the lift stand. ( p.

  • Page 82: Adjusting The Chain Tension

    12 SERVICE WORK ON THE CHASSIS 12.36 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 83: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    12 SERVICE WORK ON THE CHASSIS 12.37 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 56) Main work – Shift the transmission to idle. – Check the rear sprocket and engine sprocket for wear. »...
  • Page 84 12 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with or below the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.

  • Page 85: Checking The Frame

    – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by Husqvarna S01339-01 Motorcycles. 12.39 Checking the swingarm – Check the swingarm for damage, cracking, and deformation.

  • Page 86: Checking The Rubber Grip

    12 SERVICE WORK ON THE CHASSIS Main work – Check throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars, above the fuel tank bracket on the right of the frame to the throttle valve body. Both throttle cables must be secured behind the fuel tank contact area rubber band.

  • Page 87: Adjusting The Basic Position Of The Clutch Lever

    12 SERVICE WORK ON THE CHASSIS 12.42 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info When the adjusting screw is turned counterclockwise, the clutch lever moves away from the handlebar.

  • Page 88: Changing The Hydraulic Clutch Fluid

    12 SERVICE WORK ON THE CHASSIS – Correct the fluid level of the hydraulic clutch. Brake fluid DOT 4 ( p. 152) – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilled brake fluid immediately with water.

  • Page 89: Removing The Engine Guard

    12 SERVICE WORK ON THE CHASSIS – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 ( p. 152) – On the slave cylinder, remove bleeder screw and mount bleeding syringe V00916-10 – Now inject the fluid into the system until it emerges from drill hole of the master cylinder without bubbles.

  • Page 90: Installing The Engine Guard

    12 SERVICE WORK ON THE CHASSIS 12.46 Installing the engine guard – Attach the engine guard on the frame at the rear and swing up at the front. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis H01655-01...

  • Page 91: Brake System

    Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple...

  • Page 92: Checking The Front Brake Fluid Level

    – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 93: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...

  • Page 94: Changing The Front Brake Linings

    Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 95 13 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane K00935-10 – Manually press the brake caliper toward the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, if necessary extract excess.

  • Page 96: Checking The Free Travel Of The Foot Brake Lever

    13 BRAKE SYSTEM – Add brake fluid up to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 ( p. 152) – Position cover with membrane – Mount and tighten screws K00935-11 Info Clean up overflowed or spilled brake fluid immediately with water.

  • Page 97: Checking The Rear Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Stand the vehicle upright.

  • Page 98: Adding Rear Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 99: Checking The Brake Linings Of The Rear Brake

    Checking the brake linings of the rear brake Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 100 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 101 13 BRAKE SYSTEM – Stand the vehicle upright. – Remove the cable ties on the frame protector. – Remove screw cap with membrane and the shim. K00947-10 – Manually press the brake caliper to the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does.
  • Page 102 13 BRAKE SYSTEM – Add brake fluid to level Brake fluid DOT 4 ( p. 152) – Mount and tighten screw cap with membrane and the shim. Info Clean up overflowed or spilled brake fluid immediately with water. – Mount new cable ties on the frame protector. K00946-10...

  • Page 103: Wheels, Tires

    14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 56) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pis-...

  • Page 104: Installing The Front Wheel

    14 WHEELS, TIRES 14.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 105: Installing The Rear Wheel

    14 WHEELS, TIRES Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. –...
  • Page 106 14 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p.

  • Page 107: Checking The Tire Condition

    Checking the tire condition Info Only mount tires approved and/or recommended by Husqvarna Motorcycles. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcy- cle.

  • Page 108: Checking Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) –...

  • Page 109: Electrical System

    Preparatory work (All EU models) – Press and hold the kill switch while the engine is idling until the engine stops. (TE 250i US) – Press and hold the kill switch while the engine is idling until the engine stops. –...

  • Page 110: Installing The Battery

    15 ELECTRICAL SYSTEM 15.2 Installing the battery Main work – Insert the battery into the battery compartment with the ter- minals facing forward and secure with holding bracket Battery (HJTZ5S-FP) ( p. 148) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis –...
  • Page 111 Preparatory work (All EU models) – Press and hold the kill switch while the engine is idling until the engine stops. (TE 250i US) – Press and hold the kill switch while the engine is idling until the engine stops. –...

  • Page 112: Changing The Main Fuse

    Preparatory work (All EU models) – Press and hold the kill switch while the engine is idling until the engine stops. (TE 250i US) – Press and hold the kill switch while the engine is idling until the engine stops. –...
  • Page 113 15 ELECTRICAL SYSTEM Main work – Pull the EFI control unit upward off the rubber plugs and hang to the side. R02958-10 – Pull starter relay from the holder. V00955-10 – Take off protection caps – Remove faulty main fuse Info You can recognize a faulty fuse by a burned-out fuse wire...

  • Page 114: Changing The Fuses Of Individual Power Consumers

    Preparatory work (All EU models) – Press and hold the kill switch while the engine is idling until the engine stops. (TE 250i US) – Press and hold the kill switch while the engine is idling until the engine stops. –...

  • Page 115: Removing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Use spare fuses with the correct rating only. Fuse (75011088010) ( p. 148) Fuse (75011088005) ( p.

  • Page 116: Installing The Headlight Mask With The Headlight

    V00958-10 (All EU models) – Detach plug-in connectors and take off the headlight mask with the headlight. V00959-10 (TE 250i US) – Detach plug-in connector and take off the headlight mask with the headlight. V00982-10 15.7 Installing the headlight mask with the headlight...

  • Page 117: Changing The Headlight Bulb

    15 ELECTRICAL SYSTEM – Position the headlight mask and secure it with rubber bands The holding lugs engage. V00958-11 – Position brake line and wiring harness in the brake line guide. V00957-11 Finishing work – Check the headlight setting. ( p.

  • Page 118: Changing The Turn Signal Bulb (All Eu Models)

    15 ELECTRICAL SYSTEM – Pull out headlight bulb – Insert the new headlight bulb. Headlight (HS1/socket BX43t) ( p. 148) – Insert the protection cap with the bulb socket into the reflec- tor and turn it clockwise all the way. O-ring is correctly positioned.

  • Page 119: Checking The Headlight Setting

    15 ELECTRICAL SYSTEM 15.10 Checking the headlight setting – Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. – Make another mark a distance under the first mark.

  • Page 120: Changing The Combination Instrument

    15 ELECTRICAL SYSTEM 15.12 Changing the combination instrument Preparatory work – Remove the headlight mask with the headlight. ( p. 113) Main work – Remove screws with the washers. – Pull the combination instrument upward out of the holder. V00961-10 –...

  • Page 121: Cooling System

    16 COOLING SYSTEM 16.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 122: Checking The Coolant Level

    16 COOLING SYSTEM 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 123: Refilling With Coolant

    16 COOLING SYSTEM Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...
  • Page 124 16 COOLING SYSTEM – Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Coolant level above the radiator fins Coolant ( p. 152) 400243-10 – Push protection cap upward over the thermostat. V00965-10 – Unplug connector –...
  • Page 125 16 COOLING SYSTEM Finishing work – Check the coolant level. ( p. 120)

  • Page 126: Tuning The Engine

    17 TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Turn the handlebar as far as possible to the right. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 …...

  • Page 127: Setting The Characteristic Map Of The Throttle Response

    17 TUNING THE ENGINE Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Turn adjusting screw in as far as possible. –...

  • Page 128: Adjusting The Idle Speed

    Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Run the engine until warm.

  • Page 129: Programming Ambient Pressure

    17 TUNING THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 130: Ignition Curve Plug-In Connector

    17 TUNING THE ENGINE – Start the vehicle at the new height above sea level and switch off the engine again. – Wait for at least five seconds. – Start the vehicle again and check the response of the vehicle. »...

  • Page 131: Checking The Basic Position Of The Shift Lever

    17 TUNING THE ENGINE 17.8 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...

  • Page 132: Service Work On The Engine

    18 SERVICE WORK ON THE ENGINE 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 133: Checking 2-Stroke Oil Level

    18 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 134: Timing Oil Pump

    18 SERVICE WORK ON THE ENGINE 18.3 Timing oil pump Warning Engine failure The engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel. –...

  • Page 135: Checking The Gear Oil Level

    18 SERVICE WORK ON THE ENGINE – Plug in wake-up connector for timing the oil pump the diagnostics connector. The combination instrument lighting is activated. Info The connector is included as part of the motorcycle's separate enclosure. – Wait for at least five seconds. –...

  • Page 136: Changing The Gear Oil

    18 SERVICE WORK ON THE ENGINE – Mount and tighten the gear oil monitoring screw. Guideline Screw, gear oil level 10 Nm (7.4 lbf ft) check – Attach the foot brake lever spring. 18.5 Changing the gear oil Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. –...

  • Page 137: Adding Gear Oil

    18 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
  • Page 138 18 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 139: Cleaning, Care

    19 CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...

  • Page 140: Checks And Maintenance Steps For Winter Operation

    19 CLEANING, CARE – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 154) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 141: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info Husqvarna Motorcycles recommends raising the motorcycle. – Raise the motorcycle with a lift stand. ( p. 56) –...

  • Page 142: Preparing For Use After Storage

    20 STORAGE Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Because the engine will not warm up sufficiently, the water vapor produced during combustion will condense, causing engine parts and the exhaust system to rust.

  • Page 143: Troubleshooting

    Clean the connector and treat with is loose or oxydized contact spray. – Defect in the fuel injection sys- Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. – Engine has no idle Spark plug defective Change the spark plug.
  • Page 144 Fuel screen is very dirty Change the fuel screen. p. 130) – Defect in the fuel injection sys- Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. – Fuel supply interrupted Check the fuel tank breather. – Exhaust system leaky, Check exhaust system for damage.
  • Page 145 Check the cabling for damage and lights up or flashes the electrical plug-in connections for corrosion and damage. – Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. – The battery is discharged The battery is not being Check the charging voltage.

  • Page 146: Technical Data

    22 TECHNICAL DATA 22.1 Engine 22.1.1 All TE 250i Design 1-cylinder 2-stroke engine, water-cooled, with reed intake, exhaust control and transfer duct injection Displacement 249 cm³ (15.19 cu in) Stroke 72 mm (2.83 in) Hole 66.4 mm (2.614 in) Exhaust valve, beginning of adjustment...

  • Page 147: Engine Tightening Torques

    22 TECHNICAL DATA Conrod bearing Needle bearing Piston pin bearing Needle bearing Piston Cast aluminum Piston rings 2 rectangular rings Engine lubrication Separate lubrication X distance (upper edge of piston to upper edge of 0 … 0.10 mm (0 … 0.0039 in) cylinder) Z distance (height of control flap) 49.5 mm (1.949 in)
  • Page 148 22 TECHNICAL DATA Screw, locking lever 6 Nm (4.4 lbf ft) ® Loctite 243™ Screw, retaining bracket of 7 Nm (5.2 lbf ft) ® Loctite 2701™ exhaust control Screw, stator 6 Nm (4.4 lbf ft) ® Loctite 243™ Screw, water pump impeller 6 Nm (4.4 lbf ft) ®...

  • Page 149: Capacities

    22 TECHNICAL DATA Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) Spark plug M14x1.25 25 Nm (18.4 lbf ft) Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft) ® Loctite 648™ Nut, primary gear M18LHx1.5 150 Nm (110.6 lbf ft) ®...

  • Page 150: Electrical System

    Seat height unloaded 960 mm (37.8 in) Ground clearance unloaded 370 mm (14.57 in) Weight without fuel, approx. (TE 250i EU) 107.6 kg (237.2 lb.) Weight without fuel, approx. (TE 250i US) 105.2 kg (231.9 lb.) Weight without fuel, approx. (TE 300i EU) 107.8 kg (237.7 lb.)

  • Page 151: Fork

    22 TECHNICAL DATA 22.7 Fork Fork article number 14.15.8R.63 Fork WP Performance SystemsXplor 48 PA Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload - Preload Adjuster Comfort Standard Sport...

  • Page 152: Chassis Tightening Torques

    Fuel connection on fuel pump 10 Nm (7.4 lbf ft) Nut, foot brake lever stop 20 Nm (14.8 lbf ft) Nut, pull switch (TE 250i US) 0.4 Nm (0.3 lbf ft) Nut, rear sprocket screw 35 Nm (25.8 lbf ft) ®...
  • Page 153 22 TECHNICAL DATA Remaining nuts, chassis 25 Nm (18.4 lbf ft) Remaining screws, chassis 25 Nm (18.4 lbf ft) Screw, bottom triple clamp 15 Nm (11.1 lbf ft) Screw, chain sliding piece 15 Nm (11.1 lbf ft) Screw, engine brace 25 Nm (18.4 lbf ft) ®...

  • Page 154: Substances

    23 SUBSTANCES Brake fluid DOT 4 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties. Recommended supplier Bel‑Ray ® – Super DOT 4 Brake Fluid Coolant Guideline –...
  • Page 155 23 SUBSTANCES Recommended supplier ® Bel‑Ray – Si‑7 Synthetic 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 155) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 156: Auxiliary Substances

    24 AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel‑Ray – Foam Filter Cleaner & Degreaser High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier ® Bel‑Ray – Waterproof Grease Offroad chain spray Guideline Recommended supplier Bel‑Ray ®...

  • Page 157: Standards

    25 STANDARDS JASO T903 MA Different technical development directions required a separate specification for motorcycles – the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 158: Index Of Special Terms

    26 INDEX OF SPECIAL TERMS On-board diagnosis Vehicle system, which monitors the specified param- eters of the vehicle electronics...

  • Page 159: List Of Abbreviations

    27 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 160: List Of Symbols

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized Husqvarna Motorcy- cles workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 161: Index

    INDEX INDEX Capacity 2-stroke oil level coolant ......147 checking ......131 fuel .
  • Page 162 INDEX muddy surfaces ..... 35 Fuel screen slow speed ......35 changing .
  • Page 163 INDEX fuel ......41 Light switch ......18 Riding sag adjusting .
  • Page 164 INDEX Technical data capacities ......147 chassis ......147 chassis tightening torques .
  • Page 165 *3402171en* 3402171en 06/2017 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer, www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...

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Te 300i

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