Page 1 Workshop Manual TC 250 / 2009 TC 250 / 2010 TE 250 / 2010 TXC 250 / 2010 (USA only) Part. N. 8000 H1489 (10-2009)
Page 2 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 reflect on-going product development. Illustrations in the ma- nual may differ from actual components. No reproduction in full or in part without written authorisation.
Page 3: Foreword, Table Of Contents
Workshop Manual TC 250 / 2009 TC 250 / 2010 250:2010; TXC 250 / 2010 (USA only) 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...
Page 4 FOREWORD, TABLE OF CONTENTS Foreword This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance and repair of the models covered in this manual. The technical information provided in this manual is a critical comple- ment to operator training and operators should become thoroughly familiar with it.
Page 5: Table Of Contents
FOREWORD, TABLE OF CONTENTS Table of Contents Title Section Foreword, Table of Contents ................a Important Notices ....................b General Information .....................A Maintenance ......................B Troubleshooting ....................C Settings and Adjustments ................... D General Procedures ....................E Engine Disassembly ....................F Engine Overhaul ....................G Engine Reassembly....................
Page 7: Important Notices
IMPORTANT NOTICES Section Part. N. 8000 H1489 (10-2009)
Page 8 * 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.
Page 9: General Information
GENERAL INFORMATION Section Part. N. 8000 H1489 (10-2009)
Page 10 GENERAL INFORMATION Engine ......................A.3 Timing system ....................A.3 Fuel system ....................A.3 Lubrication ....................A.3 Cooling ......................A.3 Ignition system....................A.3 Starter ......................A.3 Drive and Transmission ................A.3 Chassis ......................A.4 Suspension ....................A.4 Brakes ......................A.4 Wheels......................A.4 Tyres ......................A.5 Electrical components location ..............A.5 Overall dimensions - Weight .................A.6 Capacities .....................A.7 Part.
Page 11: Engine
GENERAL INFORMATION Engine Single cylinder, 4 stroke Bore ......................79 mm Stroke ....................50.9 mm Displacement ................... 249.5 cu.in. Compression ratio ...................13.6:1 Timing system Type ............. 4 radially arranged titanium valves .operated by two chain and gear driven overhead camshafts via valve buckets Valve clearance ( cold with engine) INTAKE ....................
Page 12: Chassis
GENERAL INFORMATION Secondary drive Motion is transmitted from gearbox to rear wheel by 5/8" x 1/4" final drive chain ("D.I.D." 520 DS or "REGINA" 135 RX3) Transmission sprocket (TC) ................ z 13 Transmission sprocket (TE - TXC) .............. z 13 Rear wheel sprocket (TC)................
Page 13: Tyres
GENERAL INFORMATION Tyres Front (TC) ......"Pirelli" 51R-MT 32A or "Dunlop" D756; 80/100 x 21” Front (TE - TXC) .........."Michelin" ENDURO COMP. 3 or "Pirelli" MT 83 Scorpion; 90/90 x 21” Front (TE USA) .........."Metzeler KAROO"; 90/90 x 21” Rear (TC) .............."Pirelli"...
Page 14: Overall Dimensions - Weight
GENERAL INFORMATION The electrical system includes the following elements: 12V-6Ah battery under the saddle; Turning indicator flasher on left side of rear chassis; Relay for electric fan, fuel injection system and lights on right side of chassis: Electric fan; Two 15A fuses and one 20A fuse on right side of rear chassis; Coolant temperature sensor;...
Page 15: Capacities
GENERAL INFORMATION Capacities Type Quantity Fuel tank (TC) 98 octane unleaded fuel 7 litres Fuel tank (TE - TXC) 98 octane unleaded fuel 6.5 litres Gearbox/engine oil CASTROL POWER 1 RACING (SAE 10W50) 0.9 litres (oil change and oil filter replacement) 0.7 litres (oil change)
Page 17: Maintenance
MAINTENANCE Section Part. N. 8000 H1489 (10-2009)
Page 18 MAINTENANCE SCHEDULED MAINTENANCE CHART TC - TE - TXC (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING SERVICE SERVICE SERVICE SERVICE SERVICE COUPON COUPON COUPON COUPON COUPON PART AFTER FIRST EVERY EVERY...
Page 19 MAINTENANCE SCHEDULED MAINTENANCE CHART TC - TE - TXC (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING SERVICE SERVICE SERVICE SERVICE SERVICE COUPON COUPON COUPON COUPON COUPON PART AFTER FIRST EVERY EVERY...
Page 20 MAINTENANCE SCHEDULED MAINTENANCE CHART TC - TE - TXC (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING SERVICE SERVICE SERVICE SERVICE SERVICE COUPON COUPON COUPON COUPON COUPON PART AFTER FIRST EVERY EVERY...
Page 21 MAINTENANCE SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) AFTER FIRST EVERY EVERY REPLACE - STANDARD MOTORCYCLE, FOR ROAD USE 1000 KM 5000 KM 10000 KM PAGE REQUIRED (DERATED) VALVES C (•) C (•) S (#) VALVE SPRINGS...
Page 22 MAINTENANCE SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) TE - TXC AFTER FIRST EVERY EVERY REPLACE - STANDARD MOTORCYCLE, FOR ROAD USE 1000 KM 5000 KM 10000 KM PAGE (DERATED) REQUIRED SERVICE SERVICE SERVICE PART COUPON...
Page 23 MAINTENANCE SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) REPLACE EVERY EVERY AFTER FIRST - STANDARD MOTORCYCLE, FOR ROAD USE PAGE 5000 KM 10000 KM 1000 KM REQUIRED (DERATED) SERVICE SERVICE SERVICE PART COUPON COUPON COUPON REAR BRAKE DISC...
Page 25: Troubleshooting
TROUBLESHOOTING Section Part. N. 8000 H1489 (10-2009)
Page 26 TROUBLESHOOTING ENGINE Trouble Cause Remedy Engine does not start or Insufficient compression has starting trouble 1. Piston seized Replace 2. Connecting rod small or big end seized Replace 3. Worn piston rings Replace 4. Worn cylinder Replace 5. Cylinder head loosely tightened Tighten 6.
Page 27 TROUBLESHOOTING Trouble Cause Remedy Noise seems to come from the clutch 1. Worn plates Replace 2. Too much clearance between clutch housing and friction plates Replace Noise seems to come from gearbox 1. Worn gears Replace 2. Worn gear grooves Replace Noise seems to come 1.
Page 28 TROUBLESHOOTING CHASSIS Trouble Cause Remedy Handlebar turns hard 1. Insufficient tyre pressure Inflate 2. Bearing adjuster ring nut or steering stem nut overtightened Adjust 3. Bent steering stem Replace bottom yoke 4. Worn or seized steering bearings Replace Handlebar vibration 1. Bent fork legs Replace 2.
Page 29 TROUBLESHOOTING ELECTRICAL SYSTEM (see also Section M) Trouble Cause Remedy Spark plug fouls 1. Mixture too rich Adjust carburettor setting easily 2. Dirty air filter Clean 3. Worn piston rings Replace 4. Worn piston or cylinder liner Replace Spark plug electrodes 1. Mixture too lean Adjust carburettor setting overheat 2.
Page 31: Settings And Adjustments
SETTINGS AND ADJUSTMENTS Section Part. N. 8000 H1489 (10-2009)
Page 32 SETTINGS AND ADJUSTMENTS Saddle removal.....................D.4 Tank removal (TC) ..................D.4 Tank removal (TE - TXC) ................D.5 Valve clearance adjustment ................D.6 Throttle cable adjustment (TC) ..............D.7 Throttle cable adjustment (TE - TXC) ............D.8 Enrichener lever play adjustment (TE - TXC) ..........D.8 Carburettor adjustment (TC).................D.9 Idle adjustment (TC) ..................D.9 Idle adjustment (TE - TXC) ................D.9 Clutch plate replacement ................D.10...
Page 33 SETTINGS AND ADJUSTMENTS Part. N. 8000 H1489 (10-2009)
Page 34: Saddle Removal
SETTINGS AND ADJUSTMENTS Saddle removal Turn the rear fixing (1) counter clockwise, remove it and extract the saddle. Tank removal (TC) Close the fuel cock (2) and loosen the clamp (3) on the hose running to the carburettor. Detach hose (4) from carburettor making sure to drain any fuel in the hose into a container.
Page 35: Tank Removal (Te - Txc)
SETTINGS AND ADJUSTMENTS Tank removal (TE - TXC) Remove the screws (1) and the side panels. Remove the tank retaining screw (2). Lift the tank and disconnect the fuel pump connector from the main wiring har- ness. Disconnect the supply hose (3) from the outlet fitting (4) on the fuel pump, located in the rear bottom section of the tank.
Page 36: Valve Clearance Adjustment
SETTINGS AND ADJUSTMENTS Valve clearance adjustment Remove saddle and tank as outlined in the relevant paragraphs. Remove spark plug (1), both head cover screws (2) and head cover (3). Engage the 2nd gear and push and pull the motorcycle back and forth to bring the piston to Top Dead Centre.
Page 37: Throttle Cable Adjustment (Tc)
SETTINGS AND ADJUSTMENTS Throttle cable adjustment (TC) To check the correct adjustment of the throttle cable, operate as follows: remove the rubber gaiter (1) at cable end; push and pull cable (2) to make sure it has about 2 mm free play; if not so, loosen the lock ring nut (3) and suitably turn the adjuster screw (4) (loosen to decrease play or tighten to increase it);...
Page 38: Throttle Cable Adjustment (Te - Txc)
SETTINGS AND ADJUSTMENTS Throttle cable adjustment (TE - TXC) To check the correct adjustment of the throttle cable, operate as follows: Loosen the screw and remove the cover (1). Make sure the cables protrude by 10 mm (length A). If they need adjusting, loosen the check nuts (2) and turn the adjuster screws (3).
Page 39: Carburettor Adjustment (Tc)
SETTINGS AND ADJUSTMENTS Carburettor adjustment (TC) Adjust the carburettor with warm engine and with the throttle control in closed position. Proceed as follows: turn the idle speed adjuster screw (1) located on the left-hand side of the vehicle, until setting idle RPM quite high (turn clockwise to increase the speed and counter clockwise to reduce the speed).
Page 40: Clutch Plate Replacement
SETTINGS AND ADJUSTMENTS Clutch plate replacement This procedure can be performed with the motorcycle leaning to the left - there is no need to drain engine oil. Remove the brake pedal (1). Remove the six retaining screws (2) and the clutch cover (3). Using an 8 mm wrench, unscrew the six screws (4) securing the clutch springs.
Page 41: Hydraulic Clutch Lever Adjustment And Fluid Level Check
SETTINGS AND ADJUSTMENTS Remove the plates (8), lubricate the new plates with engine oil and install them (always start with a friction plate). Refit clutch actuator plate, bearing and pressure plate. Tighten the spring screws gradually in a cross pattern (8 Nm - 0.8 Kgm - 5.8 ft/ lb).
Page 42: Front Brake Lever Adjustment And Fluid Level Check
SETTINGS AND ADJUSTMENTS Front brake lever adjustment and fluid level check The adjuster (1) located on the control lever, allows adjusting of the free play (a). Free play (a) must be at least 3 mm. The level of the fluid in master cylinder reservoir must never be below the mini- mum value (2), which can be checked from the inspection window on the rear of the master cylinder body.
Page 43: Rear Brake Pedal Adjustment
SETTINGS AND ADJUSTMENTS Rear brake pedal position adjustment The position of the rear brake pedal with respect to the footrest may be adjusted according to individual needs. For adjusting, proceed as follows: Loosen the screw (1). Turn the cam (2) in order to raise or lower the brake pedal within the range available (A).
Page 44: Rear Brake Pedal Free Play Adjustment
SETTINGS AND ADJUSTMENTS Rear brake pedal free play adjustment The rear brake pedal should have 5 mm free play (B) before the brake begins to bite. Should this not happen, operate as follows: Loosen the nut (3); Operate the master cylinder linkage (4) to increase or decrease free play; Tighten the nut (3) at the end of the operation.
Page 45: Engine Oil Level Check
SETTINGS AND ADJUSTMENTS Engine oil level check Keeping the motorcycle level and upright, check the oil level through the inspec- tion window (1) on the right crankcase. Make sure level is up to window midline (1). To top up, remove the filler cap (2). Have this operation made with warmed-up engine.
Page 46: Engine Oil Replacement And Mesh Filters-Filter Cartridge Cleaning Or Replacement
SETTINGS AND ADJUSTMENTS Engine oil replacement and mesh filters-filter cartridge cleaning or replace- ment Drain the oil with WARM ENGINE; proceed as follows: Remove the oil filler cap (2). The oil sump guard (A) may be left in place. However, the procedure will be easier with the guard removed.
Page 47: Coolant Level Check
SETTINGS AND ADJUSTMENTS Coolant level check Check level (1) in right-hand radiator when engine is cold (place the motorcycle so that it is perpendicular to the ground). The coolant should be approximately 0.39 in. above the cells. The radiator cap features two locking positions: the first one is for prior discharge of pressure from the cooling system.
Page 48: Air Filter Check (Tc)
SETTINGS AND ADJUSTMENTS Air filter check (TC) Turn the rear fixing (1) counter clockwise, remove it and extract the saddle re- leasing it from the front retaining screw. Remove the screw (3), remove the complete air filter (4) and separate filter (5) from rear chassis (6).
Page 49: Air Filter Check (Te - Txc)
SETTINGS AND ADJUSTMENTS Air filter check (TE - TXC) Turn the rear fixing (1) counter clockwise, remove it and extract the saddle releasing it from the front retaining screw. Take out the battery (A) and leave it hanging on the side of the motorcycle. Remove the screw (3), remove the complete air filter (4) and separate filter (5) from intake silencer (6).
Page 50 SETTINGS AND ADJUSTMENTS Assembly Grease the edge (C) of the filter face that goes into the housing to ensure proper sealing. When refitting the filter into its housing, make sure to position it with the tab (A) pointing upwards and edge (B) at the left bottom corner of the filter housing.
Page 51: Secondary Drive Chain Adjustment
SETTINGS AND ADJUSTMENTS Secondary drive chain adjustment Chain should be checked, adjusted and lubricated as per the "Maintenance Chart" (see Section B) to ensure safety and prevent excessive wear. If the chain becomes badly worn or is poorly adjusted (i.e., if it is too loose or too taut), it could escape from sprocket or break.
Page 52: Chain Lubrication
SETTINGS AND ADJUSTMENTS Chain lubrication Lubricate the chain following these instructions. Never use grease to lubricate the chain. Grease helps to accumulate dust and mud, which act as abrasive and help to rapidly wear out the chain, the front and rear sprockets. Disassembling and cleaning When particularly dirty, remove and clean the chain before lubrication.
Page 53: Suspension Setup According To Track Condition
SETTINGS AND ADJUSTMENTS Suspension setup according to track condition Following are a few guidelines to find the right suspension setup for different types of terrain. Always start from the suspensions standard set- ting before making any change. Afterwards, increase or decrease the adjusting clicks, one at a time.
Page 54 SETTINGS AND ADJUSTMENTS Shock absorber adjustment The rear shock absorber must be adjusted to suit rider weight and terrain condi- tions. Proceed as follows: 1. Place the motorcycle on the stand and measure distance (A). 2. Sit on the motorcycle in normal riding position with full riding gear on. 3.
Page 55: Shock Absorber Spring Preload Adjustment
SETTINGS AND ADJUSTMENTS Shock absorber spring preload adjustment Proceed as follows: 1. Turn the rear fixing (1) counter clockwise and remove the saddle, unscrew the retaining screws (2) and remove the right-hand side panel (3). 2. Clean lock ring nut (4) and adjuster ring nut (5) of the spring (6). 3.
Page 56: Shock Absorber Compression And Rebound Damping Adjustment
SETTINGS AND ADJUSTMENTS Shock absorber compression and rebound damping adjustment Adjustment of the compression stroke is independent from the rebound stroke. A) COMPRESSION - Standard setting: 1) Low damping speed: -15 clicks (± 2 clicks) (adjuster 1) 2) High damping speed: -15 clicks (±...
Page 57: Marzocchi Front Fork Adjustment (Tc 2009)
SETTINGS AND ADJUSTMENTS MARZOCCHI front fork adjustment (TC 2009) a) COMPRESSION (LOWER ADJUSTER) Standard setting: -20 clicks. To reset the standard setting, remove cap (B) and turn the adjuster (A) clockwise until reaching fully closed position. Then turn it back by the mentioned clicks. In order to obtain a smooth braking action, turn the adjuster counter clockwise.
Page 58: Kayba Front Fork Adjustment (Tc - Te - Txc / 2010)
SETTINGS AND ADJUSTMENTS KAYABA front fork adjustment (TC - TE - TXC / 2010) COMPRESSION (Fig. a) (TC - TXC: TOP ADJUSTER; TE: LOWER ADJUSTER) KAYABA: -13 clicks (TC - TXC / 2010); KAYABA: -10 clicks (TE / 2010); To reset the standard setting, turn cap nut (A) clockwise to reach the fully closed position;...
Page 59: Kayba Front Fork Springs
SETTINGS AND ADJUSTMENTS KAYABA front fork springs STANDARD (TC - TXC / 2010): K=4.4 N/mm (spring part no. 8000 H2669) (TE / 2010): K=4.2 N/mm (spring part no. 8000 H2690) Part. N. 8000 H1489 (10-2009) D.29...
Page 60: Marzocchi Front Fork Springs
SETTINGS AND ADJUSTMENTS MARZOCCHI front fork springs STANDARD K=4.8 N/mm (spring + spacer part no. 8000 H1994) D.30 Part. N. 8000 H1489 (10-2009)
Page 61: Steering Bearing Clearance Adjustment
SETTINGS AND ADJUSTMENTS Steering bearing clearance adjustment For safety reasons, the steering should always be adjusted so that the handlebar turns freely and without play. To check steering adjustment, set a stand or a block under the engine and see that the front wheel is lifted from the ground. Press lightly on the handlebar grips to cause the front end to rotate;...
Page 62: Changing Handlebar Position And Height
SETTINGS AND ADJUSTMENTS Changing handlebar position and height Handlebar position (a) and height (b) can be modified to better suit your personal preferences. To perform these adjustments, remove the handlebar clamp bolts (3) and (4), and then remove the handlebar upper (1) and lower (2) clamps. a) Changing handlebar position Rotate the lower clamp by 180°...
Page 63: Supply Hose Check (Tc)
SETTINGS AND ADJUSTMENTS Supply hose check (TC) Check the hose (1) for leaks and replace it as required. Remove the supply hose as described in Section "E". Supply hose check (TE – TXC) Remove saddle and side panels as described in Section "E". Remove the tank (1) retaining screw (2).
Page 64: Silencer Sound Deadening Material Replacement
SETTINGS AND ADJUSTMENTS Silencer sound deadening material replacement Turn the rear fixing (1) counter clockwise and remove the saddle. Loosen the screws (2) and remove the left-hand side panel (3). Using an 8 mm T-wrench on the outside and a 10 mm T-wrench on the inside, remove the silencer retaining screw (4).
Page 65: Exhaust System Check
SETTINGS AND ADJUSTMENTS Exhaust system check Remove exhaust system components as described in Section "E". Check pipes (1) and (2) silencer (3) for cracks or damage: replace if cracked or damaged. Part. N. 8000 H1489 (10-2009) D.35...
Page 67: General Procedures
GENERAL PROCEDURES Section Part. N. 8000 H1489 (10-2009)
Page 68 GENERAL PROCEDURES Foreword ......................E.3 Saddle removal.....................E.4 Side panel removal ..................E.4 Removing the rear chassis complete with mudguard and air box (TC) ....................E.5 Removing the rear chassis complete with mudguard and air box (TE–TXC)..................E.5 Battery removal ....................E.7 Exhaust system removal ................E.8 Fuel tank, scoop and spoiler removal (TC)..........E.10 Fuel tank, scoop and spoiler removal (TE–TXC)........E.13 Fuel pump removal (TE–TXC)..............E.16...
Page 69: Foreword
GENERAL PROCEDURES Foreword This section describes the operations preliminary to engine removal. Please note that, in order to gain access to certain motorcycle components (rear shock absorber, electrical parts, wiring, etc.), it may be necessary to partially remove some parts. RIGHT-HAND SIDE LEFT-HAND SIDE Part.
Page 70: Saddle Removal
GENERAL PROCEDURES Saddle removal - Turn the rear fixing (1) counter clockwise and remove the saddle. Side panel removal Remove the saddle as described in the relevant paragraph. Loosen the retaining screws (1) and remove the side panels (2) and (3). Battery removal (TE - TCX) Remove the saddle as described in the relevant paragraph. First remove the BLACK negative cable (8 mm Allen wrench), then the RED positive cable (when reassembling, first connect the RED positive cable, then the BLACK negative cable);...
Page 71: Removing The Rear Chassis Complete With Mudguard And Air Box (Tc)
GENERAL PROCEDURES Removing the rear chassis complete with mudguard and air box (TC) Remove the saddle as described in the relevant paragraph. Remove the side panels as described in the relevant paragraph. Lift the tank at the rear end. Remove the exhaust silencer as described in the relevant paragraph. Slacken the clamp (1) that secures the rubber coupling (2) of the air box (3) at the carburettor end.
Page 72 GENERAL PROCEDURES Disconnect the connector (4) of the tail light unit (TE). Detach relays (5) and fuses (6) on the right-hand side of the motorcycle. - Detach the breather hose (7) from the air filter (8). H00621 Part. N. 8000 H1489 (10-2009)
Page 73 GENERAL PROCEDURES - Unscrew the clamp (9) connecting air filter (8) to throttle body (10). Remove the four screws (11) of the rear chassis (12) using a 10 mm ring wrench. Pull the rear chassis (12) rearwards together with mudguard and air box , and detach it from the main chassis. Part.
Page 74: Exhaust System Removal
GENERAL PROCEDURES Exhaust system removal TE-TXC H00625 Remove the saddle as described in the relevant paragraph. Remove the left-hand side panel as described in the relevant paragraph. Using an 8 mm T-wrench on the outside and a 10 mm T-wrench on the inside, remove the silencer (4) retaining screw (1).
Page 75 GENERAL PROCEDURES Remove the spring (2) and the screw (3) using an 8 mm T-wrench; slide out the silencer (4). Disconnect the Lambda sensor connector (7) and shear the wiring clips (TE- TXC). Part. N. 8000 H1489 (10-2009)
Page 76: Fuel Tank, Scoop And Spoiler Removal (Tc)
GENERAL PROCEDURES Loosen the two bolts (5) and remove the exhaust pipe (6). Fuel tank, scoop and spoiler removal (TC) E.10 Part. N. 8000 H1489 (10-2009)
Page 77 GENERAL PROCEDURES Remove the saddle as described in the relevant paragraph. Remove the side panels as described in the relevant paragraph. Remove the breather hose (1) from the steering stem. Turn the ring nut of the fuel cock (2) counter clockwise to shut off fuel supply and loosen the clamp (3) on the hose running to the carburettor.
Page 78 GENERAL PROCEDURES Remove the screws (4) retaining the scoops to the fuel tank. Remove the scoops (7) and the screws (5) retaining the spoilers (8) to the radiators. Remove the spoilers and slide out the tank. E.12 Part. N. 8000 H1489 (10-2009)
Page 79: Fuel Tank, Scoop And Spoiler Removal (Te-Txc)
GENERAL PROCEDURES Fuel tank, scoops and spoiler removal (TE – TXC) H00630 Remove the saddle as described in the relevant paragraph. Remove the side panels as described in the relevant paragraph. Remove the breather hose (1). Loosen the fuel tank retaining screw (2). Part.
Page 80 GENERAL PROCEDURES Remove the screws (3) retaining the scoops to the fuel tank. Remove the scoops (4) and the screws (5) retaining the spoilers (6) to the radiators and then remove the spoilers. E.14 Part. N. 8000 H1489 (10-2009)
Page 81 GENERAL PROCEDURES Disconnect the fuel pump connector (7) from the main wiring harness. - Lift the tank and disconnect the hose (8) from the fuel pump outlet fitting (9) in the bottom section of the tank. H00645 Slide out the tank (10). Part. N. 8000 H1489 (10-2009) E.15...
Page 82: Fuel Pump Removal (Te-Txc)
GENERAL PROCEDURES Fuel pump removal (TE – TXC) Remove the fuel tank as described in the relevant paragraph. - Remove the tank filler cap and pour the fuel contained in the tank into a ves- sel of adequate capacity. Use an Allen wrench to loosen the 6 screws (1) and remove the pump (2). H00648 WARNING On assembly, make sure that the pump O-ring (3) is correctly po- sitioned in its seat.
Page 83: Solenoid Starter Removal (Te-Txc)
GENERAL PROCEDURES Solenoid starter removal (TE – TXC) Remove saddle and left-hand side panel (in this order) as outlined in the relevant paragraphs. Disconnect the negative and positive cables of the battery. Disconnect the starter motor positive cable (1) from the solenoid starter. Disconnect the connector (2) and remove the solenoid starter (3) from its mount.
Page 84: Cdi Electronic Control Unit Removal
GENERAL PROCEDURES CDI electronic control unit removal Remove: saddle and fuel tank as described in the relevant paragraphs. Detach the connector (1) from the CDI electronic control unit (2) and take the control unit together with its vibration mount out of the chassis. Voltage regulator removal (TE –...
Page 85: Ignition Coil Removal
GENERAL PROCEDURES TE-TXC Loosen the two retaining screws (2) and remove the regulator (3). H00658 Ignition coil removal Remove: saddle and fuel tank as described in the relevant paragraphs. Remove the spark plug cap (1). Remove the retaining screws (2) and then the coil (3). TE-TXC H00660 Part.
Page 86: Clutch Hose Removal
GENERAL PROCEDURES Clutch hose removal - Loosen the fitting (1) of the clutch hose (2) on the left-hand of the engine. Drain any oil left in the hose. On assembly, bleed the clutch system as de- scribed in Section "P". Horn removal (TE) Remove saddle and fuel tank (in this order) as outlined in the relevant para- graphs.
Page 87: Electric Cooling Fan Removal (Te-Txc)
GENERAL PROCEDURES Electric cooling fan removal (TE – TXC) Remove saddle, fuel tank and scoops (in this order) as outlined in the relevant paragraphs. Disconnect the connector (1). Loosen the screw (2) and remove the electric fan (3). Part. N. 8000 H1489 (10-2009) E.21...
Page 88: Secondary Drive Chain Removal
GENERAL PROCEDURES Secondary drive chain removal The following procedure applies to both O-ring chains and chains without O- rings: Remove: screws (1), sprocket guard (2), clip (3), master link (4) and chain (5). Engine removal Remove the saddle as described in the relevant paragraph. Remove the side panels as described in the relevant paragraph.
Page 89 GENERAL PROCEDURES (TC) Slacken the clamps (2) and (3) securing the carburettor to the intake coupling and to the hose coupling on the air box. Pull the carburettor rearwards to release it from the intake coupling and extract it from the right-hand side of the motorcycle.
Page 90 GENERAL PROCEDURES Slacken the clamp (11) and disconnect the hose (12) connecting the radiators to the engine. Drain all fluid. Slacken the clamp (13) and disconnect the hose (14) connecting the radiator to the water pump. Remove the oil sump guard, place a pan under the engine and remove the oil filler cap (15); remove the oil drain plug (16) with a 12 mm wrench and drain the oil.
Page 91 GENERAL PROCEDURES Remove the spark plug cap (17). Remove the clamp (18) and disconnect the hose (19) from the cylinder head cover. Remove the chain as described in the relevant paragraph. Remove the chain guide plate (20) unscrewing the screw (21) with an 8 mm wrench.
Page 92 GENERAL PROCEDURES Loosen the three screws (22) and remove the clutch actuator (23). (TC) Remove the clip (24) that holds clutch hose and wiring harness together. Disconnect the connector (25) that connects wiring harness (26) to control unit. TE-TXC (TE-TXC) Remove the water temperature sensor connector (27).
Page 93 GENERAL PROCEDURES Remove the positive power supply cable (29) of the starter motor. TE-TXC H00675 TE-TXC Disconnect the gear sensor connector (30) and the ignition connectors (31). Shear the clips securing engine wiring to chassis to release the wiring har- nesses.
Page 94 GENERAL PROCEDURES Loosen the upper retaining screw (35) of the shock absorber (36) with a 14 mm wrench. Remove the guards (37) on both sides shearing the clips (38). E.28 Part. N. 8000 H1489 (10-2009)
Page 95 GENERAL PROCEDURES Remove the engine mounting bolts (39) using a 12 mm wrench on the left- hand side and a 10 mm wrench on the right-hand side. Loosen the swinging arm axle nut (40) using a 22 mm wrench; pull out the axle from the right-hand side of the engine and pull the swinging arm rearwards to facilitate engine removal.
Page 96: Radiator Removal
GENERAL PROCEDURES Radiator removal Remove the fuel tank together with scoops and spoilers as outlined in the relevant paragraphs. Remove the electric cooling fan (TE – TXC) as described in the relevant paragraph. Place a pan under the hose (1) to collect coolant, then loosen the clamp (2), detach the hose (1) and drain all coolant.
Page 97: Thermostat Removal (Te-Txc)
GENERAL PROCEDURES Loosen the screws (12) and remove the left-hand radiator (5). Loosen the screws (13) and remove the right-hand radiator (8). Thermostat removal (TE – TXC) Remove the fuel tank and the left-hand spoiler as outlined in the relevant paragraph.
Page 99: Engine Disassembly
ENGINE DISASSEMBLY Section Part. no. 8000 H1489 (10-2009)
Page 100 ENGINE DISASSEMBLY Layout of engine components ..............F.3 Cylinder head cover removal ................ F.4 Camshaft removal ..................F.4 Water pump body removal ................F.8 Water pump disassembly ................F.8 Cylinder head removal................F.10 Valve removal ..................... F.12 Cylinder removal..................F.14 Piston removal ...................
Page 101: Layout Of Engine Components
ENGINE DISASSEMBLY Layout of engine components Throttle body (TE - TXC) Carburettor (TC) Cylinder head cover Cylinder head Chain tensioner Cylinder Starter motor (TE - TXC) Head lubrication pipe Oil filter Clutch cover Kick start lever Water pump Alternator cover Sprocket H01032 H01031...
Page 102: Cylinder Head Cover Removal
ENGINE DISASSEMBLY Cylinder head cover removal Remove the two retaining screws (1) (10 mm wrench) and remove the head cover (2) with its gasket. Camshaft removal Remove the six retaining screws (1) of the alternator cover (2) (4 mm Allen wrench) and remove the cover with its gasket.
Page 103 ENGINE DISASSEMBLY To remove the gear sensor (3), loosen the two screws (4) (8 mm wrench) and its pushrod and spring. Part. no. 8000 H1489 (10-2009)
Page 104 ENGINE DISASSEMBLY Using a 17 mm wrench, bring the piston to T.D.C. at the end of the compres- sion stroke (in this condition, the two holes (5) and the two marks (6) on the gears must be positioned as shown in the figure). Cover parting line "A"...
Page 105 ENGINE DISASSEMBLY Remove the spark plug (7) (16 mm wrench) and the head lubrication pipe (8) unscrewing the drilled screw (9) (12 mm wrench). Remove the screws (10) (4 mm wrench) and the screws (11) (5 mm wrench) from both clamps (12) and (13) and remove them. Remove the intake camshaft (14) and the exhaust camshaft (15).
Page 106: Water Pump Body Removal
ENGINE DISASSEMBLY Water pump body removal Remove the four screws (1) securing pump body (2) to head (4 mm Allen wrench) and remove pump body. Water pump disassembly Loosen the screw (1) to disassemble the pump. Loosen the nut (2) to remove the impeller (3). Part.
Page 107 ENGINE DISASSEMBLY Remove the oil seal (4) and slide off the gear (5) together with the bearing (6). Remove the circlip (7) and remove the bearing (6) from the gear (5). On assembly, make sure the centring pins (8) are correctly located in their seats.
Page 108: Cylinder Head Removal
ENGINE DISASSEMBLY Cylinder head removal Remove the head cover as described in the relevant paragraph. Remove the camshafts as described in the relevant paragraph. Remove the chain tensioner (1) as follows: • Loosen the screw (2) with an 8 mm wrench. •...
Page 109 ENGINE DISASSEMBLY Remove the timing gear retaining clip (5) using a screwdriver. Loosen the two screws (6) using a Phillips screwdriver and remove the timing drive shaft (7) while holding the gear (8) with your hand. Support the gear (8) using a screwdriver or a punch, unwrap the chain (9) and remove the gear.
Page 110: Valve Removal
ENGINE DISASSEMBLY Loosen the four head bolts (10) using a 12 mm socket wrench. Mark each bolt with its position to avoid confusing them on assembly (three bolts are 112.5 mm long, one (10A) is 104.5 mm long). Remove the cylinder head (11) and its gasket (12). Be careful not to lose the locating pins positioned between head and cylinder.
Page 111 ENGINE DISASSEMBLY Use a valve spring compressor to compress the valve springs. Be careful not too damage the mating surfaces that contact the gasket or those of the combustion chamber. Make sure the valve spring compressor is aligned straight on the spring, or you might bend the valve stem. Do not compress the springs too much or they will weaken.
Page 112: Cylinder Removal
ENGINE DISASSEMBLY Cylinder removal Remove the front slider (1) of the timing chain pulling it upwards. Remove the cylinder (2) with its gasket (3). Piston removal Remove the piston pin retaining rings (1), slide out the piston pin (2) and remove the piston (3).
Page 113: Flywheel Removal
ENGINE DISASSEMBLY Flywheel removal Loosen the rotor (2) nut (1) (17 mm wrench). TE-TXC H00740 Remove the rotor (2) using the puller (3A) (part no. 8000 H2146) and the puller (3B) (part no. 8000 H1559). Part. no. 8000 H1489 (10-2009) F.15...
Page 114: Kick Start Pedal Removal
ENGINE DISASSEMBLY Remove the key (4) from the crankshaft. Kick start pedal removal Remove the pedal retaining bolt (1) (12 mm wrench), the washer and the pedal (2). Sprocket removal Lift the tab of the lock washer (1) using a chisel. F.16 Part.
Page 115 ENGINE DISASSEMBLY Loosen the nut (2) using a 22 mm wrench and remove sprocket (3) and spacer (4). Part. no. 8000 H1489 (10-2009) F.17...
Page 116: Oil Filter Removal
ENGINE DISASSEMBLY Oil filter removal Loosen the drilled nut (1) and disconnect the hose (2) from the oil pump cover (3). Loosen the three screws (4) using an 8 mm wrench. Remove the cover (3) together with its filter (5) and Belleville washer (6). F.18 Part.
Page 117: Clutch Cover Removal
ENGINE DISASSEMBLY Clutch cover removal Remove the nine screws (1) and the screw (2) securing the cover (3) (8 mm wrench) and remove the cover (3). Remove the gasket (4) and the bushings (5). Part. no. 8000 H1489 (10-2009) F.19...
Page 118: Clutch Disassembly
ENGINE DISASSEMBLY Clutch disassembly Remove the six retaining screws (2) and the clutch cover (3). Using an 8 mm wrench, unscrew the six screws (4) securing the clutch springs. Remove springs, pressure plate (5) with bearing (6) and clutch actuator plate (7).
Page 119 ENGINE DISASSEMBLY Remove the plates (8), lubricate the new plates with engine oil and install them (always start with a friction plate). Remove the clutch pushrod (9) from the opposite side of the engine. Straighten the tab of the lock washer (10). Part.
Page 120 ENGINE DISASSEMBLY Remove the nut (11) (22 mm wrench) using the clutch removal tool (A) (part no. 8000 79015 ). Remove the washer (10). Remove hub (12), washer (13) and clutch housing (14). Remove the bushing (15). F.22 Part. no. 8000 H1489 (10-2009)
Page 121: Slider Removal
ENGINE DISASSEMBLY Slider removal Use a 5 mm Allen wrench to loosen the screw (1) and remove the slider (2). Kick start disassembly Release the spring (1) from the casing (2) and remove the complete shaft assembly (3). Be careful not to lose the washer (11) located on the crank- case.
Page 122 ENGINE DISASSEMBLY Remove the snap ring (4), the washer (5) and the timing drive gear (6). Disassemble the shaft as shown in the diagram. On assembly, make sure that the dot (7) on shaft end (8) and the dot (9) on the ratchet (10) are aligned. F.24 Part.
Page 123: Starter Motor Removal (Te-Txc)
ENGINE DISASSEMBLY Starter motor removal (TE – TXC) Remove the exhaust pipe as described in the relevant paragraph. Disconnect the positive power supply cable (1) loosening the hexagonal-head screw (8 mm wrench). H00753 Unscrew the four screws (2) using a 4 mm Allen wrench. H00757 H00759 Part.
Page 124 ENGINE DISASSEMBLY Slide the starter motor (3) towards the rear end of the motorcycle to remove H00756 H00758 WARNING Upon assembly, check the gasket (4) for damage and replace it if needed. Make sure to position it correctly with the gasket hole (5) matching the hole (6) in the starter motor flange.
Page 125: Starter Motor Disassembly (Te-Txc)
ENGINE DISASSEMBLY Starter motor disassembly (TE – TXC) Separate the starter motor (1) from the starter drive (2). Starter drive disassembly (TE – TXC) Part. no. 8000 H1489 (10-2009) F.27...
Page 126 ENGINE DISASSEMBLY Remove flywheel and starter motor as outlined in the relevant paragraph. Disassemble the starter motor as outlined in the relevant paragraph. Remove the cap (1) using a 10 mm Allen wrench. Remove the circlip (2) and the bearing (3) with the bevel gear. F.28 Part.
Page 127 ENGINE DISASSEMBLY Place the wormshaft (4) assembly in a vice with aluminium jaws, loosen the nut (5) using a 10 mm T-wrench and slide out the wormshaft (4). H00772 Remove the freewheel (6). Remove the needle roller bearing (7) and the thrust ring (8). Part.
Page 128: Oil Pump Disassembly
ENGINE DISASSEMBLY Oil pump disassembly Loosen the screws (1) using a 4 mm Allen wrench and remove pump body (2) and gasket. Remove the pump rotors (3) and (4) and extract the drive pin (5) to release the gear (6). Remove drive gear (7) and oil suction stub (8).
Page 129 ENGINE DISASSEMBLY To facilitate assembly, mark the position of the gear shift pedal (1) on the shaft. Remove the retaining screw (2) of the gear shift pedal (1) (8 mm wrench) and slide the pedal from the selector shaft. Remove the selector shaft (3) from the right-hand side. Remove the two screws (4) (4 mm Allen wrench and 8 mm wrench) secur- ing the selector retaining plate (5) and remove retaining plate and ratchet mechanism (6).
Page 130 ENGINE DISASSEMBLY Remove the bolt (7) of the selector drum (8) (12 mm wrench). Release the ratchet (10) spring (9) and remove retaining ring (11), washer (12) and ratchet (10). Be careful not to lose the roller (13). F.32 Part. no. 8000 H1489 (10-2009)
Page 131: Primary Drive Gear Removal
ENGINE DISASSEMBLY Primary drive gear removal Loosen the central nut (1) using a 22 mm wrench. Remove primary gear (2) and water pump drive gear (3). Part. no. 8000 H1489 (10-2009) F.33...
Page 132: Crankcase Disassembly
ENGINE DISASSEMBLY Crankcase disassembly Remove the nine screws (1) from the left crankcase (2) (8 mm wrench). Important: the screws (1) are not all the same length. Refer to figure "A" on assembly to ensure correct installation. FIG. "A" a1= 6x60 mm a2= 6x55 mm a3= 6x70 mm a4= 6x90 mm...
Page 133: Gearbox Disassembly
ENGINE DISASSEMBLY Install the crankcase puller (3) (part no. 8000 A7015) using the flywheel cover holes and remove the left crankcase half (4). Tap the output shaft (5) with a rubber hammer at intervals during removal to keep the crankcase half from getting stuck. Gearbox disassembly Remove the shaft (1) of the output shaft shifter forks.
Page 134 ENGINE DISASSEMBLY Remove the retaining ring (5) and then the shaft (6) of the input shaft shifter fork (7). Remove the input shaft (8) and output shaft (9) being careful not to lose any shims (if fitted). F.36 Part. no. 8000 H1489 (10-2009)
Page 135: Crankshaft Disassembly
ENGINE DISASSEMBLY Crankshaft disassembly Slide the puller (1) (part no. 8000 A7015) over the right end of the crank- shaft. Secure the puller to the crankcase half and remove the crankshaft (2) from the opposite side. Bring the crankshaft in the required position and remove the crank pin (3) from one of the flywheel halves (4).
Page 136 ENGINE DISASSEMBLY Remove connecting rod (5) and needle roller bearing (6) from the flywheel half. Turn the flywheel half and remove the crank pin (3). F.38 Part. no. 8000 H1489 (10-2009)
Page 137: Engine Overhaul
ENGINE OVERHAUL Section Part. N. 8000 H1489 (10-2009)
Page 138 ENGINE OVERHAUL Cleaning parts ..................... G.3 Clearances ....................G.3 Cylinder head ....................G.3 Valve seat refacing ..................G.4 Valve guide ....................G.5 Valve guide replacement ................G.5 Valve ......................G.7 Valve spring ....................G.7 Valve bucket inspection ................G.8 Valve installation ..................G.8 Valve leak check ..................
Page 139: Cleaning Parts
ENGINE OVERHAUL Cleaning parts All parts must be cleaned with gasoline and dried with compressed air. Flammable vapours develop during this procedure and metal filings blown by compressed air may get into your eyes. Perform this procedure away from open flames or sources of ignition and wear an eye protection. Clearances To ensure the best operating conditions and maximum performance, all clearances must be within the specified tolerance.
Page 140: Valve Seat Refacing
ENGINE OVERHAUL Valve seat refacing Clean off any fouling deposits from the valve. Apply Prussian Blue to the valve and rotate it in its seat using a rubber hose or other similar tool. Remove the valve and measure the width “X” of the seating face. If width is greater than 1.2 mm (0.0472 in.), the seat needs to be refaced.
Page 141: Valve Guide Replacement
ENGINE OVERHAUL Perform a careful visual inspection of the valve guide. To determine wear, measure valve to valve guide clearance in the “x” and “y” di- rections (at right angles to each other) using a suitably positioned dial gauge. Intake valve: normal clearance: 0.008 - 0.035 mm Service limit: 0.05 mm (0.0019 in.).
Page 142: Valve
ENGINE OVERHAUL Install the new guide from the top of the head using a suitable punch. Smear the guide with oil before installation. Ream the valve guide using a suitable reamer and lubricate with cutting fluid. Rotate the reamer when extracting it to avoid scoring the valve guide. When a valve guide is changed, the valve seat must be refaced.
Page 143: Valve Spring
ENGINE OVERHAUL Inspect valve stem and valve seating face to make sure they are in good condi- tion. There should be no signs of pitting, cracking, distortion or wear. Check for the following: Valve stem runout: place valve on a V block and measure runout with a dial gauge.
Page 144: Valve Bucket Inspection
ENGINE OVERHAUL Check the valve springs for proper squareness. Maximum acceptable deviation is 1.5 mm on each side. Valve bucket inspection Check that the valve buckets (1) slides freely in their seats. If not so, replace them. Valve installation Smear valve guides and stems with oil before installation. Install spring seat (1) and springs (2) - place spring (a) at head end - and finally the spring retainer (3).
Page 145: Valve Leak Check
ENGINE OVERHAUL Tap valve stem lightly with a plastic hammer and an aluminium punch to help the valve collets become seated. Tap the valve stem tip to avoid pushing the valve off centre. Valve leak check Check the valves for proper sealing before assembling the cylinder head to the engine.
Page 146: Camshaft
ENGINE OVERHAUL Camshaft Check the contact faces of the lobes for streaks, scoring, dents and waviness. Clamp the camshaft between centres and check deviation using two dial gauges. Service limit: 0.1 mm. Check that the lobes are in pristine conditions, without signs of scoring or distortion.
Page 147: Cylinder
ENGINE OVERHAUL Cylinder Check the walls for dents or scuffing. Measure cylinder bore diameter at three different positions. Measure each diameter in two directions at right angles to each other to determine taper and out-of-round. Max. taper (wear limit): 0.05 mm. Max.
Page 148: Cylinder To Piston Clearance
ENGINE OVERHAUL Cylinder to piston clearance Cylinder diameter Measure inside diameter (Dc) with an internal bore micrometer 25 mm (0.9842 in.) below the edge (distance “A”). Piston diameter Measure piston diameter (Dp) 7 mm (0.2755 in.) above skirt edge (distance “B”). Clearance is calculated as follows = Dc-Dp.
Page 149: Piston Rings
ENGINE OVERHAUL Piston rings They should show no signs of forcing or scoring. Replacement pistons come with piston rings and piston pin. Piston ring to cylinder clearance Insert the piston ring at the bottom of the bore (where minimum wear occurs) taking care to position it squarely and measure end gap.
Page 150: Piston Ring To Groove Clearance
ENGINE OVERHAUL Piston ring to groove clearance Use a feeler gauge to measure the axial clearance (H) of piston rings. If the piston ring is marked on one side, that side must be facing up. PISTON RING END GAP ALIGNMENT PISTON MOUNTING CLEARANCE (H) SERVICE LIMIT...
Page 151: Crankshaft
ENGINE OVERHAUL Crankshaft Main journals should show no scoring or scuffing. Threads, keyways and splines must be in good condition. Crankshaft straightness Place the crankshaft (1) on a stand (2) with two dial gauges (3) positioned on the journals. Turn the crankshaft and measure runout. STANDARD SERVICE LIMIT <...
Page 152: Clutch
ENGINE OVERHAUL Clutch Inspect all clutch components to make sure they are in the best conditions. Clutch plates should show no signs of bluing, scoring or distortion. Measure the thickness of friction plates. Plate thickness when new: 3.0 mm (0.1181 in.). Service limit: 2.9 mm (0.1141 in.).
Page 153: Friction Plate To Clutch Housing Clearance
ENGINE OVERHAUL Friction plate to clutch housing clearance Measure clearance "A" between clutch housing (2) and plate (1) with a feeler gauge and compare measured clearance with the table below. STANDARD SERVICE LIMIT 0.30-0.50 mm 0.6 mm (0.012-0.020 in.) (0.024 in.) If measured clearance exceeds the service limit, replace clutch plates or housing and repeat measurement.
Page 154 ENGINE OVERHAUL 1- Pressure plate, 2- Clutch actuator plate, 3- Pushrod, 4- Piston assembly: Check these parts for signs of wear or failure. If any are found, replace the part. 5- Clutch hub: Check the steel plate slots for signs of wear or failure. If any are found, replace the part. 6- Clutch housing: Check the friction plate slots for signs of wear or failure.
Page 155: Oil Pump
ENGINE OVERHAUL Oil pump Loosen the screws (1) using a 4 mm Allen wrench and remove pump body (2) and gasket. Remove the pump rotors (3) and (4), and extract the drive pin (5) to release the gear (6). Check gear (6) and rotors (4) for wear. Replace if worn. Smear the rotors with oil and make sure to align the rotor dots (9) on assembly.
Page 156: Shifter Forks And Gears
ENGINE OVERHAUL Shifter forks and gears Visually inspect the shifter forks (1) and replace any bent forks. A bent fork will make gears hard to engage or let the transmission jump out of gear unexpect- edly under loading. Check the clearance of the each shifter fork in its gear groove using a feeler gauge.
Page 157: Carburettor Overhaul (Tc)
ENGINE OVERHAUL Carburettor overhaul (TC) Clean all carburettor components thoroughly with gasoline and dry them with compressed air. Clean all jets and holes thoroughly blowing them with compressed air. Never use tool bits or metal wire. Check that the slide valve is in good condition. It should slide freely in its housing, without too much play. Check that taper needle and main nozzle are in good condition.
Page 158: Keihin" Carburettor Adjustment (Tc)
ENGINE OVERHAUL "Keihin" carburettor adjustment (TC) Adjust the carburettor with warm engine and with the throttle control in closed position. Proceed as follows: turn the idle speed adjuster screw (1) located on the left-hand side of the vehicle, until setting idle RPM quite high (turn clockwise to increase the speed and counter clockwise to reduce the speed).
Page 159: Carburettor Inspection (Tc)
ENGINE OVERHAUL Carburettor inspection (TC) 1 . Check: Carburettor body If dirty: clean. NOTE Clean using petroleum based solvent. Blow all holes and jets with compressed air. Never use metal wire. 2. Check: Main jet (1) Idle jet (2) Main nozzle (9) Idle screw (7) Starting jet (3) Main air jet (4)
Page 160: Needle Assembly (Tc)
ENGINE OVERHAUL Needle assembly (TC) Check needle (9) and valve seat (c). If worn (a): replace needle. If dirty: clean. Throttle valve (TC) Check that the valve moves freely. Repair or replace if stuck. Insert the throttle valve (5) into carburettor body and make sure that it moves freely.
Page 161: Floater Height (Tc)
ENGINE OVERHAUL Floater height (TC) Measure: height (a). If outside specifications: adjust. Floater height: 8 mm (0.3149 in.). Measurement and adjustment points: Clamp the carburettor in an upside down position. NOTE Slowly tilt the carburettor and take the measurement when the needle is aligned with the floater arm.
Page 162: Draining The Fuel (Tc)
ENGINE OVERHAUL Draining the fuel (TC) When you need to drain the fuel from the carburettor floater bowl, close the cock tightening the ring nut (1). Insert the end of the hose (2) in a pan, slacken the drain screw (3) at the bottom of the bowl and re-tighten it after draining all fuel. WARNING Never release fuel into the environment or let the engine run in- doors.
Page 163: Engine Reassembly
ENGINE REASSEMBLY Section Part. N. 8000 H1489 (10-2009)
Page 164 ENGINE REASSEMBLY General ......................H.3 Assembly and lubrication instructions (CRANK- ALTERNATOR- LUBRICATION- LEFT CRANKCASE HALF) ......H.4 Tightening torque figures ................H.5 Assembly and lubrication instructions (GEARBOX - GEAR SHIFT CONTROL) ............H.6 Tightening torque figures ................H.7 Assembly and lubrication instructions (CLUTCH - KICK START- LUBRICATION- RIGHT CRANKCASE HALF) ...........H.10 Tightening torque figures ................H.11 Assembly and lubrication instructions...
Page 165: General
ENGINE REASSEMBLY General To reassemble, reverse the disassembly procedure. Any special instructions concerning reassembly are expressly highlighted in the text. Always replace gaskets, oil seals, metal retainers, sealing washers made from deformable material (copper, aluminium, fibre, etc.) and self-locking nuts after removal. Bearing specifications and dimensions have been calculated for a certain life.
Page 166: Assembly And Lubrication Instructions (Crank- Alternator- Lubrication- Left Crankcase Half)
ENGINE REASSEMBLY Assembly and lubrication instructions CRANK- ALTERNATOR- LUBRICATION- LEFT CRANKCASE HALF Part. N. 8000 H1489 (10-2009)
Page 167: Tightening Torque Figures
ENGINE REASSEMBLY Tightening torque figures M5 - L20 (Loctite 272) 6 Nm- 0.6 Kgm- 4.43 ft/lb M5 - L12 (Loctite 272) 6 Nm- 0.6 Kgm- 4.43 ft/lb M5 - L18 6 Nm- 0.6 Kgm- 4.43 ft/lb M5 - L35 6 Nm- 0.6 Kgm- 4.43 ft/lb M5 - L25 6 Nm- 0.6 Kgm- 4.43 ft/lb M5 - L35...
Page 168: Assembly And Lubrication Instructions (Gearbox - Gear Shift Control)
ENGINE REASSEMBLY Assembly and lubrication instructions GEARBOX - GEAR SHIFT CONTROL Part. N. 8000 H1489 (10-2009)
Page 169: Tightening Torque Figures
ENGINE REASSEMBLY Tightening torque figures M8x1.25 (+LOCTITE Alt. 243) 25 Nm- 2.55 Kgm- 18.44 ft/lb M6 - L13 (+LOCTITE 243) 8 Nm- 0.8 Kgm- 5.9 ft/lb M6 - L14 (+LOCTITE 243) 8 Nm- 0.8 Kgm- 5.9 ft/lb M5x0.8 - L12 6 Nm- 0.6 Kgm- 4.43 ft/lb M6 - L20 8 Nm- 0.8 Kgm- 5.9 ft/lb...
Page 170: Assembly And Lubrication Instructions (Clutch - Kick Start- Lubrication- Right Crankcase Half)
ENGINE REASSEMBLY Assembly and lubrication instructions GEARBOX - GEAR SHIFT CONTROL Part. N. 8000 H1489 (10-2009)
Page 171: Tightening Torque Figures
ENGINE REASSEMBLY Tightening torque figures M8x1.25 (+LOCTITE Alt. 243) 25 Nm- 2.55 Kgm- 18.44 ft/lb M6 - L13 (+LOCTITE 243) 8 Nm- 0.8 Kgm- 5.9 ft/lb M6 - L14 (+LOCTITE 243) 8 Nm- 0.8 Kgm- 5.9 ft/lb M5x0.8 - L12 6 Nm- 0.6 Kgm- 4.43 ft/lb M6 - L20 8 Nm- 0.8 Kgm- 5.9 ft/lb...
Page 172: Assembly And Lubrication Instructions (Right Crankcase Half Cover)
ENGINE REASSEMBLY Assembly and lubrication instructions CLUTCH- KICK START- LUBRICATION- RIGHT CRANKCASE HALF H.10 Part. N. 8000 H1489 (10-2009)
Page 173: Tightening Torque Figures
ENGINE REASSEMBLY Tightening torque figures M5 - L12 (+LOCTITE 270 or 272) 6 Nm- 0.6 Kgm- 4.43 ft/lb M8 X 1.25 (Al) 8 Nm- 0.8 Kgm- 5.9 ft/lb M5 - L16 8 Nm- 0.8 Kgm- 5.9 ft/lb M5 x 0.8 - L20 6 Nm- 0.6 Kgm- 4.43 ft/lb M6 x 1 (+LOCTITE 243) 8 Nm- 0.8 Kgm- 5.9 ft/lb...
Page 174: Assembly And Lubrication Instructions (Head - Cylinder - Piston - Timing System - Water Pump - Spark Plug)
ENGINE REASSEMBLY Assembly and lubrication instructions RIGHT CRANKCASE COVER H.12 Part. N. 8000 H1489 (10-2009)
Page 175 ENGINE REASSEMBLY Tightening torque figures M5 - L16 6 Nm- 0.6 Kgm- 4.43 ft/lb M6 - L22 8 Nm- 0.8 Kgm- 5.9 ft/lb M6 x 1 - L50 8 Nm- 0.8 Kgm- 5.9 ft/lb M6 x 1 - L20 8 Nm- 0.8 Kgm- 5.9 ft/lb LUBRICATION POINTS-NOTES LUBRICANT-INSTALLATION INSTRUCTIONS Engine oil...
Page 176 ENGINE REASSEMBLY Assembly and lubrication instructions HEAD - CYLINDER - PISTON - TIMING SYSTEM - WATER PUMP - SPARK PLUG H.14 Part. N. 8000 H1489 (10-2009)
Page 177: Tightening Torque Figures
ENGINE REASSEMBLY Tightening torque figures Special flanged screw L.23.4 8 Nm- 0.8 Kgm- 5.9 ft/lb Special flanged screw L.31.3 8 Nm- 0.8 Kgm- 5.9 ft/lb M5 x 0.8 - L8 (+LOCTITE 243) 6 Nm- 0.6 Kgm- 4.43 ft/lb M10 x 1.25 5 Nm- 0.5 Kgm- 3.69 ft/lb M10 - L104.5 40 Nm- 4 Kgm- 29.5 ft/lb...
Page 178: Crankshaft Assembly
ENGINE REASSEMBLY Crankshaft assembly Clean the oil galleries thoroughly. Lubricate the crank pin (1) with engine oil and insert it into the flywheel half (2). WARNING: Position the crank pin (1) so that hole “F” is lying on the same axis as connecting rod (4) and flywheel half (2). Fit the needle roller bearing (3) and lubricate it the engine oil.
Page 179 ENGINE REASSEMBLY Finally, join the parts using a press. Make sure the pin does not protrude at either ends as you join the flywheel halves. When driving the pin, observe the specified distance “B”. Measure connecting rod axial clearance in the flywheels. It should be 0.25÷0.43 mm.
Page 180 ENGINE REASSEMBLY Input shaft Output shaft H.18 Part. N. 8000 H1489 (10-2009)
Page 181: Input Shaft (5 Speed)
ENGINE REASSEMBLY Input shaft (5 SPEED) Fit roller cage (1) and 5th gear (2) on the bushing and then install the washer (3) and the retaining ring (4). The washer must be placed between gear and retaining ring. Fit 3rd gear (5), retaining ring (6) and washer (7). Fit the roller cage (8).
Page 182: Output Shaft (5 Speed)
ENGINE REASSEMBLY Output shaft (5 SPEED) Fit the roller cage (1). Fit 2nd gear (2), washer (3) and retaining ring (4). Fit 4th gear (5) and retaining ring (6). Fit the washer (7). Fit roller cage (8) and 3rd gear (9). Fit washer (10) and retaining ring (11).
Page 183 ENGINE REASSEMBLY Input shaft Output shaft Part. N. 8000 H1489 (10-2009) H.21...
Page 184: Input Shaft (6 Speed)
ENGINE REASSEMBLY Input shaft (6 SPEED) Fit roller cage (1) and 5th gear (2) on the bushing and then install the washer (3) and the retaining ring (4). The washer must be placed between gear and retaining ring. Fit 3rd/4th gear (5), retaining ring (6) and washer (7). Fit the roller cage (8).
Page 185 ENGINE REASSEMBLY Output shaft (6 SPEED) Fit the roller cage (1). Fit 2nd gear (2), washer (3) and retaining ring (4). Fit 6th gear (5) and retaining ring (6). Fit the washer (7). Fit roller cage (8) and 3rd gear (9). Fit washer (10) and 4th gear (11).
Page 186: Crankcase Assembly
ENGINE REASSEMBLY Crankcase assembly Clean the crankcase half mating faces and place crankcase half on tool no. 8A00 90662. Heat up to around 125 °C and drive the ball bearings into each crankcase half using a suitable driver tool. Fit the retaining plates (1) and (2) to the crankcase bearings. (5 Nm, 0.5 Kgm, 3.6 ft/lb + Loctite 272) for crankshaft bearing retaining plate (1).
Page 187 ENGINE REASSEMBLY Install the input and output shaft assembly making sure the output shaft (3) shim is in place. Lubricate the three shifter forks (4) with engine oil and install them. Make sure the bushings (5) are correctly in place (grease the bushings). Part.
Page 188 ENGINE REASSEMBLY Insert the selector drum (6) into its seat. Install the fork shafts (7) and (8) and make sure the forks move freely. Make sure the fork bushings (5) are correctly located in the drum grooves (6). Insert the circlip (9) of the input shaft fork shaft. Rotate the selector drum to test operation.
Page 189 ENGINE REASSEMBLY Heat up the crankshaft bearing (10) and install the crankshaft (11). Make sure both crankcase locating bushings (12) are in place. Apply a layer of “LOCTITE 5205” on the right crankcase mating surface (13), making sure not to obstruct the oil passage hole (14). Part.
Page 190 ENGINE REASSEMBLY Heat up the left crankcase bearing housings and install the crankcase. To join the crankcase halves, tap with a plastic hammer. Tighten the screws (15) using an 8 mm wrench (10 Nm, 1Kgm, 7.25 ft/lb). Make sure to fit the screws in the correct positions according the specified pattern (see Section F, paragraph "Crankcase disassembly").
Page 191: Gear Shift Control Assembly
ENGINE REASSEMBLY Gear shift control assembly Refit the spring abutment pin (1) using a 12 mm wrench (apply Loctite 243 and tighten to 20 Nm, 2.0 Kgm, 14.5 ft/lb). Install ratchet (2), spring (3), washer (4) and circlip (5). Install the selector drum (6) making sure the tab (7) locates in the recess (8) and secure drum with its screw (9).
Page 192 ENGINE REASSEMBLY Operate shifter and transmission shaft to test gearbox for proper operation. Refit the ratchet assembly (10) together with the plate, making sure ratchets and springs are in the correct positions. Tighten the upper screw (11) using a 4 mm Allen wrench (Loctite 243, 10 Nm, 1.0 Kgm, 7.2 ft/lb).
Page 193 ENGINE REASSEMBLY Turn the engine over. Make sure the spring (15) of the gear shift lever shaft is positioned correctly. Check the gear shift lever shaft (16) and the slot of the gear selector mechanism for signs of wear. Lubricate the shaft with engine oil and insert the shaft (16) into the crankcase so that the fork (17) slides over the ratchet detent and the spring (18) locates to its abutment pin.
Page 194 ENGINE REASSEMBLY Install the gear shift lever (19) and operate the gearbox manually (8 mm wrench, 8 Nm, 0.8 Kgm, 5.8 ft/lb). H.32 Part. N. 8000 H1489 (10-2009)
Page 195: Kick Start Assembly
ENGINE REASSEMBLY Kick start assembly Refit the starter ratchet release plate (1) (use a 4 mm wrench, 8 Nm, 0.8 Kgm, 5.8 ft/lb, Loctite 243). Fit the complete shaft assembly (2) to its seat (B) in the crankcase, making sure the ratchet is correctly positioned on the shaft (marks lined up) and insert the spring end (3) into the hole (D).
Page 196: Timing Chain And Primary Drive Assembly
ENGINE REASSEMBLY Timing chain and primary drive assembly Install the timing chain slider (1), tighten the screw (2) using a 5 mm wrench (10 Nm, 0.1 Kgm, 7.3 ft/lb, Loctite 243) and make sure the slider moves freely. Fit the oil pump drive gear (3) making sure the side with the dot is facing out- side.
Page 197 ENGINE REASSEMBLY Install the timing chain (5). Refit the bushing (6). Refit the clutch housing (7). Part. N. 8000 H1489 (10-2009) H.35...
Page 198 ENGINE REASSEMBLY Place a dummy gear (8) or an aluminium shim between clutch housing (7) gear and double gear (4), and then tighten the primary drive shaft nut (9) (use a 22 mm wrench, 100 Nm, 10 Kgm, 72.50 ft/lb). H.36 Part.
Page 199: Clutch Assembly
ENGINE REASSEMBLY Clutch assembly Install washer (1), hub (2), lock washer (3) and nut (4). Use the suitable tool (5) to prevent rotation and tighten to 60 Nm, 6 Kgm, 43.5 ft/lb (use a 22 mm wrench). Part. N. 8000 H1489 (10-2009) H.37...
Page 200 ENGINE REASSEMBLY Refit the plates (6) (install a friction plate first and then a steel plate and keep alternating between friction and steel plates; the last to go in should be a steel plate). Fit actuator plate (7), thrust bearing (8), thrust washer (9), pressure plate (10) and springs (11).
Page 201: Sprocket Installation
ENGINE REASSEMBLY Sprocket installation Install the oil seal retaining plate (1) and tighten the screws (2) (use an 8 mm wrench , 5.5 Nm, 0.55 Kgm, 4 ft/lb). Fit the spacer (3) with the grooved side facing inwards. Install sprocket (4), lock washer (5) and nut (6). Hold the sprocket (4) with the suitable tool (7) to prevent rotation and tighten the nut (6) (use a 22 mm wrench, 100 Nm, 10 Kgm, 72.5 ft/lb).
Page 202: Flywheel Installation (Tc)
ENGINE REASSEMBLY Flywheel installation (TC) Clean flywheel rotor to remove any debris suspended in swirling oil and captured by the magnets. Fit the tab (1) into the crankshaft and refit the rotor (2). Hold the rotor (2) to prevent rotation and place an aluminium shim or dummy gear between the primary drives gears on the right side, again to prevent rotation.
Page 203: Flywheel And Starter Motor Installation (Te-Txc)
ENGINE REASSEMBLY Flywheel and starter motor installation (TE - TXC) Clean flywheel rotor to remove any debris suspended in swirling oil and captured by the magnets. Fit the tab (1) to the crankshaft. Lubricate needle roller bearing (2) and thrust ring (3) with engine oil and install them, making sure the thrust ring slots are pointing outwards.
Page 204: Flywheel Installation (Tc)
ENGINE REASSEMBLY Flywheel installation (TC) Refit the rotor (5). Hold the rotor (5) to prevent rotation and place an aluminium shim or dummy gear between the primary drives gears on the right side, again to prevent rotation. Tighten the nut (6) to 75 Nm, 7.5 Kgm, 54.3 ft/lb. Use a 17 mm wrench.
Page 205: Piston Ring Installation
ENGINE REASSEMBLY Piston ring installation Fit the piston rings as shown in the diagram. If the piston ring is marked on one side, that side must be facing up. A= Compression ring C= Oil control ring *C1= Top oil rail end gap position *C1= Oil rail spacer end gap position *C1= Bottom oil rail end gap position Piston and cylinder installation...
Page 206 ENGINE REASSEMBLY Lubricate the cylinder liner (7) with engine oil and slide it over the piston rings. Make sure to collect the timing chain (8). Position the slider (9). H.44 Part. N. 8000 H1489 (10-2009)
Page 207: Cylinder Head Gasket Selection Table
ENGINE REASSEMBLY Fit screws and spacers (10) to temporarily secure the cylinder liner (7). (3 spacers 10a, h= 44.2 mm; 1 spacer 10b, h= 29.2 mm) Use a 12 mm wrench - 40 Nm, 4 Kgm, 29 ft/lb. Make sure that the piston is at Top Dead Centre. Measure distance "A"...
Page 208: Cylinder Head Installation
ENGINE REASSEMBLY Cylinder head installation For valve installation instructions, please see Section "G". Always use a new head gasket on assembly: see the "Cylinder head gasket selection table". Install the head (1) while supporting the timing chain (2) with a screwdriver. Tighten the head bolts (3) gradually in a cross pattern to 40 Nm, 4 Kgm, 29 ft/ lb (use a 12 mm wrench).
Page 209 ENGINE REASSEMBLY Refit the four shim (5) on the valves and the valve buckets (6) as marked on removal. Check the bearings of the timing drive upper gear (7) and replace them if needed. The gear (7) requires no timing. Refit the gear (7) with its shaft (8) and gasket (9).
Page 210: Timing Chain Tensioner Installation
ENGINE REASSEMBLY Timing chain tensioner installation Refit the chain tensioner (12) and its gasket. Tighten the two screws (13) using an 8 mm wrench (10, Nm, 1.0 Kgm, 7.25 ft/lb). WARNING On TE and TCX models, the two retaining screws feature two different lengths.
Page 211: Camshaft Installation
ENGINE REASSEMBLY Camshaft installation Secure a dial gauge (1) to the spark plug hole. Turn the crankshaft manually until bringing the piston to Top Dead Centre. Refit intake camshaft (2) and exhaust camshaft (3) with the gears positioned as shown in the figure. Cover parting line "A"...
Page 212 ENGINE REASSEMBLY Refit the camshaft covers (6) and tighten the screws (7) in a cross sequence and shown in diagram "B". Make sure to fit the screws in the correct position according to their length (see diagrams "A" and "B"). M6x35 Allen screw M6x30 Allen screw M6x25 Allen screw...
Page 213: Flywheel Cover Installation (Tc)
ENGINE REASSEMBLY Flywheel cover installation Install the stator (1) with its mark lined up with the flywheel cover mark and tighten the two retaining screws (2) (use a 4 mm Allen wrench, 6 Nm, 0.6 Kgm, 4.3 ft/lb + Loctite 272). Insert the cable guide (3) into its seat in the cover and tighten the two retaining screws (4) of the pick-up sensor (5) with its plate (6 Nm, 0.6 Kgm, 4.3 ft/lb + Loctite 272).
Page 214: Neutral Sensor Installation
ENGINE REASSEMBLY Neutral sensor installation Refit pin (1) and spring (2). Check the O-ring (3) of the sensor (4). Refit the sensor (4) and tighten the screws (5) using an 8 mm wrench (5.5 Nm, 0.55 Kgm, 4 ft/lb, Loctite 243). H.52 Part.
Page 215: Starter Motor Seat Cover Installation (Tc)
ENGINE REASSEMBLY Starter motor seat cover installation (TC) Refit the cover (1) with its gasket making sure the arrow is pointing "UP". Tighten the screws (2) with the wire clip (3) placed on the upper screw. Cylinder head cover, spark plug, oil feed hose installation Position the central seal (1).
Page 216: Right Crankcase Assembly
ENGINE REASSEMBLY Right crankcase assembly Refit the oil pump drive gear (1) and its shaft (2). Check the O-rings of the oil suction stub (3) and replace them if needed. Refit the oil suction stub (3). Refit the centring bushings (4). Refit the gasket (5).
Page 217 ENGINE REASSEMBLY Install the crankcase (8) and tighten the screws (9) following a cross pattern (use an 8 mm wrench , 10 Nm, 1.0 Kgm, 7.25 ft/lb). Make sure pump gear and drive gear engage correctly. Check the O-ring (10) for damage and replace it if needed. Refit the spring (11) of the oil filter (12).
Page 218: Filter And Drain Plug
ENGINE REASSEMBLY Filter and drain plug Fit the oil filter (1) and tighten the cap (2) into place with its gasket using a 12 mm wrench (25 Nm, 2.5 Kgm, 18.44 ft/lb). Oil feed hose installation Refit the hose (1) and tighten the drilled screws (2) with their seals using a 12 mm wrench (8 Nm, 0.8 Kgm, 5.9 ft/lb).
Page 219: Gear Shift And Kick Start Pedal Installation
ENGINE REASSEMBLY Gear shift and kick start pedal installation Install the gear shift pedal (1) and tighten the screw (2) using an 8 mm wrench (8 Nm, 0.8 Kgm, 5.8 ft/lb). Check the pedal (1) for damage. Refit the kick start pedal (3) and tighten the screw (4) using a 12 mm wrench (25 Nm, 2.5 Kgm, 18.44 ft/lb + Loctite 272).
Page 220: Installing The Engine And Assembling The Motorcycle
ENGINE REASSEMBLY Installing the engine and assembling the motorcycle Install the engine and any parts you had removed in the order given below. Place the engine in the chassis. Insert the swinging arm shaft from the right-hand side and tighten its nut using a 22 mm wrench (122.5 Nm, 12.5 Kgm, 90.3 ft/lb).
Page 221: Front Suspension
FRONT SUSPENSION Section Part. N. 8000 H1489 (10-2009)
Page 222 FRONT SUSPENSION Front fork removal ..................I.4 Front suspension Mod. TC-TXC /2010 ............I.6 Service instructions for Ø48USD Kayba fork - TC-TXC 250/2010 ..................I.6 Front suspension (TC - TXC) ............... I.7 Front fork disassembly (TC - TXC) ............... I.8 Front suspension Mod.
Page 223 FRONT SUSPENSION Part. N. 8000 H1489 (10-2009)
Page 224: Front Fork Removal
FRONT SUSPENSION Front fork removal Measure height "A" (it will need to be restored to original value on assembly). Set a block under the engine and see that the front wheel is lifted from the ground and then proceed as follows: remove the screws (1) and the brake line clamp on the left-hand side;...
Page 225 FRONT SUSPENSION loosen the bolts (4) that secure the fork legs to steering head and bottom yoke; remove the fork legs. Refit fork legs and front wheel as described in Section "Y". Set height "A" back to original value. Part. N. 8000 H1489 (10-2009)
Page 226: Front Suspension Mod. Tc-Txc /2010
FRONT SUSPENSION Front suspension Mod. TC-TXC /2010 Service instructions for Ø48USD Kayba fork - TC-TXC 250/2010 GENERAL The fork uses a multi-valve damping system with rebound and compression adjustment and spring preload adjustment for static load. Compression damping is controlled by a special valve located at the top of each fork leg.
Page 227: Front Suspension (Tc - Txc)
FRONT SUSPENSION Front suspension (TC - TXC) Front suspension is handled by a KAYABA upside-down telescopic hydraulic fork with advanced axle and 48 mm legs. Wheel travel is 300 mm. Part. N. 8000 H1489 (10-2009)
Page 228: Front Fork Disassembly (Tc - Txc)
FRONT SUSPENSION Front fork disassembly (TC - TXC) Loosen the cap nut at the top of each outer tube. (Note: it is good practice to moderately slacken the cap nuts before removing the fork legs from the motorcycle). Drain oil from the damper unit. Clamp the wheel axle carrier in a vice and loosen the adjuster screw.
Page 229 FRONT SUSPENSION Take the cartridge out of the outer tube. Do not remove the nut at the bottom end of the cartridge. Remove the bottom valve assembly from the cartridge. Hold the cartridge octagonal nut with the suitable tool to prevent rotation. Use a similar tool in the octagonal recess of the bottom valve assembly.
Page 230 FRONT SUSPENSION If outer tube and inner tube are still assembled together, place the fork leg upside down and allow at least 20 minutes for oil to drain. Remove the dust seal using a flat head screwdriver. Remove the retaining ring using a flat head screwdriver. Pull the inner tube until separating it from the outer tube.
Page 231 FRONT SUSPENSION Remove the sealing rings and the metal rings mounted on the inner tube. Do not reuse any metal parts after removal. Replace them with new components. Replace damaged sealing rings. Washer and retaining ring may be reused if they are not damaged. Check the rebound adjuster rod for distortion or damage.
Page 232 FRONT SUSPENSION Mount sealing rings and metal parts on the inner tube. See the figure below for the installation sequence. Note 1: Grease the edge of the sealing ring. Note 2: Before sliding the sealing ring over the inner tube, cover tube edge with plastic as shown in the figure.
Page 233 FRONT SUSPENSION Fit the dust seal to the outer tube. Make sure that there is not play between dust seal and outer tube. Refit the cartridge. Tighten the nut all the way onto the rebound adjuster rod. Make sure rebound adjuster rod thread length is at least 15 mm (0.6 in.). Fill the cartridge with the specified oil.
Page 234 FRONT SUSPENSION Pull the piston rod until fully extended. Check oil level. It should be about 145 mm (5.7 in.). Push the piston rod all the way down and install the bottom valve assembly. With the bottom valve assembly installed, check that the piston rod is fully extended.
Page 235 FRONT SUSPENSION Drain excess oil from the cartridge pushing the damper unit all the way home. Be careful not to distort or damage the piston rod or any other parts. Please note that excess oil may flow out from the hole located before the res- ervoir.
Page 236 FRONT SUSPENSION Push down the inner tube. Slip the tool shown in the figure between wheel axle carrier and cartridge nut. Insert the rebound adjuster rod into the piston rod and tighten the adjuster screw. Be careful not to hurt your fingers. Tighten the adjuster screw all the way in.
Page 237 FRONT SUSPENSION Clamp the wheel axle carrier in a vice and tighten the adjuster screw onto the carrier to 55 Nm (40.5 ft/lb). Fill the outer tube with the specified quantity of oil. Tighten the cylinder onto the outer tube to 29 Nm (21.4 ft/lb). I.17 Part.
Page 238: Front Suspension Mod. Te /2010
FRONT SUSPENSION Front suspension Mod. TE /2010 Front suspension (TE) Front suspension is handled by a KAYABA upside-down telescopic hydraulic fork with advanced axle and 48 mm legs. Wheel travel is 300 mm. I.18 Part. N. 8000 H1489 (10-2009)
Page 239 FRONT SUSPENSION Loosen the cap nut at the top of each outer tube. (Note: it is good practice to moderately slacken the cap nuts before removing the fork legs from the motorcycle). Loosen the fork cap nut and the nut with a wrench. Remove top cap nut, spring retainer, spring and rebound adjuster rod.
Page 240 FRONT SUSPENSION Remove nut, spring guide, O-ring and collar bushing. Hold the cartridge top end steady. Loosen and remove the bottom valve assembly. I.20 Part. N. 8000 H1489 (10-2009)
Page 241 FRONT SUSPENSION Take the cartridge out of the outer tube. Remove the dust seal using a flat head screwdriver. I.21 Part. N. 8000 H1489 (10-2009)
Page 242 FRONT SUSPENSION Remove the retaining ring using a flat head screwdriver. Pull the inner tube until separating it from the outer tube. Note: to facilitate removal, quickly (but carefully) pump the tubes back and forth until separating them. Remove the sealing rings and the metal rings mounted on the inner tube. Do not reuse any metal parts after removal.
Page 243 FRONT SUSPENSION Check the spring. Replace it if: outside diameter is damaged or exceedingly worn. Free length is 457 mm (18 in.) or less. Check the inner tube. Replace if distorted. (Never attempt to repair or reuse a distorted fork tube). If the tube shows surface defects, sand the surface.
Page 244 FRONT SUSPENSION Fit metal bushing and washer to outer tube using an appropriate installer. Fit the oil seal to the outer tube and push it home using an appropriate in- staller. Make sure that the retaining ring groove inside the outer tube is fully visible. Install the retaining ring.
Page 245 FRONT SUSPENSION Insert the cartridge into the outer tube. Hold the cartridge top end into place. Tighten the bottom valve assembly to 55 Nm (40.5 ft/lb). I.25 Part. N. 8000 H1489 (10-2009)
Page 246 FRONT SUSPENSION Fit collar bushing, O-ring, spring guide and nut onto piston rod. Insert the rebound adjuster rod into the piston rod. Make sure that at least an 18 mm (0.71 in.) portion of the rebound adjuster rod protrudes from the piston rod. Oil filling.
Page 247 FRONT SUSPENSION Filling oil to specific level Fill the damper unit with oil up to the top edge of the outer tube. Slowly pump the outer tube up and down to help oil flow equally into both inner and outer tube. Now slowly pump the piston rod up and down to help oil reach all points of the cartridge.
Page 248: Front Suspension Mod. Tc /2009
FRONT SUSPENSION Front suspension Mod. TC /2009 Front suspension Front suspension is handled by a MARZOCCHI USD telescopic upside-down hydraulic fork with advanced axle and 50 mm legs. Wheel travel is 300 mm. I.28 Part. N. 8000 H1489 (10-2009)
Page 249: Service Instructions For Ø50Usd Fork
FRONT SUSPENSION Service instructions for Ø50USD fork GENERAL The fork uses a multi-valve damping system with rebound and compres- sion adjustment and spring preload adjustment for static load. Compression damping is controlled by a special valve located at the top of each fork leg.
Page 250: Fork Components
FRONT SUSPENSION Fork components The SHIVER 50 Factory Works fork uses a multi-valve damping system with the same configuration on both fork leg. Each fork leg is a complete suspension system to be set up separately. Compression adjuster Outer tube Bottom sliding bushing Retainer Sealing ring...
Page 251: General Overhaul Instructions
FRONT SUSPENSION General overhaul instructions • After taking the fork apart, always use new, genuine Marzocchi seals on assembly. • When tightening two screws or nuts close to each other, always follow a 1-2-1 pattern and use a torque wrench; observe the speci- fied tightening torque values (see Tightening torque figures table).
Page 252: Troubleshooting
FRONT SUSPENSION Troubleshooting - Causes - Remedy Possible troubles that may occur in service are covered in this paragraph. For each trouble, possible causes and suggested remedy is indicated. TROUBLE CAUSE REMEDY Oil leaks past the sealing ring 1. Worn sealing ring 1.
Page 253: Cleaning The Fork Legs
FRONT SUSPENSION Cleaning the fork legs This can be done with the fork installed. The dust seals of Marzocchi forks are grease lubricated so the inner tubes will slide more easily, especially after long period of inactivity. This grease may melt in service and run down the inner tubes, so the fork will look like it is leaking oil.
Page 254: Bleeding
FRONT SUSPENSION Bleeding Perform this procedure with the fork legs removed and fully extended or with the fork installed and the front wheel lifted off the ground. Air entering into the fork legs in service will affect pressure and may cause the fork to malfunction.
Page 255: Draining Oil
FRONT SUSPENSION Draining oil WARNING This procedure can only be done with the fork removed. It is good practice to slightly slacken the cap nut before removing the fork leg from the yokes. Follow the motorcycle manufacturer's instructions to remove the fork leg from the yokes.
Page 256: Cartridge Removal
FRONT SUSPENSION Cartridge removal WARNING! Drain all oil from the fork leg before performing this procedure. Clamp the wheel axle carrier (70) in a vice. Loosen the bottom lock nut of the cartridge (48) using a 21 mm socket wrench. Remove the cartridge bottom lock nut (48).
Page 257 FRONT SUSPENSION Hold the rebound adjuster (24) using a 17 mm open-end wrench and loosen the check nut (27) with another 17 mm open-end wrench. Remove rebound adjuster (24) and check nut (27) from the damper rod. Apply adhesive tape over the threaded end of the rod (25). Apply one turn only, stretching the tape taut and do not overlap it.
Page 258: Rebound Adjuster Servicing
FRONT SUSPENSION Rebound adjuster servicing Disassembly Push back the return spring, away from rod end. Clamp the end of the rod (25) at the 17 mm nut in a vice. Be careful not to dam- age the washers and do not overtighten.
Page 259: Compression Valve Servicing
FRONT SUSPENSION Compression valve servicing Disassembly Clamp the compression valve (43) at the flat faces in a vice. Be careful not to damage the washers and do not overtighten. Loosen the screw (36) using a 12 mm wrench. Remove in the order: screw (36), spring (37), by-pass washer (38), piston (39) with its O-ring (40), compression washer or washer stack (41).
Page 260: Cartridge Assembly
FRONT SUSPENSION Cartridge assembly Fit the spring (23) into place on the rod. Apply adhesive tape over the threaded end of the rod (25). Apply one turn only, stretching the tape taut and do not overlap it. Grease the rod and lubricate the seals. Insert the damper rod (25) into cartridge case (35).
Page 261 FRONT SUSPENSION Pump the rod through its full stroke several times and top oil level up to about 20 mm below cartridge edge. Tighten the bleed screw (1) into compression valve unit (43). Seal cartridge end tightening the compression valve (43) and pump the rod (25) through one complete stroke.
Page 262 FRONT SUSPENSION Slide the damper rod (25) fully out (fully extended) again and top up oil up to the edge. Set the compression adjuster to 15 clicks from fully closed position. Loosen the oil drain screw (1) in the compression valve unit (43). Tighten the compression valve unit until you feel the outer O-ring starting to bind inside the cap nut body.
Page 263: Separating Inner And Outer Tube - Sealing Ring Removal
FRONT SUSPENSION Separating inner and outer tube - sealing ring removal Remove the dust seal (16) from its seat using a small flat head screwdriver. Remove the metal retaining ring (15) using the same screwdriver. Slide the inner tube (44) out of the outer tube (11); you will need to pull hard to separate the tubes.
Page 264: Assembling Inner And Outer Tube - Sealing Ring Installation
FRONT SUSPENSION Assembling inner and outer tube - sealing ring installation WARNING Never reuse sealing rings and dust seals after removal. Check the con- dition of the pilot bushings before assembly; replace them if scored or scratched. Make sure the Teflon coating of the pilot bushings is in perfect ®...
Page 265: Cartridge Assembly
FRONT SUSPENSION Install the retaining ring (15) using a small flat head screwdriver making sure it becomes fully seated in its grove. Be careful not to score the inner tube. Push the dust seal (16) into place pressing with your hands. Cartridge assembly Insert preload spacer (17) and spring (19) into the inner tube.
Page 266: Oil Filling
Restore original settings (see page I.45). Installing the fork on the motorcycle WARNING Fork installation must be in compliance with Husqvarna specifications for steering, braking system and wheel installation. Improper installation may put the safety of the rider at risk.
Page 267: Settings
FRONT SUSPENSION Settings Proper suspension tuning is the key to achieving optimal performance. This para- graph describes the proper setting procedure for the Marzocchi suspension. Achieving proper tuning is a trial and error process. You will need to determine what to adjust and how. Perform this procedure outdoors, in a low traffic area free from obstacles and potential danger.
Page 268: Spring Preload Adjustment
FRONT SUSPENSION Spring preload adjustment Spring preload can be adjusted after removing the cartridge inside the fork leg (see paragraph 4.6). Closely follow the procedure outlined below: Slide the preload adjuster (7) towards the bottom end of the cartridge so as to expose the metal ring groove.
Page 269: Compression Adjustment
FRONT SUSPENSION Compression adjustment Compression damping is adjusted by turning the adjuster (C). WARNING if the fork bottoms out severely, immediately adjust compression damping or check oil level. Improper compression setting may result in fork damage, leading to accidents, and severe or lethal injury. Hard compression setting gives more stability and faster response, enabling a more aggressive riding style;...
Page 271: Rear Suspension
REAR SUSPENSION Section Part. N. 8000 H1489 (10-2009)
Page 272 REAR SUSPENSION Rear shock absorber ..................J.3 Lubrication points (grease) ................J.3 Rear suspension....................J.4 Rear shock absorber removal ...............J.5 Disassembling, servicing and assembling the rear shock absorber ....J.6 Spring servicing .....................J.6 Shock absorber inspection ................J.6 Reservoir cap with its valve removal .............J.7 Piston assembly inspections .................J.9 Seal replacement...................J.9 Checking the setting ..................J.10...
Page 273: Rear Shock Absorber
REAR SUSPENSION Rear shock absorber TIGHTENING TORQUE FIGURES 1, 2: 52.4 Nm/ 5.35 Kgm/ 38.6 ft/lb Lubrication points (grease) Part. N. 8000 H1489 (10-2009)
Page 274 REAR SUSPENSION Rear suspension The rising-rate rear suspension is made up of a shock absorber, a linkage system and a swinging arm. The spring preload of the shock absorber can be adjusted to suit riding and terrain conditions. Hydraulic damping is also adjustable using outer adjuster screws.
Page 275: Rear Shock Absorber Removal
REAR SUSPENSION Rear shock absorber removal Set a block under the engine and see that the rear wheel is lifted from the ground. Remove saddle, side panels, silencer and rear chassis (see Section "E" - General Procedures). Loosen the front clamp (1) of the intake coupling. Remove the front bolt (2) securing the suspension linkage to the chassis, the bottom (3) and top (4) shock absorber mounting bolts and remove the shock absorber (5).
Page 276: Disassembling, Servicing And Assembling The Rear Shock Absorber
REAR SUSPENSION Disassembling, servicing and assembling the rear shock absorber Clean the shock absorber before disassembly. Spring servicing Measure the spring in place before removal. Spring removal: clamp the shock absorber in a vice taking care to avoid distorting it. Slacken lock ring nut and ring nut, spring retainer and spring. Measure spring free length.
Page 277 REAR SUSPENSION Push on the reservoir valve to discharge the gas. Aim valve away from you to prevent any debris from getting into your eyes. Reservoir cap and valve removal Locate a suitable tool to reservoir cap and push down on cap until gaining ac- cess to the retaining ring.
Page 278 REAR SUSPENSION Place the shock absorber on a bench. Unscrew or knock out the cover (depend- ing on the model). Once the tank cap is removed, push the rod guide down into the body so as to expose the circlip groove and remove the circlip with a screwdriver. Part.
Page 279: Piston Assembly Inspections
REAR SUSPENSION Clamp the top section of the shock absorber in a vice with aluminium or bronze jaws. Insert a rod or a screwdriver into the mounting hole and extract the rod guide and piston assembly from the shock absorber body. Before extracting the assembly, cover the end of the shock body with a cloth to capture leaking oil.
Page 280: Checking The Setting
REAR SUSPENSION Checking the setting If the suspension is not operating properly and you need to adjust compression damping, loosen the knob dowel (heat with an air gun before loosening). Proceed as follows: loosen the ring nut with the suitable key, slide off all parts noting their positions to ensure correct assembly.
Page 281: Reservoir Replacement
REAR SUSPENSION After the inspection, refit piston, disc, spring and slotted ring. Slide the needle shaft off the cap, tighten the ring, insert into slot pressing lightly and secure in place tightening the cap to 30 Nm (3 kgm; 29.2 ft/lb). It is strictly forbidden to change the compression washers.
Page 282: Floating Piston Removal
REAR SUSPENSION Apply Loctite and screw on the reservoir being careful not to damage the O-ring. Tighten to 40 Nm (4 kgm; 39.2 ft/lb). NOTE: Perform these procedures in a clean environment and clean any com- ponents to be reused. Floating piston removal If you have drained the shock oil, you will need to remove the floating piston.
Page 283 REAR SUSPENSION Push the floating piston quickly down to reservoir bottom while holding the rod steady in the appropriate position for top-up. The oil inside the reservoir will flow into the shock absorber body and fill it up to a certain level as it seeps through the piston washers.
Page 284 REAR SUSPENSION Refit the reservoir cap with its valve. Fit it into the reservoir and fit the circlip into the groove. Fill nitrogen (or air) through the valve and pressurise to 10-12 bar. Refit the cap to the valve and check for oil or air leaks. Drive the cap onto the body.
Page 285: Shock Absorber Damping Adjustment
REAR SUSPENSION Shock absorber damping adjustment Adjustment of the compression stroke is independent from the rebound stroke. A) COMPRESSION - Standard setting: 1) Low damping speed: -15 clicks (± 2 clicks) (adjuster screw 1) 2) High damping speed: -15 clicks (± 2 clicks) (adjuster screw 3) To reset the standard setting, turn upper adjuster screws (1) and (3) clockwise until reaching fully closed position.
Page 286: Disassembling And Servicing The Swinging Arm
REAR SUSPENSION Disassembling and servicing the swinging arm Set a stand or a block under the engine and see that the rear wheel is lifted from the ground. Remove the secondary drive chain (1) and detach the rear brake line (2) from the swinging arm (A). Remove both chassis side guards (3). Dis- engage the return spring (4) of the rear brake pedal from the chassis.
Page 287: Servicing The Swinging Arm Shaft
REAR SUSPENSION Servicing the swinging arm shaft Check shaft taper using a dial gauge. Place the shaft on two identical reference blocks. Turn the shaft and move the dial gauge horizontally to determine the amount of distortion. Service limit: 0.30 mm. Servicing the rear suspension drop and drag link With drop link (1) and drag link (2) still in place (connected to swinging arm and chassis, respectively), rock them both back and forth in all directions to check for...
Page 288: Chain Roller, Chain Guide, Chain Slider
REAR SUSPENSION Chain roller, chain guide, chain slider Check the wear of the above-mentioned elements and replace them when necessary. Check the chain guide alignment, and remember that a bent element can cause chain early wear. In this case, chain might unwrap from the sprocket.
Page 289: Brakes
BRAKES Section Part. N. 8000 H1489 (10-2009)
Page 290 BRAKES Braking system ..................... L.3 Brake disc ..................... L.4 Checking brake pads for wear / replacing the pads ........L.5 Bleeding the front braking system ..............L.6 Bleeding the rear braking system ..............L.7 Changing the fluid..................L.8 Part. N. 8000 H1489 (10-2009)
Page 291: Braking System
BRAKES Braking system The braking system uses two independent circuits. Each system is equipped with a brake calliper connected to a master cylinder with a fluid reservoir. 1. Front brake lever 2. Front brake master cylinder with fluid reservoir 3. Front brake line 4.
Page 292: Brake Disc
BRAKES Brake disc Checking the brake disc is an important safety procedure; the disc must be spot- less, i.e. free from corrosion, oil or other dirt or deep scoring. Front brake disc diameter: 260 mm Front brake disc thickness (when new): 3.0 mm Wear limit: 2.5 mm Rear brake disc diameter: 240 mm Rear brake disc thickness (when new): 4.0 mm...
Page 293: Checking Brake Pads For Wear / Replacing The Pads
BRAKES Checking brake pads for wear / replacing the pads Check brake pad wear. Service limit ”A” 3.8 mm (front and rear pads) If service limit is exceeded, always replace the pads in pairs. Be careful that no brake fluid or any oil gets on brake pads or discs. Clean off with alcohol any fluid or oil that inadvertently gets on the pads or disc.
Page 294: Bleeding The Front Braking System
BRAKES Bleeding the front braking system A long travel and mushy feel of the brake lever indicate that there is air in the system and the brake needs bleeding. Bleeding procedure is as follows: Take the rubber cap off the bleed valve (1). Attach a clear plastic hose to the calliper bleed valve and place the other end of the hose in a vessel (make sure the hose end stays dipped in the fluid throughout the procedure).
Page 295: Bleeding The Rear Braking System
BRAKES Bleeding the rear braking system A long travel and mushy feel of the brake pedal indicate that there is air in the system and the brake needs bleeding. Bleeding procedure is as follows: Remove reservoir cap (A) (21 mm wrench) and diaphragm and fill with fluid (DOT 4).
Page 296: Changing The Fluid
BRAKES Changing the fluid Brake fluid should be checked and changed as per the "Maintenance Chart" (see Section B), or earlier if contaminated with debris or water. Do not change brake fluid in the rain or with a strong wind. Use only fluid taken from a sealed container (DOT 4).
Page 297 BRAKES Remove the reservoir cap (2) or (2A) 21 mm wrench and the rubber gaiter. Loosen the bleed valve on the calliper. Pump the brake lever (3) or the brake pedal (3A) until draining all fluid. Tighten the bleed valve and fill the reservoir with fresh fluid. Loosen the bleed valve, operate lever or pedal, tighten the valve keeping lever or pedal pressed and then release quickly.
Page 298 BRAKES Periodically check the connecting hoses (C) and (D) (see Scheduled Maintenance Chart, Section B): replace worn or cracked hoses. L.10 Part. N. 8000 H1489 (10-2009)
Page 299: Electrical System
ELECTRICAL SYSTEM Section Part. N. 8000 H1489 (10-2009)
Page 301 ELECTRICAL SYSTEM Wiring diagram (TC) ..................M.5 Key to wiring diagram .................. M.5 Colour coding key ..................M.5 Wiring diagram (TE) ..................M.6 Key to wiring diagram .................. M.6 Colour coding key ..................M.6 Wiring diagram (TXC) .................. M.7 Key to wiring diagram .................. M.7 Colour coding key ..................
Page 302 ELECTRICAL SYSTEM ELECTRONIC IGNITION SYSTEM ............M.38 Wiring (TC) ....................M.39 Cable routing and electrical parts installation instructions (TC)....M.40 • HT coil position (TC) ................M.40 • Fuel injection control unit position (TC) ..........M.40 • Securing engine stop button ground cable to chassis (TC) ....M.40 •...
Page 303: Wiring Diagram (Tc)
ELECTRICAL SYSTEM Wiring diagram (TC) Key to wiring diagram Colour coding key R ..Red 1. Electronic control unit B ..Blue Sb ..Sky blue 2. Alternator Br ..Brown V ..Violet 3. Spark plug Bk ..Black W ..White 4. Gear sensor G ..Green Y ..Yellow 5.
Page 304: Wiring Diagram (Te)
ELECTRICAL SYSTEM Wiring diagram (TE) Key to wiring diagram 31. Lambda sensor 32. Air temperature sensor (40) 1. Electronic control unit 33. Coolant temperature sensor 2. Alternator 34. Pressure sensor (40) 3. Voltage regulator 35. Fuel pump 4. Rear stop light switch 37.
Page 305: Wiring Diagram (Txc)
ELECTRICAL SYSTEM Wiring diagram (TXC) Colour coding key Key to wiring diagram Y/G ....Yellow/Green B ....Blue 1. Electronic control unit Y/Sb ....Yellow/Sky blue Bk ....Black 2. Alternator Y/R....Yellow/Red Br ....Brown 3. Voltage regulator Br/Bk ..... Brown/Black 4.
Page 306: Electrical Components Location (Tc)
ELECTRICAL SYSTEM Electrical components location (TC) The ignition system includes the following elements: Generator (1), on the inner side of L.H. crankcase half cover; Electronic ignition coil (2) under the fuel tank; Electronic control unit (3) under the fuel tank; Spark plug (4) on cylinder head;...
Page 307: Electrical Components Location (Te)
ELECTRICAL SYSTEM Electrical components location (TE) The ignition system includes the following elements: Generator (1), on the inner side of L.H. crankcase half cover; Electronic ignition coil (2) under the fuel tank; Electronic control unit (3) under the fuel tank; Spark plug (4) on cylinder head;...
Page 308 ELECTRICAL SYSTEM 12V-350W starter motor (6) behind the cylinder; Solenoid starter (7) on left side of rear chassis; M.A.Q.S. sensor (air temperature, pressure, throttle position) (8) on throttle body. The electrical system includes the following elements: 12V-7Ah battery (9) under the saddle; Turning indicators flasher (10) on left side of rear chassis;...
Page 309 ELECTRICAL SYSTEM Relay (11): coil, injection system, fuel pump, on right side of rear chassis; Relay (12): electric fan, on right side of rear chassis; Relay (13): light system, turning indicators, horn, on right side of rear chas- sis; Fuses (14), (15), (16): on rear mudguard, right side: Fuse 14 (15A): coil, injection system, fuel pump;...
Page 310 ELECTRICAL SYSTEM Headlamp (20) with 12V-35/35W twin halogen bulb and 12V-5W parking light bulb; LED tail light (21); Turning indicators (22), 12V-10W bulbs; Fuel pump (23) inside the fuel tank. M.12 Part. N. 8000 H1489 (10-2009)
Page 311: Electrical Components Location (Txc)
ELECTRICAL SYSTEM Electrical components location (TXC) The ignition system includes the following elements: Generator (1), on the inner side of L.H. crankcase half cover; Electronic ignition coil (2) under the fuel tank; Electronic control unit (3) under the fuel tank; Spark plug (4) on cylinder head;...
Page 312 ELECTRICAL SYSTEM 12V-350W starter motor (6) behind the cylinder; Solenoid starter (7) on left side of rear chassis; M.A.Q.S. sensor (air temperature, pressure, throttle position) (8) on throttle body. M.14 Part. N. 8000 H1489 (10-2009)
Page 313 ELECTRICAL SYSTEM The electrical system includes the following elements: 12V-7Ah battery (9) under the saddle; Relay (10): coil, injection system, fuel pump, on right side of rear chassis; Relay (11): solenoid valve, on right side of rear chassis; Fuses (12), (13), (14): on rear mudguard, right side: Fuse 12 (15A): coil, injection system, fuel pump;...
Page 314: Checking Generator Stator Windings Resistance
ELECTRICAL SYSTEM Coolant temperature sensor (16); Lambda sensor (17); Fuel pump (18) inside the fuel tank. Checking generator stator windings resistance Disconnect the stator coil connector from the wiring and measure resistance with a meter. TE - TXC H00813-1 H00804-1 M.16 Part.
Page 315: Generator No-Load Performance (Tc)
ELECTRICAL SYSTEM 1) Take following measurements at the connector (1): EXCITER: Resistance between BLACK-RED and RED-WHITE wires: +/- 15%. CHARGE: Resistance between YELLOW-YELLOW wires: 0.65 +/- 15%. PULSER: Resistance between RED-GREEN wires: +/- 15%. TE - TXC 1) Measure across the terminals of the connector (1); correct value is about If resistance is outside the specified limits, replace the complete generator.
Page 316: Ignition System (Tc)
ELECTRICAL SYSTEM Ignition system (TC) In the Capacitor Discharge Ignition (C.D.I.) system, the capacitor is charged using the power generated by the alternator. Alternator current is then discharged to the primary winding of the ignition coil in a single discharge that it timed based on the predetermined spark advance.
Page 317: Ignition System (Te - Txc)
ELECTRICAL SYSTEM Ignition system (TE - TXC) The ignition system is controlled by the ECU (1). The ignition is an integrated digital electronic ignition system with static timing and advance using intermittent sequential phased electronic injection feed. This ignition system is composed of a crankshaft position (pick-up) sensor, an ECU, an ignition coil and an intake manifold pressure sensor.
Page 318: Key To Wiring Diagram
ELECTRICAL SYSTEM H00776-1 Key to wiring diagram Electronic control unit Alternator Voltage regulator Injector Cooling fan Battery Solenoid starter Starter motor Spark plug Gear sensor HT coil Throttle position sensor (25) R.H. switch Electric fan relay Lambda sensor Air temperature sensor (25) Coolant temperature sensor Pressure sensor (25) Fuel pump...
Page 319: Charging System (Te - Txc)
ELECTRICAL SYSTEM CHARGING SYSTEM (TE - TXC) The charging system is composed of: - Alternator (1); - Voltage regulator/rectifier (2); - Solenoid starter (3); - Battery (4). The alternated current generated by the alternator is converted into direct cur- rent by the voltage regulator/rectifier. The voltage regulator/rectifier serves a dual purpose: it provides overvoltage protection for the battery and converts alternated current into direct current.
Page 320: Charging System Inspections
ELECTRICAL SYSTEM CHARGING SYSTEM INSPECTIONS Current loss at the battery (TE - TXC) Remove the saddle (as described in the relevant paragraph) to gain access to the battery (1). Disconnect the BLACK negative cable from the battery. Measure current across the negative terminal of the battery and the negative cable using a meter.
Page 321: Electrical Starting System (Te - Txc)
ELECTRICAL SYSTEM ELECTRICAL STARTING SYSTEM (TE - TXC) The starting system is composed of: - Battery (16); - Solenoid starter (17); - Starter motor (18); - R.H. switch (25); - Clutch microswitch (27) (TE); - Ignition switch (26) (TE); - Fuses (37). For a description of wires and components, please see the key to the wiring diagram H01036...
Page 322: Starting System Inspection
ELECTRICAL SYSTEM STARTING SYSTEM INSPECTION Starter motor inspection (TE - TXC) Remove the starter motor (1) as described in the relevant paragraph. Whenever a starter motor fault is detected, check the starter motor as follows: - connect a meter across ground and starter motor contact. - Check for continuity between the positive pole and motor ground.
Page 323: Checking Coil Windings Resistance
ELECTRICAL SYSTEM Checking coil windings resistance Remove saddle and fuel tank (see relevant paragraph) to gain access to the coil (1). Disconnect the coil connector from the wiring, remove retaining screws and coil and measure resistance in the primary and secondary windings with a meter. Inductive coil for fuel-injected TE/TXC 250: Primary winding resistance: 4.5 ±15% at 20°C.
Page 324: Electronic Control Unit (Ecu)
ELECTRICAL SYSTEM Electronic control unit (ECU) Remove saddle and fuel tank (see Section E) to gain access to the electronic control unit (1). It is composed of a capacitor, a rectifier circuit that handles input signals received from the pick-up sensor, a circuit that controls ignition timing advance in accordance with pick-up sensor inputs and a switching circuit for capacitor discharge.
Page 325: Gear Position Sensor Inspection (Gps: Gear Position Sensor)
ELECTRICAL SYSTEM Gear position sensor inspection (GPS: Gear Position Sensor) Set the meter to the “Ohm” scale and disconnect the six-way connector (1) of the alternator from the main wiring harness (the gear sensor wiring is secured to the alternator wiring with a clip). Touch one meter probe to engine ground and insert the other probe into the connector hole for the WHITE/BLACK gear sensor wire (2).
Page 326: (Tps: Throttle Position Sensor) (Tc)
ELECTRICAL SYSTEM Carburettor throttle position sensor inspection (TPS: Throttle Position Sensor) (TC) Set the meter to the “Ohm” scale and disconnect the carburettor sensor connec- tor (1) from the main wiring harness. Connect the meter probes to the terminals of the YELLOW (A) and BLACK (B) wires and check that your readings match the values given in the table.
Page 327: Battery (Te - Txc)
ELECTRICAL SYSTEM BATTERY (TE - TXC) The battery (1) is a sealed-for-life, maintenance-free battery. If the vehicle remains unused for long periods, it is recommended to disconnect the battery from the electrical system and store it in a dry place. After an intensive use of the battery, it is advisable to carry out a standard slow charging cycle (12V-6Ah battery: 0.6A for 8 hours).
Page 328: Headlamp, Tail Light (Te)
ELECTRICAL SYSTEM HEADLAMP, TAIL LIGHT (TE) Headlamp adjustment The headlamp features a twin bulb for low and high beam and a festoon bulb for the city or parking light. Beam setting needs to be performed accurately; proceed as follows: Place the motorcycle 10 metres away from a vertical wall; The motorcycle must be on level ground and the optical axis of the headlamp must be perpendicular to the wall;...
Page 329: Tail Light Replacement
ELECTRICAL SYSTEM Tail light replacement Remove the tail light as follows: - Loosen the two screws (1) under the rear mudguard. - Extract the tail light (2) and disconnect the connector (3). Once the tail light has been replaced, reverse the above procedure to reas- semble.
Page 330: Handlebar Switches
ELECTRICAL SYSTEM Handlebar switches Measure continuity on the different switches using a meter. Replace any part found to be faulty. Left-hand switch (TC) COLOUR POSITION 1 Engine stop switch (TC) Left-hand switch (TE) High beam flasher (self-cancelling) High beam switch Low beam switch Left-hand turning indicators (self-cancelling) Right-hand turning indicators (self-cancelling)
Page 331: Right-Hand Switch (Te - Txc)
ELECTRICAL SYSTEM Right-hand switch (TE - TXC) 1. Engine start button 2. Engine start/stop switch H01040 Bk-Br Y-Sb H01041 Colour coding key B ....Blue Br ....Brown Br-Bk ..... Brown-Black Y-Sb ....Yellow-Sky blue Part. N. 8000 H1489 (10-2009) M.33...
Page 332: Fuses
ELECTRICAL SYSTEM FUSES • When you find a blown fuse (1), always investigate and eliminate the cause before replacing it. • Never replace a fuse with another fuse with a different rating. • Never use a wire or other makeshift repair techniques instead of installing a new fuse.
Page 333: Digital Dashboard, Warning Lights (Te)
IMPORTANT: In the event of a FUEL INJECTION SYSTEM MALFUNCTION, the word FAIL appears on the right side of the dashboard display (see page 14). When this is the case, contact your HUSQVARNA dealer. 1- SPEED (Km/h or mph) / ODO (figure 1) - SPEED: vehicle speed - maximum value: 299 Km/h or 299 mph;...
Page 334 ELECTRICAL SYSTEM 2 - SPEED / CLOCK (figure 2) - SPEED: speed - maximum value: 299 Km/h or 299 mph; - CLOCK: clock - reading from 0:00 to 23:59:59. To reset the clock, push the SCROLL button (A) and hold for more than 3 sec- onds in order to increase the hour value;...
Page 335: Speed / Number Of Rpm
ELECTRICAL SYSTEM 5 - SPEED / NUMBER of RPM (figure 5) - SPEED: speed - maximum value: 299 Km/h or 299 mph - NUMBER OF RPM: MIN. 500, MAX 14250 The display also provides a "Neutral” and a fuel injection “Fail” indication; the latter takes priority over any other indication.
Page 336: Dashboard Replacement (Te)
ELECTRICAL SYSTEM Dashboard replacement (TE) - Remove the upper retaining screw securing headlamp fairing to dashboard bracket (A); - slide the headlamp fairing (B) forward and pull upwards (C) to ease it off the two lower mounts; - disconnect the connector (2) and remove the headlamp fairing (1); Remove the two retaining screws (3) securing the dashboard to its bracket, disconnect the connector (4) and remove the dashboard (5).
Page 337 ELECTRICAL SYSTEM Wiring (TC) 1 Engine stop button 2 Coil 3 Control unit 4 Main wiring harness 5 Carburettor throttle position sensor 6 Gear sensor Part. N. 8000 H1489 (10-2009) M.39...
Page 338: Cable Routing And Electrical Parts Installation Instructions (Tc)
ELECTRICAL SYSTEM Cable routing and electrical parts installation instructions (TC) • HT coil position (1) (TC) Connect the HT coil as shown in the figure. • Fuel injection control unit position (2) (TC) Electronic control unit installed with the flat side down. •...
Page 339: Control Unit Connection (Tc)
ELECTRICAL SYSTEM • Control unit connection (TC) Connect the control unit connector (4) as shown. • Ignition coil connection (TC) Connect the ignition coil connectors (5) as shown. • Gear sensor cable connection (TC) Connect the gear sensor connector (6) as shown. Part.
Page 340: Securing The Engine Stop Button Cable (Tc)
ELECTRICAL SYSTEM • Securing the wiring (TC) Strap wiring to chassis with three clips (7) as shown in the figure. • Securing the engine stop button cable (TC) Secure the engine stop button cable (8) with two clips (9). • Securing the wiring (TC) Secure the ignition and gear sensor wiring loom to the clutch hose.
Page 341: Wiring (Te - Txc)
ELECTRICAL SYSTEM Wiring (TE - TXC) H00973 H00974 Part. N. 8000 H1489 (10-2009) M.43...
Page 342: Cable Routing And Electrical Parts Installation Instructions "Te - Txc
ELECTRICAL SYSTEM CABLE ROUTING AND ELECTRICAL PARTS INSTALLATION INSTRUC- TIONS "TE - TXC" • Coil position TE -TXC Connect the HT coil as shown in the figure. • Relay (1) and fuses (2) position (TE - TXC) On right side of motorcycle. •...
Page 343: (Te - Txc)
ELECTRICAL SYSTEM • Electronic control unit (5) and voltage regulator (6) position (TE - TXC). Electronic control unit installed with the flat side down. Voltage regulator installed over the electronic control unit. Coat voltage regulator with heat grease. • Securing the starter motor/solenoid starter cable (TE - TXC) Connect the starter motor/solenoid starter cable (7) as shown in the figure.
Page 344: Securing The Voltage Regulator Ground Cable (Te - Txc)
ELECTRICAL SYSTEM • Securing the voltage regulator ground cable (9) (TE - TXC) Secure the regulator ground cable to the right-hand screw of the injection coil. • Securing the engine ground / chassis ground cables (10). Electrical system ground Secure the engine ground / chassis ground cable and the wiring harness ground eye terminal to the coil retaining screw.
Page 345: Electric Fan Connection (Te - Txc)
ELECTRICAL SYSTEM • Connection of relays and fuses (TE - TXC) RELAYS Connect the cable marked “POW” to relay (12) Connect the cable marked “FAN” to relay (13) Connect the cable marked “DC” to relay (14) (TE only) FUSES Connect the cable marked “POW” to fuse (15) Connect the cable marked “MAN”...
Page 346: Fuel Pump Connector Position (Te -Txc)
ELECTRICAL SYSTEM • Fuel pump connector position (TE -TXC) Position the fuel pump connector (21) as shown. • MAQS connector (TE - TXC) Connect the connector (22) as shown. • Engine water temperature connector (TE - TXC) Connect the engine water temperature connectors (23) to the thermostat. • Lambda sensor position and connector (TE - TXC) Tighten the Lambda sensor (24) in the corresponding seat. Connect the Lambda sensor connector (25) as shown.
Page 347: Ignition And Gear Sensor Cable Connection
ELECTRICAL SYSTEM • Ignition and gear sensor cable connection Connect the ignition (26) and gear sensor (27) connectors as shown. • Routing of rear chassis cables, tail light connection, flasher contactor. Route the rear end of the wiring (28) as shown in the figure. Connect the tail light/turning indicators connector (29) (TE).
Page 348: Rear Stop Connection
ELECTRICAL SYSTEM • Clip installation on fuse holders Secure the three fuses to the suitable perforated panel of the rear mudguard. • Rear stop connection Connect the wiring connector (A) to the rear STOP sensor. • Routing of steering head tube wiring Secure the wiring harness with the suitable clip (34).
Page 349: Double Map Connector Cap (Te)
ELECTRICAL SYSTEM • Double map connector cap (TE) Fit the cap to the double map connector. • Speed sensor and ignition switch connectors (TE) Connect the speed sensor connector. Connect the connector (41) of the ignition switch (42). • Horn connector (TE) Connect the connector (43) to the horn.
Page 350: Securing The Wiring Harness To Rear Chassis Right Side
ELECTRICAL SYSTEM • Securing the wiring harness to rear chassis right side Strap wiring to rear chassis with clips as shown in the figure. • Securing the wiring harness to rear chassis left side Secure wiring harness with a clip as shown in the figure. •...
Page 351: Securing The Wiring Harness
ELECTRICAL SYSTEM • Securing the wiring harness Secure the generator connector as shown (26). • Securing the wiring harness Secure the ignition, gear sensor and Lambda sensor wiring loom to the clutch hose with two clips. • Securing the wiring harness Secure the ignition and gear sensor wiring loom to the clutch hose.
Page 352 ELECTRICAL SYSTEM IMPORTANT Before washing the motorcycle, it is necessary to duly protect the following parts from water: a) Rear opening of the muffler; b) Clutch and front brake levers, handgrips, handlebar switches; c) Air filter intake; d) Steering head, wheel bearings; e) Rear suspension drag drop link.
Page 353: Engine Cooling
ENGINE COOLING Section Part. N. 8000 H1489 (10-2009)
Page 354 ENGINE COOLING Coolant level check ..................N.3 Cooling circuit (TC) ..................N.4 Engine cooling system overhaul (TC)............N.5 Cooling circuit (TE-TXC) ................N.6 Engine cooling system overhaul (TE-TXC) ..........N.7 Part. N. 8000 H1489 (10-2009)
Page 355: Coolant Level Check
ENGINE COOLING Coolant level check Coolant takes the heat from the piston-cylinder-and-head assembly and transfers it to the radiator, where it is released to the atmosphere. Checking coolant level at regular periods is critical to ensuring proper operation of the cooling system. Without cooling medium (water), no heat exchange occurs between cylinder head and radiator.
Page 356: Cooling Circuit (Tc)
ENGINE COOLING Cooling circuit (TC) The forced circulation cooling system uses a centrifugal pump (located to the left of the head) and two down-draft radiators. Radiator cap Right-hand radiator Left-hand radiator Fitting Water pump Breather hose Radiator connecting pipe Radiators to cylinder head pipe Water pump to fitting pipe 10 Fitting to left-hand radiator pipe 11 Fitting to right-hand radiator pipe...
Page 357: Engine Cooling System Overhaul (Tc)
ENGINE COOLING Engine cooling system overhaul (TC) If the coolant runs too hot, check the radiators. Any foreign matter trapped between the fins (such as leaves, bugs, mud, etc.) will obstruct air flow and must be removed carefully to avoid damage to radiator. Straighten any bent fins to ensure free flow of air. If the cooling mass is clogged or damaged, no more than 20% of its surface must be affected.
Page 358: Cooling Circuit (Te-Txc)
ENGINE COOLING Cooling circuit (TE-TXC) The forced circulation cooling system uses a centrifugal pump (located to the left of the head) and two down-draft radiators. Radiator cap Right-hand radiator Left-hand radiator Thermostat Water pump Breather hose Radiator connecting pipe Radiators to cylinder head pipe Water pump to fitting pipe 10 Thermostat to radiators pipe 11 Cooling fan...
Page 359: Engine Cooling System Overhaul (Te-Txc)
ENGINE COOLING Engine cooling system overhaul (TE-TXC) If the coolant runs too hot, check the radiators. Any foreign matter trapped between the fins (such as leaves, bugs, mud, etc.) will obstruct air flow and must be removed carefully to avoid damage to radiator. Straighten any bent fins to ensure free flow of air. If the cooling mass is clogged or damaged, no more than 20% of its surface must be affected.
Page 361: Kit" Installation Instructions
“KIT” INSTALLATION INSTRUCTIONS Section Part. N. 8000 H1489 (10-2009)
Page 362 “KIT” INSTALLATION INSTRUCTIONS Carburettor KIT (TC) ..................D.3 Central engine guard (TE-TC-TXC)............. O.6 Start hook kit (TC, TXC) ................O.7 Left muffler guard (TE) ................O.9 Battery bracket and battery (TE-TXC) ............O.10 Turning indicators KIT (TE).................O.11 REAR TURNING INDICATORS ..............O.12 Rear-view mirrors (TE) ................
Page 363: Carburettor Kit (Tc)
“KIT” INSTALLATION INSTRUCTIONS Carburettor KIT (TC) Remove the breather hose (1) from the steering stem. Turn the ring nut of the fuel cock (2) counter clockwise to shut off fuel supply and loosen the clamp (3) on the hose running to the carburettor. Detach the hose at carburettor end and let fuel drain into a pan.
Page 364 “KIT” INSTALLATION INSTRUCTIONS Slacken the clamps (5) and (6) securing the carburettor to the intake coupling and to the hose coupling on the air box . Pull the carburettor rearwards to release it from the intake coupling and extract it from the right-hand side of the motorcycle. Remove the lower retaining screw (7) of the carburettor bowl, remove the bowl and drain all fuel.
Page 365 “KIT” INSTALLATION INSTRUCTIONS The kit includes: 1- Idle jet: 40, 45 1- Main jet: 170, 180, 185, 195, 200. Part. N. 8000 H1489 (10-2009)
Page 366: Central Engine Guard (Te-Tc-Txc)
“KIT” INSTALLATION INSTRUCTIONS Central engine guard (TE-TC-TXC) Part. No. Description Central engine guard M6x15 mm screw Ø7xØ9xØ4.8 mm Secure guard as shown. Part. N. 8000 H1489 (10-2009)
Page 367 “KIT” INSTALLATION INSTRUCTIONS Start hook kit (TC, TXC) Part. No. Description Ring Hook M4x8 mm screw M5x16 mm screw Part. N. 8000 H1489 (10-2009)
Page 368 “KIT” INSTALLATION INSTRUCTIONS Preliminary operations Set a stand under the engine and see that the front wheel is lifted from the ground. Loosen the four retaining screws (1, fig. 1) of the front wheel axle. Loosen and remove the retaining screw (2, fig. 1) of front wheel axle (3, fig. 2) while holding the axle at the opposite end to prevent rotation;...
Page 369: Left Muffler Guard (Te)
“KIT” INSTALLATION INSTRUCTIONS Left muffler guard (TE) Install the guard (1) using the screw (2): (M8x20 mm) that secures the rear chassis (3) at the rear end. Part. N. 8000 H1489 (10-2009)
Page 370: Battery Bracket And Battery (Te-Txc)
“KIT” INSTALLATION INSTRUCTIONS Battery bracket and battery (TE-TXC) Remove the saddle. Install the bracket as shown in the figure. Connect the RED positive cable first and then the BLACK negative cable. Secure the battery in place with its strap. O.10 Part.
Page 371: Turning Indicators Kit (Te)
“KIT” INSTALLATION INSTRUCTIONS Turning indicators KIT (TE) 1 - Front L.H. indicator (1 piece, cable L: 115-150 mm) 2 - Front R.H. indicator (1 piece, cable L: 115-150 mm) 3 - Rear L.H. indicator (1 piece, cable L: 315-350 mm) 4 - Rear R.H.
Page 372: Rear Turning Indicators
“KIT” INSTALLATION INSTRUCTIONS REAR TURNING INDICATORS Remove the saddle and the L.H. side panel. Fit the flasher to the bracket and secure it using the side retaining screw of the air box. O.12 Part. N. 8000 H1489 (10-2009)
Page 373 “KIT” INSTALLATION INSTRUCTIONS Remove the tail light and disconnect its cables from the main wiring har- ness. Insert the turning indicator cables into the hole in the number plate hold- TE: secure the indicator with the M6x20 mm screw and its nut. Route the indicator cables through mudguard and number plate holder as shown in the picture.
Page 374 “KIT” INSTALLATION INSTRUCTIONS Slide the rubber gaiter out of the mudguard, pass the indicator cables through the rubber gaiter and refit it into place. Connect the indicator and tail light cables to the main wiring harness (refer to the wiring diagram included in the Owner's Manual). Refit the tail light.
Page 375 “KIT” INSTALLATION INSTRUCTIONS Finally, secure the number plate holder to the support as shown in the figure. 1 - Number plate holder (1 piece) 2 - M5x16 mm screw (2 pieces) 3 - Bushing (2 pieces) 4 - Ø5.3xØ15x1 mm washer (2 pieces) 5 - M5 nut (2 pieces) 6 - Reflector (1 piece) 7 - Ø4.3xØ12x0.8 mm washer (2 pieces)
Page 376: Rear-View Mirrors (Te)
“KIT” INSTALLATION INSTRUCTIONS Rear-view mirrors (TE) Fit the rear-view mirrors to the clamps of the front brake and clutch levers. O.16 Part. N. 8000 H1489 (10-2009)
Page 377: Hydraulically Controlled Clutch
HYDRAULICALLY CONTROLLED CLUTCH Section Part. N. 8000 H1489 (10-2009)
Page 378 HYDRAULICALLY CONTROLLED CLUTCH Hydraulic clutch system ................P.3 Draining clutch fluid ..................P.4 Clutch master cylinder servicing ..............P.5 Bleeding the clutch system ................P.6 Part. N. 8000 H1489 (10-2009)
Page 379: Hydraulic Clutch System
HYDRAULICALLY CONTROLLED CLUTCH Hydraulic clutch system The hydraulic circuit is composed of a master cylinder with its reservoir located on the left side of the handlebar, and a piston installed on the left crankcase half. The clutch is disengaged by the piston (5) that actuates the pushrod (4) to operate the pressure plate (6).
Page 380: Draining Clutch Fluid
HYDRAULICALLY CONTROLLED CLUTCH Draining clutch fluid Connect a plastic hose to the bleed valve (1) and the loosen the valve turning it back 1 or 2 turns. Remove reservoir cap (2) and gasket (3) and operate the control lever (4) until draining all fluid. Part.
Page 381: Clutch Master Cylinder Servicing
HYDRAULICALLY CONTROLLED CLUTCH Clutch master cylinder servicing Drain the circuit, detach the master cylinder from the left side of the handlebar and take it apart. Replace all seals, reassemble the master cylinder and refit it to the handlebar. Reconnect the hose and fill fresh fluid into the reservoir; bleed the system as described in the relevant paragraph.
Page 382: Bleeding The Clutch System
HYDRAULICALLY CONTROLLED CLUTCH Bleeding the clutch system A long travel and mushy feel of the clutch lever indicate that there is air in the system and the clutch hydraulic system needs bleeding. Bleeding procedure is as follows: Take the rubber cap off the bleed valve (1). Attach a clear plastic hose to the bleed valve and place the other end of the hose in a vessel (make sure the hose end stays dipped in the fluid throughout the procedure).
Page 383: Optional Components
OPTIONAL COMPONENTS Section Part. N. 8000 H1489 (10-2009)
Page 384 OPTIONAL COMPONENTS OPTIONAL COMPONENTS (TC) Pos. Part No. Description 8F0096837 CHAIN SPROCKET Z=52 (1) 8D0096837 CHAIN SPROCKET Z=50 (1) 8C0096837 CHAIN SPROCKET Z=49 (1) 8000A7126 TRANSMISSION SPROCKET Z=12 (1) OPTIONAL COMPONENTS (TE) Pos. Part No. Description 8F0096837 CHAIN SPROCKET Z=52 (1) 8C0096837 CHAIN SPROCKET Z=49 (1) 8D0096837...
Page 385 OPTIONAL COMPONENTS OPTIONAL COMPONENTS (TXC) Pos. Part No. Description 8F0096837 CHAIN SPROCKET Z=52 (1) 8C0096837) CHAIN SPROCKET Z=49 (1) 8D0096837 CHAIN SPROCKET Z=50 (1) 8000A7126) TRANSMISSION SPROCKET Z=12 (1) Part. N. 8000 H1489 (10-2009)
Page 387: Fuel Injection System
FUEL INJECTION SYSTEM Section Part. N. 8000 H0368 (10-2009)
Page 388 FUEL INJECTION SYSTEM INJECTION FUEL FEEDING SYSTEM (TE-TXC) ........S.3 Operation Manual for "DIAGNOSTIC TOOL SOFTWARE KIT" for injection fuel feeding system (TE-TXC) ...........S.4 Fuel pump inspection (TE - TXC) ..............S.6 Relay inspection (TE - TXC) .................S.7 Part. N. 8000 H0368 (10-2009)
Page 389 FUEL INJECTION SYSTEM INJECTION FUEL FEEDING SYSTEM (TE-TXC) The injection fuel feeding system is composed of fuel tank (1), electric pump (2), pipe (3) and injector (4). The fuel in the tank is pumped by the pump. The pressurised fuel flows into the injector installed on the throttle body (6). The electronic control unit (5) located under the tank signals the injector to open and a fan-shaped spray of fuel is injected into the combustion chamber.
Page 390 FUEL INJECTION SYSTEM Operation Manual for "DIAGNOSTIC TOOL SOFTWARE KIT" for injection fuel feeding system The injection fuel feeding system does not require scheduled maintenance. The DIAGNOSTIC TOOL SOFTWARE KIT part no. 8B00 A9634 lets you test system components in the event of a malfunction. A malfunction is indicated by the word "FAIL"...
Page 391 FUEL INJECTION SYSTEM In addition to identifying any current malfunction, the software stores past malfunctions that have been resolved: store malfunc- tions can be deleted following the instructions provided in the Operation Manual. The ECU stores the number of service hours of the engine (toler- ance range: + / - 1 hour).
Page 392 FUEL INJECTION SYSTEM Fuel pump test (TE - TXC) Remove the pump as described on page S.2. A: fuel reserve sensor Make sure there is no fuel left in the sensor and then set the meter to the "Impedance" scale and measure across the BLUE and WHITE wires. Correct value is as follows: 1.3 KOhm (+/- 10%) at 20 °C.
Page 393 FUEL INJECTION SYSTEM Relay test (TE - TXC) Remove saddle and fuel tank as described in "Section E". Remove the relays (1) located on the R.H. side of the chassis. A: Set the meter to the "Impedance" scale and check the energiser coil for proper operation.
Page 395: Special Tools
SPECIAL TOOLS Section Part. N. 8000 H1489 (10-2009)
Page 396 SPECIAL TOOLS SPECIAL TOOLS 1 (8000 A7015) Crankcase puller 2 (8000 A1580) T.D.C. timing tool 3 (8000 A1559) Flywheel puller (TC) (8000 H2146) Flywheel puller (TE-TXC) 5 (8000 A7345) Jig (TC) (8000 A7345) Jig (TE-TXC) 6 (8000 H1807) USB pen drive 7 (8000 A7317) Valve installation / removal tool 8 (8000 A1625) Dial gauge mount 11 (8000 79015) Clutch hub tool...
Page 397: Tightening Torque Figures
TIGHTENING TORQUE FIGURES Section Tighten all nuts and screws to the specified torque using a torque wrench. If not tightened securely, a nut or a screw might become damaged or work itself loose, causing damage to motorcycle and injury to rider. An overtightened nut or screw might become damaged, its thread might strip, or the nut/screw might fail and work itself loose. Listed in the table are the tightening torque figures for the most important nuts and screws, which have determined in accordance with thread diameter, pitch and specific application. These figures are obtained after cleaning the threads with solvent. Part. N. 8000 H1489 (10-2009)
Page 398 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) ENGINE (8000 A7028) Cylinder head Screw TFEI M6x1-L30 10 Nm 1.02 Kgm Screw TFEI M6x1-L35 10 Nm 1.02 Kgm Screw TFEI M5-L30 5.5 Nm 0.56 Kgm Screw TFEI M5-L25 5.5 Nm 0.56 Kgm Screw TTEI M5x0.8 L.8 Blow-by labyrinth plate (+LOCTITE 243) 6 Nm 0.6 Kgm Special flanged screw L.23.4 Head cover and fuel 8 Nm 0.8 Kgm Special flanged screw L.31.3 Head cover 8 Nm 0.8 Kgm Water temperature sensor M10x1.25 5 Nm 0.5 Kgm Hole plug (water sensor) M10x1.25 8 Nm 0.8 Kgm...
Page 399 TIGHTENING TORQUE FIGURES Screw TCEI M5x0.8 L20 Oil pump body 6 Nm 0.6 Kgm Oil drain plug M14x1.5 25 Nm 2.55 Kgm Drilled screw TEF M8x1.25 (alumi- Pipe 8 Nm 0.8 Kgm nium) Oil filler plug Finger-tight Electrical System Screw TEF M6x1-CH8-L20 Coil to chassis 8 Nm 0.8 Kgm Screw TCEI M5-L12 Stator (use LOCTITE 272) 6 Nm 0.6 Kgm Screw TCEI M5-L20 Pick-up sensor (use LOCTITE 272) 6 Nm 0.6 Kgm Flanged nut M12x1 Flywheel 75 Nm 7.65 Kgm Screw TEF M6x1-CH8-L20 Regulator to chassis 8 Nm 0.8 Kgm Spark plug...
Page 400 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) CHASSIS (99669) 1 Nm = 0.73756 ft/lb NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows M5x0.8 5.6-6.2 Nm 0.57-0.63 Kgm 4.1-4.5 ft/lb M6x1 7.6-8.4 Nm 0.80-0.85 Kgm 5.8-6.1 ft/lb M8x1.25 24-26 Nm 2.4-2.6 Kgm 17.3-18.8 ft/lb Part. N. 8000 H1489 (10-2009)
Page 401 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) HANDLEBAR AND CONTROLS (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) FRONT SUSPENSION (99669) 1 Nm = 0.73756 ft/lb Part. N. 8000 H1489 (10-2009)
Page 402 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) REAR SUSPENSION (99669) 1 Nm = 0.73756 ft/lb Part. N. 8000 H1489 (10-2009)
Page 403 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) FAIRINGS AND MUDGUARDS (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) ELECTRICAL SYSTEM (99669) 1 Nm = 0.73756 ft/lb Part. N. 8000 H1489 (10-2009)
Page 404 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) FUEL SYSTEM (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) WHEELS AND BRAKES (99669) 1 Nm = 0.73756 ft/lb Part. N. 8000 H1489 (10-2009)
Page 405 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) EXHAUST (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) INSTRUMENTS (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) COOLING SYSTEM (99669) 1 Nm = 0.73756 ft/lb Part.
Page 406 TIGHTENING TORQUE FIGURES NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows (+/- 5%) Steel screws on plastic, with metal spacers M4 2 Nm 0.2 Kgm 1.45 ft/lb Steel screws on brass, copper, aluminium M4 2 Nm 0.2 Kgm 1.45 ft/lb Steel screws on iron, steel M4 3 Nm 0.3 Kgm 2.2 ft/lb Steel screws on plastic, with metal spacers 4 Nm 0.4 Kgm 3 ft/lb Steel screws on brass, copper, aluminium M5 4 Nm 0.4 Kgm...
Page 407: Chassis And Wheels
CHASSIS AND WHEELS Section Part. N. 8000 H1489 (10-2009)
Page 408 CHASSIS AND WHEELS Chassis ......................Y.3 Lubrication points (lubricant) ................ Y.4 Front wheel ....................Y.5 Front wheel removal ..................Y.6 Front wheel installation ................. Y.7 Rear wheel ....................Y.8 Rear wheel removal..................Y.9 Tightening torque figures ................Y.9 Wheel servicing ..................Y.10 Wheel axle warpage ...................
Page 409 CHASSIS AND WHEELS Chassis The single frame branches off at the exhaust and is made of steel tubes with circular, rectangular and ellipsoidal section; the rear chassis is made from light alloy. Refer to the figure for a quick inspection. Use the dimensions reported below to determine whether the chassis needs realigning or replacing.
Page 410: Lubrication Points (Lubricant)
CHASSIS AND WHEELS Lubrication points (lubricant) 1 Steering bearings (grease) Check the assemblies shown in the figure for cracks or damage. If any are found, replace the part. A ENGINE MOUNTING BOLTS B REAR CHASSIS MOUNTING BOLTS C CHAIN GUIDE ROLLER/BEARING D FOOTPEGS/PINS/SPRINGS Part.
Page 411 CHASSIS AND WHEELS Front wheel Light alloy wheel hub and rim with high-strength steel spokes. Make, type and size of wheel rims ......“TAKASAGO” Excel, light alloy: 1.6x21” (TC) Make, type and size of tyre........“Pirelli” 51R-MT 32A or Dunlop D756; 80/100 x 21” (TE - TXC) Make, type and size of tyre........"Michelin"...
Page 412 CHASSIS AND WHEELS Removing the front wheel Set a stand or a block under the engine and see that the front wheel is lifted from the ground. Loosen the bolts (1) holding the wheel axle (2) to the front fork mounts. Hold the head of the wheel axle in place, and unscrew the bolt (3) on the opposite side;...
Page 413 CHASSIS AND WHEELS Reassembling the front wheel Fit the L.H. spacer on the wheel hub. Fit the wheel between the fork legs so as to set the brake disc into the calliper. Fit the wheel axle (2) from the R.H. side, after greasing it and push it fully home against the L.H.
Page 414: Rear Wheel
CHASSIS AND WHEELS Rear wheel Light alloy wheel hub and rim with high-strength steel spokes. (TC) Make, type and size of wheel rims ....“TAKASAGO” Excel, light alloy: 1.85x19”; (TE - TXC) Make, type and size of wheel rims ....“TAKASAGO” Excel, light alloy: 2.15x18”;...
Page 415: Tightening Torque Figures
CHASSIS AND WHEELS Removing the rear wheel Set a stand or a block under the engine and see that the rear wheel is lifted from the ground. Unscrew the nut (1) of the wheel axle (3) and extract it. It is not necessary to loosen the chain tensioners (2);...
Page 416: Wheel Servicing
CHASSIS AND WHEELS Wheel servicing Check the wheel hub bearings for wear. If you find too much (radial or axial) clearance, replace the bearings as follows: place the hub on a flat surface with an appropriate hole (for when you knock out the bearing);...
Page 417: Wheel Spokes
CHASSIS AND WHEELS Wheel spokes Make sure all nipples are firmly tightened (4.4 Nm, 0.45 Kgm, 3.2 ft/lb). Re- tighten if needed. Improper tightening will affect motorcycle stability; for a quick check, simply tap the spokes with the tip of a metal tool (such as a screwdriver): a clear, crisp sound indicates proper tightening, a dull sound means that the spokes need to be tightened.
Page 418: Rear Chain Sprocket, Secondary Drive Sprocket And Chain
CHASSIS AND WHEELS Rear chain sprocket, secondary drive sprocket and chain The figure at the side shows the profiles of a normally worn and an exceedingly worn sprocket. 1 Normal wear 2 Exceeding wear If the sprocket is exceedingly worn, replace it after loosening the six screws that retain it to the hub.
Page 419: Checking Chain And Sprockets For Wear
CHASSIS AND WHEELS Checking chain and sprockets for wear Check chain wear as follows: turn the adjuster screws to stretch the chain taut; mark 20 chain links; measure distance “A” (centre distance between 1st and 21st link). Check the transmission sprocket for damage or wear. When worn down like the sprocket shown in the figure, it must be replaced.

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Tc 250 2009 Txc 250 2010

Husqvarna TC 250 2010 Workshop Manual

Table of Contents

Table of Contents

Settings and Adjustments

General Procedures

Engine Disassembly

Table of Contents

Table of Contents

Table of Contents

Rear Suspension

Brakes

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Quick Links

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Troubleshooting

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