Husqvarna TC 50 Owner's Manual
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Husqvarna TC 50 Owner's Manual

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OWNER'S MANUAL 2018
TC 50
TC 50 Mini
Art. no. 3402161en

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Summary of Contents for Husqvarna TC 50

  • Page 1 OWNER'S MANUAL 2018 TC 50 TC 50 Mini Art. no. 3402161en...
  • Page 3 DEAR HUSQVARNA MOTORCYCLES CUSTOMER Congratulations on your decision to purchase a Husqvarna motorcycle. You are now the owner of a state-of- DEAR HUSQVARNA MOTORCYCLES CUSTOMER the-art sports motorcycle that will give you and your child enormous pleasure if you service and maintain it accordingly.

  • Page 4: Table Of Contents

    Stopping, parking ....... 25 Protective clothing ........ 8 Transporting........26 Work rules..........8 Refueling ..........26 Environment.......... 8 Filling up with oil (TC 50 Mini) ..... 27 2.10 Owner's Manual........8 SERVICE SCHEDULE........28 IMPORTANT NOTES ......... 9 Additional information......28 Manufacturer and implied warranty ..
  • Page 5 TABLE OF CONTENTS 10.16 Adjusting the handlebar position ..40 11.38 Checking the chain for dirt....68 10.17 Adjusting the seat height ....41 11.39 Cleaning the chain ......69 11.40 Checking the chain tension ....69 SERVICE WORK ON THE CHASSIS ....43 11.41 Adjusting the chain tension....
  • Page 6 ..........101 15.4 Carburetor - idle (TC 50) ....101 LIST OF ABBREVIATIONS ......131 15.5 Carburetor - idle (TC 50 Mini) ... 102 INDEX ..............132 Carburetor – adjusting the idle 15.6 speed (TC 50)........ 102 Carburetor – adjusting the idle 15.7...

  • Page 7: Means Of Representation

    1 MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of the safety of your child, have these jobs performed in an authorized Husq- varna Motorcycles workshop.

  • Page 8: Safety Advice

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

  • Page 9: Tampering Warning

    Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. Have malfunctions that impair safety promptly eliminated by an authorized Husqvarna Motorcycles workshop. Adhere to the information and warning labels on the vehicle.

  • Page 10: Protective Clothing

    – When you ride a motorcycle, set an example for your child and wear suitable protective clothing. In the interest of your child’s safety, Husqvarna Motorcycles recommends that only operating the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the number in parentheses.

  • Page 11: Important Notes

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

  • Page 12: Customer Service

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

  • Page 13: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) A00076-10 Filler cap Quick release of seat Chain guide Plug-in stand ( p. 18) Choke Fuel tap ( p. 17)

  • Page 14: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) A00077-10 Kill switch ( p. 15) Throttle grip ( p. 15) Hand brake lever ( p. 15) Chassis number ( p. 13) Kick starter ( p. 18) Foot brake lever ( p.

  • Page 15: Serial Numbers

    5 SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steer- ing head. 401945-10 Type label The type label is located on the front frame tube. 402154-10 Engine number The engine number is located on the left side of the engine under the engine sprocket.

  • Page 16: Shock Absorber Article Number

    The shock absorber article number is stamped on the bottom of the shock absorber toward the right-hand side. H01186-10 (TC 50 Mini) The shock absorber article number is stamped on the top of the shock absorber toward the rear. 0 0 1...

  • Page 17: Controls

    6 CONTROLS Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The hand brake lever is used to activate the front brake. K00657-10 Throttle grip Throttle grip is fitted on the right side of the handlebar. K00657-11 Kill switch Kill switch...

  • Page 18: Closing The Filler Cap

    Mount the filler cap and turn it clockwise until the fuel tank is firmly closed. Info Route fuel tank breather hose without kinks. K00648-11 Opening oil tank cap (TC 50 Mini) – Turn the oil tank cap counterclockwise and pull it up. A00092-10...

  • Page 19: Closing Oil Tank Cap (Tc 50 Mini)

    6 CONTROLS Closing oil tank cap (TC 50 Mini) – Put the oil tank cap on and turn it clockwise. Info Run the oil tank breather hose without kinks. A00092-11 Fuel tap Fuel tap is on the left of the fuel tank.

  • Page 20: Kick Starter

    6 CONTROLS Possible states Choke function activated – The choke lever is pushed up all • the way to the stop. Choke function deactivated – The choke lever is pushed • down all the way to the stop. 6.11 Kick starter Kick starter is fitted on the right side of the engine.

  • Page 21: Service Hour Counter

    6 CONTROLS 6.14 Service hour counter Service hour counter is attached to the tail section under the left-hand side cover. It shows the total number of service hours of the engine. The service hour counter begins counting when the engine is started and stops when the engine is switched off.

  • Page 22: Preparing For Use

    7 PREPARING FOR USE Advice on first use Warning Danger of accidents A lack of physical and mental readiness on the part of the child poses a major risk. Children often underestimate or fail to recognize dangerous situations. – Your child must already be able to ride a bicycle. –...
  • Page 23 When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized Husqvarna Motorcy- cles workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.

  • Page 24: Running In The Engine

    7 PREPARING FOR USE Running in the engine – During the running-in phase, do not exceed the specified engine performance. Guideline Maximum engine performance During the first 3 operating hours < 70 % During the first 5 operating hours < 100 % –...

  • Page 25: Riding Instructions

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

  • Page 26: Starting Off

    The engine is cold (TC 50) – Pull the choke knob fully out and turn it by max. ¼ turn. (TC 50 Mini) – Push the choke lever up all the way to the stop. – Forcefully step on the kick starter, pushing it all the way forward.

  • Page 27: Applying The Brakes

    – Check the brake system and do not allow your child to continue riding until the problem is elimi- nated. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 28: Transporting

    8 RIDING INSTRUCTIONS Transporting Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. –...

  • Page 29: Filling Up With Oil (Tc 50 Mini)

    128) – Close the filler cap. ( p. 16) Filling up with oil (TC 50 Mini) Warning Engine damage The engine will not be lubricated unless there is 2-stroke oil in the oil tank. – For a full fuel tank, fill the oil tank at least up to the MINmark.

  • Page 30: Service Schedule

    9 SERVICE SCHEDULE Additional information Any further work that results from the required work or from the recommended work must be ordered sepa- rately and can be invoiced separately. Different service intervals may apply in your country, depending on the local operating conditions. Required work Every 80 operating hours Every 40 operating hours...

  • Page 31: Recommended Work

    ● Final check: Check the vehicle for safe operation and take a test ride. ○ ● ● ● Make the service entry in Husqvarna Motorcycles Dealer.net and in the Service and War- ranty Booklet. ○ One-time interval ● Periodic interval...

  • Page 32: Tuning The Chassis

    – On delivery, Husqvarna offroad motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 25 …...

  • Page 33: Compression Damping Of The Shock Absorber (Tc 50)

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

  • Page 34: Adjusting The High-Speed Compression Damping Of The Shock Absorber (Tc 50)

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber.
  • Page 35 K00659-10 Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping; turn counter- clockwise to reduce damping. (TC 50 Mini) – Raise the motorcycle with a lift stand. ( p. 43) – Remove nut V00257-10 – Remove screw –...

  • Page 36: Measuring Rear Wheel Sag Unloaded

    – Check the static sag. Static sag (TC 50) 12 mm (0.47 in) Static sag (TC 50 Mini) 10 mm (0.39 in) 0 0 B » If the static sag is less or more than the specified value: –...

  • Page 37: Checking The Riding Sag Of The Shock Absorber

    Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor- rectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Preparatory work (TC 50) –...
  • Page 38 Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring pretension. – Tighten retaining ring (TC 50 Mini) – Measure the full spring length while it is under tension and note down the value. –...

  • Page 39: Adjusting The Riding Sag

    B00292-10 Weight of rider: 35 … 40 N/mm (228 lb/in) 45 kg (77 … 99 lb.) Spring rate (TC 50 Mini) Weight of rider: 15 … 65 N/mm (371 lb/in) 25 kg (33 … 55 lb.) Weight of rider (stan- 75 N/mm (428 lb/in) dard): 25 …...

  • Page 40: Checking The Basic Setting Of The Fork

    However, if the fork frequently bottoms out (hard end stop on compression), harder springs must be fitted to avoid damage to the fork and frame. 10.13 Adjusting the fork air pressure (TC 50) Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling charac- teristic.

  • Page 41: Adjusting The Rebound Damping Of The Fork (Tc 50)

    80 seconds. – Mount the protection cap. Finishing work – Remove the motorcycle from the lift stand. ( p. 43) 10.14 Adjusting the rebound damping of the fork (TC 50) Info The hydraulic rebound damping determines the fork suspension behavior.

  • Page 42: Handlebar Position

    10 TUNING THE CHASSIS – Turn adjusting screw clockwise all the way. Info Adjusting screw is located at the upper end of the right fork leg. – Turn counterclockwise by the number of clicks correspond- ing to the fork type. Guideline S01479-10 Rebound damping...

  • Page 43: Adjusting The Seat Height

    10 TUNING THE CHASSIS – Place the handlebar support in the required position. Mount and tighten screws Guideline Screw, handle- 40 Nm (29.5 lbf ft) ® Loctite 243™ bar support – Position the handlebar. Info Make sure the cables and wiring are positioned cor- rectly.
  • Page 44 10 TUNING THE CHASSIS – Mount nut and tighten fitting. Guideline Screw, top 45 Nm (33.2 lbf ft) ® Loctite 243™ shock absorber A00095-10 Finishing work – Remove the motorcycle from the lift stand. ( p. 43)

  • Page 45: Service Work On The Chassis

    Bleeding the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 43) Main work (TC 50) – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws.

  • Page 46: Cleaning The Dust Boots Of The Fork Legs

    11 SERVICE WORK ON THE CHASSIS (TC 50 Mini) – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. H01183-11 Finishing work – Remove the motorcycle from the lift stand. ( p.

  • Page 47: Removing The Fork Protector

    11 SERVICE WORK ON THE CHASSIS 11.5 Removing the fork protector – Remove screws and take off the clamp. – Remove screws on the left fork leg. Take off the fork pro- tector. A00079-10 – Remove screws on the right fork leg. Take off the fork protector.

  • Page 48: Removing The Fork Legs

    – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. H01853-10 (TC 50 Mini) – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg.
  • Page 49 – Tighten screws Guideline Screw, bottom 15 Nm (11.1 lbf ft) triple clamp H01853-11 (TC 50 Mini) – Position the fork legs. Bleeder screws are positioned toward the front. Info The second milled groove (from the top) must be flush with the top edge of the upper triple clamp.

  • Page 50: Removing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS 11.9 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 43) – Remove the front wheel. p. 90) – Remove the fork legs. p. 46) – Remove the start number plate.
  • Page 51 – Position the upper triple clamp with the handlebar. – Mount nut , but do not tighten it yet. H01857-10 (TC 50) – Position the fork legs. Bleeder screws are positioned toward the rear. Info The second milled groove (from the top) must be flush with the top edge of the upper triple clamp.

  • Page 52: Tighten Screws Guideline Screw, Top Triple Clamp

    11 SERVICE WORK ON THE CHASSIS Guideline Screw, top triple 20 Nm (14.8 lbf ft) clamp (TC 50 Mini) – Position the fork legs. Bleeder screws are positioned toward the front. Info The second milled groove (from the top) must be flush with the top edge of the upper triple clamp.

  • Page 53: Checking Play Of Steering Head Bearing

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

  • Page 54: Adjusting The Steering Head Bearing Play

    Tighten screws Guideline Screw, top triple 20 Nm (14.8 lbf ft) clamp – Position the fuel tank breather in the steering stem. (TC 50 Mini) – Pull fuel tank breather out of the steering stem. – Loosen screws – Loosen screw –...

  • Page 55: Greasing The Steering Head Bearing

    11 SERVICE WORK ON THE CHASSIS Guideline Nut, steering M20x1.5 10 Nm (7.4 lbf ft) head Nut, steering M20x1.5 9 Nm (6.6 lbf ft) Only applies when head using: Holding wrench for steering head bearing (45229050000) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.

  • Page 56: Installing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. –...

  • Page 57: Removing The Start Number Plate

    11 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. –...

  • Page 58: Installing The Start Number Plate

    11 SERVICE WORK ON THE CHASSIS 11.17 Installing the start number plate – Attach the start number plate to the brake line. – Position the start number plate. Holding lugs engage in the fender. A00104-10 – Mount and tighten screw Guideline Screw, start number 4 Nm (3 lbf ft)

  • Page 59: Removing The Right Side Cover

    11 SERVICE WORK ON THE CHASSIS – Position front fender. Mount and tighten screws Guideline Screw, fender 6 Nm (4.4 lbf ft) K00665-11 11.20 Removing the right side cover Preparatory work – Remove the seat. ( p. 63) Condition Right side cover secured. –...

  • Page 60: Installing The Right Side Cover

    11 SERVICE WORK ON THE CHASSIS 11.21 Installing the right side cover Main work – Position the side cover on collar bushings , and push toward the rear. – Engage the side cover in areas K00684-10 Condition Right side cover secured. –...

  • Page 61: Securing Right Side Cover

    11 SERVICE WORK ON THE CHASSIS 11.22 Securing right side cover Preparatory work – Remove the seat. ( p. 63) – Remove the right side cover. ( p. 57) Main work – Drill a hole at marking Guideline Diameter 6.5 mm (0.256 in) S01545-10 Finishing work –...

  • Page 62: Installing The Left Side Cover

    11 SERVICE WORK ON THE CHASSIS – Pull off the side cover sideways in areas , and remove toward the front. K00682-10 11.24 Installing the left side cover Main work – Position the side cover on collar bushings , and push toward the rear.

  • Page 63: Securing Left Side Cover

    Removing the shock absorber Preparatory work (TC 50) – Raise the motorcycle with a lift stand. ( p. 43) (TC 50 Mini) – Raise the motorcycle with a lift stand. ( p. 43) – Remove the rear wheel. p. 91)

  • Page 64: Installing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS (TC 50 Mini) – Remove nut A00098-10 – Remove screw and lower the swingarm carefully. – Remove screw , push splash protector to the side, and remove the shock absorber. A00099-10 11.27 Installing the shock absorber Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride...

  • Page 65: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS (TC 50 Mini) – Push splash protector to the side. – Position the shock absorber with screw , depending on the desired seating height. – Raise the swingarm; position the shock absorber with screw A00099-11 –...

  • Page 66: Removing The Air Filter

    11 SERVICE WORK ON THE CHASSIS – Close quick release K00654-11 11.30 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. –...

  • Page 67: Cleaning The Air Filter And Air Filter Box

    11 SERVICE WORK ON THE CHASSIS 11.32 Cleaning the air filter and air filter box Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam.

  • Page 68: Installing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS Main work – Remove screw – Remove screw – Pull off the main silencer from the manifold at rubber sleeve K00673-10 11.34 Installing the main silencer Main work – Mount the main silencer with rubber sleeve –...

  • Page 69: Removing The Engine Sprocket Cover

    Raise the motorcycle with a lift stand. ( p. 43) Main work (TC 50) – Remove screws – Remove screw – Take off the engine sprocket cover. A00080-10 (TC 50 Mini) – Remove screws – Remove screw – Take off the engine sprocket cover. A00100-10...

  • Page 70: Installing The Engine Sprocket Cover

    – A00080-10 Tighten screws Guideline Screw, engine 12 Nm (8.9 lbf ft) sprocket cover (TC 50 Mini) – Position the engine sprocket cover. Mount screws do not tighten yet. – Mount and tighten screw Guideline Screw, engine 12 Nm (8.9 lbf ft) sprocket cover –...

  • Page 71: Cleaning The Chain

    11 SERVICE WORK ON THE CHASSIS 11.39 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. – Remove the lubricant from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...

  • Page 72: Adjusting The Chain Tension

    » If the chain tension does not meet the specification: – Adjust the chain tension. ( p. 70) (TC 50 Mini) – Press the chain upward at the end of the chain sliding piece and determine chain tension Info The upper part of the chain must be taut.

  • Page 73: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    11 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Adjust the chain tension by turning adjusting nuts left and right. Guideline Chain tension 5 … 8 mm (0.2 … 0.31 in) Turn adjusting nuts equally on the left and right. The rear wheel must be aligned with the front wheel.
  • Page 74 11 SERVICE WORK ON THE CHASSIS Info When a new chain is mounted, the rear sprocket and engine sprocket should also be changed. New chains wear out faster on old, worn sprockets. – Check the chain sliding guard for wear. »...

  • Page 75: Adjusting The Chain Guide

    11 SERVICE WORK ON THE CHASSIS – Check the chain guide for wear. Info Wear can be seen on the front of the chain guide. » If the light part of the chain guide is worn: – Change the chain guide. 400985-01 –...

  • Page 76: Checking The Frame

    – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by Husqvarna S00876-01 Motorcycles. 11.45 Checking the swingarm – Check the swingarm for damage, cracking, and deformation.

  • Page 77: Checking The Rubber Grip

    11 SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. The throttle cable must be routed to the carburetor behind the handlebars and underneath the fuel tank bracket. The throttle cable must be fixed on the fuel tank bracket with a rubber band.

  • Page 78: Brake System

    12 BRAKE SYSTEM 12.1 Checking play of handbrake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. –...

  • Page 79: Checking The Brake Discs

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

  • Page 80: Checking The Front Brake Fluid Level

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

  • Page 81: Adding Front Brake Fluid

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

  • Page 82: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 83 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 84 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.

  • Page 85: Checking The Free Travel Of The Foot Brake Lever

    12 BRAKE SYSTEM – Position the brake caliper. – Mount and tighten screw Guideline Screw, brake linings 8 Nm (5.9 lbf ft) – Mount lock washer – Mount and tighten screws Guideline Screw, front M8x60 20 Nm (14.8 lbf ft) A00089-10 ®...

  • Page 86: Adjusting The Free Travel Of The Foot Brake Lever

    12 BRAKE SYSTEM 12.10 Adjusting the free travel of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

  • Page 87: Checking The Rear Brake Fluid Level

    – Check the brake system and ensure that nobody drives the vehicle before the problem is elimi- nated. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect.
  • Page 88 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 89: Checking The Rear Brake Linings

    Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 90 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 91 12 BRAKE SYSTEM – Remove screws – Take off cover with washer and membrane – Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir, sucking it away if necessary. H01448-11 –...

  • Page 92: Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 43) Main work – Remove screw – Loosen screws A00086-10 Warning Danger of accidents Damaged brake discs reduce the braking effect. –...

  • Page 93: Removing The Rear Wheel

    13 WHEELS, TIRES – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change front wheel bearing. – Clean and grease the contact surfaces of the spacers. Long-life grease ( p. 129) –...

  • Page 94: Installing The Rear Wheel

    13 WHEELS, TIRES Warning Danger of accidents Damaged brake discs reduce the braking effect. – Always lay the wheel down in such a way that the brake disc is not damaged. – Take the rear wheel out of the swingarm. Info Do not operate the foot brake lever when the rear wheel is removed.

  • Page 95: Checking The Tire Condition

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

  • Page 96: Checking Tire Air Pressure

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized Husqvarna Motorcycles workshop will be glad to help.)
  • Page 97 13 WHEELS, TIRES – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diameter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indica- tion of different spoke tensions.

  • Page 98: Cooling System

    14 COOLING SYSTEM 14.1 Cooling system The water pump in the engine forces the coolant to flow. The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 99: Checking The Coolant Level

    14 COOLING SYSTEM – Check the coolant level in the radiator. 10 mm (0.39 in) Coolant level above the radiator fins » If the coolant level does not match the specified value: – Correct the coolant level. Coolant ( p. 127) –...

  • Page 100: Draining The Coolant

    14 COOLING SYSTEM 14.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
  • Page 101 14 COOLING SYSTEM Main work – Make sure that screw is tightened. – Position the motorcycle upright. – Add coolant to level Guideline 10 mm (0.39 in) Distance above the radi- ator fins Coolant 0.7 l (0.7 qt.) Coolant ( p.

  • Page 102: Tuning The Engine

    15 TUNING THE ENGINE 15.1 Checking the installation position of the throttle grip Warning Danger of accidents The throttle cable may slip out of the guide if the throttle grip installation posi- tion is incorrect. The throttle slide will then no longer be closed and the speed can no longer be controlled. –...

  • Page 103: Adjusting The Play In The Throttle Cable

    Check the play in the throttle cable. ( p. 100) 15.4 Carburetor - idle (TC 50) The idle setting of the carburetor has a big influence on the start- ing behavior, stable idling, and the response to throttle opening. This means that an engine with a correctly set idle speed is eas- ier to start than if the idle speed is set wrongly.

  • Page 104: Carburetor - Idle (Tc 50 Mini)

    The idle mixture is adjusted with the idle mixture adjusting screw 15.5 Carburetor - idle (TC 50 Mini) The idle setting of the carburetor has a big influence on the start- ing behavior, stable idling, and the response to throttle opening.

  • Page 105: Carburetor - Adjusting The Idle Speed (Tc 50 Mini)

    Following extreme air temperature or altitude changes, adjust the idle speed again. Carburetor – adjusting the idle speed 15.7 (TC 50 Mini) – Screw in idle air adjusting screw all the way and turn it to the specified basic position.

  • Page 106: Checking The Clutch Setting

    15 TUNING THE ENGINE – Turn idle air adjusting screw slowly in a clockwise direc- tion until the idle speed begins to fall. – Note the position and turn the idle air adjusting screw slowly counterclockwise until the idle speed again begins to fall. –...

  • Page 107: Removing The Clutch Cover

    15 TUNING THE ENGINE Guideline ≤ 3 s – Read the speed. Slip speed 8,700 … 9,300 rpm » If the specified value is not reached: – Adjust the clutch. p. 105) 15.9 Removing the clutch cover Warning Environmental hazard Improper handling of fuel is a danger to the environment. –...
  • Page 108 15 TUNING THE ENGINE Main work – Turn the outer clutch hub until adjusting screws become accessible. V00539-10 Condition If there is no reference point: – Turn adjusting screws counterclockwise to the last detectable click. – Turn adjusting screws clockwise by 9 clicks to the basic setting.

  • Page 109: Installing The Clutch Cover

    15 TUNING THE ENGINE 15.11 Installing the clutch cover Main work – Position clutch cover with the seal ring. – Mount and tighten screws Guideline Screw, clutch cover 10 Nm (7.4 lbf ft) V00538-11 Finishing work – Check the gear oil level. ( p.

  • Page 110: Service Work On The Engine

    16 SERVICE WORK ON THE ENGINE 16.1 Checking oil level (TC 50 Mini) Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Check the oil level in the oil tank. For a full fuel tank, the oil tank must be filled up toMIN mark at a minimum.

  • Page 111: Checking The Gear Oil Level

    The engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work (TC 50 Mini) – Remove screw – Check the gear oil level. A small quantity of gear oil must run out of the drilled hole.

  • Page 112: Changing The Gear Oil

    Drain gear oil with engine at operating temperature. Preparatory work – Stand the motorcycle on the plug-in stand on a horizontal surface. Main work (TC 50 Mini) – Place a suitable container under the engine. – Remove oil drain plug with the magnet.

  • Page 113: Adding Gear Oil

    16 SERVICE WORK ON THE ENGINE (TC 50) – Place a suitable container under the engine. – Remove oil drain plug with the magnet. – Let the gear oil drain fully. – Thoroughly clean the oil drain plug with magnet.
  • Page 114 16 SERVICE WORK ON THE ENGINE Main work (TC 50) – Remove screw for checking gear oil level A00081-10 (TC 50 Mini) – Remove screw for checking gear oil level A00102-10 – Remove filler plug – Add gear oil until it flows out of the hole of the gear oil level screw.

  • Page 115: Cleaning, Care

    17 CLEANING, CARE 17.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 116 17 CLEANING, CARE – Push back the protection caps on the handlebar controls to allow water to evaporate. – After the motorcycle has cooled off, lubricate all moving parts and bearings. – Clean the chain. ( p. 69) – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor.

  • Page 117: Storage

    94) 401058-01 – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info Husqvarna Motorcycles recommends raising the motorcycle. – Raise the motorcycle with a lift stand. ( p. 43) – Cover the vehicle with a tarp or similar cover that is perme- able to air.

  • Page 118: Preparing For Use After Storage

    18 STORAGE 18.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 43) – Perform checks and maintenance measures when preparing for use. ( p. 23) – Take a test ride. 401059-01...

  • Page 119: Troubleshooting

    Check the fuel tank breather. – Clean the fuel tap. (TC 50) – Check/set the carburetor compo- nents. (TC 50 Mini) – Check/set the carburetor compo- nents. – Spark plug oily or wet Clean and dry the spark plug, or change it if necessary.
  • Page 120 The carburetor is flowing over (TC 50) – Check/set the carburetor compo- because the float needle is nents. dirty or worn (TC 50 Mini) – Check/set the carburetor compo- nents. Loose carburetor jets (TC 50) – Check/set the carburetor compo- nents.
  • Page 121 19 TROUBLESHOOTING Faults Possible cause Action – Engine overheats Damaged cylinder head or Check the cylinder head or cylinder cylinder head gasket head gasket. – Bent radiator hose Change the radiator hose. – White smoke emission (steam Damaged cylinder head or Check the cylinder head or cylinder in exhaust gas) cylinder head gasket...

  • Page 122: Technical Data

    Screw, bearing retainer 5 Nm (3.7 lbf ft) Screw, kickstarter 6 Nm (4.4 lbf ft) ® Loctite 243™ Screw, oil pump (TC 50 Mini) 6 Nm (4.4 lbf ft) Screw, stator clamp 6 Nm (4.4 lbf ft) ® Loctite 222™...

  • Page 123: Carburetor With Carburetor Tuning

    3 turns Main jet Jet needle Idling jet Needle jet 262AU Throttle slide Cold start jet 20.3.2 TC 50 Mini Carburetor type Dell`Orto PHVA 12XS Needle position 3rd position from top Idle air adjusting screw Open 1 turn Main jet...

  • Page 124: Capacities

    Fuel tank capacity, approx. 2.3 l (2.4 qt.) Super unleaded (95 octane) mixed (TC 50) with 2-stroke engine oil (1:60) p. 128) Fuel tank capacity, approx. (TC 50 2.1 l (2.2 qt.) Super unleaded (ROZ 95/RON Mini) 95/PON 91) ( p. 128) 20.5...

  • Page 125: Tires

    252 mm (9.92 in) Ground clearance unloaded (TC 50 Mini) 184 mm (7.24 in) Weight without fuel, approx. (TC 50) 41.5 kg (91.5 lb.) Weight without fuel, approx. (TC 50 Mini) 40 kg (88 lb.) 20.6 Tires Validity Front tire...

  • Page 126: Shock Absorber

    Riding sag 80 mm (3.15 in) Fitted length 275 mm (10.83 in) Shock absorber oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 128) 20.8.2 TC 50 Mini Shock absorber article number 03.18.9Q.01 Shock absorber WP Performance Systems 3614 BAEM...

  • Page 127: Chassis Tightening Torques

    20 TECHNICAL DATA Rebound damping Standard 12 clicks Spring preload Standard 5 mm (0.2 in) Spring rate Weight of rider: 15 … 25 kg (33 … 55 lb.) 65 N/mm (371 lb/in) Weight of rider (standard): 25 … 35 kg (55 … 75 N/mm (428 lb/in) 77 lb.) Weight of rider: 35 …...
  • Page 128 20 TECHNICAL DATA Screw, front brake caliper M8x60 20 Nm (14.8 lbf ft) ® Loctite 243™ Screw, handlebar clamp 20 Nm (14.8 lbf ft) Screw, rear sprocket 25 Nm (18.4 lbf ft) ® Loctite 243™ Screw, top triple clamp 20 Nm (14.8 lbf ft) Nut, swingarm pivot 45 Nm (33.2 lbf ft) Remaining nuts, chassis...

  • Page 129: Substances

    21 SUBSTANCES Brake fluid DOT 4 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties. Recommended supplier Bel‑Ray ® – Super DOT 4 Brake Fluid Coolant Guideline –...
  • Page 130 21 SUBSTANCES Gear oil (SAE 75W) Standard/classification – SAE ( p. 130) (SAE 75W) Guideline – Use only gear oils that comply with the specified standards (see specifications on the container) and that exhibit the required properties. Recommended supplier Bel‑Ray ®...

  • Page 131: Auxiliary Substances

    22 AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel‑Ray – Foam Filter Cleaner & Degreaser Grip adhesive (00062030051) Recommended supplier KTM AG – GRIP GLUE High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier ®...

  • Page 132: Standards

    23 STANDARDS JASO FD JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions. The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity.

  • Page 133: List Of Abbreviations

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

  • Page 134: Index

    INDEX INDEX Chassis number ..... . 13 Choke ......17 Accessories .
  • Page 135 INDEX Fork part number ..... 13 removing ......65 Fork protector Misuse .
  • Page 136 INDEX Rubber grip engine tightening torques ... . . 120 checking ......75 fork .
  • Page 137 *3402161en* 3402161en 05/2017 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer, www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...

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