Husqvarna TC 125 2021 Owner's Manual
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Husqvarna TC 125 2021 Owner's Manual

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OWNER'S MANUAL 2021
TC 125
Art. no. 3402439en

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Summary of Contents for Husqvarna TC 125 2021

  • Page 1 OWNER'S MANUAL 2021 TC 125 Art. no. 3402439en...
  • 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, sporty motorcycle that you will continue to enjoy for a long time if you maintain it properly.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS PREPARING FOR USE........20 MEANS OF REPRESENTATION......5 Advice on preparing for first use..20 Symbols used ........5 Running in the engine ......21 Formats used ........5 Preparing the vehicle for difficult SAFETY ADVICE ..........
  • Page 5 TABLE OF CONTENTS 10.10 Adjusting the spring preload of the 11.32 Removing the fuel tank ....64 shock absorber ....... 39 11.33 Installing the fuel tank ..... 65 10.11 Adjusting the riding sag ....40 11.34 Checking the chain for dirt....67 10.12 Checking the basic setting of the 11.35 Cleaning the chain ......
  • Page 6 TABLE OF CONTENTS 14.5 Checking the antifreeze and coolant 20.9 Chassis tightening torques ....123 level............. 96 SUBSTANCES..........126 14.6 Checking the coolant level....97 AUXILIARY SUBSTANCES......128 14.7 Draining the coolant ......98 14.8 Refilling with coolant ....... 98 STANDARDS ..........

  • Page 7: Means Of Representation 1

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interests of your own safety, have these jobs performed by an authorized Husqvarna Motorcycles workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports 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 immediately eliminated by an authorized Husqvarna Motorcycles work- shop. Adhere to the information and warning labels on the vehicle.

  • Page 10: Protective Clothing

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, Husqvarna Motorcycles recommends that you only operate the vehicle while wearing protective clothing. Work rules Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).

  • Page 11: Important Notes 3

    IMPORTANT NOTES 3 Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized Husqvarna Motorcy- cles workshop and confirmed in the Husqvarna Motorcycles Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer 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 4 View of vehicle, front left (example) S04233-10 Hand brake lever ( p. 15) Clutch lever ( p. 15) Air filter box cover Shift lever ( p. 17) Fuel tap ( p. 17)

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

    4 VIEW OF VEHICLE View of vehicle, rear right (example) S04234-10 Seat Fuel tank filler cap Switch-off button ( p. 15) Throttle grip ( p. 15) Kick starter lever ( p. 18) Foot brake lever ( p. 18) Shock absorber compression adjustment Level viewer for brake fluid, rear Shock absorber rebound adjustment...

  • Page 15: Serial Numbers 5

    SERIAL NUMBERS 5 Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number The engine number is located on the left side of the engine under the engine sprocket.

  • Page 16: Shock Absorber Article Number

    5 SERIAL NUMBERS Shock absorber article number The shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 401948-10...

  • Page 17: Controls 6

    CONTROLS 6 Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. S03435-10 Hand brake lever The hand brake lever is located on the right side of the han- dlebar.

  • Page 18: Opening Fuel Tank Filler Cap

    6 CONTROLS Opening fuel tank filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 19: Fuel Tap

    CONTROLS 6 Fuel tap The fuel tap is on the left side of the fuel tank. Open or close the supply of fuel to the carburetor using tap han- on the fuel tap. Possible states Fuel supply closed OFF – Fuel cannot flow from the fuel •...

  • Page 20: Kick Starter Lever

    6 CONTROLS The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears. 401950-11 6.10 Kick starter lever Kick starter lever is fitted on the right side of the engine. The kick starter lever can be swiveled.

  • Page 21: Service Hour Counter

    CONTROLS 6 6.13 Service hour counter The service hour counter is fitted in front of the handlebar. 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. Info The value indicated by the service hour counter cannot be cleared or adjusted.

  • Page 22: Preparing For Use

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-sale inspection work has been carried out by an authorized Husqvarna Motorcycles workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 23: Running In The Engine

    PREPARING FOR USE 7 – Adjust the basic position of the hand brake lever. ( p. 77) – Adjust the basic position of the foot brake lever. p. 83) – Set the basic position of the shift lever. p. 108) –...

  • Page 24: Preparing Vehicle For Rides On Dry Sand

    In the event of scalding, rinse the area affected immediately with lukewarm water. – Change the radiator cap. – Mount the air filter dust cover. Air filter dust cover (79006920000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01272-01...

  • Page 25: Preparing Vehicle For Rides On Wet Sand

    PREPARING FOR USE 7 – Mount the air filter sand cover. Air filter sand cover (79006922000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01273-01 – Adjust the carburetor jetting and setting. Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop.
  • Page 26 – Change the radiator cap. – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01274-01 – Adjust the carburetor jetting and setting. Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop.

  • Page 27: Preparing Vehicle For Rides On Wet And Muddy Circuits

    Preparing vehicle for rides on wet and muddy circuits – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01274-01 – Adjust the carburetor jetting and setting. Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop.

  • Page 28: Preparing Vehicle For Low Temperatures Or Snow

    97) Preparing vehicle for low temperatures or snow – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01274-01 – Adjust the carburetor jetting and setting. Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop.

  • Page 29: Riding Instructions 8

    RIDING INSTRUCTIONS 8 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 30: Starting Off

    Do not change into a low gear at high engine speed. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an autho- rized Husqvarna Motorcycles workshop. First gear is used for starting off and for steep inclines. –...

  • Page 31: Applying The Brakes

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

  • Page 32: Transporting

    8 RIDING INSTRUCTIONS – Park the vehicle on a firm and level surface. – Ensure that nobody sits on the vehicle when the vehicle is parked on a stand. Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. –...

  • Page 33: Refueling

    RIDING INSTRUCTIONS 8 Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling.

  • Page 34: Service Schedule

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up- to-date service schedule can always be found on Husqvarna Motorcycles Dealer.net. Your authorized Husq- varna Motorcycles dealer will be glad to advise you.

  • Page 35: Recommended Work

    ● Final check: Check the vehicle for operating safety and take a test ride. ○ ● ● ● ● Make a service entry in the Husqvarna Motorcycles Dealer.net. ○ One-time interval ● Periodic interval Recommended work after every race Every 40 operating hours...

  • Page 36: 10 Tuning The Chassis

    – In the delivered condition, Husqvarna motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 75 …...

  • Page 37: Compression Damping Of The Shock Absorber

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

  • Page 38: Adjusting The High-Speed Compression Damping Of The Shock Absorber

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

  • Page 39: Measuring The Rear Wheel Dimension Unloaded

    TUNING THE CHASSIS 10 – Turn adjusting screw clockwise up to the last perceptible click. – Turn counterclockwise by the number of clicks correspond- ing to the shock absorber type. Guideline Rebound damping Comfort 17 clicks Standard 15 clicks H01522-10 Sport 13 clicks Info...

  • Page 40: Checking The Static Sag Of The Shock Absorber

    10 TUNING THE CHASSIS 10.8 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 37) – Hold the motorcycle upright with aid of an assistant. – Measure the distance again between the rear axle and mark- ing SAG on the rear fender using the sag gage.

  • Page 41: Adjusting The Spring Preload Of The Shock Absorber

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

  • Page 42: Adjusting The Riding Sag

    10 TUNING THE CHASSIS 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) – Remove the shock absorber. p. 55) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 43: Adjusting The Fork Air Pressure

    TUNING THE CHASSIS 10 10.13 Adjusting the fork air pressure Warning Danger of accident Modifications to the suspension setting may seriously alter the handling charac- teristic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components. –...

  • Page 44: Adjusting The Compression Damping Of The Fork

    10 TUNING THE CHASSIS When disconnecting, excess pressure will escape from the hose – the fork leg itself does not lose any air. The fork airpump indicator switches off automatically after 80 seconds. – Mount the protection cap. Info Only mount the protection cap by hand. Finishing work –...

  • Page 45: Handlebar Position

    TUNING THE CHASSIS 10 Guideline Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Info Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds. – Mount protection cap 10.16 Handlebar position The holes on the handlebar supports are placed at a distance from the center.
  • Page 46 10 TUNING THE CHASSIS Main work – Remove screws . Take off the handlebar clamp. Remove the handlebar and lay it to one side. Info Cover the components to protect them against dam- age. Do not kink the cables and lines. –...

  • Page 47: Service Work On The Chassis 11

    SERVICE WORK ON THE CHASSIS 11 11.1 Raising the motorcycle with a lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle. –...

  • Page 48: Cleaning The Dust Boots Of The Fork Legs

    11 SERVICE WORK ON THE CHASSIS Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. H01182-12 Finishing work – Remove the motorcycle from the lift stand. ( p. 45) 11.4 Cleaning the dust boots of the fork legs Preparatory work...

  • Page 49: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 11.5 Removing the fork protector – Remove screws on the left fork leg. Take off the clamp. – Remove screws on the left fork leg. Take off the left fork protector. – Remove screws on the right fork leg.

  • Page 50: Installing The Fork Legs

    11 SERVICE WORK ON THE CHASSIS – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. S03438-10 11.8 Installing the fork legs Main work – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front.

  • Page 51: Removing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 11.9 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) – Remove the front wheel. p. 88) – Remove the fork legs. p. 47) – Remove the start number plate.

  • Page 52: Installing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS 11.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 128) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 53 SERVICE WORK ON THE CHASSIS 11 – Tighten screws Guideline Screw, bottom triple 12 Nm (8.9 lbf ft) clamp S03438-12 – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head K01253-10 – Mount and tighten screw Guideline Screw, top 20 Nm (14.8 lbf ft)

  • Page 54: Checking Steering Head Bearing Play

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

  • Page 55: Adjusting Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 11.12 Adjusting steering head bearing play Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) – Remove the handlebar cushion. Main work – Loosen screws – Remove screw – Loosen and retighten screw Guideline Screw, top steering M20x1.5...

  • Page 56: Removing The Start Number Plate

    11 SERVICE WORK ON THE CHASSIS 11.14 Removing the start number plate – Remove screw – Remove screw and take off the brake line guide and start number plate. F01639-10 11.15 Installing the start number plate – Position the brake line and brake line guide on the start num- ber plate.

  • Page 57: Installing Front Fender

    SERVICE WORK ON THE CHASSIS 11 11.17 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis K01078-10 Finishing work – Install the start number plate. ( p. 54) 11.18 Removing the shock absorber Preparatory work...
  • Page 58 11 SERVICE WORK ON THE CHASSIS – Press angle lever toward the rear. – Press linkage lever downward. K01092-10 – Remove screws – Pull off foot brake cylinder from the push rod. K01277-10 – Remove the connecting link of the chain. –...

  • Page 59: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 11.19 Installing the shock absorber Main work – Carefully position the shock absorber into the vehicle from the bottom. – Mount and tighten screw Guideline Screw, top 60 Nm (44.3 lbf ft) ® Loctite 2701™...

  • Page 60: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS Guideline Screw, bottom 60 Nm (44.3 lbf ft) ® Loctite 2701™ shock absorber Info Raise the wheel slightly to be able to mount the screw more easily. – Attach frame protector in area and position. –...

  • Page 61: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 11 11.21 Mounting the seat Main work – Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket. – Push the seat forward. – Make sure the seat is latched in place correctly. H02218-11 –...

  • Page 62: Removing The Air Filter

    11 SERVICE WORK ON THE CHASSIS – Engage the air filter box cover in areas K01256-11 11.24 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 63: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 128) Info Only press the air filter to dry it, never wring it out. –...

  • Page 64: Removing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS 11.27 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. –...

  • Page 65: Removing The Right Side Cover

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove screws . Pull out inner tube – Remove the glass fiber yarn filling from the inner tube. – Clean the parts that need to be reinstalled and check for damage. –...

  • Page 66: Installing The Right Side Cover

    11 SERVICE WORK ON THE CHASSIS 11.31 Installing the right side cover Main work – Attach side cover with the holding lugs from below and push upward. – Engage the side cover in areas K01269-10 Finishing work – Mount the seat. ( p.

  • Page 67: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 – Remove the seat. ( p. 58) – Remove the right side cover. ( p. 63) Main work – Pull off the fuel hose. Info Remaining fuel may flow out of the fuel hose. –...
  • Page 68 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 69: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS 11 11.34 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 67) 400678-01 11.35 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. –...

  • Page 70: Checking The Chain Tension

    11 SERVICE WORK ON THE CHASSIS 11.36 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 71: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 11 Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55 … 58 mm (2.17 … 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks...
  • Page 72 11 SERVICE WORK ON THE CHASSIS – Pull on the top section of the chain with the specified weight Guideline Weight, chain wear mea- 10 … 15 kg (22 … 33 lb.) surement – Measure distance of 18 chain rollers in the lower chain section.
  • Page 73 SERVICE WORK ON THE CHASSIS 11 – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.

  • Page 74: 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 K01114-01 Motorcycles. 11.40 Checking the link fork – Check the link fork for damage, cracking, and deformation.

  • Page 75: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 11 Main work – Check the throttle cable routing. The throttle cable must be routed along the back of the handlebar, to the right of the frame, above the fuel tank bracket, and to the carburetor. The throttle cable must be secured on the fuel tank bracket with a rubber strap.

  • Page 76: Adjusting The Basic Position Of The Clutch Lever

    11 SERVICE WORK ON THE CHASSIS 11.43 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info When the adjusting screw is turned counterclockwise, the clutch lever moves away from the handlebar.

  • Page 77: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 11 Info Clean up overflowed or spilled brake fluid immediately with water. 11.45 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. –...
  • Page 78 11 SERVICE WORK ON THE CHASSIS – Now press the fluid into the system until it emerges from the hole of the master cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. –...

  • Page 79: Brake System 12

    Do not make any adjustments while riding. 12.3 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.)

  • 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.) Preparatory work –...

  • 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.) Note 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 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.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 84: Checking The Free Travel Of Foot Brake Lever

    12 BRAKE SYSTEM – Check that spring plate in the brake caliper and sliding plate in the brake caliper bracket are seated correctly. 100397-01 – Insert the new brake linings, insert pin , and mount the cotter pins Info Always change the brake linings in pairs. –...

  • Page 85: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKE SYSTEM 12 – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake 3 … 5 mm (0.12 … 0.2 in) lever »...

  • Page 86: Checking The Rear Brake Fluid Level

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

  • Page 87: Checking The Brake Linings Of The Rear Brake

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

  • Page 88: Changing The Rear Brake Linings

    Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 89 BRAKE SYSTEM 12 – Stand the vehicle upright. – Remove screw cap with membrane and the O-ring. K01275-10 – Manually press the brake caliper toward the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, if necessary extract excess.

  • Page 90: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) Main work – Manually press the brake caliper toward the brake disc to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pis- tons.

  • Page 91: Installing The Front Wheel

    WHEELS, TIRES 13 13.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 92: Installing The Rear Wheel

    13 WHEELS, TIRES Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pis- ton.
  • Page 93 WHEELS, TIRES 13 Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surfaces of the spacers. Long-life grease ( p.

  • Page 94: 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 pressure of the tires all have a major impact on the handling characteristic of the motorcycle.

  • Page 95: Checking Spoke Tension

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

  • Page 96: 14 Cooling System

    14 COOLING SYSTEM 14.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 97: Installing The Radiator Cover

    COOLING SYSTEM 14 14.3 Installing the radiator cover – Remove screws – Remove screws – Take off radiator shield K01265-10 – Position the matching radiator cover ( p. 94). The larger holding lug is located at the top left. Info Do not use both radiator covers at the same time.

  • Page 98: Removing The Radiator Cover

    14 COOLING SYSTEM 14.4 Removing the radiator cover – Remove screws – Remove screws – Take off radiator shield – Remove the radiator cover. – Position radiator shield – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis –...

  • Page 99: Checking The Coolant Level

    COOLING SYSTEM 14 – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...

  • Page 100: Draining The Coolant

    14 COOLING SYSTEM 14.7 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: Changing The Coolant

    COOLING SYSTEM 14 – Make sure that screw is tightened. – Position the motorcycle upright. – Completely fill the radiator with coolant. Coolant ( p. 126) K01245-10 – Loosen screw until coolant escapes without bubbles. – Mount and tighten screw Guideline Bleeder screw, cylin- 8 Nm (5.9 lbf ft)
  • Page 102 14 COOLING SYSTEM Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...

  • Page 103: Tuning The Engine 15

    TUNING THE ENGINE 15 15.1 Checking throttle cable play – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Throttle cable play 2 …...

  • Page 104: Carburetor Tuning

    15 TUNING THE ENGINE – Turn barrel adjuster so that there is play in the throttle cable at the throttle grip. Guideline Throttle cable play 2 … 3 mm (0.08 … 0.12 in) – Tighten nut – Slide on sleeve 400192-11 Finishing work –...
  • Page 105 TUNING THE ENGINE 15 If the engine stutters when accelerating with a partially open throttle slide, the jet needle must be lowered. If the engine knocks when accelerating at the full power rpm range, the jet needle must be raised. Cylindrical part of the needle CYL The cylindrical part of the needle has the greatest influence when the throttle slide is almost closed.

  • Page 106: Carburetor - Idle Setting

    15 TUNING THE ENGINE Needle overview The jet needles available are shown in the following table. 402674-01 Column 2 corresponds to a needle in the standard position. Column 1 corresponds to a needle which is half a clip leaner. Column 3 corresponds to a needle which is half a clip richer. Column 4 specifies the diameter of the first cylindrical part of the needle.

  • Page 107: Carburetor - Adjusting The Idle Speed

    TUNING THE ENGINE 15 Super unleaded (98 octane) mixed with 2-stroke engine oil (1:40) ( p. 127) The idle speed is adjusted with adjusting screw The idle mixture is adjusted using the idle air adjusting screw 15.5 Carburetor - adjusting the idle speed –...

  • Page 108: Emptying The Carburetor Float Chamber

    15 TUNING THE ENGINE Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. If the procedure described here does not lead to sat- isfactory results, the cause may be a wrongly dimen- sioned idling jet.

  • Page 109: Plug-In Connector Of Ignition Timing Map Adjustment

    TUNING THE ENGINE 15 Main work – Place a cloth under the carburetor to capture the draining fuel. – Remove screw plug – Fully drain the fuel. – Mount and tighten the screw plug. S01290-10 15.7 Plug-in connector of ignition timing map adjustment Plug-in connector of the ignition timing map adjustment is located on the frame under the fuel tank.

  • Page 110: Adjusting The Basic Position Of The Shift Lever

    15 TUNING THE ENGINE 15.10 Adjusting the basic position of the shift lever – Remove screw with the washers and take off shift lever 401950-12 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing.

  • Page 111: Service Work On The Engine 16

    SERVICE WORK ON THE ENGINE 16 16.1 Checking the gear oil level Info The gear oil level must be checked when the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Remove gear oil level monitoring screw –...

  • Page 112: Adding The Gear Oil

    16 SERVICE WORK ON THE ENGINE Main work – Remove gear oil drain plug with magnet. – Remove gear oil drain plug – Remove filler plug with the O-ring. – Let the gear oil drain fully. – Thoroughly clean the gear oil drain plug. –...
  • Page 113 SERVICE WORK ON THE ENGINE 16 Main work – Remove gear oil level monitoring screw K01259-10 – Remove filler plug with the O-ring. – Add gear oil until it emerges from the drill hole of the gear oil level monitoring screw. Engine oil (15W/50) ( p.

  • Page 114: 17 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 115 CLEANING, CARE 17 – After the motorcycle has cooled off, lubricate all moving parts and pivot points. – Clean the chain. ( p. 67) – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p.

  • Page 116: 18 Storage

    Check tire pressure. ( p. 92) – 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. 45) –...

  • Page 117: Preparing For Use After Storage

    STORAGE 18 18.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 45) – Perform checks and maintenance measures when preparing for use. ( p. 27) – Make a test ride. 401059-01...

  • Page 118: 19 Troubleshooting

    19 TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start Operating error Carry out start procedure. ( p. 27) – The motorcycle has been in Empty the carburetor float cham- disuse for an extended period ber. p. 106) and old fuel is in the float chamber –...
  • Page 119 TROUBLESHOOTING 19 Faults Possible cause Action – Engine has too little power Diaphragm or reed valve hous- Check the diaphragm and reed valve ing damaged housing. – Engine stalls or is popping into Lack of fuel Turn the tap handle of the fuel tap to the carburetor the ON position.

  • Page 120: 20 Technical Data

    20 TECHNICAL DATA 20.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing...
  • Page 121 TECHNICAL DATA 20 Screw, stator 6 Nm (4.4 lbf ft) ® Loctite 243™ Screw, water pump wheel 6 Nm (4.4 lbf ft) ® Loctite 243™ Bleeder screw, cylinder head 8 Nm (5.9 lbf ft) Drain plug, water pump cover 10 Nm (7.4 lbf ft) Nut, adjusting screw, power valve 8 Nm (5.9 lbf ft) Screw, alternator cover...

  • Page 122: Carburetor

    20 TECHNICAL DATA 20.3 Carburetor Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 87 Needle position 2nd position from top Jet needle 6BFY43-71 (6BFY42-71) Main jet 500 (480, 490, 520, 540, 560) Idling jet 35 (30 / 32.5 / 37.5 / 40) Choke nozzle Needle jet S‑7...

  • Page 123: Basic Carburetor Setting For Sandy Surfaces

    TECHNICAL DATA 20 Main jet Info Do not use on sandy terrain. 20.3.2 Basic carburetor setting for sandy surfaces Idle air adjusting screw open 2 turns Idling jet 37.5 Jet needle 6BFY42‑71 Needle position 3rd position from top Main jet Info If the engine is not running smoothly, use a smaller main jet.

  • Page 124: Tires

    80/100 - 21 51M TT 100/90 - 19 57M TT Dunlop GEOMAX MX3S Dunlop GEOMAX MX3S The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com 20.7 Fork Fork article number 34.15.8U.01 Fork...

  • Page 125: Shock Absorber

    TECHNICAL DATA 20 20.8 Shock absorber Shock absorber article number 18.15.7U.01 Shock absorber WP XACT 5750 Lowspeed compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Highspeed compression damping Comfort 2 turns Standard 1.5 turns Sport 1 turn Rebound damping Comfort 17 clicks...
  • Page 126 20 TECHNICAL DATA Screw on fuel tank 6 Nm (4.4 lbf ft) Screw, ball joint of push rod on 10 Nm (7.4 lbf ft) ® Loctite 243™ foot brake cylinder Screw, chain sliding guard 6 Nm (4.4 lbf ft) ® Loctite 243™...
  • Page 127 TECHNICAL DATA 20 Screw-in fitting, cooling system M24x1.5 18 Nm (13.3 lbf ft) ® Loctite 243™ Nut, rear wheel spindle M25x1.5 80 Nm (59 lbf ft)
  • Page 128 21 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 ®...
  • Page 129 SUBSTANCES 21 Recommended supplier ® MOTOREX – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 130) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.
  • Page 130 22 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier ® MOTOREX – Racing Bio Dirt Remover Chain cleaner Recommended supplier ® MOTOREX – Chain Clean Fuel additive Recommended supplier ® MOTOREX – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 131 AUXILIARY SUBSTANCES 22 Preserving materials for paints, metal and rubber Recommended supplier ® MOTOREX – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier ® MOTOREX – Quick Cleaner Universal oil spray Recommended supplier ®...
  • Page 132 23 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.
  • Page 133 LIST OF ABBREVIATIONS 24 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...
  • Page 134 INDEX INDEX Chain tension adjusting ......68 Accessories ......9 checking .
  • Page 135 INDEX installing ......48 removing ......47 Link fork Fork part number .
  • Page 136 INDEX Right side cover Throttle cable play installing ......64 adjusting ......101 removing .
  • Page 137 *3402439en* 3402439en 04/2020 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer/KISKA, www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...

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