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Husqvarna TX 300i 2021 Owner's Manual

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OWNER'S MANUAL 2021
TX 300i
Art. no. 3402441en

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Summary of Contents for Husqvarna TX 300i 2021

  • Page 1 OWNER'S MANUAL 2021 TX 300i Art. no. 3402441en...
  • 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 vehicle which, with appropriate care, will bring you pleasure for a long time to come.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS 6.15 Foot brake lever ........19 MEANS OF REPRESENTATION......5 6.16 Side stand........... 19 Symbols used ........5 6.17 Service hour counter......20 Formats used ........5 PREPARING FOR USE........21 SAFETY ADVICE ..........6 Advice on preparing for first use..
  • Page 5 TABLE OF CONTENTS 10.7 Measuring the rear wheel dimension 11.27 Removing the main silencer....65 unloaded ..........40 11.28 Installing the main silencer....65 10.8 Checking the static sag of the 11.29 Changing the glass fiber yarn filling shock absorber ........41 of the main silencer ......
  • Page 6 TABLE OF CONTENTS ELECTRICAL SYSTEM........97 22.2 Engine tightening torques....131 22.3 Capacities ......... 133 14.1 Removing the 12-V battery ..... 97 22.3.1 Gear oil ......... 133 14.2 Installing the 12-V battery ....98 22.3.2 Coolant ......... 133 14.3 Charging the 12-V battery ....

  • 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) V01562-10 Clutch lever ( p. 15) Fuel tank filler cap Air filter box cover Side stand ( p. 19) Shift lever ( p. 19) Engine number ( p. 13)

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

    4 VIEW OF VEHICLE View of vehicle, rear right (example) V01563-10 2-stroke oil tank cap Switch-off button ( p. 15) Start button ( p. 16) Throttle grip ( p. 15) Hand brake lever ( p. 15) Foot brake lever ( p.

  • 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 embossed on the left side of the engine above 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. K01317-10 Hand brake lever The hand brake lever is located on the right side of the han- dlebar.

  • Page 18: Map Switch

    6 CONTROLS Map switch The map switch is fitted on the right side of the handlebar. Possible states Map switch in position I – The ignition timing map Perfor- • mance is active in this position. Map switch in position II – The ignition timing map Soft is •...

  • Page 19: Closing The Fuel Tank Filler Cap

    CONTROLS 6 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. – In case of skin contact, rinse the affected area with plenty of water. –...

  • Page 20: Closing 2-Stroke Oil Tank Cap

    6 CONTROLS 6.11 Closing 2-stroke oil tank cap – Put the 2-stroke oil tank cap on and turn it clockwise. – Fold loop down. The 2-stroke oil tank cap engages. K01333-10 6.12 Cold start button The cold start button is fitted on the side of the throttle valve body.

  • Page 21: Shift Lever

    CONTROLS 6 6.14 Shift lever Shift lever is mounted on the left of the engine. 401950-10 The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears. 401950-11 6.15 Foot brake lever Foot brake lever is located in front of the right footrest.

  • Page 22: Service Hour Counter

    6 CONTROLS The side stand is used for parking the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber strap 401944-10 6.17 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.

  • Page 23: Preparing For Use 7

    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 24: Running In The Engine

    7 PREPARING FOR USE – Adjust the basic position of the hand brake lever. ( p. 80) – Adjust the basic position of the foot brake lever. p. 86) – Set the basic position of the shift lever. p. 113) –...

  • Page 25: Preparing The Vehicle For Difficult Operating Conditions

    PREPARING FOR USE 7 not faulty, but needs to be warmed up internally to increase its starting power (current output). The starting power increases as the battery warms up. Preparing the vehicle for difficult operating conditions Info Use of the vehicle under difficult conditions, such as on sand or on wet and muddy circuits/surfaces, can lead to considerably more rapid wear of components such as the drive train, brake system, or sus- pension components.

  • Page 26: Preparing The Vehicle For Riding On Wet Sand

    7 PREPARING FOR USE – Mount the air filter dust cover. Air filter dust cover (79006920000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01272-01 – Mount the air filter sand cover. Air filter sand cover (79006922000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories.

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

    – 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 – Clean the chain. Chain cleaner ( p. 140) –...

  • Page 28: Preparing Vehicle For High Temperatures Or Slow Riding

    7 PREPARING FOR USE – Mount the steel sprocket. – Clean motorcycle. ( p. 123) – Straighten the bent radiator fins carefully. 600868-01 Preparing vehicle for high temperatures or slow riding – Check the radiator cap. Value on the radiator cap 1.8 bar (26 psi) »...

  • Page 29: Preparing The Vehicle For Low Temperatures Or Snow

    PREPARING FOR USE 7 Preparing the 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...

  • Page 30: 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 31: 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 32: 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 33: Transporting

    RIDING INSTRUCTIONS 8 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 34: Refueling

    8 RIDING INSTRUCTIONS 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 35: Adding 2-Stroke Oil

    RIDING INSTRUCTIONS 8 Adding 2-stroke oil Warning Engine failure The engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel. –...

  • Page 36: 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 37: Recommended Work

    ● Final check: Check the vehicle for operating safety and take a test ride. ○ ○ ● ● ● Read out the fault memory after the test ride using the Husqvarna Motorcycles diag- nostics tool. ○ ○ ● ● ●...
  • Page 38 9 SERVICE SCHEDULE Every 80 operating hours Every 40 operating hours After 20 operating hours / Every 20 operating hours After 10 operating hours / Every 10 operating hours every 48 months every 12 months ● Perform major engine service including removing and installing the engine. Change the piston and check the cylinder.

  • Page 39: Tuning The Chassis 10

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

  • Page 40: 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 41: 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 42: Measuring The Rear Wheel Dimension Unloaded

    10 TUNING THE CHASSIS – 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 43: Checking The Static Sag Of The Shock Absorber

    TUNING THE CHASSIS 10 10.8 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 40) – 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 44: 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 45: Adjusting The Riding Sag

    TUNING THE CHASSIS 10 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 48) – Remove the shock absorber. p. 58) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 46: Adjusting The Fork Air Pressure

    10 TUNING THE CHASSIS 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 47: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 10 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 48: Handlebar Position

    10 TUNING THE CHASSIS Guideline Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 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 49 TUNING THE CHASSIS 10 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 50: 11 Service Work On The Chassis

    11 SERVICE WORK ON THE CHASSIS 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 51: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 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. 48) 11.4 Cleaning the dust boots of the fork legs Preparatory work...

  • Page 52: Removing The Fork Protector

    11 SERVICE WORK ON THE CHASSIS 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 53: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. V01589-10 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 54: 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. 48) – Remove the front wheel. p. 91) – Remove the fork legs. p. 50) – Remove the start number plate.

  • Page 55: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 11.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 140) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 56 11 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, bottom triple 12 Nm (8.9 lbf ft) clamp V01569-10 – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head V01570-10 – Mount and tighten screw Guideline Screw, top 20 Nm (14.8 lbf ft)

  • Page 57: 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 58: Adjusting Steering Head Bearing Play

    11 SERVICE WORK ON THE CHASSIS 11.12 Adjusting steering head bearing play Preparatory work – Raise the motorcycle with a lift stand. ( p. 48) – Remove the handlebar cushion. Main work – Loosen screws – Remove screw – Loosen and retighten screw Guideline Screw, top steering M20x1.5...

  • Page 59: Removing The Start Number Plate

    SERVICE WORK ON THE CHASSIS 11 11.14 Removing the start number plate – Remove screw – Remove screw and take off the brake line guide and start number plate. K01332-10 11.15 Installing the start number plate – Position the brake line and brake line guide on the start num- ber plate.

  • Page 60: Installing Front Fender

    11 SERVICE WORK ON THE CHASSIS 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. 57) 11.18 Removing the shock absorber Preparatory work...
  • Page 61 SERVICE WORK ON THE CHASSIS 11 – Press angle lever toward the rear. – Press linkage lever downward. K01092-10 – Remove screws – Pull off foot brake cylinder from the push rod. V01575-10 – Remove the connecting link of the chain. Info Cover the components to protect them against dam- age.

  • Page 62: Installing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS 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 63: Removing The Seat

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

  • Page 64: Mounting The Seat

    11 SERVICE WORK ON THE CHASSIS 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 that the seat is locked in correctly. H02218-11 –...

  • Page 65: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 – Engage the air filter box cover in areas V01582-11 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 66: Installing The Air Filter

    11 SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 140) Info Only press the air filter to dry it, never wring it out. –...

  • Page 67: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11 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 68: Removing The Right Side Cover

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

  • Page 69: Installing The Right Side Cover

    SERVICE WORK ON THE CHASSIS 11 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 V01603-10 Finishing work – Mount the seat. ( p.
  • Page 70 11 SERVICE WORK ON THE CHASSIS – Remove the seat. ( p. 61) – Remove the right side cover. ( p. 66) Main work – Unplug connector of the fuel pump. – Clean quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 71: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 11.33 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 72: Checking The Chain For Dirt

    11 SERVICE WORK ON THE CHASSIS – Plug in connector for the fuel pump. – Remove the wash cap set and thoroughly clean the quick release coupling using compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 73: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with a lift stand. ( p. 48) Main work – Rinse off loose dirt with a soft jet of water. –...

  • Page 74: Adjusting The Chain Tension

    11 SERVICE WORK ON THE CHASSIS 11.37 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 75: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 11 11.38 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 48) Main work – Shift the transmission into the neutral position. –...
  • Page 76 11 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with, or below, the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.

  • Page 77: 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 78: Checking The Rubber Grip

    11 SERVICE WORK ON THE CHASSIS – Remove the right side cover. ( p. 66) – Remove the fuel tank. p. 67) Main work – Check the throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars, above the fuel tank bracket on the right of the frame to the throttle valve body.

  • Page 79: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 11 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 80: Changing The Hydraulic Clutch Fluid

    11 SERVICE WORK ON THE CHASSIS Brake fluid DOT 4 / DOT 5.1 ( p. 138) – Position the cover with the membrane. Mount and tighten the screws. Info Immediately clean up any brake fluid that has over- flowed or spilled with water. 11.45 Changing the hydraulic clutch fluid Warning...
  • Page 81 SERVICE WORK ON THE CHASSIS 11 – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 138) – Remove the protection cap. – Loosen bleeder screw – Mount bleeding syringe on the clutch slave cylinder.

  • Page 82: 12 Brake System

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

  • Page 83: 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 84: Checking The Front Brake Linings

    Clean up overflowed or spilled brake fluid immediately with water. V01606-10 12.5 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.)

  • Page 85: Changing The Front Brake Linings

    Changing the front brake linings Warning Danger of accidents Incorrect servicing will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation.
  • Page 86 12 BRAKE SYSTEM – Move the brake reservoir mounted on the handlebar to a hori- zontal position. – Remove screws – Take off cover with membrane V01605-10 – Manually press the brake caliper toward the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, if necessary extract excess.

  • Page 87: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 12 – Add brake fluid up to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 ( p. 138) – Position cover with membrane – Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water.

  • Page 88: Adjusting The Basic Position Of The Foot Brake Lever

    Warning 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.)

  • Page 89: Adding Rear Brake Fluid

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

  • Page 90: 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 91 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 92 12 BRAKE SYSTEM – Remove the brake linings. – Clean the brake caliper and brake caliper bracket. – Check that spring plate in the brake caliper and sliding plate in the brake caliper bracket are seated correctly. H02369-10 – Insert the new brake linings. –...

  • Page 93: Wheels, Tires 13

    WHEELS, TIRES 13 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 48) 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 94: Installing The Front Wheel

    13 WHEELS, TIRES 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 95: Installing The Rear Wheel

    WHEELS, TIRES 13 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 96 13 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surfaces of the spacers. Long-life grease ( p.

  • Page 97: 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 98: 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 99: Electrical System 14

    ELECTRICAL SYSTEM 14 14.1 Removing the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms.

  • Page 100: Installing The 12-V Battery

    14 ELECTRICAL SYSTEM 14.2 Installing the 12-V battery Main work – Position the 12-V battery in the battery compartment with the terminals facing forward, and secure with holding bracket 12-V battery (HJTZ5S-FP-C) ( p. 134) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft)
  • Page 101 ELECTRICAL SYSTEM 14 Note 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 Even if there is no load on the 12-V battery, it discharges each day. The charging level and the method of charging are very important for the service life of the 12-V battery.

  • Page 102: Changing The Main Fuse

    14 ELECTRICAL SYSTEM These battery chargers are only suitable for lithium iron phosphate batteries. Read the accompanying instructions for Husqvarna Motorcycles accessories. Info Never remove cover – Switch off the battery charger after charging and disconnect it from the 12-V battery.

  • Page 103: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 14 – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. – Insert a new main fuse. Fuse (58011109110) ( p.

  • Page 104: Diagnostics Connector

    14 ELECTRICAL SYSTEM Main work – Open fuse box cover – Remove faulty fuse. Guideline Fuse 1 - 10 A - EFI control unit, oil pump, electronic fuel injection, diagnostics connector Fuse 2 - not assigned Fuse 3 - not assigned V01633-10 Fuse 4 - 5 A - fuel pump Fuses SPARE - 10 A/5 A - spare fuse...

  • Page 105: Cooling System 15

    COOLING SYSTEM 15 15.1 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 106: Checking The Coolant Level

    15 COOLING SYSTEM 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 107: Refilling With Coolant

    COOLING SYSTEM 15 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 108 15 COOLING SYSTEM – Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Coolant level above the radiator fins Coolant ( p. 138) 400243-10 – Push protection cap upward over the thermostat. – Unplug connector –...

  • Page 109: Changing The Coolant

    COOLING SYSTEM 15 – Check the coolant level. ( p. 104) 15.6 Changing 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 110 15 COOLING SYSTEM – Push protection cap upward over the thermostat. E01426-10 – Unplug connector – Remove thermostat with O-ring and wait until the coolant escapes without bubbles. – Mount thermostat with the O-ring and tighten. Guideline Screw, cylinder head M10x1.25 12 Nm (8.9 lbf ft) temperature sensor...

  • Page 111: Tuning The Engine 16

    TUNING THE ENGINE 16 16.1 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 112: Adjusting The Characteristic Map Of The Throttle Response

    16 TUNING THE ENGINE Guideline Throttle cable play 2 … 3 mm (0.08 … 0.12 in) – Unscrew barrel adjuster until the smooth operation or play in the throttle cable deteriorates. – Turn adjusting screw approx. two turns further. – Tighten nut –...

  • Page 113: Adjusting The Idle Speed

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

  • Page 114: Programming Ambient Pressure

    16 TUNING THE ENGINE Info Turn clockwise to decrease the idle speed. Turn counterclockwise to increase the idle speed. Make the setting in small steps. An incorrect idle speed can have a negative impact on overall engine running. 16.5 Programming ambient pressure Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

  • Page 115: Adjusting The Basic Position Of The Shift Lever

    TUNING THE ENGINE 16 16.7 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 116: 17 Service Work On The Engine

    17 SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 117: Checking 2-Stroke Oil Level

    SERVICE WORK ON THE ENGINE 17 17.2 Checking 2-stroke oil level Warning Engine failure The engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel. –...
  • Page 118 17 SERVICE WORK ON THE ENGINE Main work – Pull EFI control unit upward off rubber lugs and hang to the side. – Remove protection cap of the diagnostics connector. V01622-10 – Put throttle grip into full throttle position and secure. V01621-10 –...

  • Page 119: Cleaning The Oil Screen In The Oil Tank

    SERVICE WORK ON THE ENGINE 17 – Check whether air bubbles are visible in the hose » If air bubbles are visible: – Repeat the entire procedure until air bubbles are no longer visible. – Mount protection cap on the diagnostics connector. –...
  • Page 120 17 SERVICE WORK ON THE ENGINE – Loosen clamps of the throttle valve body. – Lift the subframe slightly and secure it. Info Pay attention to intake flange – Pull throttle valve body towards the rear, out of the intake flange, and hang it to the side.

  • Page 121: Checking The Gear Oil Level

    SERVICE WORK ON THE ENGINE 17 – Mount throttle valve body – Remove the locking piece and position the subframe. Info Pay attention to intake flange – Position and tighten clamps of the throttle valve body. Guideline Screw, intake 6 Nm (4.4 lbf ft) flange/reed valve housing V01632-10...

  • Page 122: Changing The Gear Oil

    17 SERVICE WORK ON THE ENGINE Main work – Remove gear oil level monitoring screw – Check the gear oil level. A small quantity of gear oil must run out of the drilled hole. » If no gear oil runs out: –...

  • Page 123: Adding The Gear Oil

    SERVICE WORK ON THE ENGINE 17 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.
  • Page 124 17 SERVICE WORK ON THE ENGINE Finishing work Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 125: Cleaning, Care 18

    CLEANING, CARE 18 18.1 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 126 18 CLEANING, CARE – After the motorcycle has cooled down, lubricate all moving parts and pivot points. – Clean the chain. ( p. 70) – 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 127: Storage 19

    95) 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. 48) – Cover the vehicle with a tarp or a similar cover that is perme- able to air.

  • Page 128: Preparing For Use After Storage

    19 STORAGE 19.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 48) – Perform checks and maintenance measures when preparing for use. ( p. 28) – Make a test ride. 401059-01...

  • Page 129: Troubleshooting 20

    Clean the connector and treat it with is loose or oxidized contact spray. – Error in the electronic fuel Read out the fault memory using the injection Husqvarna Motorcycles diagnostics tool. – The engine has no idle speed Spark plug defective Change the spark plug. –...
  • Page 130 Possible cause Action – Engine has too little power Error in the electronic fuel Read out the fault memory using the injection Husqvarna Motorcycles diagnostics tool. – Fuel supply interrupted Check the fuel tank breather. – Exhaust system leaky, Check exhaust system for damage.

  • Page 131: Blink Code 21

    BLINK CODE 21 Blink code for malfunc- tion indicator lamp 14 Malfunction indicator lamp flashes 1x long, 4x short Crankcase pressure sensor – difference too high between sensor and engine Error level condition electronics control unit Blink code for malfunc- tion indicator lamp 09 Malfunction indicator lamp flashes 9x short Error level condition...
  • Page 132 21 BLINK CODE Blink code for malfunc- tion indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short Ignition coil – circuit fault Error level condition Blink code for malfunc- tion indicator lamp 02 Malfunction indicator lamp flashes 2x short Crankshaft speed sensor –...

  • Page 133: Technical Data 22

    TECHNICAL DATA 22 22.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake, exhaust control and transfer duct injection Displacement 293.15 cm³ (17.8892 cu in) Stroke 72 mm (2.83 in) Hole 72 mm (2.83 in) + 0.2 + 0.008 Exhaust control - setting measurement mm (0.091 −...
  • Page 134 22 TECHNICAL DATA Screw, exhaust control cap 5 Nm (3.7 lbf ft) Screw, exhaust control cover 4 Nm (3 lbf ft) Screw, injection valve holder 5 Nm (3.7 lbf ft) ® Loctite 243™ Screw, locking lever 6 Nm (4.4 lbf ft) ®...

  • Page 135: Capacities

    TECHNICAL DATA 22 Screw, cylinder head temperature M10x1.25 12 Nm (8.9 lbf ft) sensor Nut, rotor M12x1 60 Nm (44.3 lbf ft) Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) Spark plug M14x1.25 25 Nm (18.4 lbf ft) Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft)

  • Page 136: Electrical System

    90/90 - 21 54M TT 110/100 - 18 64M TT Dunlop GEOMAX AT81F Dunlop GEOMAX AT81 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com 22.7 Fork Fork article number 34.18.8U.73 Fork...

  • Page 137: Shock Absorber

    TECHNICAL DATA 22 Grease capacity, left cartridge 5 g (0.18 oz) Special grease (00062010053) p. 141) Oil capacity, right cartridge 380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1) p. 139) 22.8 Shock absorber Shock absorber article number 18.18.7U.73 Shock absorber WP XACT 5750 Lowspeed compression damping...
  • Page 138 22 TECHNICAL DATA Screw, throttle valve body hose 2.8 Nm (2.07 lbf ft) clamp Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) Remaining nuts, chassis 5 Nm (3.7 lbf ft) Remaining screws, chassis 5 Nm (3.7 lbf ft) Screw, battery terminal...
  • Page 139 TECHNICAL DATA 22 Engine bracket screw 60 Nm (44.3 lbf ft) Remaining nuts, chassis 45 Nm (33.2 lbf ft) Remaining screws, chassis 45 Nm (33.2 lbf ft) Screw, bottom shock absorber 60 Nm (44.3 lbf ft) ® Loctite 2701™ Screw, handlebar support 40 Nm (29.5 lbf ft) ®...

  • Page 140: 23 Substances

    23 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 141 SUBSTANCES 23 Recommended supplier ® MOTOREX – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 142) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 142: 24 Auxiliary Substances

    24 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 143 AUXILIARY SUBSTANCES 24 Silicone spray Recommended supplier ® MOTOREX – Silicone Spray Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier ® MOTOREX – Quick Cleaner Special grease (00062010053) Recommended supplier ® Klüber Lubrication – KLÜBERFOOD NH1 34‑401 Universal oil spray Recommended supplier...

  • Page 144: 25 Standards

    25 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 145: Index Of Special Terms 26

    INDEX OF SPECIAL TERMS 26 Injection in the transfer ducts Electronic fuel injection in which two injection valves in the transfer ducts of the cylinders are used On-board diagnosis Vehicle system, which monitors the specified param- eters of the vehicle electronics...

  • Page 146: 27 List Of Abbreviations

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

  • Page 147: List Of Symbols 28

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Stop, and contact an authorized Husqvarna Motorcycles workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 148: Index

    INDEX INDEX Capacity 12-V battery coolant ......133 installing ......98 gear oil .
  • Page 149 INDEX Environment ......8 Handlebar position ....46 adjusting .
  • Page 150 INDEX Starting power of lithium-ion batteries at low temperatures ......22 Rear sprocket Steering head bearing checking ......73 lubricating .
  • Page 151 *3402441en* 3402441en 04/2020 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer/KISKA, www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...

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