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Husqvarna TC 65 2020 Owner's Manual

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OWNER'S MANUAL 2020
TC 65
Art. no. 3402329en

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Summary of Contents for Husqvarna TC 65 2020

  • Page 1 OWNER'S MANUAL 2020 TC 65 Art. no. 3402329en...
  • 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 that will continue to give you and your child pleasure 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 ......22 Formats used ........5 RIDING INSTRUCTIONS ......... 23 SAFETY ADVICE ..........6 Use definition –...
  • Page 5 TABLE OF CONTENTS SERVICE WORK ON THE CHASSIS ....40 11.43 Checking the throttle cable routing ..67 11.44 Checking the rubber grip ....68 11.1 Raising the motorcycle with a lift 11.45 Additionally securing the rubber stand ........... 40 grip............
  • Page 6 TABLE OF CONTENTS TUNING THE ENGINE ........96 15.1 Checking throttle cable play ....96 15.2 Adjusting the throttle cable play ..96 Carburettor – idle speed ..... 97 15.3 Carburetor – adjusting the idle 15.4 speed ..........97 15.5 Emptying the carburetor float chamber ..........

  • Page 7: Means Of Representation 1

    MEANS OF REPRESENTATION 1 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 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 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 SAFETY ADVICE 2 The Owner's Manual is also available for download from your authorized Husqvarna Motorcycles dealer and on the Husqvarna Motorcycles website. International Husqvarna Motorcycles website: www.husqvarna-motorcycles.com...

  • Page 12: Important Notes

    3 IMPORTANT NOTES Manufacturer and 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 13: Customer Service

    IMPORTANT NOTES 3 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 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) F02242-10 Hand brake lever ( p. 16) Valve for fork airpump Clutch lever ( p. 16) Quick release for seat lock Shock absorber rebound adjustment Choke ( p. 18) Shift lever ( p.

  • Page 15: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) F02243-10 Fuel tank filler cap Kill switch ( p. 16) Fork rebound adjustment Throttle grip ( p. 16) Vehicle identification number ( p. 14) Kick starter lever ( p. 19) Foot brake lever ( p.

  • Page 16: Serial Numbers

    5 SERIAL NUMBERS 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 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 17: Shock Absorber Article Number

    SERIAL NUMBERS 5 Shock absorber article number The shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the left- hand side. H01141-10...

  • Page 18: Controls

    6 CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. M01544-10 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. M01545-10 Throttle grip Throttle grip...

  • Page 19: Opening The Fuel Tank Filler Cap

    CONTROLS 6 Opening the 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 refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 20: Fuel Tap

    6 CONTROLS Fuel tap Fuel tap is on the left of the fuel tank. Possible states Fuel tap is closed – The knurled screw is turned all the way • clockwise. Fuel cannot flow out of the fuel tank. Fuel tap is open – The knurled screw is turned all the way •...

  • Page 21: Kick Starter Lever

    CONTROLS 6 6.10 Kick starter lever Kick starter lever is fitted on the right side of the engine. The kick starter lever can be swiveled. Info Before riding, swing the kick starter lever inwards towards the engine. 401954-10 6.11 Foot brake lever Foot brake lever is located in front of the right footrest.

  • Page 22: Preparing For Use

    7 PREPARING FOR USE Advice on preparing for 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 the motorcycle, remember that others may be disturbed by excessive noise. – Ensure 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 – Run the engine in. ( p. 22) 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 <...

  • Page 25: 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 26: Starting Off

    Make it clear to your child that he or she must not change into a low gear at high engine speed. Info If unusual noises occur while riding, stop immediately, switch off the engine, and contact an authorized Husqvarna Motorcycles workshop. First gear is used for starting off and for steep inclines. –...

  • 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 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. – Park the vehicle on a firm and level surface. –...
  • Page 29 RIDING INSTRUCTIONS 8 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 30: 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 31: Recommended Work

    ● ● Final check: Check the vehicle for safe operation and take a test ride. ○ ● ● ● Make a service entry in Husqvarna Motorcycles Dealer.net. ○ One-time interval ● Periodic interval Recommended work Every 80 operating hours Every 40 operating hours...

  • Page 32: 10 Tuning The Chassis

    10 TUNING THE CHASSIS 10.1 Checking the basic chassis setting with rider's weight Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork. – For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, link fork and frame, the basic settings of the suspension components must match the rider's weight.

  • Page 33: 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 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

    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: Measuring The Dimension Of The Rear Wheel 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 18 clicks Standard 15 clicks F02173-10 Sport 12 clicks Info...

  • Page 36: 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. 33) – 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 37: Adjusting The Spring Preload Of The Shock Absorber

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached 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 –...

  • Page 38: Adjusting The Riding Sag

    10 TUNING THE CHASSIS 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 40) – Remove the right side cover. ( p. 50) – Remove the silencer. ( p. 58) – Remove the shock absorber. p.

  • Page 39: Adjusting The Fork Air Pressure

    Info This is due to the volume of the hose and not due to a defect in the fork airpump or the fork. Read the accompanying instructions for Husqvarna Motorcycles accessories. – Adjust the air pressure as specified. Guideline Air pressure...

  • Page 40: Adjusting The Rebound Damping Of The Fork

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

  • Page 41: Adjusting The Handlebar Position

    TUNING THE CHASSIS 10 10.16 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result. – Change the handlebar if the handlebar is damaged or bent. –...

  • Page 42: 11 Service Work On The Chassis

    11 SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (80329955100) Neither wheel is in contact with the ground.

  • Page 43: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 40) – Remove the fork protector. ( p. 41) Main work – Push dust boots of both fork legs downward.

  • Page 44: Installing The Fork Protector

    11 SERVICE WORK ON THE CHASSIS – Remove screws on the right fork leg. Take off the fork protector. S01483-10 11.6 Installing the fork protector – Position fork protector on the right fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S01483-11...

  • Page 45: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. S01485-10 11.8 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the rear. Info The second milled groove (from the top) must be flush with the upper edge of the upper triple clamp.

  • Page 46: 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. 40) – Remove the front wheel. p. 86) – Remove the fork legs. p. 42) – Remove the start number plate.
  • Page 47 SERVICE WORK ON THE CHASSIS 11 – Position the upper triple clamp with the handlebar. – Mount nut , but do not tighten it yet. Guideline Nut, steering head M20x1.5 10 Nm (7.4 lbf ft) S01488-10 – Position the fork legs. Bleeder screws are positioned toward the rear.

  • Page 48: Checking The 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 Motorcy- cles 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 49: Adjusting The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bear- ing. » If there is detectable play: –...

  • Page 50: Greasing The Steering Head Bearing

    11 SERVICE WORK ON THE CHASSIS 11.13 Greasing the steering head bearing – Remove the lower triple clamp. p. 44) – Install the lower triple clamp. p. 44) H02387-01 11.14 Removing the start number plate – Remove screw – Unhook the start number plate from the brake line and remove it.

  • Page 51: Removing Front Fender

    SERVICE WORK ON THE CHASSIS 11 11.16 Removing front fender – Remove screws . Take off the front fender. S01496-10 11.17 Installing front fender – Position start number plate on the fender. The holding lugs of the start number plate engage in drill holes of the fender.

  • Page 52: Removing The Right Side Cover

    11 SERVICE WORK ON THE CHASSIS 11.18 Removing the right side cover Condition Right side cover secured. – Remove screw S01542-10 – Pull off the side cover sideways in areas , and remove toward the front. S01498-10...

  • Page 53: Installing The Right Side Cover

    SERVICE WORK ON THE CHASSIS 11 11.19 Installing the right side cover – Position the side cover on collar bushings , and push toward the rear. – Engage the side cover in areas S01514-10 Condition Right side cover secured. – Mount and tighten screw Guideline EJOT PT...

  • Page 54: Removing The Left Side Cover

    11 SERVICE WORK ON THE CHASSIS Main work – Drill a hole at marking Guideline Diameter 6.5 mm (0.256 in) S01544-10 Finishing work – Install the right side cover. ( p. 51) 11.21 Removing the left side cover Condition Left side cover secured. –...

  • Page 55: Installing The Left Side Cover

    SERVICE WORK ON THE CHASSIS 11 – Pull off the side cover sideways in areas , and remove toward the front. S01521-10 11.22 Installing the left side cover – Position the side cover on collar bushings , and push toward the rear. –...

  • Page 56: Securing Left Side Cover

    11 SERVICE WORK ON THE CHASSIS 11.23 Securing left side cover Preparatory work – Remove the left side cover. ( p. 52) Main work – Drill a hole at marking Guideline Diameter 6.5 mm (0.256 in) S01543-10 Finishing work – Install the left side cover.

  • Page 57: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 – Take the brake line out of the holders. – Remove screw and lower the rear wheel with the link fork as far as possible without blocking the rear wheel. Secure the rear wheel in this position. –...

  • Page 58: Mounting The Seat

    11 SERVICE WORK ON THE CHASSIS 11.27 Mounting the seat – Hook seat onto screw and lower the seat at the rear and push it forward. Holding lug hooks into the fuel tank. S01516-10 – Close quick release S01515-11 11.28 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine.

  • Page 59: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 11.29 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 118) 100818-10 – Insert both parts together, position them, and secure them using air filter holding bracket Info If the air filter is not mounted correctly, dust and dirt...

  • Page 60: Removing The Silencer

    11 SERVICE WORK ON THE CHASSIS Finishing work – Install the air filter. p. 57) – Mount the seat. ( p. 56) 11.31 Removing the silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. –...

  • Page 61: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    SERVICE WORK ON THE CHASSIS 11 11.33 Changing the glass fiber yarn filling of 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. Info Over time, the fibers of the glass fiber yarn escape and the damper “burns”...
  • Page 62 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 63: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 11.35 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 refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 64: Checking The Chain For Dirt

    11 SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the fuel tank breather in the steering stem. S01520-11 Finishing work – Install the right side cover. ( p.

  • Page 65: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p. 118) – After drying, apply chain spray. Off-road chain spray ( p.

  • Page 66: Adjusting The Chain Tension

    11 SERVICE WORK ON THE CHASSIS 11.39 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 67 SERVICE WORK ON THE CHASSIS 11 Main work – Shift the transmission into neutral. – Check the chain, rear sprocket, and engine sprocket for wear. » If the chain, rear sprocket or engine sprocket is worn: – Change the drivetrain kit. Info The engine sprocket, rear sprocket, and chain 400227-01...
  • Page 68 11 SERVICE WORK ON THE CHASSIS – 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 69: 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 601599-01 Motorcycles. 11.42 Checking the link fork – Check the link fork for damage, cracking, and deformation.

  • Page 70: Checking The Rubber Grip

    11 SERVICE WORK ON THE CHASSIS Finishing work – Install the fuel tank. p. 61) – Install the right side cover. ( p. 51) – Install the left side cover. ( p. 53) – Mount the seat. ( p. 56) 11.44 Checking the rubber grip –...

  • Page 71: Checking The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 11 11.47 Checking the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch facing discs. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 72: Changing The Hydraulic Clutch Fluid

    11 SERVICE WORK ON THE CHASSIS Info Clean up overflowed or spilled brake fluid immediately with water. 11.49 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. –...
  • Page 73 SERVICE WORK ON THE CHASSIS 11 – Inject the liquid into the system only until it emerges from drill hole of the master cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. –...

  • Page 74: 12 Brake System

    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 75: Checking The Front Brake Fluid Level

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

  • Page 76: Adding The 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 77: 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 78 12 BRAKE SYSTEM 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 Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
  • Page 79 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 80: Checking The Free Travel Of The Foot Brake Lever

    12 BRAKE SYSTEM – Add brake fluid up to level Guideline Brake fluid level under top 5 mm (0.2 in) level of container Brake fluid DOT 4 / DOT 5.1 ( p. 116) 309386-11 – Position cover with membrane – Mount and tighten screws Info Immediately clean up any brake fluid that has over-...

  • Page 81: Adjusting The Free Travel Of The Foot Brake Lever

    BRAKE SYSTEM 12 12.9 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 82: 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 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 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 85 BRAKE SYSTEM 12 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 Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
  • Page 86 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 87 BRAKE SYSTEM 12 Info Immediately clean up any brake fluid that has over- flowed or spilled with water. Finishing work – Remove the motorcycle from the lift stand. ( p. 40)

  • Page 88: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 40) Main work – Remove screw E00547-10 – Loosen screws Warning Danger of accidents Damaged brake discs reduce the braking effect. –...

  • Page 89: Removing The Rear Wheel

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

  • Page 90: Installing The Rear Wheel

    13 WHEELS, TIRES Main work – Remove nut – Take off chain adjuster E00544-11 – Pull out wheel spindle far enough to allow the rear wheel to be pushed forward. – Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket.

  • Page 91: 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 92: Checking Tire Pressure

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. Husqvarna Motorcycles recommends that the tires be H01144-10 changed after 5 years at the latest, regardless of the actual wear.

  • Page 93: 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.) – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diameter.

  • Page 94: 14 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 95: Checking The Coolant Level

    COOLING SYSTEM 14 14.3 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 96: Refilling With Coolant

    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 97 COOLING SYSTEM 14 – Move the vehicle into the position shown and prevent it from rolling away. Height difference must be reached. Guideline 50 cm (19.7 in) Height difference Info For all of the air to be able to escape from the cooling system, the vehicle must be raised at the front.

  • Page 98: 15 Tuning The Engine

    15 TUNING THE ENGINE 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 3 …...

  • Page 99: Carburettor - Idle Speed

    TUNING THE ENGINE 15 – Turn barrel adjuster until there is throttle cable play the bottom throttle cable sleeve. Guideline Throttle cable play 3 … 5 mm (0.12 … 0.2 in) – Tighten nut – Slide on sleeve 400192-11 Finishing work –...

  • Page 100: Emptying The Carburetor Float Chamber

    15 TUNING THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.
  • Page 101 TUNING THE ENGINE 15 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 102: 16 Service Work On The Engine

    16 SERVICE WORK ON THE ENGINE 16.1 Checking the gear oil level Condition The engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Remove screw – Check the gear oil level. A small quantity of gear oil must run out of the drilled hole. »...

  • Page 103: Adding The Gear Oil

    SERVICE WORK ON THE ENGINE 16 Info Too little gear oil or poor-quality gear oil results in pre- mature wear to the transmission. – Remove filler plug with the O-ring, and fill up with gear oil. Gear oil 0.50 l Engine oil (15W/50) (0.53 qt.) p.
  • Page 104 16 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 105: Cleaning, Care 17

    CLEANING, CARE 17 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 106 17 CLEANING, CARE Info The heat produced causes water at inaccessible loca- tions in the engine and on the brake system to evapo- rate. – 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 pivot points.

  • Page 107: Storage 18

    Check tire pressure. ( p. 90) – 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. 40) –...

  • Page 108: Preparing For Use After Storage

    18 STORAGE 18.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 40) – Perform checks and maintenance measures when preparing for use. ( p. 23) – Take a test ride. 401059-01...

  • Page 109: Troubleshooting 19

    TROUBLESHOOTING 19 Faults Possible cause Action – Engine turns but does not start Operating error Carry out the start procedure. p. 23) – Motorcycle was out of use for Empty the carburetor float cham- a long time and there is old ber.
  • Page 110 19 TROUBLESHOOTING Faults Possible cause Action – Engine has too little power Fault in ignition system Check the ignition system. – Adjust the ignition. – Diaphragm or reed valve hous- Check the diaphragm and reed valve ing damaged housing. – Noticeable wear Overhaul the engine.

  • Page 111: Technical Data 20

    TECHNICAL DATA 20 20.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 64.85 cm³ (3.9574 cu in) Stroke 40.8 mm (1.606 in) Bore 45 mm (1.77 in) Idle speed 1,400 … 1,500 rpm Control Exhaust control PCEV (Pneumatic Controlled Exhaust Valve) Crankshaft bearing 2 grooved ball bearings...
  • Page 112 20 TECHNICAL DATA Screw, retaining bracket for return 6 Nm (4.4 lbf ft) ® Loctite 243™ spring of shift shaft Screw, shift drum locating 6 Nm (4.4 lbf ft) ® Loctite 243™ Screw, water pump impeller 2 Nm (1.5 lbf ft) ®...

  • Page 113: Carburetor

    TECHNICAL DATA 20 Nut, primary gear wheel M14x1.25 40 Nm (29.5 lbf ft) ® Loctite 243™ 20.3 Carburetor Carburetor type MIKUNI TM 24 Needle position 2nd position from top Idle air adjusting screw Open 3.5 turns Main jet Jet needle 5IPL43 (5N17) Idling jet Needle jet...

  • Page 114: Capacities

    20 TECHNICAL DATA Needle position from top Main jet The carburetor tuning depends on the defined ambient and operating conditions. 20.4 Capacities 20.4.1 Gear oil Gear oil 0.50 l (0.53 qt.) Engine oil (15W/50) ( p. 116) 20.4.2 Coolant Coolant 0.55 l (0.58 qt.) Coolant ( p.

  • Page 115: Chassis

    TECHNICAL DATA 20 Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload 5 mm (0.2 in) Spring rate Weight of rider: 35 kg (77 lb.) 35 N/mm (200 lb/in) Weight of rider: 40 kg (88 lb.) 40 N/mm (228 lb/in) Weight of rider: 45 kg (99 lb.) 45 N/mm (257 lb/in)

  • Page 116: Tires

    80/100 - 12 41M TT Maxxis MAXX CROSS SI Maxxis MAXX CROSS SI The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com 20.9 Chassis tightening torques Screw, brake line bracket EJOT 1.7 Nm (1.25 lbf ft)
  • Page 117 TECHNICAL DATA 20 Screw, rear brake caliper M8x40 18 Nm (13.3 lbf ft) ® Loctite 243™ Screw, rear sprocket 25 Nm (18.4 lbf ft) ® Loctite 243™ Screw, steering stem 20 Nm (14.8 lbf ft) Screw, subframe 35 Nm (25.8 lbf ft) ®...

  • Page 118: 21 Substances

    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 119 SUBSTANCES 21 Recommended supplier ® MOTOREX – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 120) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 120: 22 Auxiliary Substances

    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 121 AUXILIARY SUBSTANCES 22 Rubber grip adhesive (00062030051) Recommended supplier KTM AG – GRIP GLUE Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier ® MOTOREX – Quick Cleaner Special grease (00062010053) Recommended supplier ® Klüber Lubrication –...

  • Page 122: 23 Standards

    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 123: List Of Abbreviations 24

    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 124: Index

    INDEX INDEX Cleaning ......103-104 Clutch Accessories ......10 fluid level, checking .
  • Page 125 INDEX Front wheel Motorcycle installing ......86 cleaning ......103 removing .
  • Page 126 INDEX Shock absorber article number ... 15 View of vehicle front left ......12 Side cover, left rear right .
  • Page 127 *3402329en* 3402329en 04/2019 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer/KISKA, www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...

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