KTM TC 50 2020 Owner's Manual
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KTM TC 50 2020 Owner's Manual

KTM TC 50 2020 Owner's Manual

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OWNER'S MANUAL 2020
TC 50
TC 50 Mini
Art. no. 3402328en

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  • Page 1 OWNER'S MANUAL 2020 TC 50 TC 50 Mini Art. no. 3402328en...
  • 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 ....42 11.40 Checking the chain tension ....68 11.41 Adjusting the chain tension....69 11.1 Raising the motorcycle with a lift 11.42 Checking the chain, rear sprocket, stand ........... 42 engine sprocket, and chain guide..70 11.2 Removing the motorcycle from the 11.43 Adjusting the chain guide...
  • Page 6 TABLE OF CONTENTS TUNING THE ENGINE ........105 21.5 Chassis ..........132 21.6 Tires ..........133 15.1 Checking the installation position 21.7 Fork........... 133 of the throttle grip ......105 21.7.1 TC 50..........133 15.2 Checking throttle cable play ..... 105 21.7.2 TC 50 Mini ........

  • 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

    SAFETY ADVICE 2 Tampering warning Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof: The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replace- ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or the use of the vehicle after such device or element of design has been removed or rendered inoperative by...

  • Page 10: Protective Clothing

    2 SAFETY ADVICE Protective clothing Warning Risk of injury Missing or poor protective clothing presents an increased safety risk. – Ensure your child wears appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides. –...
  • 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. International Husqvarna Motorcycles website: www.husqvarna-motorcycles.com...

  • Page 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) F02220-10 Fuel tank filler cap Quick release of seat Chain guide Plug-in stand ( p. 19) Choke Fuel tap ( p. 18)

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

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) F02221-10 Kill switch ( p. 16) Throttle grip ( p. 16) Hand brake lever ( 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 (TC 50) The type label is located on the front frame tube. 402154-10 (TC 50 Mini) Type label is fixed to the front of the steering head.

  • Page 17: Fork Part Number

    SERIAL NUMBERS 5 Fork part number The fork part number is stamped on the outside of the axle clamp. 401947-10 Shock absorber article number (TC 50) The shock absorber article number is stamped on the bottom of the shock absorber toward the right-hand side. H01186-10 (TC 50 Mini) The shock absorber article number...

  • Page 18: Controls

    6 CONTROLS Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The hand brake lever is used to activate the front brake. K01169-10 Throttle grip Throttle grip is fitted on the right side of the handlebar. K01169-11 Kill switch Kill switch...

  • 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 Oil Tank Cap (Tc 50 Mini)

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

  • Page 21: Kick Starter Lever

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

  • 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 PREPARING FOR USE 7 Warning Danger of accidents The suspension components will become damaged or destroyed if overloaded. – Do not exceed the maximum permissible weight of the rider. Warning Risk of misappropriation People who act without authorization endanger themselves and others. –...

  • 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

    8 RIDING INSTRUCTIONS Info If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable ele- ments of the fuel evaporate after a long time of standing. If the float chamber is filled with fresh fuel, the engine starts immediately. Preliminary work –...

  • Page 27: Applying The Brakes

    RIDING INSTRUCTIONS 8 Applying the brakes Warning Danger of accidents Excessively forceful application of the brakes blocks the wheels. – Explain to your child that he or she must adapt the braking to the traffic situation and the road con- ditions. Warning Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.

  • Page 28: Transporting

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

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

    RIDING INSTRUCTIONS 8 – Fill the fuel tank with fuel up to level Guideline 35 mm (1.38 in) Level Fuel tank capacity, 2.1 l (2.2 qt.) Super unleaded approx. (TC 50 Mini) (ROZ 95/RON 95/PON 91) p. 138) Fuel tank capacity, 2.3 l (2.4 qt.) Super unleaded 400214-10...

  • Page 30: Service Schedule

    9 SERVICE SCHEDULE Additional information Any further work that results from the compulsory work or from the recommended work must be ordered sepa- rately and invoiced separately. 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.

  • Page 31: Recommended Work

    SERVICE SCHEDULE 9 Every 80 operating hours Every 40 operating hours Every 20 operating hours After 10 operating hours ● ● ● Change the glass fiber yarn filling of the main silencer. p. 65) ● ● Service the fork. ● Perform the shock absorber service.

  • 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 (Tc 50)

    TUNING THE CHASSIS 10 10.3 Compression damping of the shock absorber (TC 50) The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed. High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.

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

    10 TUNING THE CHASSIS 10.5 Adjusting the high-speed compression damping of the shock absorber (TC 50) Caution 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. –...
  • Page 35 TUNING THE CHASSIS 10 (TC 50) – Turn adjusting screw clockwise up to the last percep- tible click. – Turn counterclockwise by the number of clicks corre- sponding to the shock absorber type. Guideline Rebound damping Comfort 17 clicks F02185-10 Standard 15 clicks Sport...

  • Page 36: Measuring The Rear Wheel Dimension Unloaded

    10 TUNING THE CHASSIS – Position the shock absorber and rear wheel. – Mount and tighten screw and nut Guideline Screw, bot- 45 Nm (33.2 lbf ft) ® Loctite 243™ tom shock absorber – Remove the motorcycle from the lift stand. ( p.

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

    TUNING THE CHASSIS 10 10.9 Checking the riding sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 34) – With another person holding the motorcycle, the rider, wear- ing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.
  • Page 38 10 TUNING THE CHASSIS – Measure the total spring length while the spring is not under tension. – Tighten the spring to the specified measurement by turn- ing adjusting ring Guideline Spring preload 3 mm (0.12 in) Info The spring preload is the difference between the relaxed spring length and the tensioned spring length.

  • Page 39: Adjusting The Riding Sag

    TUNING THE CHASSIS 10 10.11 Adjusting the riding sag Preparatory work (TC 50) – Raise the motorcycle with a lift stand. ( p. 42) (TC 50 Mini) – Raise the motorcycle with a lift stand. ( p. 42) – Remove the rear wheel. p.

  • Page 40: Checking The Basic Setting Of The Fork

    10 TUNING THE CHASSIS 10.12 Checking the basic setting of the fork Info For various reasons, no exact riding sag can be determined for the fork. (TC 50) – Smaller differences in the rider's weight can be compen- sated for by the fork air pressure. –...

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

    TUNING THE CHASSIS 10 Info This is due to the volume of the hose and not due to a defect in the fork airpump or the fork. Observe the accompanying instructions for Husq- varna Motorcycles accessories. – Adjust the air pressure as specified. Guideline Air pressure 2 bar (29 psi)

  • Page 42: Handlebar Position

    10 TUNING THE CHASSIS Info Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds. 10.15 Handlebar position On the upper triple clamp, there are 2 holes at a distance of to each other. 15 mm (0.59 in) Hole distance The holes on the handlebar support are placed at a distance...

  • Page 43: Adjusting The Seat Height

    TUNING THE CHASSIS 10 Guideline Screw, handlebar 20 Nm (14.8 lbf ft) clamp Info Make sure the installed gaps are even. 10.17 Adjusting the seat height Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling charac- teristic.

  • Page 44: 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 45: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 (TC 50 Mini) – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. F02192-10 Finishing work – Remove the motorcycle from the lift stand. ( p.

  • Page 46: Removing The Fork Protector

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

  • Page 47: Removing Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.7 Removing fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) – Remove the front wheel. p. 94) Main work – Remove screws and take off the clamp. –...
  • Page 48 11 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, top triple 20 Nm (14.8 lbf ft) clamp – Tighten screws Guideline Screw, bottom 15 Nm (11.1 lbf ft) triple clamp H01853-11 (TC 50 Mini) – Position the fork legs. Bleeder screws are positioned toward the rear.

  • Page 49: 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. 42) – Remove the front wheel. p. 94) – Remove the fork legs. p. 45) – Remove the start number plate.
  • Page 50 11 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the handlebar. – Mount nut , but do not tighten it yet. H01857-10 (TC 50) – Position the fork legs. Bleeder screws are positioned toward the rear. Info The second milled groove (from the top) must be flush with the upper edge of the upper triple...
  • Page 51 SERVICE WORK ON THE CHASSIS 11 (TC 50 Mini) – 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 52: Checking The Steering Head Bearing Play

    11 SERVICE WORK ON THE CHASSIS Guideline Screw, brake line EJOT 1.7 Nm (1.25 lbf ft) bracket Finishing work – Install front fender. ( p. 55) – Install the start number plate. ( p. 54) – Check that the wiring harness, throttle cables, and brake and clutch lines can move freely and are routed correctly.

  • Page 53: Adjusting The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 11.12 Adjusting the steering head bearing play Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work (TC 50) – Pull fuel tank breather out of the steering stem. –...

  • Page 54: Greasing The Steering Head Bearing

    11 SERVICE WORK ON THE CHASSIS 11.13 Greasing the steering head bearing – Remove the lower triple clamp. p. 47) – Install the lower triple clamp. p. 47) H02387-01 11.14 Removing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled.

  • Page 55: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 – Raise the fuel tank. – Pull off fuel hose Info Remaining fuel may flow out of the fuel hose. – Pull fuel tank breather out of the steering stem. – Take off the fuel tank. K00664-10 11.15 Installing the fuel tank...

  • Page 56: Removing The Start Number Plate

    11 SERVICE WORK ON THE CHASSIS – Position the fuel tank. – Make sure that no cables or throttle cables are trapped or damaged. – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the fuel tank breather in the steering stem. K00663-11 Finishing work –...

  • Page 57: Removing Front Fender

    SERVICE WORK ON THE CHASSIS 11 11.18 Removing front fender – Remove screws . Take off the front fender. K00665-10 11.19 Installing front fender – Position the fender with drill holes in the holding lugs on the start number plate. K00675-10 –...

  • Page 58: Installing The Right Side Cover

    11 SERVICE WORK ON THE CHASSIS Condition Right side cover secured. – Remove screw S01546-10 – Pull off the side cover sideways in areas , and remove toward the front. F02230-10 11.21 Installing the right side cover Main work – Position the side cover on collar bushings , and push toward the rear.

  • Page 59: Preparing The Right Side Cover For Securing

    SERVICE WORK ON THE CHASSIS 11 Condition Right side cover secured. – Mount and tighten screw Guideline EJOT PT ® Screw, side cover 2 Nm (1.5 lbf ft) K60x20-Z S01546-11 Finishing work – Mount the seat. ( p. 62) 11.22 Preparing the right side cover for securing Preparatory work –...

  • Page 60: Removing The Left Side Cover

    11 SERVICE WORK ON THE CHASSIS 11.23 Removing the left side cover Preparatory work – Remove the seat. ( p. 62) Condition Left side cover secured. – Remove screw S01547-10 – Pull off the side cover sideways in areas , and remove toward the front.

  • Page 61: Installing The Left Side Cover

    SERVICE WORK ON THE CHASSIS 11 11.24 Installing the left side cover Main work – Position the side cover on collar bushings , and push toward the rear. – Engage the side cover in areas F02232-10 Condition Left side cover secured. –...

  • Page 62: Preparing The Left Side Cover For Securing

    11 SERVICE WORK ON THE CHASSIS 11.25 Preparing the left side cover for securing Preparatory work – Remove the seat. ( p. 62) – Remove the left side cover. ( p. 58) Main work – Drill a hole at marking Guideline Diameter 6.5 mm (0.256 in)

  • Page 63: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 (TC 50 Mini) – Remove nut K01167-10 – Remove screw and lower the link fork carefully. – Remove screw , push splash protector to the side, and remove the shock absorber. K01168-10 11.27 Installing the shock absorber Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling charac- teristic.

  • Page 64: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS (TC 50 Mini) – Push splash protector to the side. – Position the shock absorber with screw , depending on the desired seating height. – Raise the link fork; position the shock absorber with screw K01168-11 –...

  • Page 65: Removing The Air Filter

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

  • Page 66: Cleaning The Air Filter And Air Filter Box

    11 SERVICE WORK ON THE CHASSIS 11.32 Cleaning the air filter and air filter box 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 Do not clean the air filter with fuel or petroleum since these substances attack the foam.

  • Page 67: Installing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11 11.34 Installing the main silencer Main work – Position main silencer. – Mount the main silencer with sleeve – Mount the silent block with screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis –...

  • Page 68: Removing The Engine Sprocket Cover

    11 SERVICE WORK ON THE CHASSIS Finishing work – Install the main silencer. ( p. 65) – Install the right side cover. ( p. 56) – Mount the seat. ( p. 62) 11.36 Removing the engine sprocket cover Preparatory work –...

  • Page 69: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS 11 (TC 50 Mini) – Position the engine sprocket cover. Mount screws do not tighten yet. – Mount and tighten screw Guideline Screw, engine 12 Nm (8.9 lbf ft) sprocket cover – Tighten screws A00100-10 Guideline Screw, engine 12 Nm (8.9 lbf ft)

  • Page 70: Checking The Chain Tension

    11 SERVICE WORK ON THE CHASSIS Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p. 139) – After drying, apply chain spray. Off-road chain spray ( p.

  • Page 71: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 » If the chain tension does not meet the specification: – Adjust the chain tension. ( p. 69) Finishing work – Remove the motorcycle from the lift stand. ( p. 42) 11.41 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents.

  • Page 72: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    11 SERVICE WORK ON THE CHASSIS (TC 50 Mini) – Loosen nut – Adjust the chain tension by turning adjusting nuts left and right. Guideline Chain tension 5 … 8 mm (0.2 … 0.31 in) Turn adjusting nuts equally on the left and right. The rear wheel must be aligned with the front wheel.
  • Page 73 SERVICE WORK ON THE CHASSIS 11 Info When a new chain is mounted, the rear sprocket and engine sprocket should also be changed. New chains wear out faster on old, worn sprockets. (TC 50) – Check the chain sliding guard for wear. »...
  • Page 74 11 SERVICE WORK ON THE CHASSIS – Check the chain guide for wear. Info Wear can be seen on the front of the chain guide. » If the light part of the chain guide is worn: – Change the chain guide. 400985-01 –...
  • Page 75 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 76: Adjusting The Chain Guide

    11 SERVICE WORK ON THE CHASSIS 11.43 Adjusting the chain guide Info The size of the chain wheel varies with the number of teeth. The chain guide can be adjusted on small sprockets. (TC 50) – Loosen screw – Position the chain guide. –...

  • Page 77: Checking The Throttle Cable Routing

    SERVICE WORK ON THE CHASSIS 11 Info Always replace a damaged link fork. Husq- varna Motorcycles does not permit repair- ing link forks. (TC 50 Mini) – Check the link fork for damage, cracking, and deforma- tion. » If the link fork shows signs of damage, cracking, or deformation: –...

  • Page 78: Checking The Rubber Grip

    11 SERVICE WORK ON THE CHASSIS 11.47 Checking the rubber grip – Check the rubber grips on the handlebar for damage, wear, and looseness. » If a rubber grip is damaged, worn, or loose: – Change the rubber grip. Rubber grip adhesive (00062030051) ( p.

  • Page 79: Brake System 12

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

  • Page 80: Checking The Brake Discs

    12 BRAKE SYSTEM Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the han- dlebar. Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar. The range of adjustment is limited. –...

  • Page 81: Checking The Front Brake Fluid Level

    BRAKE SYSTEM 12 12.5 Checking the front brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

  • Page 82: Adding The Front Brake Fluid

    12 BRAKE SYSTEM Info Clean up the overflowed or spilled brake fluid immedi- ately with water. 12.6 Adding the front brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

  • Page 83: Checking The Front Brake Linings

    BRAKE SYSTEM 12 Main work – Move the brake fluid reservoir mounted on the handlebar into a horizontal position. – Remove screws – Take off cover with membrane – Correct the brake fluid level. Guideline Brake fluid level under top 5 mm (0.2 in) V00549-10 level of container...
  • Page 84 12 BRAKE SYSTEM Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. –...
  • Page 85 BRAKE SYSTEM 12 – Remove lock ring – Loosen screw – Remove screw – Press back the brake linings by slightly tilting the brake caliper laterally on the brake disc. Carefully pull the brake caliper backward from the brake disc. –...
  • Page 86 12 BRAKE SYSTEM – Position the brake caliper. – Mount and tighten screw Guideline Screw, brake linings 8 Nm (5.9 lbf ft) – Mount lock ring – Mount screw , but do not tighten yet. Guideline Screw, front M8x60 20 Nm (14.8 lbf ft) F02237-10 ®...

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

    BRAKE SYSTEM 12 12.9 Checking 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 88: Adjusting The Basic Position Of The Foot Brake Lever

    12 BRAKE SYSTEM 12.11 Adjusting the basic position 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 89: Adding Rear Brake Fluid

    BRAKE SYSTEM 12 – Stand the vehicle upright. – Check the brake fluid level in level viewer » If an air bubble is visible in viewer – Add rear brake fluid. p. 87) H01654-11 12.13 Adding rear brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail.

  • Page 90: Checking The Brake Linings Of The Rear Brake

    12 BRAKE SYSTEM Main work – Remove screws – Take off cover with washer and membrane H01448-10 – Add brake fluid up to level Guideline 10 mm (0.39 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 91: Changing The Brake Linings Of The Rear Brake

    BRAKE SYSTEM 12 (TC 50 Mini) – Check the brake linings for minimum thickness ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – Change the brake lingings of the rear brake. p.
  • Page 92 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 93 BRAKE SYSTEM 12 – Position the new brake linings. Info Always change the brake linings in pairs. Ensure that the brake linings are correctly posi- tioned in the holding spring. – Position the brake caliper on the brake disc. The brake linings are correctly positioned. F02207-11 –...
  • Page 94 12 BRAKE SYSTEM – Remove screws – Take off cover with washer and membrane – Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir; extract some if necessary. F02166-10 –...
  • Page 95 BRAKE SYSTEM 12 Finishing work – Remove the motorcycle from the lift stand. ( p. 42)

  • Page 96: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work – Remove screw – Loosen screws A00086-10 Warning Danger of accidents Damaged brake discs reduce the braking effect. –...

  • Page 97: 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 the contact surfaces of the spacers. Long-life grease ( p. 139) –...
  • Page 98 13 WHEELS, TIRES – 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. Info Cover the components to protect them against damage.

  • Page 99: Installing The Rear Wheel

    WHEELS, TIRES 13 Info Do not operate the foot brake lever when the rear wheel is removed. – Remove spacers F02175-11 13.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...

  • Page 100: Checking The Tire Condition

    13 WHEELS, TIRES – Mount nut , but do not tighten it yet. – Make sure that the chain adjusters are fitted correctly on the adjusting screws. – Check the chain tension. ( p. 68) – Tighten nut Guideline Nut, rear wheel M12x1 40 Nm (29.5 lbf ft) spindle...

  • Page 101: Checking Tire Pressure

    WHEELS, TIRES 13 – Check the front and rear tires for cuts, embedded objects, and other damage. » If the tires have cuts, run-in objects, or other damage: – Change the tires. – Check the tread depth. Info Observe the minimum profile depth required by national law.

  • Page 102: Checking Spoke Tension

    13 WHEELS, TIRES 13.7 Checking spoke tension Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage. The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel.

  • Page 103: Cooling System 14

    COOLING SYSTEM 14 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 104: Checking The Coolant Level

    14 COOLING SYSTEM 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 105: Refilling With Coolant

    COOLING SYSTEM 14 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 106 14 COOLING SYSTEM – 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 107: Tuning The Engine 15

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

  • Page 108: Adjusting The Throttle Cable Play

    15 TUNING THE ENGINE 15.3 Adjusting the throttle cable play Preparatory work – Check the installation position of the throttle grip. ( p. 105) – Remove the seat. ( p. 62) – Remove the left side cover. ( p. 58) –...

  • Page 109: Carburetor - Idle Setting (Tc 50 Mini)

    TUNING THE ENGINE 15 Carburetor – idle setting (TC 50 Mini) 15.5 The idle setting of the carburetor has a big influence on the starting behavior, stable idle speed, and the response to throttle opening. This means that an engine with a correctly set idle speed will be easier to start than one with an incorrectly set idle speed.

  • Page 110: Carburetor - Adjusting The Idle Speed (Tc 50 Mini)

    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 111: Checking The Clutch Setting

    TUNING THE ENGINE 15 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 112: Removing The Clutch Cover

    15 TUNING THE ENGINE 15.9 Removing the clutch cover Note Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. Info Fuel can emerge via the carburetor. Capture emerging fuel using a suitable container.

  • Page 113: Installing The Clutch Cover

    TUNING THE ENGINE 15 – Turn adjusting screws clockwise. Guideline 1 click increases the slip 250 … 350 rpm speed by Info The springs may not be pretensioned by more than 17 clicks from the stop using the adjusting screws. Condition If the slip speed is too high: –...

  • Page 114: 16 Service Work On The Engine

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

  • Page 115: Checking The Gear Oil Level

    SERVICE WORK ON THE ENGINE 16 – Remove screws – Take off the oil pump. – Pull off oil line from the carburetor. M01537-10 – Turn oil pump gear wheel counterclockwise until oil flows out of oil line without bubbles. V00276-10 –...

  • Page 116: Changing The Gear Oil

    16 SERVICE WORK ON THE ENGINE (TC 50) – Remove 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: – Add the gear oil. p.

  • Page 117: Adding The Gear Oil

    SERVICE WORK ON THE ENGINE 16 (TC 50) – Place an appropriate container under the engine. – Remove oil drain plug with the magnet. – Let the gear oil drain fully. – Thoroughly clean the oil drain plug with magnet. –...
  • Page 118 16 SERVICE WORK ON THE ENGINE Main work (TC 50) – Remove gear oil level monitoring screw K01173-11 (TC 50 Mini) – Remove gear oil level monitoring screw K01172-11 – Remove filler plug with the O-ring. – Add gear oil until it flows out of the hole of the gear oil level plug.

  • Page 119: Carburetor 17

    CARBURETOR 17 17.1 Removing the carburetor (TC 50 Mini) 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 120: Removing The Carburetor (Tc 50)

    17 CARBURETOR – Loosen hose clip – Loosen hose clip – Pull the carburetor out of the intake flange. – Pull the carburetor forward out of the inlet sleeve. R03039-10 – Remove screw – Take off the throttle slide cover and pull the throttle slide out of the carburetor.
  • Page 121 CARBURETOR 17 Preparatory work – Turn the knurled screw on the fuel tap all the way clockwise. Main work – Pull off fuel hose Info Remaining fuel may flow out of the fuel hose. R04503-10 – Loosen hose clip – Loosen hose clip R04485-10 –...

  • Page 122: Installing The Carburetor (Tc 50 Mini)

    17 CARBURETOR 17.3 Installing the carburetor (TC 50 Mini) Main work – Attach throttle cable wire R03042-10 – Position spring retainer – Position the throttle slide spring. R03041-11 – Position the throttle slide and throttle slide cover. – Mount and tighten screw Guideline Screw, throttle slide 3 Nm (2.2 lbf ft)

  • Page 123: Installing The Carburetor (Tc 50)

    CARBURETOR 17 – Connect fuel hose R03037-11 Finishing work – Bleed the oil pump. p. 112) – Check the throttle cable play. ( p. 105) – Carburetor – adjust the idle speed. p. 108) 17.4 Installing the carburetor (TC 50) Main work –...
  • Page 124 17 CARBURETOR – Mount the carburetor. – Mount the engine breather hose and position clamp R04502-11 – Mount the inlet sleeve. – Position and tighten hose clip – Position and tighten hose clip R04485-11 – Mount fuel hose R04503-11 Finishing work –...

  • 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 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 127: Storage 19

    STORAGE 19 19.1 Storage 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 128: Preparing For Use After Storage

    19 STORAGE 19.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 42) – Perform checks and maintenance measures when preparing for use. ( p. 23) – Take a test ride. 401059-01...

  • Page 129: Troubleshooting 20

    TROUBLESHOOTING 20 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 130 20 TROUBLESHOOTING Faults Possible cause Action Engine does not speed up The carburetor is flowing over (TC 50) – Check/set the carburetor compo- because the float needle is nents. dirty or worn (TC 50 Mini) – Check/set the carburetor compo- nents.
  • Page 131 TROUBLESHOOTING 20 Faults Possible cause Action – Engine overheats Bent radiator hose Change the radiator hose. – White smoke emission (steam Damaged cylinder head or Check the cylinder head or cylinder in exhaust gas) cylinder head gasket head gasket. – Gear oil exits at the vent hose Too much gear oil added Check the gear oil level.

  • Page 132: 21 Technical Data

    21 TECHNICAL DATA 21.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake Displacement 49.0 cm³ (2.99 cu in) Stroke 40 mm (1.57 in) Bore 39.5 mm (1.555 in) Crankshaft bearing 2 grooved ball bearings Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast...

  • Page 133: Carburetor With Carburetor Tuning

    TECHNICAL DATA 21 Screw, ignition coil 4 Nm (3 lbf ft) ® Loctite 243™ Screw, intake flange 5 Nm (3.7 lbf ft) ® Loctite 243™ Screw, pressure plate 10 Nm (7.4 lbf ft) ® Loctite 243™ Screw, water pump cover 10 Nm (7.4 lbf ft) Screw, cylinder head 18 Nm (13.3 lbf ft)

  • Page 134: Capacities

    21 TECHNICAL DATA 21.4 Capacities 21.4.1 Gear oil Gear oil 0.20 l (0.21 qt.) Gear oil (ATF Dexron 3) ( p. 138) 21.4.2 Coolant Coolant 0.7 l (0.7 qt.) Coolant ( p. 137) 21.4.3 Fuel Fuel tank capacity, approx. 2.3 l (2.4 qt.) Super unleaded (95 octane) mixed (TC 50) with 2-stroke engine oil (1:60)

  • Page 135: Tires

    TECHNICAL DATA 21 Steering head angle (TC 50) 66° Steering head angle (TC 50 Mini) 67.4° Wheelbase (TC 50) 1,032 ± 10 mm (40.63 ± 0.39 in) Wheelbase (TC 50 Mini) 914 ± 10 mm (35.98 ± 0.39 in) Seat height unloaded (TC 50) 684 mm (26.93 in) Seat height unloaded (TC 50 Mini) 558 mm (21.97 in)

  • Page 136: Shock Absorber

    21 TECHNICAL DATA Spring rate Weight of rider: 15 … 25 kg (33 … 55 lb.) 1.8 N/mm (10.3 lb/in) Weight of rider (standard): 25 … 35 kg (55 … 2.0 N/mm (11.4 lb/in) 77 lb.) Weight of rider: 35 … 45 kg (77 … 99 lb.) 2.2 N/mm (12.6 lb/in) Spring length with preload spacer(s) 337.5 mm (13.287 in)

  • Page 137: Chassis Tightening Torques

    TECHNICAL DATA 21 Spring preload Standard 5 mm (0.2 in) Spring rate Weight of rider: 15 … 25 kg (33 … 55 lb.) 65 N/mm (371 lb/in) Weight of rider (standard): 25 … 35 kg (55 … 75 N/mm (428 lb/in) 77 lb.) Weight of rider: 35 …...
  • Page 138 21 TECHNICAL DATA Screw, engine bracket 25 Nm (18.4 lbf ft) ® Loctite 243™ Screw, front brake caliper M8x60 20 Nm (14.8 lbf ft) ® Loctite 243™ Screw, front brake caliper M8x40 20 Nm (14.8 lbf ft) ® Loctite 243™ Screw, handlebar clamp 20 Nm (14.8 lbf ft) Screw, rear sprocket...

  • Page 139: Substances 22

    SUBSTANCES 22 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 140 22 SUBSTANCES Gear oil (ATF Dexron 3) Standard/classification – Dexron III (ATF Dexron 3) Guideline – Use only ATF gear oils that comply with the specified standards (see specifications on the container) and that possess the necessary properties. Recommended supplier MOTOREX ®...

  • Page 141: Auxiliary Substances 23

    AUXILIARY SUBSTANCES 23 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 142 23 AUXILIARY SUBSTANCES 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 143: Standards 24

    STANDARDS 24 JASO FD JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first-rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions. The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity.

  • Page 144: 25 List Of Abbreviations

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

  • Page 145: Index

    INDEX INDEX Chain tension adjusting ......69 Accessories ......10 checking .
  • Page 146 INDEX Frame checking ......74 Main silencer Front fender glass fiber yarn filling, changing ..65 installing .
  • Page 147 INDEX Rubber grip Throttle cable play checking ......76 adjusting ......106 securing .
  • Page 148 *3402328en* 3402328en 04/2019 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer/KISKA, www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...

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