Related Manuals for Husqvarna TE 125 EU 2015
Summary of Contents for Husqvarna TE 125 EU 2015
- Page 1 OWNER'S MANUAL 2015 TE 125 EU TE 125 US TE 250 EU TE 250 AU TE 250 US TE 300 EU TE 300 AU TE 300 US Art. no. 3402022en...
- Page 3 Husqvarna accepts no liability for deliv- ery options, deviations from illustrations and descriptions, as well as misprints and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS Message on the speedometer......21 MEANS OF REPRESENTATION ......... 5 Setting the speedometer........21 Symbols used ............5 Setting kilometers or miles ........22 Formats used............5 Setting the clock ..........22 SAFETY ADVICE ..............6 Setting the service display........ - Page 5 TABLE OF CONTENTS 12.5 Loosening the fork protection....... 44 13.8 Changing the front brake linings ....... 70 12.6 Positioning the fork protection......44 13.9 Checking the free travel of the foot brake lever..71 12.7 Removing the fork legs ........44 13.10 Adjusting the basic position of the foot brake lever ..............
- Page 6 TABLE OF CONTENTS STORAGE ..............104 20.1 Storage.............. 104 20.2 Preparing for use after storage ......104 TROUBLESHOOTING ............ 105 TECHNICAL DATA ............107 22.1 Engine..............107 22.1.1 All TE 125............107 22.1.2 All TE 250............107 22.1.3 All TE 300............108 22.2 Engine tightening torques........
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Page 7: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized Husqvarna workshop. There, your motorcycle will be opti- mally maintained by specially trained experts using the specialist tools required. -
Page 8: Safety Advice
Use definition - intended use (TE EU/AU) Husqvarna sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcy- cles comply with currently valid regulations and categories of the top international motorsport organizations. -
Page 9: Safe Operation
Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. In the interest of your own safety, Husqvarna recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are needed for certain tasks. -
Page 10: Owner's Manual
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized Husqvarna dealer. -
Page 11: Important Notes
Warranty The work prescribed in the service schedule must be carried out by an authorized Husqvarna workshop only and confirmed in the cus- tomer's service booklet and in the Husqvarna Dealer.net; otherwise, all warranty claims will be void. No warranty claims can be con- sidered for damage resulting from manipulations and/or alterations to the vehicle. -
Page 12: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) L02602-10 Filler cap Air filter box lid Fuel tap ( p. 18) Choke ( p. 18) Shift lever ( p. 18) Side stand ( p. 19) -
Page 13: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) L02603-10 Fork compression adjustment Clutch lever ( p. 14) Kill switch ( p. 14) Horn button ( p. 15) Light switch ( p. 15) Turn signal switch ( p. 15) Speedometer overview Emergency OFF switch ( p. -
Page 14: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 401945-10 Type label (TE EU/AU) The type label is fixed to the front of the steering head. 401946-10 Key number (TE EU/AU) ... -
Page 15: Shock Absorber Part Number
SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the upper part of the shock absorber above the adjusting ring. 0 0 1 401948-10... -
Page 16: Controls
CONTROLS Clutch lever (All TE 125) The clutch lever is fitted on the left side of the handlebar. The clutch is activated hydraulically and adjusts itself automatically. L01701-11 (All TE 250/300) The clutch lever is fitted on the left side of the handlebar. The clutch is activated hydraulically and adjusts itself automatically. -
Page 17: Kill Switch (Te Us)
CONTROLS Kill switch (TE US) The kill switch is fitted on the left side of the handlebar. Possible states in basic position – In this position, the ignition circuit is closed and the • Kill switch engine can be started. is pressed –... -
Page 18: Emergency Off Switch (All Te Au)
CONTROLS 6.10 Emergency OFF switch (All TE AU) The emergency OFF switch is fitted on the right side of the handlebar. Possible states Ignition off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. Ignition on –... -
Page 19: Opening The Filler Cap
CONTROLS 6.15 Opening the filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 20: Fuel Tap
CONTROLS 6.17 Fuel tap The fuel tap is found on the left side of the fuel tank. Tap handle on the fuel tap can be used to open or close the fuel supply to the carbu- retor. Possible states Fuel supply closed OFF –... -
Page 21: Kick Starter
CONTROLS 6.20 Kick starter The kick starter is fitted on the right side of the engine. The top part can be swiveled. 0 0 1 401954-10 6.21 Foot brake lever The foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. -
Page 22: Locking The Steering (Te Eu/Au)
CONTROLS 6.24 Locking the steering (TE EU/AU) Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Park the vehicle. – Turn the handlebar as far as possible to the right. –... -
Page 23: Speedometer
Message on the speedometer Possible states Battery voltage of the speedometer – Battery voltage of the speedometer is too low. Change the battery. Service – Service is due. Contact an authorized Husqvarna workshop. 401901-01 Setting the speedometer Condition The motorcycle is stationary. -
Page 24: Setting Kilometers Or Miles
SPEEDOMETER – Wait for 5 seconds. The speedometer changes to the next menu item. The symbol flashes. Resetting the time – Press the left button. The value decreases. Advancing the time – Press the right button. The value increases. 401912-01 –... -
Page 25: Setting The Service Display
SPEEDOMETER – Wait for 5 seconds. The speedometer changes to the next menu item. The symbol flashes. Resetting the time – Press the left button. The value decreases. Advancing the time – Press the right button. The value increases. 401912-01 Setting the service display Condition The motorcycle is stationary. -
Page 26: Speed, Time, And Dst2 Distance 2
SPEEDOMETER Speed, time, and DST2 distance 2 – Press one of the buttons until DST2 appears on the speedometer. KM/H or M/H shows the speed. shows the time. DST2 shows the distance 2 since the last reset, such as between two refueling stops. Info If the value of 39999.9 is exceeded, DST2 is automatically reset to 0.0. -
Page 27: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized Husqvarna workshop. You will receive a delivery certificate and the service booklet at vehicle handover. -
Page 28: Running In The Engine
PREPARING FOR USE – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu- tion between the front and rear wheels. -
Page 29: Preparing For Rides On Dry Sand
PREPARING FOR USE Preparing for rides on dry sand – Check the radiator cap. Value on radiator cap 1.8 bar (26 psi) » If the displayed value does not equal the setpoint value: Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. -
Page 30: Preparing For Rides On Wet And Muddy Surfaces
PREPARING FOR USE – Change the radiator cap. – Mount a rain cover on the air filter. Rain cover for air filter (77206921100) Info Observe the Husky Power fitting instructions. – Adjust the carburetor jetting and setting. Info B00437-01 The recommended carburetor tuning is available from your authorized Husq- varna workshop. -
Page 31: Preparing For Rides At Low Temperature And In Snow
PREPARING FOR USE – Change the radiator cap. – Adjust the secondary drive to the road conditions. Info The transmission oil heats up quickly when the clutch is operated frequently due to an excessively high secondary drive. – Clean the chain. –... -
Page 32: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance steps when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the gear oil level. ( p. 98) –... -
Page 33: Starting Off
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized Husqvarna workshop. First gear is used for starting off or for steep inclines. -
Page 34: Stopping, Parking
RIDING INSTRUCTIONS – On sandy, wet, or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. –... -
Page 35: Refueling
RIDING INSTRUCTIONS Refueling Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 36: Service Schedule
Check the headlight setting. ( p. 86) ● ● Check the idle. ● ● Final check: Check the vehicle for safe operation and take a test ride. ● ● Make the service entry in Husqvarna Dealer.net and in the service booklet. ● Periodic interval... -
Page 37: Service Work (As Additional Order)
SERVICE SCHEDULE 10.2 Service work (as additional order) Annually Every 80 operating hours/every 40 operating hours when used for motorsports Every 40 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. ● Change the hydraulic clutch fluid. p. -
Page 38: Tuning The Chassis
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized Husqvarna work- shop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 39: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized Husqvarna work- shop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber. -
Page 40: Measuring The Sag Of The Unloaded Rear Wheel
TUNING THE CHASSIS – Turn adjusting screw clockwise up to the last perceptible click. – Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping (All TE 125) Comfort 17 clicks Standard 15 clicks Sport 13 clicks S00522-10... -
Page 41: Checking The Riding Sag Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized Husqvarna work- shop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 42: Adjusting The Riding Sag
TUNING THE CHASSIS Finishing work – Install the shock absorber. p. 51) – Mount the seat. ( p. 52) – Install the main silencer. ( p. 55) – Install the right side cover. ( p. 56) – Remove the motorcycle from the lift stand. ( p. -
Page 43: Adjusting The Compression Damping Of The Fork
TUNING THE CHASSIS – As with the shock absorber, smaller rider weight differences can be compensated by the spring preload. – However, if the fork is often overloaded (hard end stop on compression), stiffer springs must be fit to avoid damage to the fork and frame. 401000-01 11.12 Adjusting the compression damping of the fork... -
Page 44: Handlebar Position
TUNING THE CHASSIS Guideline Rebound damping (All TE 125) Comfort 15 clicks Standard 13 clicks Sport 11 clicks Rebound damping (All TE 250/300) Comfort 15 clicks Standard 13 clicks Sport 11 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. -
Page 45: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame below the engine. Lift stand (81329955000) Neither wheel is in contact with the ground. -
Page 46: Loosening The Fork Protection
SERVICE WORK ON THE CHASSIS Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Clean and oil the dust boots and inner fork tube of both fork legs. -
Page 47: Installing The Fork Legs
SERVICE WORK ON THE CHASSIS – Release screws . Take out the left fork leg. – Release screws . Take out the right fork leg. S00526-10 12.8 Installing the fork legs Main work – Position the fork legs. ... -
Page 48: Installing The Fork Protector
SERVICE WORK ON THE CHASSIS Main work – Remove screws on the left fork leg. Lift off the fork protector. – Remove the screws on the right fork leg. Lift off the fork protector. 101327-10 12.10 Installing the fork protector Main work –... -
Page 49: Installing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS 12.12 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 123) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. -
Page 50: Checking The Play Of The Steering Head Bearing
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized Husqvarna workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing, and the bearing seats in the frame can become damaged over time. -
Page 51: Adjusting The Play Of The Steering Head Bearing
SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: –... -
Page 52: Removing The Front Fender
SERVICE WORK ON THE CHASSIS 12.16 Removing the front fender Preparatory work – Switch off all power consumers and switch off the engine. – Remove the headlight mask with the headlight. ( p. 83) Main work – Remove screws ... -
Page 53: Removing The Shock Absorber
SERVICE WORK ON THE CHASSIS 12.18 Removing the shock absorber Preparatory work – Raise the motorcycle with the lift stand. ( p. 43) – Remove the right side cover. ( p. 56) – Remove the main silencer. ( p. 54) –... -
Page 54: Removing The Seat
SERVICE WORK ON THE CHASSIS – Install the right side cover. ( p. 56) – Remove the motorcycle from the lift stand. ( p. 43) 12.20 Removing the seat – Remove screws in the recessed grips on the left and right. –... -
Page 55: Removing The Air Filter
SERVICE WORK ON THE CHASSIS 12.24 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 56: Installing The Air Filter
SERVICE WORK ON THE CHASSIS 12.26 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. 123) L00943-10 – Insert both parts together, position them, and fasten them using air filter holder ... -
Page 57: Installing The Main Silencer
SERVICE WORK ON THE CHASSIS 12.29 Installing the main silencer Main work – Mount the main silencer with rubber sleeve – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) L02628-10 Finishing work – Install the right side cover. -
Page 58: Removing The Right Side Cover
SERVICE WORK ON THE CHASSIS 12.31 Removing the right side cover – Remove screw – Pull off the side cover in area sideways and remove it toward the rear. L02626-10 12.32 Installing the right side cover – Position the side cover and engage in area –... -
Page 59: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Remove screw with the rubber bushing. – Remove the tube from the fuel tank vent line. L02625-11 – Pull both spoilers sideways off of the radiator bracket and take off the fuel tank toward the top. -
Page 60: Checking The Chain For Dirt
SERVICE WORK ON THE CHASSIS (TE EU/AU) – Mount and tighten screws with the horn and collar bushings. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) (TE US) – Mount and tighten screws with the collar bushings. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) -
Page 61: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS 12.37 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases. -
Page 62: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide
SERVICE WORK ON THE CHASSIS Info The wide adjustment range of the chain adjusters (32 mm (1.26 in)) enables different secondary ratios with the same chain length. Chain adjusters can be turned by 180°. Finishing work – Remove the motorcycle from the lift stand. ( p. -
Page 63: Checking The Frame
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 the chain sliding piece for tightness. »... -
Page 64: Checking The Swingarm
If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info A damaged swingarm must always be changed. Repair of the swingarm is not authorized by Husqvarna. 401520-01 12.42 Checking the throttle cable routing Preparatory work –... -
Page 65: Checking The Rubber Grip
SERVICE WORK ON THE CHASSIS 12.43 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 and secure the rubber grip. Rubber grip adhesive (00062030051) ( p. -
Page 66: Checking/Rectifying The Fluid Level Of The Hydraulic Clutch
SERVICE WORK ON THE CHASSIS 12.46 Checking/rectifying the fluid level of the hydraulic clutch Info The fluid level rises with increased wear of the clutch facing discs. (All TE 125) – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –... -
Page 67: Removing The Engine Guard
SERVICE WORK ON THE CHASSIS – Inject the liquid into the system until it escapes from hole of the master cylin- der without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe. Mount and tighten the bleeder screw. –... -
Page 68: Installing The Engine Guard
SERVICE WORK ON THE CHASSIS 12.49 Installing the engine guard (All TE 125) – Attach the engine guard on the frame at the rear and swing up at the front. – Turn quick release clockwise all the way. L01704-10 (All TE 250/300) –... -
Page 69: Brake System
BRAKE SYSTEM 13.1 Checking the free travel of the hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating. -
Page 70: Checking The Brake Discs
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. -
Page 71: Checking The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 72: Changing The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. -
Page 73: Checking The Free Travel Of The Foot Brake Lever
BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 0 0 6 100397-01 – Insert the new brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs. -
Page 74: Adjusting The Basic Position Of The Foot Brake Lever
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna workshop will be glad to help.) – Stand the vehicle upright. -
Page 75: Adding Rear Brake Fluid
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 76: Checking The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. - Page 77 BRAKE SYSTEM – Stand the vehicle upright. – Remove screw cap with membrane and the O-ring. B01793-10 – Press the brake caliper onto the brake disc by hand in order to push back the brake piston and ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does.
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Page 78: Wheels, Tires
WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 43) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 79: Removing The Rear Wheel
WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. The brake linings are positioned. – Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly against on the brake disc. -
Page 80: Installing The Rear Wheel
Checking the tire condition Info Only mount tires approved and/or recommended by Husqvarna. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have an important impact on the handling characteristics of the motorcycle. -
Page 81: Checking The Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized Husqvarna workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. - Page 82 WHEELS, TIRES – Briefly strike each spoke with the tip of a screwdriver. Info The tone frequency depends on the length of the spoke and the spoke diam- eter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions.
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Page 83: Electrical System
ELECTRICAL SYSTEM 15.1 Removing the battery (All TE 250/300) Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –... -
Page 84: (All Te 250/300)
– Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give it to your Husqvarna dealer or to a disposal center for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 85: Changing The Main Fuse (All Te 250/300)
ELECTRICAL SYSTEM 15.4 Changing the main fuse (All TE 250/300) Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box lid. Preparatory work –... -
Page 86: Installing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM (TE US) – Detach brake line and wiring harness – Release rubber straps . Slide the headlight mask up and swing it forward. L02616-10 – Detach plug-in connector and take off the headlight mask with the headlight. S00512-11 15.6 Installing the headlight mask with the headlight... -
Page 87: Changing The Headlight Bulb
ELECTRICAL SYSTEM – Position the headlight mask and secure it with rubber straps The holding lugs engage. L02617-10 – Position brake line and wiring harness in the brake line guide. S00510-10 Finishing work – Check the headlight setting. ( p. -
Page 88: Changing The Turn Signal Bulb (Te Eu/Au)
ELECTRICAL SYSTEM – Pull out headlight bulb – Insert the new headlight bulb. Headlight (HS1 / Sockel BX43t) ( p. 117) – Insert the protection cap with the bulb socket into the reflector and turn it all the way clockwise. -
Page 89: Adjusting The Headlight Range
ELECTRICAL SYSTEM » If the light-dark border does not meet specifications: – Adjust the headlight range. ( p. 87) 15.10 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 86) Main work – Loosen screw –... -
Page 90: Cooling System
COOLING SYSTEM 16.1 Cooling system (All TE 125) Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. -
Page 91: Checking The Coolant Level
COOLING SYSTEM 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. -
Page 92: Refilling With Coolant
COOLING SYSTEM (All TE 250/300) – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) L02611-11 16.5... - Page 93 COOLING SYSTEM – Place the vehicle back on a level surface. – Fill the radiator completely with coolant. – Mount radiator cap – Run the engine until it is warm. – Check the coolant level. ( p. 89) L02610-10...
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Page 94: Tuning The Engine
TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back and forth slightly to ascertain play in the throttle cable. Play in throttle cable 2…... -
Page 95: Carburetor
TUNING THE ENGINE 17.3 Carburetor The idle setting of the carburetor has a big influence on the starting behavior, on sta- ble idling, and on the vehicle response when the throttle is opened. This means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly. Info The carburetor and its components are subject to greater wear due to engine vibrations. -
Page 96: Emptying The Carburetor Float Chamber
TUNING THE ENGINE Guideline Idle air adjusting screw (TE 125 EU) Open 2.75 turns Idle air adjusting screw (TE 125 US) Open 1.5 turns Idle air adjusting screw (TE 250 EU) Open 1.5 turns Idle air adjusting screw (TE 250 US) Open 2.0 turns Idle air adjusting screw (All TE AU) -
Page 97: Plug-In Connection, Ignition Timing Map
TUNING THE ENGINE Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. -
Page 98: Checking The Basic Position Of The Shift Lever
TUNING THE ENGINE 17.8 Checking the basic position of the shift lever – Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10…... -
Page 99: Engine Characteristic - Setting The Auxiliary Spring (All Te 250/300)
TUNING THE ENGINE 17.11 Engine characteristic - setting the auxiliary spring (All TE 250/300) Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these components to cool down before starting work on them. -
Page 100: Service Work On The Engine
SERVICE WORK ON THE ENGINE 18.1 Checking the gear oil level Info The gear oil level must be checked while the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work (All TE 125) –... -
Page 101: Draining The Gear Oil
SERVICE WORK ON THE ENGINE 18.3 Draining the gear oil Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 102: Adding Gear Oil
SERVICE WORK ON THE ENGINE Main work – Remove screw cap and fill up gear oil. Gear oil (All 0.70 l (0.74 qt.) Engine oil (SAE 10W/40) ( p. 121) TE 125) Gear oil (All 0.80 l (0.85 qt.) Engine oil (SAE 10W/40) ( p. - Page 103 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effec- tive exhaust extraction system.
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Page 104: Cleaning, Care
CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts. -
Page 105: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt. -
Page 106: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info Husqvarna recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 43) – Cover the vehicle with an air-permeable cover or blanket. -
Page 107: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Go through the steps of starting the engine. tric starter) p. 30) (All TE 250/300) Battery discharged – Recharge the battery. p. 82) – Check the charging voltage. –... - Page 108 TROUBLESHOOTING Faults Possible cause Action – Engine has too little power Diaphragm or reed valve housing Check the diaphragm and reed valve housing. damaged – Engine stalls or is popping into the Lack of fuel Turn tap handle on the fuel tap to position carburetor ON.
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Page 109: Technical Data
TECHNICAL DATA 22.1 Engine 22.1.1 All TE 125 Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing... -
Page 110: All Te 300
TECHNICAL DATA Transmission ratio First gear 14:32 Second gear 16:26 Third gear 20:25 Fourth gear 22:23 Fifth gear 25:22 Sixth gear 26:20 Ignition Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan Ignition point (BTDC) 1.9 mm (0.075 in) Spark plug NGK BR 7 ES Spark plug electrode gap... -
Page 111: All Te 250
TECHNICAL DATA 22.2 Engine tightening torques 22.2.1 All TE 125 ® – EJOT DELTA PT Screw, inner membrane sheets 35x25 1 Nm (0.7 lbf ft) ® – Screw, membrane support plate EJOT DELTA PT 30x12 1 Nm (0.7 lbf ft) –... - Page 112 TECHNICAL DATA ® – Screw, outer clamping plate EJOT DELTA PT 30x6 1 Nm (0.7 lbf ft) ® Screw, angle lever, exhaust control 6 Nm (4.4 lbf ft) Loctite 243™ – Screw, clutch spring retainer 6 Nm (4.4 lbf ft) ®...
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Page 113: Carburetor
TECHNICAL DATA 22.3 Carburetor 22.3.1 TE 125 EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK125 Needle position 4th position from top Jet needle N84I (N1EF/N1EG) Main jet 100 (172/175) Idling jet 38x38 (42/45) Starting jet 50 (85) Idle air adjusting screw Open 2.75 turns... -
Page 114: Te 250 Us
TECHNICAL DATA Throttle slide 7 with cut-out Slide stop Present 22.3.5 TE 250 US Carburetor type KEIHIN PWK 36S AG Carburetor identification number Needle position 3rd position from top Jet needle N2ZW (N2ZH/N2ZJ) Main jet 175 (172) Idling jet 38 (40) Starting jet Idle air adjusting screw Open... -
Page 115: Carburetor Tuning
TECHNICAL DATA 22.4 Carburetor tuning 22.4.1 Carburetor tuning (All TE 125) Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homolo- gous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. 402138-01 M/FT ASL Sea level... -
Page 116: Carburetor Tuning (All Te 250)
TECHNICAL DATA 22.4.2 Carburetor tuning (All TE 250) Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homolo- gous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. 402140-01 M/FT ASL Sea level... -
Page 117: Carburetor Tuning (All Te 300)
TECHNICAL DATA 22.4.3 Carburetor tuning (All TE 300) Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homolo- gous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. 402141-01 M/FT ASL Sea level... -
Page 118: General Carburetor Tuning
TECHNICAL DATA 22.4.4 General carburetor tuning 1... 5 Needle position from above The five possible needle positions are shown here. 0 0 1 The carburetor tuning depends on the defined ambient and operating conditions. 0 0 2 0 0 3 0 0 4 0 0 5 B00075-10... -
Page 119: Electrical System
140/80 - 18 M/C 70R TT Michelin ENDURO COMPETITION IV Michelin ENDURO COMPETITION IIIe (TE US) 90/90 - 21 M/C 51M TT 110/100 - 18 M/C 64M TT Dunlop GEOMAX AT81F Dunlop GEOMAX AT81 Additional information is available in the Service section under: www.husqvarna-motorcycles.com... -
Page 120: Fork
TECHNICAL DATA 22.9 Fork 22.9.1 All TE 125 Fork part number 24.18.7N.61 Fork WP Suspension Up Side Down 4860 4CS Compression damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Rebound damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Spring length with preload spacer(s) 470 mm (18.5 in) -
Page 121: Shock Absorber
TECHNICAL DATA 22.10 Shock absorber 22.10.1 All TE 125 Shock absorber part number 18.15.7N.61 Shock absorber WP Suspension 5018 BAVP DCC Compression damping, low-speed Comfort 20 clicks Standard 18 clicks Sport 16 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1.5 turns... -
Page 122: Chassis Tightening Torques
TECHNICAL DATA Static sag 30 mm (1.18 in) Riding sag 100 mm (3.94 in) Fitted length 490 mm (19.29 in) Shock absorber fluid ( p. 122) SAE 2.5 22.11 Chassis tightening torques – Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) –... -
Page 123: Substances
SUBSTANCES Brake fluid DOT 4 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. Recommended supplier ® Bel‑Ray – Super DOT 4 Brake Fluid Coolant Guideline –... - Page 124 SUBSTANCES Hydraulic oil (15) Standard/classification – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...
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Page 125: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel‑Ray – Foam Filter Cleaner & Degreaser High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier ® Bel‑Ray – Waterproof Grease Offroad chain spray Guideline Recommended supplier ®... -
Page 126: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines. -
Page 127: Index
INDEX INDEX Cleaning, care ......102-103 Clutch Accessories ....... . . 9 fluid level, checking/rectifying . - Page 128 INDEX Foot brake lever free travel, checking ......71 Ignition timing map Foot brake pedal ......19 changing .
- Page 129 INDEX securing ....... . . 63 Throttle cable play adjusting ....... . . 92 Throttle cable routing Safe operation .
- Page 130 *3402022en* 3402022en 07/2014 Husqvarna Motorcycles GmbH 5230 Mattighofen Stallhofnerstraße 3 Photo: Austria Mitterbauer/Husqvarna Motorcycles GmbH...
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