Husqvarna SMR Owner's Manual
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Husqvarna SMR Owner's Manual

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Summary of Contents for Husqvarna SMR

  • Page 1 ENGLISH...

  • Page 2: Presentation

    Information covering repair of major units such as engine, transmission, etc. is provided in the Husqvarna Service Manual. The information concerning details or main work of repair or 2) TE and SMR are STREET LEGAL ENDURO maintenance are described in the Husqvarna Service Manual.
  • Page 3 Parts Replacement or damaged. Even slight or involuntary bumps can cause usage very different from those presented on the road. When parts replacement is required, use only Husqvarna the vehicle to topple over, with subsequent risk of se- ORIGINAL parts.

  • Page 4: Table Of Contents

    Page TABLE OF CONTENTS Note G References to the “left” or “right” of the motorcycle are in the sense of a person facing forwards. PRESENTATION................2 IMPORTANT NOTICES...............2 IDENTIFICATION DATA .............5 G Z: number of teeth TECHNICAL DATA ..............10 G A: Austria LUBRICATION TABLE, SUPPLIES ..........12 AUS:...

  • Page 5: Identification Data

    IDENTIFICATION DATA The engine number is printed on the upper side of the engine case, whereas the frame number is printed on the steering tube . Always state the number stamped on the frame (and write it on this booklet), when placing orders for spare parts, or when asking for information on your motorcycle.
  • Page 6 VEHICLE IDENTIFICATION NUMBER (V.I.N.) The full 17 digit serial, or Vehicle Identification Number, is stamped on the steering head tube (R.H. side). 1. Frame serial number 2. Engine serial number (*): Progressiv nr. (l): Year of the model...
  • Page 7 VEHICLE IDENTIFICATION NUMBER (V.I.N.) The full 17 digit serial, or Vehicle Identification Number, is stamped on the steering head tube (R.H. side). 1. Frame serial number 2. Engine serial number (*): Progressiv nr. (l): Year of the model...
  • Page 8 VEHICLE IDENTIFICATION NUMBER (V.I.N.) The full 17 digit serial, or Vehicle Identification Number, is stamped on the steering head tube (R.H. side). (*): Progressiv nr. (l): Year of the model 1. Frame serial number 2. Engine serial number...
  • Page 9 Control location 1. Front brake lever 10. L.H. commutator (TE, SMR) 2. Throttle grip 10. Engine stop button (TC-TXC) 3. Rear brake control pedal 11.Clutch control lever 4. Choke (L.H. side) 12. Fuel cock (TC-TXC) 5. Fuel tank filler cap 13.

  • Page 10: Technical Data

    CLUTCH Type .............single cylinder, 4 stroke Type.......oil bath multiple disc clutch, hydraulic control Type (TE-SMR)...............Electronic injection feed Cooling.......liquid with electric fan on TE-SMR models e (TC-TXC 250) ”Keihin” FCR-MX 37 with acceleration pump and TRANSMISSION Bore (250)..............2.99 in. throttle position sensor Type ...............constant mesh gear type...
  • Page 11 Front (TE, TC, TXC) ..TAKASAGO “Excel” in light alloy: 1,6x21” 5th gear (TC 510) ............8,778 (•)Cold tire press. (front SMR, rider and passenger) 2,0 kg/cm 2 --28.4 p.s.i. Front (SMR)......SANREMO in light alloy: 3,50x17” 5th gear (SMR 450-510) ..........7,560 Rear (TE, TXC) ..TAKASAGO “Excel”...
  • Page 12 Dry weight, “ready to race” (TE 250 I.E.) ....lb 235.9 AGIP FORK 2,5 (SAE 2,5) Dry weight, “ready to race” (TE 450-510 I.E.) ..... lb 246.9 Dry weight, “ready to race” (SMR 450-510 I.E.) ..lb 260.1 Electric contact protection AGIP CONTACT CLEANER...

  • Page 13: Controls

    CONTROLS 1 Loosen the input plug (1) on the fuel tank and close the tap; FUEL INJECTION ENGINE (TE-SMR) 2 Remove the fuel hose (3) from the carburetor and insert the On vehicles which are fitted with a fuel injection engine, the FUEL COCK (TC-TXC) hose in a vessel;...
  • Page 14 SIDESTAND FUEL A sidestand (1) is supplied with every motorcycle. Recommended fuel: premium grade unleaded fuel. (R.O.N. 98). WARNING*: The stand is designed to sup- Note*: Do not continue operation if the en- port the weight of the MOTORCYCLE ONLY. gine pings or knocks.
  • Page 15 CARBURETOR CHOKE (TC-TXC) COLD START (TE-SMR) The starter knob, located on the left side of the carburetor, is For a cold start, the models with a fuel injection engine are fit- used to enrich the mixture during the engine start.
  • Page 16 “NEUTRAL” in case of FUEL INJECTION SYSTEM 3- SPEED / CLOCK (figure 3, page 17) malfunction (contact your local HUSQVARNA Dealer) The motorcycle is equipped with a digital instrument; on the 4- SPEED / TRIP 1 (figure 4, page 18)
  • Page 17 1- SPEED (kmh or mph) / ODO / RPM (fig- 3- SPEED / CLOCK / RPM (figure 3) 2- SPEED / H / RPM (figure 2) ure 1) - SPEED: motorcycle speedmaximum value: 299 kmh or 299 - SPEED: motorcycle speedmaximum value: 299 kmh or 299 mph; - SPEED: motorcycle speed- maximum value: 299 kmh or 299 mph;...
  • Page 18 4- SPEED / TRIP 1 / RPM (figure 4) 6- SPEED / AVS 1 / RPM (figure 6) 5- SPEED / STP 1 / RPM (figure 5) - SPEED: motorcycle speedmaximum value: 299 kmh or 299 - SPEED: motorcycle speedmaximum value: 299 kmh or 299 - SPEED: motorcycle speedmaximum value: 299 kmh or 299 mph;...
  • Page 19 7- SPEED / V MAX / RPM (figure 7) 8- SPEED / TRIP 2 / RPM (figure 8) 10- SPEED /RPM (engine r.p.m. numerical value) (figure 10) - SPEED: motorcycle speedmaximum value: 299 kmh or 299 - SPEED: motorcycle speedmaximum value: 299 kmh or 299 mph;...
  • Page 20 THROTTLE CONTROL STEERING LOCK (TE-SMR) The throttle knob (1), is located on the right hand side of the The motorcycle is equipped with a steering lock (1) on the R.H. handlebar. The position of the throttle control can be adjusted side of the steering head tube.
  • Page 21 The right commutator has the following controls: CONTROLS: cated the engine stop button. 1) Engine start button 3) Engine start - stop switch (TE-SMR) CLUTCH CONTROL High beam flash (self cancelling) The hydraulic clutch control lever is located on the left-hand...
  • Page 22 The lever (1) is placed on the left-hand side of the engine. The operator must release the lever after each gear change to al- the motorcycle. On models TE and SMR as stop switch, during the braking action, causes the rear light to come on.

  • Page 23: Riding

    Check bearing play. Change the oil and carry out all the necessary maintenance op- B. fuel level 11. Check the electric system (TE- SMR). Start the erations. After the first half-hour of driving, lightly increase the C. coolant level engine and check that the front and rear lamps, the stop rev number, but never run the engine at full throttle.
  • Page 24 ENGINE START (TE-SMR) 3) pull the clutch lever (3); NOTE 4) shift gear pedal (4) in neutral position then release the A safety switch is set on the clutch lever support. This switch al- With cold engine, as after a prolonged inactivity of the motor- clutch control lever;...
  • Page 25 STARTING DECOMPRESSOR ENGINE START (TXC) Though the engine is provided with an automatic decompressor, Make sure the fuel tap is in the OPEN position, then shift gear can be necessary, in some cases (carburetor flooding or starting pedal in neutral position. difficulties due to a battery inadequate charge), to use the man- Pull the starter knob (BLACK knob (2) for cold starting*, RED ual starting decompressor on the L.H.
  • Page 26 ENGINE START (TC-TXC) 3) pull the starter knob (BLACK knob 2 for cold starting*, 4) lower the starter pedal (4) until a certain resistance is no- RED knob 3 for warm starting) ticed (piston at T.D.C.); Proceed as follows: 1) make sure the fuel tap (A) is in the Open position; *: after a prolonged inactivity of the motorcycle or in presence 2) shift gear pedal (1) in neutral positio.
  • Page 27 5) pull the lever (5) and lower further, by a limited stroke, the 6) at this point, release the lever (5) and the pedal (4); 7) in the case of COLD STARTING, completely rotate the throttle pedal until the abovementioned resistance is overcome (6) twice (in the case of warm starting DO NOT carry out this operation);...
  • Page 28 8) COMPLETELY lower the pedal (4) until the engine starts. IMPORTANT IMPORTANT NOTE IN CASE OF COLD STARTS AT Never accelerate the engine after a cold start. LOW TEMPERATURES WARM STARTING: BEFORE MOTORCYCLE STARTING, PRESS RED CHOKE KNOB (3) ON WARNING*: Exhaust contains poisonous car- It is recommended to briefly warm-up the engine at idle until, CARBURETOR TOWARD THE INSIDE IN ORDER...
  • Page 29 HOT START (TC-TXC) 3) pull the clutch lever (3); 5) Then release the clutch lever (3). 4) push the kick-starter pedal (5) to start the vehicle. If it is a problem to start the engine when hot, or following a BEFORE MOVING OFF, DEACTIVATE THE RED fall, proceed as follows: KNOB (2) OF THE STARTER ON THE CARBURET-...
  • Page 30 WARNING*: In the event of stuck throttle or - TC-TXC: close the fuel cock (4). other malfunction which causes the engine - TE-SMR: turn towards left the ignition key. - Close the throttle (1) completely so that the engine will help to run uncontrollably, immediately depress slow down the motorcycle.
  • Page 31 CHECKING THE OIL LEVEL - remove the three filters (4), (5) and (6) on the L.H. side of ENGINE OIL REPLACEMENT AND BAG FILTERS-FIL- the engine, check O-Rings for wear then clean filters with fu- TER CARTRIDGE CLEANING OR REPLACEMENT Keeping the motorbike level and in a vertical position, check the el;...
  • Page 32 The coolant should be approximately 10 mm above cells and FIRST remove the screw (1) then SLOWLY open the R.H. radia- besides, on TE-TXC and SMR models, it doesn't exceed the mid- tor cap; slope the motorcycle on the right side to drain the...
  • Page 33 Periodically check the connecting hoses (see “Periodical main- THROTTLE CABLE ADJUSTMENT NOTE tenance card”): this will avoid coolant leakages and conse- To check the correct adjustment of the throttle operate as fol- In case of throttle control cables (1) and (2) replacement it is quent engine seizure: If hoses (A) show cracks, swelling or lows: necessary to respect, during reassembly, the measure Á...
  • Page 34 ADJUSTING THE CARBURETTOR (TC-TXC) ADJUSTING THE IDLE (TE-SMR) Adjust the carburettor with warm engine and with the throttle Adjust the carburetor with warm engine and with the throttle in closed position. control in closed position. Proceed as follows: Work as follows:...
  • Page 35 SPARK PLUG CHECK Correct heat rating: VOLTAGE REGULATOR (TXC-TE-SMR) The tip of the insulator should be dry and the colour should be Use NGK CR8EB spark plug; the gap is 0.027 in. The voltage regulator (3) is fitted to the right side of the chas- light brown or grey.
  • Page 36 ADJUSTING THE VALVE PLAY HOW TO REMOVE THE TANK (TC-TXC) Remove the locking screw (A) and pull out the tank with its conveyors. To check the valve clearance, proceed as follows , WITH COLD Close the fuel tap (2) and loosen the strap (3) on the connect- ENGINE: ing pipe to the carburettor, pull the pipe out of the carburettor.
  • Page 37 Lift the tank, then disconnect the connector of the fuel pump Pull out the tank with its conveyors. HOW TO REMOVE THE TANK (TE-SMR) from the main cabling. Remove the screws (1) and the side panels. Remove the lock- Disconnect the feeding pump (B) from the outlet coupling (C) ing screw (A) of the tank.
  • Page 38 Remove the spark plug (5), the four cylinder head cover fas- Otherwise, lift the retaining clip (7) using a hook, let the rock- Check, by means of a feeler gauge, that the valve clearance is tening screws (6) and the cylinder head cover. er arm slide to one side, extract the pad with a pair of pliers 0,10÷0,15 mm (0.004÷0.006 in.) for INTAKE and 0,15÷0,20 Engage second gear and, moving the vehicle forwards and...
  • Page 39 AIR FILTER CHECK AIR FILTER AND CLEANING ASSEMBLY Turn rear pin (1) counterclockwise, remove the saddle from the Wash the filter with a specific detergent (AGIP” Filter clean To ensure tight fit, slightly (C) grease filter edge on side facing front afstening screw.
  • Page 40 STEERING WHEEL BALL PLAY ADJUSTMENT If play is noticed, proceed with adjustment as follows: Tighten steering sleeve nut (1) to a torque setting of lloosen steering sleeve nut (1). 57,9÷65,1 Lb/ft; (78,4÷88,3 Nm). To ensure maximum safety, the steering wheel should always be lLoosen four screws that fix steering head to fork rods (3).
  • Page 41 ADJUSTMENT OF THE CONTROL LEVER AND on the rear side of the pump body (TE, TC). For SMR model, CAUTION*: Do not spill brake fluid on to CHECK OF THE FRONT BRAKE FLUID LEVEL any painted surface or lenses. check the level on the fluid reservoir.
  • Page 42 REAR BRAKE PEDAL POSITION ADJUSTMENT The adjusting operation carried out, adjust the idle stroke of Should this not happen as follows: the pedal as indicated in page 43. - loosen nut (3); The position of the rear foot brake pedal as to the footrest may operate the pump rod (4) to increase or decrease the idle be adjusted according to the individual needs.
  • Page 43 CHECKING THE FLUID LEVEL - by keeping the master cylinder (3) in horizontal position, CAUTION*: NEVER use brake fluid. check the fluid level is NOT BELOW 4 mm (0.16 in.) from the The level (A) must be set between the pump tank notches. upper surface (D) of the pump body;...
  • Page 44 HYDRAULIC CLUTCH BLEEDING The fluid level MUST NEVER BE below 4 mm from the top (A) of the clutch pump body (see picture). Reassemble the re- Proceed as follows: moved parts. - remove screws (1), cap (2) and rubber pump diaphragm; - remove the bleeding nipple (3);...
  • Page 45 ADJUSTING THE SUSPENSIONS ACCORDING TO NOTE: PARTICULAR TRACK CONDITIONS When the fork results as either too soft or too hard for any ad- much oil inside the fork will involve a more frequent air justment conditions, check the oil level inside the forkrod. drainage.
  • Page 46 The springs available upon request, Standard calibration: - 15 clicks (TC-TXC); TE-SMR: set the motorcycle on a central stand and release the together with the preload spacers, are shown on pages 95, 96, Standard calibration: - 12 clicks (TE-SMR).
  • Page 47 OIL QUANTITY IN EACH FORK LEG - TC: 310 cm 3 (18.9 cu. in.) - TE: 775 cm 3 (47.3 cu. in.) - SMR: 740 cm 3 (45.1 cu. in.) A=100mm (3.94 in.) - SMR A=120mm (4.72 in.) - TE...
  • Page 48 HANDLEBAR POSITION AND HEIGHT CHANGE a) Handlebar position change b) Handlebar height change Turn the lower clamp (2) 180° to move forward or backward Remove the lower spacer (A) then replace the screw (4) with a The handlebar position (a) and height (b) can be changed for (10mm- 0.04in.) the handlebar position with respect to the new one of L=65 mm (2.56 in.) height.
  • Page 49 ADJUSTING THE SHOCK ABSORBER 4. The difference between these two measurements constitutes ADJUSTING THE SHOCK ABSORBER SPRING PRELOAD the “SAG” of the motorcycle’s rear end. The rear shock absorber must be adjusted according to the rid- Suggested SAG: 4 in. with cold shock absorber. 3.7 in. with er weight and track conditions.
  • Page 50 2. Clean ringnut (1) and adjusting nut (2) of the spring (3). SHOCK ABSORBER DAMPING ADJUSTMENT B) EXTENSION - Standard calibration: 3. Either with a hook wrench or an aluminium punch, loosen - 18 clicks (± 2 clicks) Adjustment of the compression stroke is independent from the the ringnut .
  • Page 51 CHAIN ADJUSTMENT Fast adjustment (Fig. B). In the point shown in the figure, fit a bush (a), 35 mm diame- Fig. B Chain should be checked, adjusted and lubricated as per the ter (or alternatively a shim in the same size) and make sure Maintenance Chart to ensure security and prevent excessive the lower branch (C) of the chain is slightly taut.
  • Page 52 CHECKING THE WEAR OF CHAIN, PINION AND Check the pinion damages or wear and replace it should the LUBRICATING THE CHAIN SPROCKET wear degree be as the one shown in figure. Remove the wheel and check the wear of the rear sproket Lubricate the chain following these instructions.
  • Page 53 2 - Check that the chain is neither worn out nor damaged. If the Lubricating the chain with OR WARNING: The chain oil has NEVER to get in rollers or the links are damaged, replace the chain by fol- Lubricate all metallic and rubber (OR) elements using a brush, contact with the tires or the rear brake lowing the instructions given in the Periodical Maintenance and use engine oil with SAE 80-90 viscosity for the internal...
  • Page 54 (2) to the front fork stanchions. SMR: remove the two screws (A) and the brake caliper. Hold the head of the wheel axle (2) in place, unscrew the bolt (3) on the opposite side; draw the wheel axle out.
  • Page 55 7.7 ft-lb). brake disc is fitted into the caliper. SMR: fit the brake caliper on the disc; assemble the caliper on SMR: Fit the wheel between the front fork legs. its holding plate and tighten the screws (A) at 25,5 Nm/ 2,6 Fit the wheel axle (2) from the R.H.
  • Page 56 REMOVING THE REAR WHEEL NOTES Do not operate the rear brake pedal when the wheel has been Unscrew the nut (1) of the wheel pin (3) and extract it. It is not removed; this causes the caliper piston to move outwards. necessary to unloose the chain adjusters (2);...
  • Page 57 2. Front brake pump with oil reservoir (TE, TC,TXC) 11. Rear brake control pedal THE TREAD 2. Front brake pump (SMR) 2A. Oil reservoir (SMR) FRONT 3 mm (TC,TE,TXC); 2 mm (SMR) 3. Front brake hose REAR 3 mm (TC,TE,TXC); 2 mm (SMR) TE-TC-TXC...
  • Page 58 PADS WEAR (TE-TC-TXC) PADS WEAR (SMR) BRAKE PADS REMOVAL Inspect pads for wear. a) In front: thickness “A” must never be lower than the one - Remove springs (1). Service limit " A" is: 3,8 mm (0.15 in.). pointed out by the wear control notches.
  • Page 59 PADS CLEANING WARNING! Do not attempt to ride the motorcycle until Be careful that no disc brake fluid or any oil gets on brake the brake lever or pedal are pads or discs. Clean off any fluid or oil that inadverently gets fully effective.
  • Page 60 Replace the disc if it has worn past the service Replace the disc if warpage is more than service limit. limit. Disc Thickness DISC STANDARD SERVICE LIMIT Front 3 mm 2,5 mm (TE-TC-TXC) Front 5 mm 4,5 mm TE-TC-TXC (SMR) Rear 4 mm 3,5 mm TE-TC-TXC...
  • Page 61 DISC CLEANING FLUID CHANGE Poor braking can also be caused by oil on the disc. Oil or The brake fluid should be checked and changed in accordance grease on the disc must be cleaned off with a high flash-point with the Periodic Maintenance Chart or whenever it is contami- oil free solvent, such as acetone or lacquer thinner.
  • Page 62 To replace the fluid, proceed as follows: TE-TC-TXC - Remove the rubber cap on the bleeding valve (1) or (1A). - Attach a clear plastic hose to the bleeding valve on the brake caliper and turn the other end of the hose into a container. - Remove fluid reservoir cap (2)or (2A: 21 mm wrench) and the rubber.
  • Page 63 - Pump with brake lever (3) or brake pedal (3A) in order to - Restore the brake fluid level (A) or (B) then reassemble the push brake fluid out of line. rubber and the fluid reservoir cap (page 62). - Close the bleeding valve and fill the reservoir with fresh brake fluid.
  • Page 64 FRONT BRAKING SYSTEM BLEEDING (TE, TC, TXC) WARNING! The braking system must be bled after the fluid replacement or Brake fluid quickly ruins painted surfaces; when, due to air in the circuit, the lever stroke is long and any spilled fluid should be completely spongy.
  • Page 65 - Remove fluid reservoir cap (2), the rubber and fill the reser- WARNING! voir with fresh brake fluid. During the bleed operation the fluid level If the lever stroke gets stretchy and - Open the bleeding valve and pump with brake lever (3) sev- inside the reservoir must never be lower the braking action results as poor in eral times until the fluid, clear and without bubbles, comes...
  • Page 66 - Attach a clear plastic hose to the bleeding valve on the brake - Open the bleeding valve and pump with brake lever several FRONT BRAKING SYSTEM BLEEDING (SMR) caliper and turn the other end of the hose into a container...
  • Page 67 - Restore the brake fluid level (A) then reassemble the rubber During the bleeding of the braking REAR BRAKING SYSTEM BLEEDING and the fluid reservoir cap. circuit keep the handlebar turned leftwards. This is the way to lift the The braking system must be bled after the fluid replacement or when, due to air in the circuit, the pedal stroke is long and pump tank and to make easier the bleeding of the braking system.
  • Page 68 - Attach a clear plastic hose to the bleed valve (1) on the cal - Depress the pedal (2) and keep it full down. - Close the bleed union to the prescribed torque and check the per and turn the other end of the hose into a container. - Loosen the bleed union letting out fluid (at first, only air will fluid level (B) inside the reservoir before reassemblle the cap come out), then, closing the union slightly.
  • Page 69 EXHAUST MUFFLER NOTE: When diffuculties are found in remov- REPLACING THE MUFFLER DEADENING MATERIAL ing the muffler, lightly beat with a rubber The muffler reduces the noise of the exhaust gases, but it is an First turn counterclockwise fastening rear pin (1) then remove or plastic hammer.

  • Page 70: Service Limits

    This chapter shows the main checks to be carried out when the engine and some parts of the byke must be overhauled. More detailed information, together with the disassembly/re- assembly procedures are carried in the Husqvarna’s Workshop Manual. CYLINDER-PISTON FITTING The cylinder and piston are supplied matched;...
  • Page 71 Take the piston diameter at “B” distance of 6 mm/0.24 in. (TE- TC 250), 9 mm/0.35 in. (TC 450-510), 10 mm/0.39 in. (TE- CLEARANCE WEAR LIMIT SMR 450) o 11 mm/0.43 in. (TE-SMR 510) from the base. 250: 0,020÷0,046 mm 250: 0,10 mm 250: 0.00079÷0.00181 in.
  • Page 72 "C" TE, TC 250: 0,040÷0,110 mm 0,22 mm "C" TC 450-510: 0,040÷0,120 mm 0,24 mm "C" TE- SMR 450: 0,020÷0,110 mm 0,20 mm "C" TE- SMR 510: 0,010÷0,180 mm 0,35 mm PISTON RING CUT SETTING *: “d” CUT POSITION PISTON RING CUT SETTING...
  • Page 73 (H) between the two piston ring end gap. 250 (A): 0,20÷0,35 mm/0.00787÷0.0138 in. 250 (A): 0,5 mm/0.0197 in. TE-SMR 450, TC-TXC 510 (A): 0,25÷0,40 mm/0.0094÷0.0157 in. TE-SMR 450, TC 510 (A): 0,7 mm/0.027 in. TE-SMR 510 (A): 0,20÷0,45 mm/0.00787÷0.0177 in.
  • Page 74 COUPLING THE CONNECTION ROD SMALL END PIN When assembling, the coupling play must be 0.012÷0.027 The maximum wear limit allowed is 0.055 mm. CRANKSHAFT OUT-OF-AXIS CONNECTING ROD BIG END RADIAL PLAY CONNECTING ROD BIG END SIDE CLEARANCE MAX DESALIGNMENT MAX WEAR MAX WEAR STANDARD STANDARD...
  • Page 75 CLUTCH UNIT Check the distortion of each plate (both lined and unlined) by resting on a flat surface; use a feeler gauge. The clutch plates should not be burnt or scored. Wear limit: 0,2 mm (0.00078 in.). Check the thickness of the clutch lining plate. CLUTCH HOUSING-FRICTION DISC CLEARANCE STANDARD MAX-WEAR LIMIT...
  • Page 76 CLUTCH SPRING VALVE GUIDE - check the concetricity of the valve head by resting an angle comparator against the head and then rotate the valve in a Vee block. Wear limit:0.0012 in. Measure the free length “L” of each spring using a gauge. Accurately check the valve guide.
  • Page 77 CAMSHAFT VALVE SPRING The weakening of the springs causes a decrease of the engine Check that cam surfaces are scored, stepped, grooved etc. power and it aften is responsible of the noise and the vibra- Insert the camshaft between two references and then check de- viation using two comparators.
  • Page 78 OVERHAULING THE WHEELS DEFORMATION RIM WHEEL SPOKES The tables hereunder show the type of control the rim and Check to make sure that all the nipples are tight; tighten them wheel axle are to be submitted to. STANDARD MAX.LIMIT if necessary. Remember that an insufficient stretch jeopardizes the motorcy- Note*: if the rim is badly, it should be re- less than 0,5 mm...
  • Page 79 - Electronic coil (2) under the fuel tank; - Flashing indicator device (17) - Electronic power unit C.D.I. (3) under the fuel tank; - Voltage regulator (4) under the fuel tank (TE-TXC-SMR) - LAMBDA probe (18) - Spark plug (5) on the R.H. side of cylinder head;...
  • Page 80 - Fuel pump (19) into the tank fuel. O/Bk Orange/Black LEGENDA SCHEMA ELETTRICO (TE -SMR) Pink Cable colour coding 1.Electronic power unit 36. Fall sensor (SMR) 2. Alternator 37. Fuses Blue R/Bk Red/Black 3. Voltage regulator 38. Power relay B/Bk...
  • Page 81 TE-SMR TURN HORN PASSING 2 3 4 5 6 7 9 10 11 13 14 15 16 18 19 20 23 24 25 26 27 29 30 31 32 33 34 1 2 3 4 5 6 7 8 9...
  • Page 82 Cable colour coding KEY TO ELECTRIC DIAGRAM (TC-TXC 250) 1. Electronic power unit Blue 2. Alternator Brown 3. Voltage regulator 4. Condenser Black 5. Battery Green 6. Electric start remote control switch Grey 7. Starting motor Gr/R Grey/Red 8. Spark plug Orange 9.
  • Page 83 TC-TXC 250 CENTRALINA CONDENSATORE GENERATORE SENSORE MARCE REGOLATORE BATTERIA Bk-W TELERUTTORE INTERR. AVVIO FRIZIONE MOTORE ARRESTO W-Br MOTORE BOBINA MOTORINO BK-R BK-R AVVIAMENTO CANDELA SENSORE APERTURA SCHEMA PER INSERIMENTO AVVIAMENTO ELETTRICO FARFALLA *: ELECTRIC STARTER KIT...
  • Page 84 Cable colour coding KEY TO ELECTRIC DIAGRAM (TC,TXC 450-510) 1. Electronic power unit 2. Alternator Blue 3. Voltage regulator Brown 4. Condenser Black 5. Battery Green 6. Electric start remote control switch 7. Starting motor Grey 8. Spark plug Gr/R Grey/Red 9.
  • Page 85 TC,TXC 450-510 CONDENSATORE CENTRALINA GENERATORE SENSORE MARCE REGOLATORE BATTERIA Bk-W TELERUTTORE INT. AVVIO ARRESTO FRIZIONE MOTORE W-Br MOTORE BOBINA MOTORINO BK-R BK-R AVVIAMENTO CANDELA SENSORE APERTURA FARFALLA SCHEMA PER INSERIMENTO AVVIAMENTO ELETTRICO *: ELECTRIC STARTER KIT...
  • Page 86 When electrolyte leaks, or other failures to the electrical system - remove the battery (3) from its housing. are detected, apply to the HUSQVARNA Dealer. Always check the charge level bifore reinstalling it on the vehi- If the vehicle remains unused for long periods, it is recom- Check, using a voltmeter, that battery voltage is not less than cle.
  • Page 87 WARNING*: Batteries produce explosive gas, ventilate when charging or using in en- closed space. When using a battery charger before turning on the charger. This proce- dure prevents sparks at the battery termi- nals which could ignite any battery gases. INDICATIVE VALUES RELATIVE TO THE CHARGING TIME DEPENDING ON BATTERY STATUS VOLTAGE * (V) % CHARGE CHARGE TIME (THE “AMPERE”...
  • Page 88 HEADLAMP BULBS REPLACEMENT (TE-SMR) REAR TAIL LIGHT BULB REPLACEMENT (TE- SMR) To gain access to the healamp bulbs, proceede as follows: - remove the two fastening elastics (1) and the headlamp Remove the two fastening screws (1) in the inner side of the holder;...
  • Page 89 Pull the lamp (3) inside, turn it counterclockwise then remove REPLACING THE NUMBER PLATE LAMP (TE- SMR) it from the lamp holder. Pull out the number plate lampholder (4) from the back of the After replacement, reverse operations for reassembly.
  • Page 90 ADJUSTMENT OF HEADLIGHT (TE- SMR) Adjust the preadlamp aiming by turning screw (1) to lower or lift the high beam. When checking the proper orienting of headlight, inflate tires at right pressure, sat a person on the saddle and place the mo- torcycle perpendicular with its longitudinal axis 10 meter (33 ft) from a wall or screen.

  • Page 91: Special Tools

    SPECIAL TOOLS 1517 94702 Crankcase puller 8000 A1580 Crankshaft guard 8000 A1559 Flywheel extractor (TC) 8000 B0144 Flywheel extractor (TE-SMR) 8000 A1512 Ignition checking tool 8A00 90622 Support for assy 8000 A5773 Half cone assembling tool (250: intake and exhaust)

  • Page 92: Tightening Torques

    Centrifugal disc on INTAKE CAMSHAFT fastening M6x1 (+LOCTITE 243) 8 Nm 5,8 ft/lb M6x1 4,9 Nm 3.6 ft/lb Front brake hose upper fastening screw (TE, SMR) screw M10x1 19 Nm 14 ft/lb Front brake hose upper fastening screw (TC-TXC) Timing chain slider fastening screw...
  • Page 93 Rocker arm to frame fastening pivot M10x1,25 52,4 Nm 38.6 ft/lb Front brake caliper fastening screw M8x1,25 25,5 Nm 18.8 ft/lb Chain guide to rear swing arm fastening screw (TE-SMR) M8x1,25 25 Nm 18.4 ft/lb Brake hoses lower fastening screw M10x1 19 Nm 14 ft/lb...

  • Page 94: Kits

    Carburetor KEIHIN 41 Kit (TC -TXC 450/510)-RACING 2A 80A0 A6211 Hand guards kit (TE) 3 8000 B0157 Engine guard (TE-TC-TXC) 4 8000 B0152 Compl. footrest Kit (TE-SMR) 5 8000B0150 Blinkers Kit (TE-SMR) 6 8000A6441 Hook Kit for race starting TC-TXC phase (TC-TXC)

  • Page 95: Optional Parts List

    OPTIONAL PARTS LIST (TE) 1- Engine seals kit (250) 8000 B0373 Engine seals kit (450-510) 8000 B0364 2- Rear sprocket 8A00 96837 (Z=47) & 8B00 96837 (Z=48) 8C00 96837 (Z=49) 8D00 96837 (Z=50) § 3-Drive sprocket 8000 63827 (Z=12) 8000 63828 (Z=13) * 8000 63829 (Z=14) 8000 63830 (Z=15) 4- Workshop manual...
  • Page 96 OPTIONAL PARTS LIST (TC) 1- Engine seals kit (250) 8000 A5735 Engine seals kit (450-510) 8000 A5736 2. Workshop manual 8000 B0148 3. Rear sprocket 8A00 96837 (Z=47) && 8B00 96837 (Z=48) 8C00 96837 (Z=49) 8D00 96837 (Z=50) §,& 4. Drive sprocket 8000 63827 (Z=12) §...
  • Page 97 OPTIONAL PARTS LIST (TXC) 1- Engine seals kit (250) 8000 A5735 Engine seals kit (450-510) 8000 A5736 2. Workshop manual 8000 B0148 3. Rear sprocket 8A00 96837 (Z=47) 8B00 96837 (Z=48) 8C00 96837 (Z=49) 8D00 96837 (Z=50) § 4. Drive sprocket 8000 63827 (Z=12) 8000 63828 (Z=13) * 8000 63829 (Z=14)
  • Page 98 OPTIONAL PARTS LIST (SMR) 1- Engine seals kit 8000 B0364 2- Rear sprocket 8000 A4859 (Z=42) * 8A00 A4859 (Z=43) 8B00 A4859 (Z=44) 8G00 96837 (Z=45) 3- Drive sprocket 8000 63829 (Z=14) * 4- Workshop manual 8000B0148 5- Front fork oil (1000 cm3 container)

  • Page 99: Appendix

    APPENDIX - Lubricate the drive chain and all the cables. CLEANING - Spray oil on all unpainted metal surfaces to prevent rusting. AFTER-RACE CHECK POINTS Avoid getting oil on rubber parts or in the brakes. IMPORTANT RECOMMENDATION After racing, first clean the motorcycle and then inspect the en- - Set the motorcycle on a box or stand so that both wheels are Premised that, before the motorcycle washing, it is necessary to tire motorcycle, with special attention to the items listed in...
  • Page 100 1) Preparation for washing 2) Where to be careful WARNING*: Never wax or lubricate the Before washing, precautions must be taken to keep water out Avoid spraying water with any great force near the following brake disc. Loss of braking and an accident of the following places: places: could result.

  • Page 101: Pre-Delivery Inspection

    PRE -DELIVERY INSPECTION Description Operation Pre-delivery Description Operation Pre-delivery Engine oil Check level Tyres Check pressure Side stand Check operation Two-stroke mix oil level Check level Coolant Check / Restore level Side stand switch Check operation Cooling system Check for leakage Electrical equipment Check operation J A A...
  • Page 102 NOTES FOR USA/CDN MODEL DISCLAIMER OF WARRANTY IN ACCEPTING DELIVERY OF THIS MOTORCYCLE THE BUYER OR TRANSFEREE ACKNOWLEDGES THAT HE HAS THOROUGHLY INSPECTED THE MOTORCYCLE, AND FURTHER AGREES TO ACCEPT THE MOTORCYCLE AS IS WITH ALL DEFECTS OR FAULTS, CONCEALED OR OBVIOUS. HE FURTHER AGREES THAT NO WARRANTIES ATTACH, EXPRESS OR IMPLIED, INCLUDING ANY WAR- RANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
  • Page 103 Tampering warning Warning statement Tampering with Noise Control System Prohibited. This product should be checked for repair or replacement if the Federal law prohibits the following acts or causing thereof: motorcycle noise has increased significantly through use. (1) The removal or rendering inoperative by any person other Otherwise, the owner may become subject to penalties under than for purposes of maintenance, repair, or replacement, state and local ordinances.
  • Page 104 (8); then pull out the muffler. the screws in the correct position, providing a tight connec- The TE/TXC/SMR models are equipped with a U.S. Forest tion between endcap and silencer’s body, using, if neces- Service approved spark arrester for maximum efficienty and Note*: If silencer or exhaust are difficult to sary, a silicone paste;...

  • Page 105: Tampering Warning

    NOTES FOR “AUS” MODEL Tampering Warning: Tampering with Noise Control System Prohibited. Federal law prohibits the following acts or causing therefor: 1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, 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, and 2) The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 107 Adjusting shock absorber preload spring ..........49 Engine oil replacement ..............31 Adjusting the rear brake pedal position..........42 Engine start (TC)................24 Adjusting the steering bearing play..........40 Engine start (TE-SMR) ..............26 Rear brake control ..............22 Adjusting the suspensions according Engine stop..................30 Rear braking system bleeding............67 to the track special conditions ............45...

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