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Husqvarna TE 125 EU Owner's Manual

Husqvarna motorcycles 2014 owner's manual
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OWNER'S MANUAL 2014
TE 125 EU
TE 250 EU
TE 250 AUS
TE 250 USA
TE 300 EU
TE 300 AUS
TE 300 USA
Art. no. 3402005en

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  Summary of Contents for Husqvarna TE 125 EU

  • Page 1 OWNER'S MANUAL 2014 TE 125 EU TE 250 EU TE 250 AUS TE 250 USA TE 300 EU TE 300 AUS TE 300 USA Art. no. 3402005en...
  • Page 3 Husqvarna accepts no liability for delivery options, deviations from illustrations and descriptions or misprints and other errors.
  • 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 ..........23 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 ...... 69 12.6 Positioning the fork protection......44 13.9 Checking the free travel of the foot brake lever..70 12.7 Removing the fork legs ........44 13.10 Adjusting the basic position of the foot brake lever ..............
  • Page 6 TABLE OF CONTENTS STORAGE ..............102 20.1 Storage.............. 102 20.2 Preparing for use after storage ......102 TROUBLESHOOTING ............ 103 TECHNICAL DATA ............105 22.1 Engine..............105 22.1.1 TE 125 ............105 22.1.2 All TE 250............105 22.1.3 All TE 300............106 22.2 Engine tightening torques........
  • 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/AUS) 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 Information

    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) L01612-10 Filler cap Air filter box lid Fuel tap ( p. 17) 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) L01613-10 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/AUS) The type label is fixed to the front of the steering head. 401946-10 Key number (TE EU/AUS) The key number for the steering lock is stamped onto the key connector.
  • 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 The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. C00530-10 Hand brake lever The hand brake lever is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. L01615-10 Throttle grip The throttle grip...
  • Page 17: Horn Button (Te Eu/Aus)

    CONTROLS Horn button (TE EU/AUS) The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – The horn is operated in this position. • Horn button C00546-11 Light switch (TE EU/AUS) The light switch is fitted on the left side of the handlebar.
  • Page 18: Electric Starter Button (Te 250/300 Eu/Usa)

    CONTROLS 6.11 Electric starter button (TE 250/300 EU/USA) The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in the basic position pressed – The electric starter is actuated in this position. •...
  • Page 19: Closing The Filler Cap

    CONTROLS 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 20: Choke

    CONTROLS 6.18 Choke The choke knob is fitted on the left side of the carburetor. Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function must be deactivated.
  • Page 21: Side Stand

    CONTROLS 6.22 Side stand The side stand is on the left side of the vehicle. 401943-10 The side stand is used to park the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber band 401944-10 6.23...
  • Page 22: Unlocking The Steering (Te Eu/Aus)

    CONTROLS 6.25 Unlocking the steering (TE EU/AUS) – Insert the key in the steering lock, turn it to the left, pull it out, and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock.
  • 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 Clock

    SPEEDOMETER Setting the clock Condition The motorcycle is stationary. – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. – Wait for the menu of the clock to flash. – Press one of the buttons to select the 24h or 12h display of the clock. 401911-01 –...
  • Page 26: Speed, Time, And Dst Distance 1

    SPEEDOMETER Speed, time, and DST distance 1 – Press one of the buttons until DST appears on the speedometer. KM/H or M/H shows the speed. shows the time. DST shows the distance since the last reset, such as between two refueling stops. Info If the value of 39999.9 is exceeded, DST 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. 96) –...
  • 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 Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –...
  • 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. 84) ● ● 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 (TE 125) Comfort 17 clicks Standard 15 clicks Sport 13 clicks L01669-12 Rebound damping (TE 250/300)
  • 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) – Install the main silencer. ( p. 54) – Install the right side cover. ( p. 55) – Remove the motorcycle from the lift stand. ( p. 43) 11.10 Adjusting the riding sag Preparatory work...
  • Page 43: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn the white adjusting screw all the way clockwise. Info Adjusting screw is located at the upper end of the left fork leg. The compression damping is located in the left fork leg COMP (white adjust- ing screw).
  • Page 44: Handlebar Position

    TUNING THE CHASSIS 11.14 Handlebar position On the upper triple clamp, there are two holes a distance of apart. Hole distance A 15 mm (0.59 in) The holes on the handlebar support are placed at a distance of from the center. Hole distance B 3.5 mm (0.138 in) The handlebar can be mounted in four different positions.
  • 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) The wheels should no longer touch 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 – Loosen screws . Remove the fork leg on the left. – Loosen screws . Remove the fork leg on the right. L01667-10 12.8 Installing the fork legs Main work – Position the fork legs. Info The rebound damping is located in the right fork leg (red adjusting screw).
  • 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. 121) – 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 » If detent positions are noticeable: – Adjust the play of the steering head bearing. p. 49) – Check the steering head bearing and change if necessary. Finishing work – Remove the motorcycle from the lift stand. ( p.
  • Page 52: Installing The Front Fender

    SERVICE WORK ON THE CHASSIS – Remove screws . Take off the fender. C00572-12 12.17 Installing the front fender Main work – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) C00572-11 –...
  • Page 53: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS – Remove screw – Lift off the shock absorber. L01664-11 12.19 Installing the shock absorber Main work – Slip in the shock absorber from the top. – Position the shock absorber. – Mount and tighten screw Guideline Loctite ®...
  • Page 54: Removing The Air Filter Box Lid

    SERVICE WORK ON THE CHASSIS 12.22 Removing the air filter box lid – Release catch , pull off the air filter box lid sideways in areas remove toward the rear. L01631-10 12.23 Installing the air filter box lid – Position the air filter box lid and tab .
  • Page 55: Cleaning The Air Filter And Air Filter Box

    SERVICE WORK ON THE CHASSIS – Insert both parts together, position them, and fasten them using air filter holder area The arrow of marking UP faces up. Info If the air filter is not correctly mounted, dust and dirt can enter the engine and cause damage.
  • Page 56: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 12.28 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Preparatory work – Remove the right side cover.
  • Page 57: Removing The Right Side Cover

    SERVICE WORK ON THE CHASSIS Main work – Remove screws . Pull out inner tube – Pull the glass fiber yarn filling from the inner tube. – Clean the parts that are to be reinstalled. – Mount the new glass fiber yarn filling on the inner tube.
  • Page 58: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 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.
  • Page 59: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS Main work – Position the fuel tank and fit the two spoilers to the sides of the radiator bracket. – Make sure that no cables are trapped or damaged. L01671-10 – Mount the fuel tank vent hose. –...
  • Page 60: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly and then treat with chain spray. 400725-01 12.37 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. –...
  • Page 61: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning the left and right adjusting screws Guideline Chain tension 55… 58 mm (2.17… 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks .
  • Page 62 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with or below the chain sliding guard: – Change the chain sliding guard. – Check the chain sliding guard for tightness. »...
  • Page 63: Checking The Frame

    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 64: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS (TE 250/300) – Check the throttle cable routing. The throttle cable must be routed to the carburetor on the left side of the upper frame tube behind the handlebars. » If the throttle cable is not routed as specified: –...
  • Page 65: Checking/Rectifying The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS Info Turn the adjusting screw counterclockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw clockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force.
  • Page 66: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 12.47 Changing the hydraulic clutch fluid Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. (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: 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 69: 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 70: 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 71: 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 72: 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 the pin, and mount the cotter pin. Info Always change the brake linings in pairs.
  • Page 73: Checking The Rear Brake Fluid Level

    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 74: 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 Environmental hazard Hazardous substances cause environmental damage.
  • Page 75: Changing 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 76 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated properly. L00194-10 – Insert the new brake linings, insert the pin, and mount the cotter pin. Info Always change the brake linings in pairs. –...
  • Page 77: 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 78: 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 M24x1.5 45 Nm (33.2 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly against on the brake disc.
  • Page 79: 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 80: 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 81 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.
  • Page 82: Electrical System

    ELECTRICAL SYSTEM 15.1 Removing the battery 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 83: Recharging The Battery (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 84: Changing The Main Fuse (Te 250/300)

    ELECTRICAL SYSTEM 15.4 Changing the main fuse (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 85: Installing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 15.6 Installing the headlight mask with the headlight Main work – Plug in connector – Check that the lighting is functioning properly. – Attach headlight holder at catch and position the headlight mask. B01787-11 – Position rubber bands around the fork legs and close them.
  • Page 86: Changing The Turn Signal Bulb (Te Eu/Aus)

    ELECTRICAL SYSTEM 15.8 Changing the turn signal bulb (TE EU/AUS) Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.
  • Page 87: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 15.10 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 84) Main work – Turn adjusting screw to adjust the headlight range. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with a rider (instructions on how to apply the mark: Checking the head- light setting).
  • Page 88: Cooling System

    COOLING SYSTEM 16.1 Cooling system (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 89: 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 90: Refilling With Coolant

    COOLING SYSTEM (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) L01653-11 16.5 Refilling with coolant Warning...
  • Page 91 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. 87) L01708-10...
  • Page 92: 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 93: 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 94: Emptying The Carburetor Float Chamber

    TUNING 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.
  • Page 95: Plug-In Connection, Ignition Timing Map

    TUNING THE ENGINE Main work – Place a cloth beneath the carburetor to soak up emerging fuel. – Remove screw plug – Completely drain the fuel. – Mount and tighten the screw plug. L01657-10 17.6 Plug-in connection, ignition timing map Plug-in connection is located in front of the fuel tank on the left side of the frame.
  • Page 96: Engine Characteristic - Auxiliary Spring (Te 250/300)

    TUNING THE ENGINE – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gear- ing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.
  • Page 97 TUNING THE ENGINE – Mount the required auxiliary spring and adjusting spring and slide them into the clutch cover together. Auxiliary spring with yellow marking (54637072300) Auxiliary spring with green marking (54837072100) Auxiliary spring with red marking (54837072000) The cut-out of spring insert engages in the angle lever.
  • Page 98: 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 (TE 125) – Remove screw from the opening used to check the gear oil level.
  • Page 99: 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 100: Adding Gear Oil

    SERVICE WORK ON THE ENGINE Main work – Remove screw cap and fill up gear oil. Gear oil (TE 125) 0.70 l (0.74 qt.) engine oil (15W/50) ( p. 119) Gear oil 0.80 l (0.85 qt.) engine oil (15W/50) ( p.
  • Page 101 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.
  • Page 102: 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 103 CLEANING, CARE – Clean the motorcycle. ( p. 100) – Clean the brakes. Info After EVERY trip on salted roads, thoroughly wash the brake calipers and brake linings with cold water and dry carefully. This should be done after the parts are cooled down and while they are installed.
  • Page 104: 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 105: 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) (TE 250/300) Battery discharged – Recharge the battery. p. 81) – Check the charging voltage. –...
  • Page 106 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.
  • Page 107: Technical Data

    TECHNICAL DATA 22.1 Engine 22.1.1 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 108: 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 109: Engine Tightening Torques

    TECHNICAL DATA 22.2 Engine tightening torques 22.2.1 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 110: Capacities

    TECHNICAL DATA ® – Screw, outer membrane sheets 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) ®...
  • Page 111: Chassis

    TECHNICAL DATA 22.4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing WP Suspension Up Side Down 4860 4CS Fork Suspension travel Front 300 mm (11.81 in) Rear 330 mm (12.99 in) Fork offset (TE 125) 22 mm (0.87 in) Fork offset (TE 250/300) 20 mm (0.79 in) Shock absorber...
  • Page 112: Electrical System

    (TE USA) 80/100 - 21 M/C 51M TT 110/100 - 18 M/C 64M TT Dunlop GEOMAX MX51 FA Dunlop GEOMAX MX51 Additional information is available in the Service section under: www.husqvarna-motorcycles.com 22.7 Fork 22.7.1 TE 125 Fork part number 24.18.7N.61...
  • Page 113: Shock Absorber

    TECHNICAL DATA 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) 472 mm (18.58 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.0 N/mm (22.8 lb/in) Weight of rider: 75…...
  • Page 114: Chassis Tightening Torques

    TECHNICAL DATA Standard 18 clicks Sport 16 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Rebound damping Comfort 20 clicks Standard 18 clicks Sport 16 clicks Spring preload 10 mm (0.39 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 51 N/mm (291 lb/in) Weight of rider: 75…...
  • Page 115: Carburetor

    TECHNICAL DATA – Engine bracket screw 60 Nm (44.3 lbf ft) – Remaining nuts, chassis 45 Nm (33.2 lbf ft) – Remaining screws, chassis 45 Nm (33.2 lbf ft) ® Screw, bottom shock absorber 60 Nm (44.3 lbf ft) Loctite 2701™...
  • Page 116: 22.10.4 Te 250 Usa

    TECHNICAL DATA Open 3.5 turns Throttle slide 7 with cut-out Slide stop Present 22.10.4 TE 250 USA Carburetor type KEIHIN PWK 36S AG Carburetor identification number Needle position 4th position from top Jet needle N8RJ (N8RW / N8RK) Main jet 168 (165) Idling jet 40 (38 / 42)
  • Page 117: Carburetor Tuning

    TECHNICAL DATA 22.11 Carburetor tuning 22.11.1 Carburetor tuning (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. 401769-01 M/FT ASL Sea level...
  • Page 118: Carburetor Tuning (All Te 250)

    TECHNICAL DATA 22.11.2 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. 401770-01 M/FT ASL Sea level...
  • Page 119: Carburetor Tuning (All Te 300)

    TECHNICAL DATA 22.11.3 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. 401767-01 M/FT ASL Sea level...
  • Page 120: General Carburetor Tuning

    TECHNICAL DATA 22.11.4 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 121: Substances

    SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. Coolant Guideline – Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming. –...
  • Page 122 SUBSTANCES Shock absorber oil (SAE 2.5) (50180342S1) Standard/classification – SAE ( p. 122) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...
  • Page 123: Auxiliary Substances

    AUXILIARY SUBSTANCES High viscosity grease Recommended supplier ® – LGHB 2 Rubber grip adhesive (00062030051) Recommended supplier KTM-Sportmotorcycle AG – GRIP GLUE...
  • Page 124: 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 125: Index

    INDEX INDEX Cleaning, care ......100-101 Clutch Accessories ....... . . 9 fluid level, checking/rectifying .
  • Page 126 INDEX Foot brake lever free travel, checking ......70 Ignition timing map Foot brake pedal ......18 changing .
  • Page 127 INDEX securing ....... . . 62 Throttle cable play adjusting ....... . . 90 Throttle cable routing Safe operation .
  • Page 128 *3402005en* 3402005en 10/2013 Husqvarna Motorcycles GmbH 5230 Mattighofen Stallhofnerstraße 3 Photo: Austria Mitterbauer/Husqvarna Motorcycles GmbH...