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Husqvarna 125 TC EU Owner's Manual

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Service Work on Engine
OWNER'S MANUAL 2014
125 TC EU
250 TC EU
Art. no. 3402001en

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  Summary of Contents for Husqvarna 125 TC EU

  • Page 1 OWNER'S MANUAL 2014 125 TC EU 250 TC EU Art. no. 3402001en...
  • Page 3 Husqvarna accepts no liability for deliv- ery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS Starting off ............21 MEANS OF REPRESENTATION ......... 4 Shifting, riding ............21 Symbols used ............4 Braking ..............21 Formats used............4 Stopping, parking..........22 SAFETY ADVICE ..............5 Transport ............. 22 Use definition - intended use........5 Refueling..............
  • Page 5 Installing the radiator cover........70 20.10 Carburetor tuning..........97 14.4 Removing the radiator cover ........ 71 20.10.1 Carburetor tuning (125 TC EU) ......97 14.5 Checking the antifreeze and coolant level..... 71 20.10.2 Carburetor tuning (250 TC EU) ......98 14.6...

  • Page 6: 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 cared for by specially trained experts using the special tools required.

  • Page 7: Safety Advice

    SAFETY ADVICE Use definition - intended use Husqvarna sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations. Info The motorcycle may only be used in closed off areas remote from public road traffic.

  • Page 8: Protective Clothing

    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 9: Important Information

    Manufacturer and implied 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 & warranty booklet and in the Husqvarna dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 10: View Of Vehicle

    VIEW OF VEHICLE View of the vehicle from the left front (example) L01903-10 Filler cap Air filter box lid Fuel tap ( p. 13) Choke ( p. 13) Shift lever ( p. 13) Plug-in stand ( p. 14)

  • Page 11: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) L01904-10 Clutch lever ( p. 11) Kill switch ( p. 11) Fork compression adjustment Throttle grip ( p. 11) Hand brake lever ( p. 11) Shock absorber rebound adjustment Level viewer for brake fluid, rear Shock absorber compression adjustment Foot brake lever ( p.

  • Page 12: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 13: Controls

    CONTROLS Clutch lever (125 TC EU) The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. L01907-10 (250 TC EU) The clutch lever is fitted on the left side of the handlebar.

  • Page 14: Map-Select Switch (250 Tc Eu)

    CONTROLS Map‑Select switch (250 TC EU) The Map‑Select switch is fitted on the right side of the handlebar. Possible states Performance – This position is used for higher performance. Soft – This position is used for better rideability. The engine characteristic can be changed on the handlebar using the Map‑Select switch.

  • Page 15: Fuel Tap

    6.10 Shift lever Shift lever is mounted on the left side of the engine. 401950-10 (125 TC EU) The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11...

  • Page 16: Kick Starter

    CONTROLS (250 TC EU) The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-13 6.11 Kick starter The kick starter is fitted on the right side of the engine. The top part can be swiveled. L01606-10 6.12 Foot brake lever...

  • Page 17: 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 receive a delivery certificate and the service record at vehicle handover.

  • Page 18: Running In The Engine

    PREPARING FOR USE – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 335 kg (739 lb.) Maximum permissible front axle load 145 kg (320 lb.) Maximum permissible rear axle load 190 kg (419 lb.) –...

  • Page 19: Preparations For Riding On Wet Sand

    PREPARING FOR USE – Change the radiator cap. – Mount the dust cover for the air filter. Dust cover for air filter (77206920100) Info Observe the Husky Power fitting instructions. B00435-01 – Mount the dust cover for the air filter for sand. Sand cover for air filter (59006922000) Info Observe the Husky Power fitting instructions.

  • Page 20: Preparations For Riding On Wet And Muddy Surfaces

    PREPARING FOR USE – Clean the chain. – Mount the steel sprocket. Do not grease the chain. – Clean the radiator fins. – Carefully align bent radiator fins. – If used in sand regularly, replace the piston every 10 operating hours. 600868-01 Preparations for riding on wet and muddy surfaces –...

  • Page 21: Preparing For Riding At Low Temperatures Or In Snow

    PREPARING FOR USE Preparing for riding at low temperatures or in snow – Mount the rain cover for 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-...

  • Page 22: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance work 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. 81) –...

  • Page 23: 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 24: 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 25: Refueling

    7.5 l (1.98 US gal) Super unleaded (98 octane) mixed with capacity, approx. 2-stroke engine oil (1:40) ( p. 101) (125 TC EU) Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60) ( p. 101) 401522-10 (250 TC EU) Engine oil, 2-stroke ( p.

  • Page 26: Service Schedule

    ● ● ● 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 27: Service Work (As Additional Order)

    SERVICE SCHEDULE Service work (as additional order) Annually Every 40 operating hours - corresponds to about 280 liters of fuel (74 US gal) Once after 20 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. ●...

  • Page 28: 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 29: 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 30: Measuring The Sag Of The Unloaded Rear Wheel

    – 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 (125 TC EU) Comfort 17 clicks Standard 15 clicks Sport 13 clicks...

  • Page 31: 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 32: Adjusting The Riding Sag

    After removing the shock absorber, clean it thoroughly. Main work – Choose and mount a suitable spring. Guideline Spring rate (125 TC EU) Weight of rider: 65… 75 kg (143… 45 N/mm (257 lb/in) 165 lb.) Weight of rider: 75… 85 kg (165…...

  • Page 33: Adjusting The Compression Damping Of The Fork

    Make the same adjustment on both fork legs. – Turn counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping (125 TC EU) L01909-10 Comfort 14 clicks Standard...

  • Page 34: Handlebar Position

    TUNING THE CHASSIS 10.14 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 35: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with the lift stand – Raise the motorcycle at the frame below the engine. The wheels should no longer touch the ground. – Secure the motorcycle against falling over. Lift stand (54829055000) 401942-01 11.2 Removing the motorcycle from the lift stand...

  • Page 36: 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 37: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11.8 Installing the fork legs Main work – Position the fork legs. Bleeder screws face forward. Info Grooves are milled into the side of the upper end of the fork legs. The sec- ond milled groove (from the top) must be flush with the top edge of the upper triple clamp.

  • Page 38: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11.10 Installing the fork protector Main work – Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the fork protection on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)

  • Page 39: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11.12 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 102) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 40: 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 41: Adjusting The Play Of The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS – Move the handlebar to and fro over the entire steering range. The handlebar must be able to move easily over the entire steering range. There should be no perceptible detent positions. » If detent positions are noticeable: –...

  • Page 42: Installing The Start Number Plate

    SERVICE WORK ON THE CHASSIS 11.17 Installing the start number plate – Position the start number plate. Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) The holding lugs engage. – Position brake line in the brake line guide. B01875-10 11.18 Removing the front fender...

  • Page 43: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11.20 Removing the shock absorber Preparatory work – Raise the motorcycle with the lift stand. ( p. 33) – Remove the right side cover. ( p. 45) – Remove the main silencer. ( p. 44) Main work –...

  • Page 44: Removing The Seat

    SERVICE WORK ON THE CHASSIS 11.22 Removing the seat – Remove screws in the recessed grips on the left and right. – Raise the rear of the seat, push the seat back, and lift it off. B01819-10 11.23 Mounting the seat –...

  • Page 45: Cleaning The Air Filter And Air Filter Box

    SERVICE WORK ON THE CHASSIS Main work – Push air filter holder toward the air filter at position and detach it at end Swing the air filter holder to one side and remove the air filter with the air filter sup- port.

  • Page 46: Sealing The Air Filter Box

    SERVICE WORK ON THE CHASSIS 11.29 Sealing the air filter box – Seal the air filter box in the marked area 401559-01 11.30 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. –...

  • Page 47: 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 48: 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 49: 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 50: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS – Clean the chain regularly and then treat with chain spray. 400725-01 11.39 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.

  • Page 51: 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 adjusting screws to the left and right. 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 52 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower bolt edge of the chain is in line with or below the chain sliding guard: – Change the chain sliding guard. – Check the chain sliding guard for tightness. »...

  • Page 53: 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 11.44 Checking the routing of the throttle cable Preparatory work –...

  • Page 54: Checking The Rubber Grip

    The twisted wire ends face away from the hands and are bent toward the rubber grip. 401198-01 11.47 Adjusting the basic position of the clutch lever (125 TC EU) – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw L01907-11...

  • Page 55: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    11.48 Checking/correcting the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining discs. (125 TC EU) – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 56: Changing The Hydraulic Clutch Fluid

    Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. (125 TC EU) – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
  • Page 57 SERVICE WORK ON THE CHASSIS – Inject the liquid into the system until it escapes from bore hole of the master cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe. Mount and tighten the bleeder screw. –...

  • Page 58: Brake System

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized Husqvarna workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disc to...

  • Page 59: Checking The Front Brake Fluid Level

    (Your authorized Husqvarna workshop will be glad to help.) 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.) Preparatory work –...

  • Page 60: 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 61 BRAKE SYSTEM Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container! –...

  • Page 62: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM – Correct the brake fluid to level Guideline 5 mm (0.2 in) Dimension (brake fluid level below top edge of container) Brake fluid DOT 4 / DOT 5.1 ( p. 100) – Position cover with membrane – Mount and tighten screws Info Wash off overflowed or spilled brake fluid immediately with water.

  • Page 63: Checking The Rear Brake Fluid Level

    (Your authorized Husqvarna workshop will be glad to help.) 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.) Preparatory work –...

  • Page 64: 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 65 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 66 BRAKE SYSTEM – Insert the brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs. Info Make sure that decoupling plate is mounted on the piston side of the brake lining. – Operate the foot brake lever several times until the brake linings are lying correctly against the brake disc and there is a pressure point.

  • Page 67: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 33) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

  • Page 68: Removing The Rear Wheel

    WHEELS, TIRES – 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 the brake disc. – Remove the motorcycle from the lift stand. ( p.

  • Page 69: 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 70: 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 71 WHEELS, TIRES » If the spoke tension varies: – Correct the spoke tension. – Check the spoke torque. Guideline Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Spoke nipple, rear wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Torque wrench with various accessories in set (58429094000)

  • Page 72: Cooling System

    COOLING SYSTEM 14.1 Cooling system (125 TC EU) 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 73: Removing The Radiator Cover

    COOLING SYSTEM – Position the corresponding radiator cover and attach the radiator shield at hold- ing lugs . Attach mounting points at the radiator. L01813-10 14.4 Removing the radiator cover – Detach radiator shield at mounting points and remove it. Remove radiator cover L01812-10 –...

  • Page 74: Checking The Coolant Level

    COOLING SYSTEM » If the level of the coolant does not meet specifications: – Correct the coolant level. Alternative 1 Coolant ( p. 100) Alternative 2 Coolant (mixed ready to use) ( p. 100) – Mount the radiator cap. 14.6 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

  • Page 75: Refilling With Coolant

    COOLING SYSTEM (125 TC EU) – 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)
  • Page 76 COOLING SYSTEM – Move the vehicle into the position shown and prevent it from rolling away. Height difference must be reached. Guideline 75 cm (29.5 in) Height difference Info For all of the air to be able to escape from the cooling system, the vehicle must be raised at the front.

  • Page 77: Tuning The Engine

    TUNING THE ENGINE 15.1 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 determine the play in throttle cable Play in throttle cable 2…...

  • Page 78: Carburetor - Idle

    Carburetor - adjusting the idle speed – Screw in idle air adjusting screw all the way and turn it to the specified basic position. Guideline Idle air adjusting screw (125 TC EU) Open 2 turns Idle air adjusting screw (250 TC EU) Open 2 turns –...

  • Page 79: 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 80: Plug-In Connection, Ignition Timing Map (125 Tc Eu)

    – Mount and tighten the plug. L01657-10 15.6 Plug-in connection, ignition timing map (125 TC EU) Plug-in connection is located under the fuel tank on the frame. Possible states Performance – The plug-in connection is connected to achieve higher performance.

  • Page 81: Adjusting The Basic Position Of The Shift Lever

    TUNING THE ENGINE 15.9 Adjusting the basic position of the shift lever – Remove screw and take off shift lever 401950-12 – 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.
  • Page 82 TUNING THE ENGINE – Take cap , adjusting spring , auxiliary spring , and spring insert out of the clutch cover. – Pull both springs off of the spring insert. B00056-11 – Mount the required auxiliary spring and adjusting spring and slide them into the clutch cover together.

  • Page 83: Service Work On The Engine

    The gear oil level must be checked while the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work (125 TC EU) – Remove screw from the opening used to check the gear oil level. –...

  • Page 84: Draining The Gear Oil

    Preparatory work – Park the motorcycle on a level surface. – Place a suitable container under the engine. Main work (125 TC EU) – Remove the gear oil drain plug with magnet – Remove gear oil drain plug – Completely drain the gear oil.

  • Page 85: Adding Gear Oil

    The gear oil must be added while the engine is cold. Preparatory work – Park the motorcycle on a level surface. Main work (125 TC EU) – Remove screw from the opening used to check the gear oil level. L01711-10 (250 TC EU) –...
  • Page 86 SERVICE WORK ON THE ENGINE – Start the engine and check that it is oil-tight.

  • Page 87: Cleaning, Care

    CLEANING, CARE 17.1 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 88: Storage

    401058-01 – 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. 33) – Cover the vehicle with a tarp or cover that is permeable to air.

  • Page 89: Troubleshooting

    Clean and dry the spark plug, or change it if necessary. – Electrode distance (plug gap) of spark Adjust the plug gap. plug too wide Guideline (125 TC EU) Spark plug electrode gap 0.60 mm (0.0236 in) (250 TC EU) Spark plug electrode gap 0.60 mm (0.0236 in) –...
  • Page 90 TROUBLESHOOTING Faults Possible cause Action – Engine overheats Foam formation in cooling system Drain the coolant. p. 72) – Refill with coolant. p. 73) – Damaged cylinder head or cylinder Check the cylinder head or cylinder head gas- head gasket ket.

  • Page 91: Technical Data

    TECHNICAL DATA 20.1 Engine 20.1.1 125 TC EU 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...

  • Page 92: Engine Tightening Torques

    NGK BR 8 ECM Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kick starter 20.2 Engine tightening torques 20.2.1 125 TC EU – ® Screw, inner membrane sheets EJOT DELTA PT 35x25 1 Nm (0.7 lbf ft) ®...

  • Page 93: Tc Eu

    TECHNICAL DATA – Nut, rotor M12x1 60 Nm (44.3 lbf ft) – Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) – Spark plug M14x1.25 25 Nm (18.4 lbf ft) ® Nut, primary gear M16LHx1.5 130 Nm (95.9 lbf ft) Loctite 243™...

  • Page 94: Capacities

    Ground clearance unloaded (125 TC EU) 395 mm (15.55 in) Ground clearance unloaded (250 TC EU) 385 mm (15.16 in) Weight without fuel, approx. (125 TC EU) 92.3 kg (203.5 lb.) Weight without fuel, approx. (250 TC EU) 97.8 kg (215.6 lb.) Maximum permissible front axle load 145 kg (320 lb.)

  • Page 95: Tires

    TECHNICAL DATA 20.5 Tires Validity Front tires Rear tires (125 TC EU) 80/100 - 21 51M TT 100/90 - 19 57M TT Dunlop GEOMAX MX51 FA Dunlop GEOMAX MX51 (250 TC EU) 80/100 - 21 51M TT 110/90 - 19 62M TT...

  • Page 96: Shock Absorber

    Oil capacity fork leg without 380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 100) cartridge 20.7 Shock absorber 20.7.1 125 TC EU Shock absorber part number 18.15.7N.51 Shock absorber WP Suspension 5018 BAVP DCC Compression damping, low-speed Comfort 17 clicks...

  • Page 97: Chassis Tightening Torques

    TECHNICAL DATA Weight of rider: 85… 95 kg (187… 209 lb.) 57 N/mm (325 lb/in) Spring length 260 mm (10.24 in) Gas pressure 10 bar (145 psi) Static sag 30 mm (1.18 in) Riding sag 100 mm (3.94 in) Fitted length 486 mm (19.13 in) Shock absorber oil ( p.

  • Page 98: Carburetor

    42 (40, 45) Starting jet Idle air adjusting screw Open 2 turns Throttle slide 7 with cut-out 20.9.2 Carburetor - basic setting for sandy surfaces (125 TC EU) Idle air adjusting screw Open 1.5 turns Idling jet Jet needle NOZG Needle position...

  • Page 99: Carburetor Tuning

    TECHNICAL DATA 20.10 Carburetor tuning 20.10.1 Carburetor tuning (125 TC EU) 401762-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from above Main jet Info Not for sandy surfaces...

  • Page 100: Carburetor Tuning (250 Tc Eu)

    TECHNICAL DATA 20.10.2 Carburetor tuning (250 TC EU) 401764-01 M/FT ASL Sea level TEMP Temperature Open idle air adjusting screw Idling jet Needle Needle position from above Main jet Info Not for sandy surfaces...

  • Page 101: General Carburetor Tuning

    TECHNICAL DATA 20.10.3 General carburetor tuning 1... 5 Needle position from top 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 102: 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 103 SUBSTANCES Shock absorber oil (SAE 2.5) (50180342S1) Standard/classification – SAE ( p. 103) (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 98 / RON 98 / PON 94) Standard/classification –...

  • Page 104: Auxiliary Substances

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

  • Page 105: 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 106: Index

    INDEX INDEX Compression damping fork, adjusting ......31 Accessories ....... . . 7 Compression damping, high-speed Air filter shock absorber, adjusting .
  • Page 107 INDEX Fork protector installing ....... . . 36 Operating substances ......7 removing .
  • Page 108 INDEX Starting ........20 Steering head bearing greasing .
  • Page 109 *3402001en* 3402001en 11/2013 Husqvarna Motorcycles GmbH 5230 Mattighofen Stallhofnerstraße 3 Photo: Austria Mitterbauer/Husqvarna Motorcycles GmbH...

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250 tc eu