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TXC 450 2009
Husqvarna TXC 450 2009 Manuals
Manuals and User Guides for Husqvarna TXC 450 2009. We have
1
Husqvarna TXC 450 2009 manual available for free PDF download: Workshop Manual
Husqvarna TXC 450 2009 Workshop Manual (412 pages)
Brand:
Husqvarna
| Category:
Motorcycle
| Size: 62.52 MB
Table of Contents
5
Table of Contents
3
Workshop Manual
7
Important Notices
11
General
12
Table of Contents
13
Cooling
13
Fuel Feeding
13
Ignition
13
Lubrication
13
Timing System
14
Transmission
16
Brakes
16
Frame
16
Suspensions
16
Tires
16
Wheels
19
Capacities
21
Maintenance
29
Troubles and Remedies
35
Settings and Adjustments
36
Table of Contents
41
Adjustment of Starter Decompression Device
42
Throttle Cable Adjustment
43
Carburettor Adjustment (TC, TXC)
43
Idle Adjustment (TC, TXC, SMR 450-R)
43
Idle Adjustment (TE, SMR)
44
Clutch Discs Replacement (TC-TE-TXC-SMR)
45
Adjustment of the Control Lever and Check of the Clutch Fluid Level
46
Adjustment of Front Brake Control Lever and Fluid Level Control (TE-TC-TXC- SMR)
47
Rear Brake Pedal Position Adjustment
48
Checking the Rear Brake Fluid Level
48
Rear Brake Idle Stroke Adjustment
49
Checking the Engine Oil Level
50
Engine Oil Replacement and Bag Filters-Cartridge Filter Cleaning or Replacement
51
Coolant Level Check
51
Replacement of Coolant
52
Air Filter Check (TC-TXC)
53
Air Filter Check (TE-SMR)
55
Secondary Transmission Chain Adjustment
56
Lubricating the Transmission Chain
57
Adjusting the Suspensions According to Particular Track Conditions
58
Adjusting the Shock Absorber
59
Adjusting the Shock Absorber Spring Preload
60
Shock Absorber Hydraulic Brake Adjustment
60
Shock Absorber Springs
61
Adjusting the Front Fork
62
Front Fork Springs
63
Lock Adjustment
63
Steering Bearings Play Adjustment
64
Handlebar Position and Height Change (TE-TC-TXC-SMR)
65
Checking the Fuel Hose
66
Replacing the Muffler Deadening Material (TC-TE-TXC)
67
Replacing the Muffler Deadening Material (SMR)
68
Checking the Exhaust System
69
General Operations
70
General Operations
71
Foreword
72
Removal of Engine From Motorcycle
83
Removal of Saddle and Battery
84
Removal of Side Panels
85
(TE- SMR: with Tail Light) and Air Filter Box Assy
85
Removal of Rear Frame with Fender
88
Removal of Exhaust System
91
Removal of Fuel Tank, Conveyors and Spoiler
93
Removal of Cooling Fan (TE-SMR), Radiators and Coolant Expansion Tank (TE-SMR)
94
Removal of Electronic Power Unit C.D.I., Electronic Coil, Voltage Regulator and Clutch Hose
94
Removal of Secondary Drive Chain
95
Engine Disassembly
96
Table of Contents
98
Camshaft Disassembly
98
Cylinder Head Cover Disassembly
100
Water Pump Body Disassembly
101
Cylinder Head Disassembly
102
Valve Disassembly
104
Cylinder Disassembly
104
Piston Disassembly
105
Flywheel Disassembly
106
Kick Start Pedal Disassembly (TC-TE-TXC)
107
Transmission Cover Disassembly
109
Kick Start Components Disassembly (TC-TE-TXC)
110
Electric Starting System Disassembly (TE, TXC; SMR 450-510)
111
Oil Pump Disassembly
112
Gear Control Pedal and Gear Shifter Disassembly
114
Primary Transmission Driving Gear Disassembly
115
Crankcase Disassembly
116
Gearbox Disassembly
118
Crankshaft and Counter Balancing Shaft Disassembly (SMR 450-510)
121
Engine Overhauling
122
Assemblies
122
Cleaning of Components
122
Cylinder Head
123
Recutting the Valve Seats
125
Replacement of Valve Guides
125
Valve Guides
126
Valve
126
Valve Spring
127
Installation of Valves
128
Inspection of Rocker Arm
128
Starter Decompressor
129
Camshaft
130
Camchain Tensioner
130
Camshaft Chain and Gearing
131
Cylinder
131
Piston
132
Cylinder-Piston Fitting
133
Gudgeon Pin
134
Piston Rings
134
Piston Rings/Cylinder Clearance
135
Piston Ring/Piston Rings Groove Clearance
136
Connecting Rod Big End Side Clearance
136
Crankshaft
137
Connecting Rod Small End Bush Replacement
138
Clutch Housing-Friction Disc Clearance
138
Clutch Spring
138
Clutch Unit
140
Gear Selector Fork and Gearing
140
Oil Pump
141
Selector Drum
147
Engine Reassembly
148
Engine Reassembly
149
General Directions
150
Instructions for Assembly and Lubrication
162
Reassembly of Counter Balancing Shaft Driving Gear (SMR 450-510)
163
Reassembly of Transmission (TE-TXC-SMR)
166
Reassembly of Crankcase
170
Reassembly of Gearshift Mechanism, Electric Starting System and Oil Pump
172
Reassembly of Kick Start Components (TE-TC-TXC)
173
Reassembly of Clutch (TE-TXC-TC; SMR 450-510)
175
Reassembly of Timing System Drive Gear and Chain
176
Reassembly of Flywheel
177
Reassembly of Transmission Cover
185
Reassembly of Cylinder Head Cover, Spark Plug, Lubrication Hose
185
Reassembly of Gear Shift Position Sensor
186
Reassembly of Flywhel Cover
187
Reassembly of the Engine Oil Filters and Drain Plug
188
Engine and Motorcycle Reassembly
190
Cylinder Head Gasket Selection Chart
191
Front Suspension
192
Table of Contents
194
Front Suspension (TE-SMR)
196
Components of the Fork
197
General Rules for a Proper Overhauling
197
Instructions for Clamping in the Vice
198
General Maintenance Operations
198
Problems - Possible Causes - Solutions
199
Bleeding the Air
200
Draining the Oil
201
Braking Down the Pumping Element and the Bottom Valve
203
Braking Down the Fork Leg - Slider and Removing the Oil Seals
204
Cartridge Overhauling (Rebound Braking)
204
Overhauling and Modifying the Cartridge and Bottom Valve Setting
205
Bottom Valve Overhauling (Compression Braking)
206
Re- Assembling the Fork Leg - Slider and Oil Seals
208
Re- Assembling the Pumping Element Unit and the Bottom Valve
211
Filling with Oil
212
Fitting the Fork Back On Themotorcycle
213
Adjustments
213
Compression Adjustment
213
Rebound Adjustment
214
Removing the Front Fork
216
Front Suspension (TC-TXC)
218
Components of the Fork
219
General Rules for a Proper Overhauling
219
Instructions for Clamping in the Vice
221
Cleaning the Fork Legs
222
Bleeding the Air
223
Draining the Oil
224
Valve Setting
226
Checking the Rebound Adjusting Unit
227
Compression Valve Overhauling
228
Re-Assembling the Cartridge Unit
231
Breaking Down the Fork Leg - Slider and Removing the Sealing Rings
232
Re-Assembling the Fork Leg - Slider and Sealing Rings
233
Re-Assembling the Cartridge
234
Filling with Oil
234
Fitting the Fork Back On Themotorcycle
235
Adjustments
235
Initial Suspension Bottoming Adjustment
236
Rebound Adjustment
236
Spring Preload Adjustment
237
Compression Adjustment
238
Removing the Front Fork
241
Rear Suspension
242
Rear Suspension
245
Checking the Shock Absorber
245
Disassembly, Overhauling and Reassembly of the Rear Shock Absorber
245
Overhaul the Spring
246
Removing the Reservoir Plug and the Valve
248
Checks On the Piston Unit
248
Replacing the Gasket
249
Checking the Adjustment
250
Reservoir Replacement
251
Disassembling the Air/Oil Diaphragm of the Reservoir
251
Reassembling the Shock Absorber
254
Shock Absorber Damping Adjustment
255
Disassembly and Overhauling the Rear Swing Arm
256
Overhauling the Rear Swing Arm Axle
256
Overhauling the Rocking Lever and the Rear Suspension Tie Rod
257
Chain Tension Rollers, Chain Driving Roller, Chain Guide, Chain Runner
259
Brakes
271
Brakes
273
Cable Colour Coding (TE-SMR)
274
Cable Colour Coding (TXC 250)
275
Cable Colour Coding (TC, TXC 450-510)
276
Electrical Components Location (Te-Smr)
278
Electrical Components Location (Tc-Txc)
280
Charging System (Tc-Txc)
280
Charging System (Te-Smr)
282
Battery Current Leakage
282
Charging System Checks
282
Generator Stator Coil Resistance Check
282
Regulated Voltage
285
Voltage Regulator-Rectifier Check (TE-SMR-TXC)
286
Electric Starting System (Te-Smr)
286
Electric Starting System (Txc)
287
Starter Motor Check
287
Starter Motor Disassembly
287
Starter System Checks
288
Electric Start Remote Control Switch Check (TE-SMR-TXC)
288
Starter Motor Maintenance
288
Starter Motor Test Diagram
289
Electronic Ignition System (Tc-Txc)
290
Electronic Ignition System (Te-Smr)
290
Electronic Power Unit (ECU)
294
Electronic Power Unit Wiring Diagram (Ecu) (Te-Smr)
295
Voltage Regulator (TE-SMR-TXC)
295
Voltage Regulator-Rectifier Wiring Diagram
296
Spark Plug
297
Gear Shift Position Sensor Check (GPS)
299
Battery Recharge
300
Headlamp Adjustment
300
Headlamp, Tail Lamp (Te-Smr)
301
Rear Tail Light Bulb Replacement
302
Replacing the Licence Plate Light Lamp
303
Handlebar Commutators
305
Connectors
305
Couplings
305
Notes
306
Battery
306
Fuses
306
Semiconductors Parts
307
Digital Instrument, Warning Lights (Te-Smr)
310
Instrument Replacement
310
Locating Operating Troubles
311
Wire Harness TC-TXC
311
Wire Harness TE-SMR
312
Cable Runway and Assembling Instructions for the 'Te/Smr' Electric Parts
325
Important Recommendation
327
Engine Cooling System
333
Table of Contents
334
Blinkers Kit (SMR)
334
Blinkers Kit (TE)
334
Central Engine Guard
334
Hand Guards Kit (TE)
334
Hook Kit for Race Starting Phase (TC-TXC)
334
Passenger Footrest Kit (SMR)
369
Hydraulic Control Clutch
371
Hydraulic Clutch System
372
Discharge of Hydraulic System Fluid
372
Overhaul of the Control Pump for Clutch Release
373
Bleeding of the Hydraulic System
375
Optional Parts List
379
Fuel Injection System
385
Lubrication System
389
Specific Tools
391
Torque Wrench Settings
398
Frame
401
Front Wheel
406
Rear Wheel
408
Wheels Overhauling
409
Wheel Spokes
409
Rims Warpage
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