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Husqvarna TXC449 Manuals
Manuals and User Guides for Husqvarna TXC449. We have
1
Husqvarna TXC449 manual available for free PDF download: Workshop Manual
Husqvarna TXC449 Workshop Manual (385 pages)
Brand:
Husqvarna
| Category:
Motorcycle
| Size: 28.69 MB
Table of Contents
5
Table of Contents
3
Foreword, Table of Contents
3
Workshop Manual
5
Table of Contents
7
Important Notices
9
General Information
10
Table of Contents
11
Cooling
11
Engine
11
Fuel System
11
Ignition System
11
Lubrication
11
Timing System
12
Chassis
12
Suspension
13
Brakes
13
Tyres
13
Wheels
14
Electrical Components Location
15
Supplies
16
Overall Dimensions - Weight
19
Maintenance
25
Troubleshooting
31
Settings and Adjustments
32
Settings and Adjustments
34
Saddle Removal
34
Side Panel Removal
36
Engine Guard Removal
36
Scoop Removal
38
Idle Adjustment (TC)
38
Idle Adjustment (TE - TXC - SMR)
39
Front Brake Lever Adjustment and Fluid Level Check (TC - TE - TXC)
39
Hydraulic Clutch Lever Adjustment and Fluid Level Check
40
Front Brake Lever Adjustment and Fluid Level Check (SMR)
41
Rear Brake Pedal Free Play Adjustment
41
Rear Brake Pedal Position Adjustment
42
Engine Oil Level Check
42
Rear Brake Fluid Level Check
43
Engine Oil Replacement and Mesh Filters-Filter Cartridge Cleaning or Replacement
44
Coolant Level Check
45
Coolant Replacement
46
Air Filter Check
46
Air Filter Cleaning
47
Chain Adjustment
48
Chain Lubrication
48
Disassembling and Cleaning
48
Lubricating Chain with O-Rings (TE - TXC - SMR)
48
Lubricating Chain Without O-Rings (TC)
48
Washing Chain Without O-Rings (TC)
49
Suspension Setup According to Track Condition
50
Shock Absorber Adjustment
51
Shock Absorber Spring Preload Adjustment (TE-TC-TXC)
52
Shock Absorber Spring Preload Adjustment (SMR)
53
Shock Absorber Damping Adjustment
54
KAYABA Fork Adjustment (TC - TE - TXC)
55
Fork Oil Level (SMR)
55
Marzocchi Fork Adjustment (SMR)
56
Steering Angle Adjustment
56
Steering Bearing Clearance Adjustment
57
Fuel Supply Hose Inspection
58
Exhaust System Check
59
General Procedures
60
Table of Contents
61
Saddle Removal
61
Side Panel Removal
63
Front Mudguard Removal
63
Number Plate Holder Removal (TE - SMR)
64
Rear Mudguard Removal
65
Battery Removal
65
Tank Removal
69
Cock Removal
69
Fuel Pump Removal
70
Throttle Body Removal
73
Exhaust System Removal (SMR)
74
Exhaust System Removal (TE - TXC)
77
Exhaust System Removal (TC)
79
Rear Chassis Removal
81
Rear Tank Removal
81
Solenoid Starter Removal
82
CDI Electronic Control Unit Removal
82
Voltage Regulator Removal
83
Coil Removal and Spark Plug Check
85
Clutch Hose Removal
86
Electric Cooling Fan Removal (TE - TXC - SMR)
86
Horn Removal (TE - SMR)
87
Air Filter Box Removal
89
Engine Guard Removal
89
Gear Shift Pedal Removal
90
Chain Slider Removal
93
Engine Removal
97
Radiator Removal
99
Adjustments - Engine
107
Engine Disassembly/Reassembly
108
Table of Contents
113
Oil Filter Cover On Crankcase
114
Engine Oil Filter Disassembly
115
Engine Oil Filter Assembly
113
Oil Filters Replacement
113
Oil Filter Disassembly
113
Oil Filter Assembly
116
Spark Plug Recess Ignition Coil
116
Spark Plug Recess Ignition Coil Disassembly
116
Spark Plug Recess Ignition Coil Assembly
117
Spark Plug Recess
117
Spark Plug Recess Disassembly
117
Spark Plug Recess Assembly
118
Spark Plug
118
Spark Plug Disassembly
118
Spark Plug Assembly
119
Oil Pressure Adjustment Valve Replacement
119
Oil Pressure Adjustment Valve Disassembly
119
Oil Pressure Adjustment Valve Assembly
120
Cylinder Head Cover
120
Removing Cylinder Head Cover
120
Fitting Cylinder Head Cover
121
Engine Positioning at Ignition TDC
121
Securing Crankshaft at TDC
122
Camshaft Assembly
122
Bearing Mount Disassembly
122
Camshaft Check
123
Bearing Mount Assembly
123
Bearing Mount Fitting
122
Camshaft Disassembly
124
Engine Left Crankcase
124
Engine Left Crankcase Cover Disassembly
124
Engine Left Crankcase Cover Assembly
125
Alternator Replacement
125
Flywheel Disassembly
126
Stator Disassembly
126
Freewheel Disassembly
126
Freewheel Assembly
127
Stator Assembly
127
Flywheel Assembly
128
Crankcase Left Cover Replacement
128
Stator Disassembly
128
Stator Assembly
130
Crankshaft Sensor Replacement
130
Crankshaft Sensor Disassembly
130
Crankshaft Sensor Assembly
131
Freewheel Gear Replacement
131
Freewheel Gear Disassembly
131
Freewheel Gear Assembly
132
Clutch Disassembly and Reassembly or Replacement
132
Clutch Cover Disassembly
132
Removing Clutch Pressure Plate
133
Removing Clutch Plates
133
Clutch Hub Disassembly
133
Clutch Housing Disassembly
134
Clutch Crankcase Clearance Check
134
Clutch Housing Clearance Reading
136
Clutch Housing Assembly
136
Clutch Hub Assembly
136
Removing Clutch Plates
137
Pressure Plate Assembly
137
Clutch Cover Assembly
138
Replacing Clutch Disengagement Bearing
138
Clutch Disengagement Bearing Disassembly
138
Clutch Disengagement Bearing Assembly
138
Checking the Clutch Pack Thickness
139
Engine Right Crankcase
139
Engine Right Crankcase Cover Disassembly
139
Engine Right Crankcase Cover Assembly
141
Clutch Thrust Washer
141
Clutch Thrust Washer Disassembly
141
Clutch Thrust Washer Assembly
142
Clutch Housing Axial Bearing
142
Clutch Housing Axial Bearing Disassembly
142
Clutch Housing Axial Bearing Assembly
143
Coolant Pump Disassembly and Assembly
143
Coolant Pump Cover Disassembly
143
Coolant Pump Rotor Disassembly
144
Coolant Pump Rotor Assembly
144
Coolant Pump Cover Assembly
145
(Crankcase Cover Removed)
145
Coolant Pump Control Rear Oil Seal Disassembly
145
Coolant Pump Control Shaft Check
145
Coolant Pump Control Rear Oil Seal Assembly
145
Coolant Pump Inside Crankcase Oil Seal Replacement
146
Coolant Pump Drive Replacement (Crankcase Cover Removed)
146
Slider Loosening at the Lower Area
146
Coolant Pump Shaft Disassembly
147
Coolant Pump Shaft Assembly
147
Slider Assembly at the Lower Area
148
Chain Front Sprocket
148
Chain Front Sprocket Removal
148
Front Sprocket Assembly
149
Chain Tensioner Disassembly and Reassembly or Replacement
149
Chain Tensioner Disassembly
149
Chain Tensioner Assembly
150
Cylinder Head Disassembly and Reassembly/Head Gasket Replacement
150
Preliminary Operations
150
Cylinder Head Disassembly
150
Cylinder Head Assembly
151
Cylinder Head Replacement (Cylinder Head Removed)
151
Valve Disassembly
152
Removing Valve Spring
152
Removing Valve Stem Seal
153
Rocker Arm Disassembly
153
Rocker Arm Shaft Disassembly
154
Valve Seat Width Check
154
Valve Guide Clearance Check
155
Rocker Arm Shaft Assembly
156
Rocker Arm Assembly
156
Fitting Valve Stem Seal
156
Valve Spring Assembly
157
Valves Assembly
158
Chain Slider
158
Chain Tensioning Slider Disassembly
158
Slider Disassembly
158
Chain Sliding and Tensioning Slider Check
159
Slider Assembly
159
Chain Tensioner Assembly
160
Cylinders Disassembly and Reassembly or Replacement
160
Cylinder Disassembly
161
Piston Disassembly
161
Cylinder Check
162
Piston Assembly
162
Piston Diameter Check
162
Piston Stroke Clearance Definition
163
Piston Ring Assembly
163
Piston with Cylinder Assembly
164
Subsequent Actions
165
Timing Chain Disassembly and Reassembly or Replacement
165
Timing Chain Disassembly
166
Timing Chain Assembly
166
Subsequent Actions
166
Chain, Chain Sprocket Check
166
Timing Chain Check
167
Replacing Oil Pump Gears (Crankcase Cover Removed)
167
Oil Pump Idler Gear Disassembly
167
Oil Pump Control Gear Disassembly
168
Disassembly of Crankshaft Gear Pointing Oil Pump Idler Gear
168
Assembly of Crankshaft Gear with Oil Pump Idler Gear
168
Oil Pump Control Gear Assembly
169
Oil Pump Idler Gear Assembly
170
Oil Intake Pump Replacement (Crankcase Cover Removed)
170
Removing Oil Intake Pump
170
Fitting Oil Intake Pump
171
Removing and Assembling or Replacing Pressure Oil Pump
171
Oil Force Pump Disassembly
171
Oil Force Pump Assembly
172
Oil Pump Shaft
172
Oil Pump Shaft Disassembly
172
Oil Pump Shaft Assembly
173
Replacing Gearbox Control Shaft Radial Sealing Ring
173
Removing Oil Seal From Gearbox Shaft
173
Fitting Gearbox Shaft Oil Seal
174
Replacing Output Shaft Oil Seal
174
Gearbox Output Shaft Left Oil Seal Disassembly
174
Gearbox Output Shaft Right Oil Seal Disassembly
174
Gearbox Output Shaft Right Oil Seal Assembly
174
Gearbox Output Shaft Left Oil Seal Assembly
175
Disassembling/Assembling Starter Motor
175
Disassembling Starter Motor
175
Assembling Starter Motor
176
Starter Drive Gear Replacement
176
Gear Disassembly with Starter Motor Protected against Overload
176
Starter Motor Drive Gear Disassembly
177
Freewheel Gear Disassembly
177
Freewheel Gear Assembly
178
Starter Motor Drive Gear Fitting
178
Gear Assembly with Starter Motor Protected against Overload
179
Starter Motor Drive Gear
179
Starter Motor Drive Gear Disengagement
179
Starter Motor Drive Gear Fitting
180
Crankshaft Axial Clearance Check
180
Crankshaft, Countershaft, and Relevant Bearings
180
Crankcase Left Half Disassembly
181
Control Gear Disassembly
181
Removing Crankshaft and Countershaft
182
Crankshaft Right Bearing Bushing Disassembly
182
Crankshaft for Countershaft Gear Disassembly
183
Crankshaft Left Bearing Bushing Disassembly
183
Crankshaft Axial Clearance Adjustment
184
Crankshaft Wear Check
184
Connecting Rod Wear Check
184
Crankshaft Replacement
185
Crankshaft Axial Clearance Adjustment, Left Side
185
Crankshaft Axial Clearance Adjustment, Right Side
186
Crankshaft Left Bearing Disassembly
186
Crankshaft Right Bearing Disassembly
186
Crankshaft Left Bearing Assembly
187
Crankshaft Right Bearing Assembly
187
Countershaft Right Bearing Disassembly
187
Countershaft Left Bearing Disassembly
188
Countershaft Left Bearing Assembly
188
Countershaft Right Bearing Assembly
189
Crankshaft Left Bearing Bushing Assembly
189
Oil Pump Gear Assembly Onto Crankshaft
190
Control Gear Assembly
190
Fitting Crankshaft and Countershaft
190
Crankshaft Right Bearing Bushing Assembly
191
Gearbox Unit - Disassembly / Assembly
191
Crankcase Left Half Disassembly
191
Gearbox Disassembly
191
Gearbox Check
192
Disassembly/Reassembly of the Gearbox (5 Speed) (TC)
194
Disassembly/Reassembly of the Gearbox (6 Speed) (TE-TXC-SMS)
196
Gearbox Oil Pipe Disassembly
196
Gearbox Oil Pipe Assembly
196
Gearbox Input Shaft Right Bearing Disassembly
196
Gearbox Input Shaft Left Bearing Disassembly
197
Gearbox Output Shaft Right Bearing Disassembly
197
Gearbox Output Shaft Left Bearing Disassembly
198
Gearbox Shaft Right Bearing Disassembly
198
Gearbox Shaft Left Bearing Disassembly
198
Gearbox Input Shaft Idler Gear Bearing Disassembly
199
Gearbox Input Shaft Idler Gear Bearing Assembly
199
Gearbox Shaft Left Bearing Assembly
200
Gearbox Output Shaft Left Bearing Assembly
200
Gearbox Output Shaft Right Bearing Assembly
200
Gearbox Shaft Right Bearing Assembly
201
Gearbox Input Shaft Left Bearing Assembly
201
Gearbox Input Shaft Right Bearing Assembly
201
Clutch Check Inside Primary Drive Unit
203
Idler Gear Disassembly
203
Idler Gear Assembly
204
Gearbox Shaft Replacement (Crankcase Cover Removed)
205
Selector Cylinder Replacement
206
Gear Selector Fork Replacement
206
Gear Selector Forks Assembly
207
Gearbox Assembly
207
Crankcase Left Half Assembly
208
Stop Lever Replacement
208
Gear Selector Lock Disassembly
208
Gear Selector Lock Assembly
212
Front Suspension
213
Front Fork Removal
215
Service Instructions for Ø48USD Kayaba Fork - TC-TXC
216
Front Suspension (TC - TXC)
217
Front Fork Disassembly (TC - TXC)
227
Front Suspension (TE)
228
Front Fork Disassembly (TE)
237
Front Suspension (SMR)
238
Instructions for Use of Ø50Usd Fork (Smr)
239
Components of the Fork
240
General Rules for a Proper Overhauling
241
Instructions for Clamping in the Vice
242
Problems - Possible Causes - Solutions
243
Bleeding the Air
243
Cleaning the Dust Seal
244
Draining the Oil
245
Braking Down the Pumping Element and the Bottom Valve
247
Braking Down the Fork Leg - Slider and Removing the Oil Seals
248
Cartridge Overhauling (Rebound Braking)
248
Overhauling and Modifying the Cartridge and Bottom Valve Setting
249
Bottom Valve Overhauling (Compression Braking)
250
Re- Assembling the Fork Leg - Slider and Oil Seals
252
Re- Assembling the Pumping Element Unit and the Bottom Valve
255
Filling with Oil
258
Table of Contents
259
Lubrication Points (Grease)
259
Rear Shock Absorber
259
Rear Suspension
261
Rear Shock Absorber Removal
262
Disassembling and Servicing the Swinging Arm
264
Linkage Disassembly
265
Chain Roller, Chain Guide, Chain Slider
265
Chain Sprocket Removal
268
Brakes
269
Braking System
271
Brake Disc
272
Checking Brake Pads for Wear / Replacing the Pads (TC-TE-TXC)
274
Bleeding the Front Braking System (TC-TE-TXC)
275
Bleeding the Front Braking System (SMS)
276
Bleeding the Rear Braking System
277
Changing the Fluid
282
Electrical System
284
Engine Wiring Diagram (TC)
286
Engine Wiring Diagram (TE-TXC-SMR)
288
Adapter (TXC)
290
Electrical Components Location (TC)
293
Electrical Components Location (TE - SMR)
298
Electrical Components Location (TXC)
302
Generator No-Load Performance
302
Generator Stator Windings Resistance (1) Inspection
302
MAX 13A at 14V
303
Condenser Inspection
304
Ignition System (TC)
306
Ignition System (TE - TXC - SMR)
308
Charging System
308
Charging System Wiring Diagram
309
Charging System Inspections
309
Current Loss at the Battery
309
Electrical Starting System
309
Voltage Regulator
309
Voltage Regulator/Rectifier Inspection
309
Voltage Regulator/Rectifier Wiring Diagram
311
Solenoid Starter Inspection
311
Solenoid Starter Wiring Diagram
311
Starter Motor Inspection
311
Starting System Inspection
312
Coil Windings Resistance Inspection
312
Electronic Control Unit (ECU)
313
Battery
313
Battery Charger
313
Spark Plug
314
Headlamp Adjustment
314
Headlamp Bulb Replacement (TE - SMR)
314
Headlamp, Tail Light (Te - Smr)
317
Tail Light Replacement (TE - SMR)
317
Turning Indicator Bulb Replacement (TE - SMR)
318
Handlebar Switches
318
Left-Hand Switch (TC)
318
Number Plate Bulb Replacement (TE - SMR)
319
Left-Hand Switch (TE - SMR)
320
Right-Hand Switch (TE - TXC - SMR)
321
Right-Hand Switch (TC)
322
Fuses
322
Semiconductor Parts
323
Relay Test
325
Digital Dashboard, Warning Lights (Te)
325
Speed
327
Dashboard Replacement (TE - SMR)
328
Charging System
328
Electronic Ignition System
328
Starting System
328
Troubleshooting
329
Connector Position (TE - SMR)
333
Connector Position (TC)
335
Connector Position (TXC)
338
Important
346
Hydraulically Controlled Clutch
347
Hydraulic Clutch System
348
Draining Clutch Fluid
349
Clutch Master Cylinder Servicing
350
Bleeding the Clutch System
364
Chassis and Wheels
365
Chassis
366
Lubrication Points (Lubricant)
367
Front Wheel (TC - TE - TXC)
368
Front Wheel (SMR)
369
Removing the Front Wheel
370
Reassembling the Front Wheel
373
Rear Wheel (TC - TE - TXC)
374
Rear Wheel (SMR)
375
Removing the Rear Wheel
376
Axle Runout Over 100 MM
376
Wheel Axle Warpage
376
Wheel Servicing
377
Wheel Rim Warpage
377
Wheel Spokes
378
Rear Chain Sprocket, Secondary Drive Sprocket and Chain
378
Tightening Torque Figures
379
Checking Pinion and Sprockets for Wear
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