Husqvarna TR 650 TERRA 2013 Workshop Manual
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Husqvarna TR 650 TERRA 2013 Workshop Manual

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TR 650 TERRA 2013
TR 650 STRADA 2013
Workshop Manual
Ed. 09-2012
Rev 01

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Summary of Contents for Husqvarna TR 650 TERRA 2013

  • Page 1 TR 650 TERRA 2013 TR 650 STRADA 2013 Workshop Manual Ed. 09-2012 Rev 01...
  • Page 2 Tightening torque figures have been revised. HUSQVARNA MOTORCYCLES S.R.L. - Varese disclaims all liabilities for any errors or omissions in this manual and reserves the right to make changes to reflect on-going product development. Illustrations in the manual may differ from actual components.

  • Page 3: Foreword, Table Of Contents

    FOREWORD, TABLE OF CONTENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Workshop Manual TR 650 TERRA 2013 TR 650 STRADA 2013 Copyright by HUSQVARNA MOTORCYCLES S.R.L. BMW Group Technical Service Via Nino Bixio, 8 21024 (Varese) - Italy tel.

  • Page 4: Tr 650 Terra 2013 - Tr 650 Strada 2013

    TR 650 TERRA 2013 - TR 650 STRADA 2013 Foreword This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance and repair of the models covered in this manual. The technical information provided in this manual is a critical comple- ment to operator training and operators should become thoroughly familiar with it.

  • Page 5: Table Of Contents

    FOREWORD, TABLE OF CONTENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Table of Contents Title Section Foreword, table of contents ................. a Important notices ....................b General information .....................A Maintenance ......................B Troubleshooting ....................C Settings and adjustments ................... D General procedures .....................E...

  • Page 7: Important Notices

    IMPORTANT NOTICES TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Workshop Manual Ed. 09-2012...

  • Page 8: Engine

    IMPORTANT NOTICES TR 650 TERRA 2013 - TR 650 STRADA 2013 GENERAL SAFETY WARNINGS Read these general recommendations carefully before using the vehicle. Carbon monoxide Only run the engine in an open or very well ventilated area. If you do work in an enclosed area, make sure you use a fume extraction system.

  • Page 9: Tr 650 Terra 2013 - Tr 650 Strada 2013

    IMPORTANT NOTICES TR 650 TERRA 2013 - TR 650 STRADA 2013 Battery Recharge the battery in well ventilated areas since the battery produces toxic, highly inflammable gases when being recharged; do not smoke or use naked flames or sparks. The liquid in the battery is highly corrosive. If it comes into contact with the skin, rinse thoroughly with running water.

  • Page 10: Tr 650 Terra 2013 - Tr 650 Strada 2013

    IMPORTANT NOTICES TR 650 TERRA 2013 - TR 650 STRADA 2013 RECOMMENDED SHOP PRACTICES Before disassembling components or before performing repair operations, clean the motorbike removing possible mud, dust, or foreign bodies. Put the vehicle in a well lit area;...

  • Page 11: General Information

    GENERAL INFORMATION TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Workshop Manual Ed. 09-2012...
  • Page 12 GENERAL INFORMATION TR 650 TERRA 2013 - TR 650 STRADA 2013 Sommario Engine ......................A.3 Timing system ....................A.3 Lubrication ....................A.3 Ignition ......................A.3 Fuel system ....................A.3 Primary drive ....................A.3 Clutch ......................A.3 Transmission ....................A.3 Transmission ratio ..................A.3 Secondary drive....................A.3 Final ratios ....................A.4 Chassis ......................A.4 Front suspension ..................A.4...

  • Page 13: Timing System

    GENERAL INFORMATION TR 650 TERRA 2013 - TR 650 STRADA 2013 Engine Single cylinder, 4 stroke engine with four valves Cooling ................liquid and electric fan Bore ..................3,937 in (100 mm) Stroke ..................3,268 in (83 mm) Displacement ..............39,787 in (652 cm Compression ratio ..................12,3:1...

  • Page 14: Final Ratios

    GENERAL INFORMATION TR 650 TERRA 2013 - TR 650 STRADA 2013 Final ratios 1st gear....................15.722 2nd gear ....................10.005 3rd gear ....................7.506 4th gear .....................5.974 5th gear .....................2.898 Chassis Single frame, in round, rectangular and ellipsoidal steel pipes; rear steel chassis Front suspension Upside down type hydraulic fork......ø...

  • Page 15: Electrical Components Location

    GENERAL INFORMATION TR 650 TERRA 2013 - TR 650 STRADA 2013 Table for lubrication, supplies Engine, gearbox and primary drive lubricating oil........ CASTROL POWER1 RACING SAE 10W-50 Engine coolant ........CASTROL MOTORCYCLE COOLANT Brake fluid ...........CASTROL RESPONSE SUPER DOT 4 Grease lubrication ............CASTROL LM GREASE 2...

  • Page 16: Dimensions, Weight, Capacity

    GENERAL INFORMATION TR 650 TERRA 2013 - TR 650 STRADA 2013 Dimensions, weight, capacity Wheelbase ..........................55,055 in (1500 mm) Total length (STRADA) ......................88,504 in (2248 mm) Total length (TERRA)......................89,252 in (2267 mm) Overall width ...........................34,843 in (885 mm) Max.

  • Page 17: Maintenance

    MAINTENANCE TR 650 TERRA 2013 - TR 650 STRADA 2013 Section All tightening indicated with the letter "S" (Safety) in section X "Tightening Torques" must be checked at each service or whenever other maintenance/repair work is carried out. Workshop Manual Ed. 09-2012...
  • Page 18 MAINTENANCE TR 650 TERRA 2013 - TR 650 STRADA 2013 TR 650 STRADA SCHEDULED MAINTENANCE CHART TR 650 TERRA (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) ENGINE SERVICE SERVICE SERVICE SERVICE SERVICE COUPON COUPON COUPON COUPON COUPON AFTER EVERY...
  • Page 19 MAINTENANCE TR 650 TERRA 2013 - TR 650 STRADA 2013 TR 650 STRADA SCHEDULED MAINTENANCE CHART TR 650 TERRA (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) CHASSIS SERVICE SERVICE SERVICE SERVICE SERVICE COUPON COUPON COUPON COUPON COUPON AFTER THE...

  • Page 21: Troubleshooting

    TROUBLESHOOTING TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Manuale d'officina Ed. 09-2012...
  • Page 22 TROUBLESHOOTING TR 650 TERRA 2013 - TR 650 STRADA 2013 ENGINE Trouble Possible causes Remedy Ignition switch not in ON position Switch ignition switch to position ON Engine-stop-switch on OFF position Switch to position ON Starter motor does not operate or does not...
  • Page 23 TROUBLESHOOTING TR 650 TERRA 2013 - TR 650 STRADA 2013 Trouble Possible causes Remedy Check fuel pressure sensor, fuel pump and Fuel pressure too low fuel supply Leak air Check / replace intake socket Engine runs irregularly at higher speed...
  • Page 24 TROUBLESHOOTING TR 650 TERRA 2013 - TR 650 STRADA 2013 Trouble Possible causes Remedy Not enough coolant in cooling system, cool- Refill coolant, check system under pressure ing system leaking, air in cooling system Cooling fan motor defective Replace cooling fan motor...
  • Page 25 TROUBLESHOOTING TR 650 TERRA 2013 - TR 650 STRADA 2013 Trouble Possible causes Remedy Pressure regulating piston blocked (bypass Check/replace pressure regulating piston valve stuck in closed position) High engine oil pressure Oil circuit blocked Clean oil ducts Manuale d'officina Ed. 09-2012...
  • Page 26 TROUBLESHOOTING TR 650 TERRA 2013 - TR 650 STRADA 2013 Trouble Possible causes Remedy Noise is heard when the engine is started: Sprag clutch, sprag clutch housing or free- Replace Sprag clutch, sprag clutch housing wheel gear worn or freewheel gear...
  • Page 27 TROUBLESHOOTING TR 650 TERRA 2013 - TR 650 STRADA 2013 Trouble Possible causes Remedy Fatigue of clutch springs Replace clutch springs Clutch slips Clutch plates worn or warped Replace clutch plates Engine oil not according to specifications Exchange engine oil...
  • Page 28 TROUBLESHOOTING TR 650 TERRA 2013 - TR 650 STRADA 2013 CHASSIS Trouble Cause Remedy Insufficient tyre pressure Inflate Bearing adjuster ring nut or steering stem Adjust nut overtightened Handlebar turns hard Bent steering stem Replace bottom yoke Worn or seized steering bearings...
  • Page 29 TROUBLESHOOTING TR 650 TERRA 2013 - TR 650 STRADA 2013 ELECTRICAL SYSTEM (see also Section M) Trouble Cause Remedy Dirty air filter Clean Spark plug fouls easily Worn piston rings Replace Worn piston or cylinder liner Replace Spark plug electrode gap too close...

  • Page 31: Settings And Adjustments

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Workshop Manual Ed. 09-2012...
  • Page 32 SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Sommario Saddle removal.....................D.3 Removal of central upper cover..............D.4 Side panel removal ..................D.4 Throttle cable adjustment ................D.5 Throttle control....................D.5 Throttle position adjustment .................D.5 Front brake control ..................D.5 Position adjustment ..................D.5 Front brake lever adjustment and fluid level check ........D.6...

  • Page 33: Saddle Removal

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Saddle removal To remove the saddle proceed as follows: Insert the key in the lock (1) positioned in the rear part of the motorcycle; turn the key clockwise to release the saddle (2), and then lift it and pull it out towards the rear, releasing it from the front fastener.

  • Page 34: Removal Of Central Upper Cover

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Removal of central upper cover Unscrew the four screws (1) that fasten the cover (2) and remove it. H11662 Side panel removal Remove the saddle as described in the relevant paragraph.

  • Page 35: Throttle Cable Adjustment

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Throttle cable adjustment To check the correct adjustment of the throttle control cable, operate as follows: remove the reservoir and the filter box as outlined in the relevant sections;...

  • Page 36: Front Brake Lever Adjustment And Fluid Level Check

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Front brake lever adjustment and fluid level check The level of the fluid in the master cylinder reservoir must never be below the minimum level visible through the inspection sight glass (1) on the side of the master cylinder (2) body.

  • Page 37: Clutch Control Lever Distance Adjustment

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Clutch control lever distance adjustment The lever (1) can be adjusted (3 settings available) to suit the rider's hand size To regulate the position of the lever (1) push it outwards and then select the required position by means of the adjuster screw (2).

  • Page 38: Rear Brake Pedal Free Play Adjustment

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Rear brake pedal free play adjustment Before staring the braking action, rear brake pedal (1) shall have a free play (B) of 5-10 mm (0,196 ÷ 0,39 in.). Should this not happen, operate as follows: Loosen the nut (2);...

  • Page 39: Oil Level Check

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Oil level check The oil level must be checked with the vehicle in vertical position on a flat sur- face. - Start the motorcycle and heat the engine until the cooling fan starts; wait for another 3 minutes and switch off the engine.

  • Page 40: Replacement Of Cartridge Filter

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Replacement of cartridge filter - Unscrew the screws (5) and remove the sprocket casing (6). - Unscrew the screws (7) and remove the oil filter cover (8). - Replace the filter (9) with a new one, then refit the cover (8) making sure that the O-ring (10) is not damaged and positioned correctly on the cover.

  • Page 41: Filling

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Filling - Remove the cap (1) with the dipstick. - Pour 1.5 litres of oil into the chassis tank. - Run the engine for 30 seconds and then switch it off.

  • Page 42: Coolant Replacement

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Coolant replacement Drainage - Place the motorcycle on its side stand. - Remove the cap (1) of the expansion tank (2). - Place a 2 litre container under the water pump and unscrew the screw (3).

  • Page 43: Air Filter Check

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Air filter check Note: Clean the filter area before removing the cover. - Unscrew the screws (1) and remove the cover (2) together with the filter (3); - remove the filter (3) and check that it is not clogged/dirty; replace if neces- sary;...

  • Page 44: Chain Tension Adjustment

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Chain tension adjustment Chain should be checked, adjusted and lubricated as per the Maintenance Chart to ensure safety and prevent excessive wear. If the chain becomes badly worn or is adjusted incorrectly (i.e., it is too loose or too tight), it could jump out of the sprocket or break.

  • Page 45: Suspension

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Suspension The vehicle leaves the factory with standard settings for the front and rear sus- pension that meet most requirements. Before making any change and afterwards, if the adjustment is not satisfactory, always start from the standard suspension setting and increase or decrease the adjusting clicks, one at a time.

  • Page 46: Rebound Shock Absorber Hydraulic Damping Adjustment

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Rebound shock absorber hydraulic damping adjustment It is possible to adjust the rebound travel of the shock absorber. B) REBOUND - Standard setting: - 11 clicks (adjuster 1) To reset the standard setting, turn lower adjuster (1) clockwise until reaching fully closed position.

  • Page 47: Exhaust System Check

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Exhaust system check Perform a visual inspection of the exhaust system first, in order to identify pos- sible gas leaks from the sealing elements (gaskets), and to ensure that the Silent-Blocks are not damaged.

  • Page 48: Idle Speed Adjustment

    SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Idle speed adjustment The idle speed is pre-set by the control unit (1550 rev/min.) and the stepper motor ensures that this value is preserved. No manual adjustment is possible, nor any adjustment through the diagnostic tool.
  • Page 49 SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 - Loosen the clamp (9) and remove the intake coupling (10) from the cylinder head. When refitting the intake coupling (10) make sure you place the prong (A) on the slot (B) of the intake manifold.

  • Page 51: General Procedures

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Workshop Manual Ed. 09-2012...
  • Page 52 GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Sommario Stand removal / replacement................E.3 Saddle removal.....................E.4 Removal of central upper cover..............E.4 Side panel removal ..................E.5 Removal of luggage rack ................E.5 Removal of tail cover ..................E.6 Removal of rear panels ................E.6 Removal of antitheft device compartment cover ..........E.7...

  • Page 53: Stand Removal / Replacement

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Stand removal / replacement Loosen the nut (1) and remove the rotary type switch (2). H11790 H11791 Release the spring (3). Loosen the screw (4) and remove the stand (5).

  • Page 54: Saddle Removal

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Saddle removal To remove the saddle proceed as follows: Insert the key in the lock (1) positioned in the rear part of the motorcycle; turn the key clockwise to release the saddle (2), and then lift it and pull it out towards the rear, releasing it from the front fastener.

  • Page 55: Side Panel Removal

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Side panel removal Remove the saddle as described in the relevant paragraph. Remove the upper cover as described in the relevant paragraph. Unscrew the five screws (1) and remove the left side panel (2) by releasing the fixing tabs.

  • Page 56: Removal Of Tail Cover

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Removal of tail cover Remove the saddle and luggage rack as described in the relevant paragraphs. Unscrew the screws (1) and remove the tail (2). H11795 Removal of rear panels Remove the saddle, luggage rack, rear tail cover and the side panels as described in the relevant paragraphs.

  • Page 57: Removal Of Antitheft Device Compartment Cover

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Removal of antitheft device compartment cover Remove the saddle, the luggage rack and the rear tail cover as described in the relevant paragraphs. Unscrew the two lower screws (1) and the two upper screws (2) and remove the cover (3).

  • Page 58: Replacement Of The Saddle Lock Key Lock

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Replacement of the saddle lock key lock Remove the saddle, the luggage rack, the rear tail cover and the antitheft device compartment cover as described in the relevant paragraphs.

  • Page 59: Removal Of Saddle Lock

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Removal of saddle lock Remove the saddle, the luggage rack and the rear tail cover as described in the relevant paragraphs. H11806 Removal of number plate holder Remove the saddle, the luggage rack, the rear tail cover and the antitheft device compartment cover as described in the relevant paragraphs.
  • Page 60 GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Disconnect the tail light connector (4) and the turning indicator connectors (5). H11808 H11809 Remove the licence plate light bulb holder (6). H11810 Unscrew the two screws (7) of the lock (8) and remove the cable (9).
  • Page 61 GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Pull the two rear panels (3) apart so that you can access the screws (10). Unscrew the screws (10) of the number plate holder (11) and remove it along with the key block, tail light and turning indicators.

  • Page 62: Removal Of Tail Light

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Removal of tail light Remove the saddle, the luggage rack, the rear tail cover and the antitheft device compartment cover as described in the relevant paragraphs. Unscrew the two screws (1), disconnect the connector (2) and remove the tail light (3).

  • Page 63: Removal Of Radiator Guards

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Removal of radiator guards Remove the side panels as described in the relevant paragraph. Unscrew the screws (1). Put the guard (2) out and release it from the fittings (top fitting with clip (3), bottom fitting with rubber ring (4)).

  • Page 64: Removal Of Lower Tail Cover

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Removal of lower tail cover Remove the saddle, the luggage rack, the rear tail cover, the antitheft device compartment cover, the side panels and the rear panels as described in the relevant paragraphs.
  • Page 65 GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Unscrew the two front screws (10) in the battery compartment and the two rear screws (11) and then remove the lower cover (12). H11827 H11828 H11829 Workshop Manual Ed. 09-2012...

  • Page 66: Removal Of Tail Chassis

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Removal of tail chassis Remove the lower tail cover and the number plate holder as described in the relevant paragraphs. Unfasten the two clips (1) of the shock absorber protection (2).

  • Page 67: Front Fairing Removal

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Front fairing removal Unscrew the screws (1) and remove the front fairing (2). H11835 H11836 Workshop Manual Ed. 09-2012 E.17...

  • Page 68: Front Turning Indicator Removal

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Front turning indicator removal Remove the front fairing as described in the relevant paragraph. Unscrew the screw (1) and remove the support (2). H11898 Disconnect the left turning indicator connector (3).

  • Page 69: Combined Dashboard Removal

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Combined dashboard removal Remove the front fairing as described in the relevant paragraph. Remove the clips (1) and raise the dashboard (2). H11902 Disconnect the connector (3) and remove the dashboard (2).

  • Page 70: Removal Of Front Mudguard

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Removal of front mudguard STRADA version: Unscrew the two screws (1) and release the front brake hose (2) from the cable ring. Unscrew the screws (3) on both sides and remove the mudguard (4).

  • Page 71: Removal Of Fuel Tank

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Removal of fuel tank Remove the saddle, side panels and rear panels, the battery, silencers and the central exhaust manifold. While disassembling the tank, do not bend, force or pull the cable harness too hard.
  • Page 72 GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Disconnect the fuel pipe (12) by pressing the ring nut (5) and lifting the union (6). H111028 Disconnect the connector (7) from the fuel pump. H11914 Unscrew the two screws (8) on both sides that secure the upper part of the rear chassis and loosen the lower screws (9).
  • Page 73 GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Remove the central part of the cable harness (10) from the chassis. H11917 Turn the chassis to the right and remove the tank (11). Follow the same steps in reverse order to reassemble the tank and make sure you put the cable harness back in the same position it was before.

  • Page 74: Fuel Pump Removal

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Fuel pump removal This operation cannot be performed when the tank is completely full because the fuel will leak out: we recommend emptying the tank by drawing the fuel through suction using a special tool.
  • Page 75 GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Remove the pump (7) from the tank. Check the seal (8) for wear, change it if dry or damaged. H11923 When reassembling the pump, align the tab (9), located under the connec- tor, with the seat (10) of the ring nut and the seat (11) of the ring nut with the bump (12) on the tank.

  • Page 76: Fuel Pump Inspection

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Fuel pump inspection Remove the pump as described in the relevant paragraph. Connect the positive pole (12V) of the power supply to the pin of the red cable in the pump connector;...

  • Page 77: Removal Of Filter Box

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Removal of filter box Remove the front panels, the radiator guards, the rear panels, the exhaust silenc- ers and the central exhaust manifold, as described in the relevant paragraphs.
  • Page 78 GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Unscrew the screw (6) on the right side of the tank. H11930 Unscrew the two upper screws (7) of the chassis and loosen the two lower screws (8). H11931...

  • Page 79: Dismantling Of Filter Box

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Check that the rubber seal element (11) is not worn/damaged; re- place if necessary. When reassembling, fit the filter box onto the throttle body until the seal element (11) is pushed all the way down. To make it easier to insert, use special lubricants and slightly rock the filter box.

  • Page 80: Throttle Body Removal

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Throttle body removal Remove the filter box as described in the relevant paragraph. Disconnect the injector connector (1), the throttle position sensor connector (2) and the idle speed adjustment actuator connector (3).

  • Page 81: Exhaust System Removal

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Exhaust system removal H11943 Key: 1) Left silencer 2) Right silencer 3) Clamps 4) Gaskets 5) Central manifold 6) Manifold 7) Lambda sensor 8) Gasket Workshop Manual Ed. 09-2012...
  • Page 82 GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Exhaust system removal Remove the saddle as described in the relevant paragraph. Unscrew the rear support (1) on both sides. H11944 Loosen the clamps (2) on both sides and remove both silencers (3) by sliding them out of the support (4).
  • Page 83 GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Disconnect the Lambda sensor connector (7). Undo the nuts (8) fastening the exhaust manifold (9) to the cylinder head, remove the manifold and retrieve the steel gasket (10). When reassembling, fit the steel gasket (10) onto the manifold making sure that the support tabs are inserted on the pipe.

  • Page 84: Lambda Sensor Removal

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Lambda sensor removal Disconnect the connector (1). Unscrew the Lambda sensor (2) from the exhaust manifold. H11953 Coil / Stick-Coil removal and spark plug test Remove the filter box as described in the relevant paragraph.

  • Page 85: Horn Removal

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Horn removal Undo the nut (1). Disconnect the connector (2) and remove the horn (3). H11957 H11958 Radiator removal Remove the saddle and the radiator guards, as described in the relevant paragraphs.
  • Page 86 GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Unscrew the two upper screws (6). H11960 H11961 Cut the clamp (7) that secures the electric fan cable harness. H11962 Disconnect the electric fan connector (8). H11963 Workshop Manual Ed. 09-2012...

  • Page 87: Removal Of Electric Fan

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Slide the radiator (9) out from the left and remove it from its special support (10). When reassembling, make sure that the support (10) is correctly inserted in the retaining pin (11).

  • Page 88: Gearbox Lever Removal

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Gearbox lever removal Loosen the screw (1) and remove the lever (2). H11969 Workshop Manual Ed. 09-2012 E.38...

  • Page 89: Removal Of Engine

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Removal of engine Remove the following components in order as described in the relevant para- graphs/sections: exhaust; fuel tank; filter box; throttle body; sprocket casing; voltage regulator. Remove the voltage regulator support plate (1) by unscrewing the screws (2).
  • Page 90 GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Unscrew the screw (5) and disconnect the ground cable (6). H11973 Remove clutch cable (7). H11974 Unfasten the nut (8) of the starter motor power supply cable (9). H11975 Remove the clip (10) and remove the master cylinder (11) from the brake lever (12).
  • Page 91 GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Unfasten the nut (13) and remove the chain tensioner slider (14). H11977 Slightly ease the pin (15) in order to release the left slider (16). H11978 Move the wheel towards the engine to remove the chain (17) from the sprocket.

  • Page 92: Reassembly Of Engine

    GENERAL PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Remove the front support cross-member (18) by unscrewing the upper screws (19) that connect it to the chassis and the lower screws (20) that connect it to the engine.

  • Page 93: Engine Settings And Adjustments

    ENGINE SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Refer to chapter F4 for all engine tightening torques. Workshop Manual Ed.09-2012...
  • Page 94 ENGINE SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Sommario VALVE CLEARANCE CHECK ..............F.3 Valve clearance check .................. F.3 Valve clearance measurement ..............F.3 PAD REPLACEMENT ................. F.4 Locking the crankshaft.................. F.4 Chain tensioner disassembly................ F.5 Chain guide disassembly................

  • Page 95: Valve Clearance Check

    ENGINE SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 VALVE CLEARANCE CHECK Remove the coil / spark plug cap, spark plugs and the head cover as described in chapter "F1". Valve clearance check Remove the screw plug (1).

  • Page 96: Pad Replacement

    ENGINE SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 PAD REPLACEMENT Bring the to the top dead centre as described in the previous paragraph and lock the crankshaft. H11487 Locking the crankshaft Remove the screw (1) with the sealing ring.

  • Page 97: Chain Tensioner Disassembly

    ENGINE SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Chain tensioner disassembly Remove the screw (1) with the sealing ring (2) and chain tensioner (3). H11491 H11490 Chain guide disassembly Remove the screws (1) and chain guide (2).

  • Page 98: Camshaft Removal

    ENGINE SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Camshaft removal Remove the screws (1) with the washers.(2). Remove the top part of the support (3). - Remove the chain (4) from the gears and fix to a point safe to avoid it from falling into the engine. Remove the camshafts (5) with the chain gears.

  • Page 99: Chain Tensioner Installation

    ENGINE SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 Chain tensioner installation Insert the chain tensioner (1) and tighten the screw (2) replacing the gaskets (3). H11496 H11497 Chain guide installation Clean the threading and screws.

  • Page 100: Timing Check

    ENGINE SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 TIMING CHECK Remove the coil / spark plug cap, head cover, spark plugs and chain tensioner and the head cover as described in chapter "F1". Remove the screw (1) with the sealing ring.

  • Page 101: Engine Phasing

    ENGINE SETTINGS AND ADJUSTMENTS TR 650 TERRA 2013 - TR 650 STRADA 2013 ENGINE PHASING Proceed as follows to rephase the engine. Remove the head cover as described in chapter "F1". Lock the crankshaft as previously described. Remove the chain tensioner and guide as previously described.

  • Page 103: General Engine Procedures

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Refer to chapter F4 for all engine tightening torques. Workshop Manual Ed.09-2012 F1.1...
  • Page 104 GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Sommario CLUTCH COVER REMOVAL / INSTALLATION .........F1.3 Gearbox lever removal/installation ............F1.3 Clutch cover removal ................F1.3 Remove the left engine crankcase cover ..........F1.3 Coolant pump cover removal ..............F1.4 Left engine cover removal ..............

  • Page 105: Clutch Cover Removal / Installation

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 CLUTCH COVER REMOVAL / INSTALLATION Gearbox lever removal/installation Removal: Loosen the screw (1) then remove the lever (2). Installation: Fit the lever (2) and tighten the screw to torque (1).

  • Page 106: Coolant Pump Cover Removal

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Coolant pump cover removal Remove the pipe (1) from the pump cover (2). Remove the screws (3). Remove the coolant pump cover (2) and its gasket. H11760 Check gasket condition when refitting and replace if necessary.

  • Page 107: Clutch Engagement Lever Removal/Refitting

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Clutch engagement lever removal/refitting Removal: Undo the screws (1) and slide the lever out upwards (2). H11514 Installation: Manually turn the shaft (3) clockwise until reaching the limit.

  • Page 108: Clutch Disengagement Shaft Bearing Removal

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Clutch disengagement shaft bearing removal Remove the two needle roller bearing using an appropriate tool (1). H11519 Installation of both clutch disengagement shaft bearings Lightly lubricate both bearings with engine oil.

  • Page 109: Left Engine Crankcase Cover Assembly

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Left engine crankcase cover assembly - Clean the sealing faces and fit a new gasket. Turn the water pump impeller until the transmission sprocket mates correctly. Tighten the screws (1) replacing the sealing ring (2). Check that the broaching of the clutch disengagement shaft mates properly with the clutch centre pin.

  • Page 110: Crankshaft Sensor And Stator Removal

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Crankshaft sensor and stator removal Unscrew the screws (1). Remove the bracket (2) with the sensor (4). Remove the cable ring (3). H11527 Unscrew the screws (5). Remove the cable ring (6) and stator (7).

  • Page 111: Mounting The Ignition Cover

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Mounting the ignition cover - Clean the sealing faces and fit a new gasket. Install the cover (2), being careful with the washer (3) (arrow) and bushing (4). Install the screws (1) of the engine casing cover, right side, tightening to torque in a cross pattern.

  • Page 112: Flywheel And Starter Motor Idle Gear Removal

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Flywheel and starter motor idle gear removal - Remove the right crankcase and fix the engine at the top dead centre, as described in the relevant paragraphs. - Heat the flywheel hub (1) to a temperature of approx. 100°C. Unscrew the nut (2) and washer (3). - Remove the flywheel together with the freewheel (4) using a suitable puller. H11535 H11536 Removal/installation of the freewheel from/on the flywheel - Heat the freewheel to about 120°C.

  • Page 113: Starter Motor Idle Gear Removal/Installation

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Starter motor idle gear removal/installation Remove the washer (1) and bushing (2). Remove the dual gearbox (4). Remove the idle gear (3). H11539 Remove the freewheel gear (5) Reassemble all parts, in the reverse order compared to disassembly.

  • Page 114: Chain Sprocket Removal/Installation

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 CHAIN SPROCKET REMOVAL/INSTALLATION Removal: Remove the screw (1). Remove the bushing (2) and the tapered washer (3). Remove the sprocket (4), using a puller if necessary, being careful not to ruin the shaft threading.

  • Page 115: Removing The Neutral Position Sensor

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 REMOVING THE NEUTRAL POSITION SENSOR Remove the screw (2). Remove the connection cable. Unscrew the sensor (1) and replace it. Screw on a new sensor with Loctite 243.
  • Page 116 GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Remove the washer (12) and the "OR" gasket (13). Disassemble the clutch housing (14), paying attention to the needle roller bearings (15) and to the washer (16). H11554 Installation: Lubricate the needle roller bearings (15) with engine oil.
  • Page 117 GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Fit the thrust washer (8) and the Belleville washer (7) so that the greater diameter faces outwards. Lubricate the lined plates (6) with engine oil. - Insert first a lined plate (5) then a steel disc (6) and alternate layers until ending with a lined plate.

  • Page 118: Clutch Pressure Plate Disassembly

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Clutch pressure plate disassembly Disassemble the pressure plate (1) as described in the paragraph "Clutch disassembly". Remove the circlip (2). Remove the actuator pin (3), the rounded washer (4) and the Belleville washer (5).

  • Page 119: Pumps

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 PUMPS Oil pump removal/installation Remove the clutch as described in the relevant paragraph. A) Supply pump B) Intake oil pump Removal: Remove the retaining ring (2). Disassemble the gear (3).

  • Page 120: Replacement Of The Oil Pressure Valve And Unidirectional Valve

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 REPLACEMENT OF THE OIL PRESSURE VALVE AND UNIDIRECTIONAL VALVE - Position a container under the oil filter cover in order to collect the oil in the filter seat and oil filter. Loosen the two screws (1) and remove the oil pump cover (2). - Remove the oil filter (3). - Clean the filter box of residual oil.

  • Page 121: Coolant Fluid Pump Removal/Installation

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 COOLANT FLUID PUMP REMOVAL/INSTALLATION Remove the pump cover and left cover as described in the relevant paragraph. Removal: Remove the transmission sprocket (1) of the pump shaft. Remove the pin (2) paying attention to the washer (3).

  • Page 122: Removal/Installation Or Replacement Of The Timing Chain

    GENERAL ENGINE PROCEDURES TR 650 TERRA 2013 - TR 650 STRADA 2013 REMOVAL/INSTALLATION OR REPLACEMENT OF THE TIMING CHAIN Remove the head cover and the camshafts as described in the relevant paragraphs. Fix the timing chain with metal wire so that it does not slip into the engine.

  • Page 123: Cylinder Head Removal/Disassembly

    CYLINDER HEAD REMOVAL/DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Refer to chapter F4 for all engine tightening torques. Workshop Manual Ed.09-2012 F2.1...
  • Page 124 CYLINDER HEAD REMOVAL/DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Sommario Removal of the ignition coils ...............F2.3 Cylinder head cover removal/installation ............F2.3 Chain tensioner removal/installation............F2.4 Locking the crankshaft................F2.4 Crankshaft locking screw removal ..............F2.5 Camshaft removal/replacement..............F2.5 Checking the decompression lever ............F2.6 Removing the decompression lever ............F2.6...

  • Page 125: Removal Of The Ignition Coils

    CYLINDER HEAD REMOVAL/DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Removal of the ignition coils Using an appropriate tool remove the coil (1) of the main spark plug, and the coil (2) of the secondary spark plug. Do not mount coils in inverse positions.

  • Page 126: Chain Tensioner Removal/Installation

    CYLINDER HEAD REMOVAL/DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Chain tensioner removal/installation Removal: Remove the screw (1) with the sealing ring (2). Remove the chain tensioner (3) from the hole. Installation: Insert the chain tensioner (3) into the hole.

  • Page 127: Crankshaft Locking Screw Removal

    CYLINDER HEAD REMOVAL/DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Crankshaft locking screw removal Remove the locking screw (1) and re-tighten the screw (2) to torque, replac- ing the gasket. H11499 H11654 Camshaft removal/replacement Remove the head cover and lock the engine at the top dead centre, as de- scribed in the relevant paragraphs.

  • Page 128: Checking The Decompression Lever

    CYLINDER HEAD REMOVAL/DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Checking the decompression lever - With the spring fully extended, the minimum projection of the weight is equal to A: 0.7 mm (0.03 in). - When activated, the projection of the centrifugal weight on the base circum- ference of the cam must not be less than the measurement (A). Replace the decompression lever if the distance is lower.

  • Page 129: Camshaft Assembly

    CYLINDER HEAD REMOVAL/DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Camshaft assembly Lubricate all contact surfaces with engine oil. - Fit the camshaft exhaust (1a), then the cam shaft intake (1b) with the timing chain and positioning them in phase. Mount the top part of the support (2). Tighten the screws (3) with the washers.(4).

  • Page 130: Cylinder Head Removal/Installation - Replacement Of Cylinder Head Gasket

    CYLINDER HEAD REMOVAL/DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Cylinder head removal/installation - replacement of cylinder head gasket Remove the camshafts, timing chain sliders as described in the relevant paragraphs. Removal: Undo screws (1) and (2) H11581...
  • Page 131 CYLINDER HEAD REMOVAL/DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Remove the gasket (8). Installation: Clean the sealing surfaces and eliminate all traces of oil and grease. Replace the gasket (8) and position it on the cylinder. Pull the timing chain (9) through the well.

  • Page 132: Valve Removal

    CYLINDER HEAD REMOVAL/DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Valve removal - Mark the valve buckets (1) so that they can be refit in the same positions, use a suitable tool to remove them. Remove the pads (2) and position on their respective valve buckets. H11590 Place the cylinder head on the support plate (3) so that the valves do not come into contact with the work bench.

  • Page 133: Crankcase Disassembly

    CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Refer to chapter F4 for all engine tightening torques. Workshop Manual Ed.09-2012 F3.1...
  • Page 134 CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Sommario Cylinder disassembly/installation..............F3.3 Piston removal/ installation .................F3.4 Measurement of a piston and cylinder............F3.5 CRANKCASE DISASSEMBLY ..............F3.6 Crankshaft disassembly ................F3.8 Crankshaft and countershaft installation ..........F3.10 Crankshaft axial clearance check .............F3.10 Removal/refitting the countershaft and checking axial clearance.....

  • Page 135: Cylinder Disassembly/Installation

    CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Cylinder disassembly/installation Removal: Remove the head cover as described in the relevant paragraph. Remove the complete head as described in the relevant paragraph. Remove the screws (1). Press the chain tensioner forward and extract the cylinder with care, making sure that the piston does not strike the engine casing.

  • Page 136: Piston Removal/ Installation

    CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Piston removal/ installation Remove the cylinder as described in the relevant paragraph. Removal: Cover the engine crankcase with paper. Mark the exhaust side of the piston crown with a marker.

  • Page 137: Measurement Of A Piston And Cylinder

    CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Measurement of a piston and cylinder Inspecting the cylinder: Check that the cylinder liner and sealing surfaces are not damaged. Using a bore gauge for internal areas, measure the cylinder diameter in three points (1), (2) and (3).
  • Page 138 CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 CRANKCASE DISASSEMBLY Crankcase disassembly: Remove the starter motor. Remove the flywheel. Remove the starter motor idle gear. Remove the chain sprocket. Remove the coolant pump cover. Remove the complete clutch.
  • Page 139 CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Assembly: Check that the washers (1) are installed correctly (also see the relevant paragraph on checking the axial clearance). Clean the sealing faces and fit a new gasket (2).

  • Page 140: Crankshaft Disassembly

    CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Crankshaft disassembly Disassemble the crankcase as described in the relevant paragraph. Removal: Match the marking (1) of the countershaft and marking (2) of the crankshaft with the crankcase marking (3).
  • Page 141 CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Check the wear of the crankshaft in correspondence of the "Z" contact area of the bushings: wear limit ø 45.96 mm (1.81 in.). Replace the crankshaft and bearings if this value is exceeded.

  • Page 142: Crankshaft And Countershaft Installation

    CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Crankshaft and countershaft installation Place the right crankcase half with the flywheel side facing down. Oil the crankcase bearing seats. Position the crankshaft washer on the right casing. Insert the countershaft (1) and the crankshaft (2) in the crankcase and phase them;...

  • Page 143: Removal/Refitting The Countershaft And Checking Axial Clearance

    CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Removal/refitting the countershaft and checking axial clearance Disassemble the crankcase as described in the relevant paragraph. Removal: Match the marking (1) of the countershaft and marking (2) of the crankshaft with the crankcase marking (3).

  • Page 144: Countershaft Clearance Check

    CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Countershaft clearance check On the right crankcase half of the engine with an appropriate tool measure the distance from countershaft bearing seat to the outer surface of the crankcase (B).

  • Page 145: Crankshaft Gear Removal

    CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Crankshaft gear removal Place the crankshaft in a vice with protection clamps. Use a puller to extract the gear. H11624 Gear installation Heat the gear to approx. 140°C. Fit a pin (1) into the gear (2) and mount onto the crankshaft until it stops by using a suitable tool, centring the pin (1) with the hole in the crankshaft.

  • Page 146: Gearbox Shafts Removal/Installation

    CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Installation: Heat the left crankcase half to approx. 100°C. Use an appropriate tool to install the bearing (1) into the crankcase half with the closed side towards the outside.

  • Page 147: Gearbox Shafts Installation

    CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Gearbox shafts installation Oil the gearbox shaft main bearing seats. Install the input shaft (3) and output shaft (4) of the gearbox. Use a plastic mallet to tap the shafts until they are fully mated with their seats.

  • Page 148: Disassembly/Assembly Of The Gearbox Input Shaft (Shaft Removed)

    CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Disassembly/assembly of the gearbox input shaft (shaft removed) Disassembly: Secure the gearbox input shaft (1) in a vice with protective clamps. Remove the cogwheels (2) and (3). Be careful not to damage the needle roller bearings during disas- sembly.

  • Page 149: Disassembly/Assembly Of The Gearbox Output Shaft (Shaft Removed)

    CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Disassembly/assembly of the gearbox output shaft (shaft removed) H11634 Disassembly: Secure the gearbox output shaft (1) in a vice with protective clamps. Remove the ring (2). Extract the gear (3) and (4) with the needle roller bearing (5) and washer (6).

  • Page 150: Replacement Of The Gearbox Control Shaft (Engine Disassembled)

    CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Replacement of the gearbox control shaft (engine disassembled) Removal: Move the lever (1) outwards and extract the gearbox shaft (2) complete with lever (1). Extract the ratchet (3) and spring...

  • Page 151: Replacement Of The Selector Drum (Engine Disassembled)

    CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Replacement of the selector drum (engine disassembled) Lift the pins (1) slightly until extracting them from the crankcase. Move the pins and forks to free the drum (2). Extract the selector drum (2).

  • Page 152: Replacement Of The Gearbox Shaft Bearings (Shafts Removed)

    CRANKCASE DISASSEMBLY TR 650 TERRA 2013 - TR 650 STRADA 2013 Replacement of the gearbox shaft bearings (shafts removed) Removal: Heat the crankcase to about 80-100°C. Extract the bearing (1) of the input shaft and the bearing (2) of the output shaft with a puller.

  • Page 153: Engine Torque Figures

    ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Tighten all nuts and screws to the specified torque using a torque wrench. An insufficiently tightened screw or nut could get damaged or come completely loose, damaging the motorcycle and/or injuring the rider. A screw or nut tightened beyond the permitted max.
  • Page 154 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 : Lubricate with engine oil. : Grease. : Tighten manually. CONVERSION TABLE 1 Nm = 0.1 Kgm 1 Nm = 0.73756 ft/lb Workshop Manual Ed. 09-2012 F4.2...
  • Page 155 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 20 Nm 38 Nm H11772 Workshop Manual Ed. 09-2012 F4.3...
  • Page 156 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 12 Nm + 12 Nm + Loctite 243 Loctite 243 12 Nm 193 ± 1mm 3 Nm + Loctite 243 12 Nm 17 Nm H11773 Workshop Manual Ed. 09-2012...
  • Page 157 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 13 ± 2 Nm 10 Nm H11774 Workshop Manual Ed. 09-2012 F4.5...
  • Page 158 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 10 Nm 30 Nm 16 Nm 22 ± 1 mm 1) 20 Nm 2) 60 Nm 25 Nm 30 Nm 30 Nm H11775 Workshop Manual Ed. 09-2012 F4.6...
  • Page 159 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 10 Nm 10 Nm H11776 Workshop Manual Ed. 09-2012 F4.7...
  • Page 160 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 12 Nm 11 Nm 12 Nm 12 Nm H11777 Workshop Manual Ed. 09-2012 F4.8...
  • Page 161 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 4 Nm 4 Nm 10 Nm AIR BOX 11 Nm H11778 Workshop Manual Ed. 09-2012 F4.9...
  • Page 162 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 H11779 Workshop Manual Ed. 09-2012 F4.10...
  • Page 163 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 60 Nm 40 Nm 10 Nm 60 Nm 10 Nm + Loctite 243 180 Nm + Loctite 243 H11780 Workshop Manual Ed. 09-2012 F4.11...
  • Page 164 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 10 Nm PRESSURE PUMP 6 Nm + Loctite 243 SCAVENGE PUMP 6 Nm + Loctite 243 40 Nm H11781 Workshop Manual Ed. 09-2012 F4.12...
  • Page 165 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 10 Nm H11782 Workshop Manual Ed. 09-2012 F4.13...
  • Page 166 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 10 Nm H11783 Workshop Manual Ed. 09-2012 F4.14...
  • Page 167 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 8 Nm 6 Nm 10 Nm H11784 Workshop Manual Ed. 09-2012 F4.15...
  • Page 168 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 35 Nm + Loctite 648 7 Nm + Loctite 243 180 Nm + Loctite 243 10 Nm + Loctite 243 H11785 Workshop Manual Ed. 09-2012 F4.16...
  • Page 169 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 6 Nm H11786 Workshop Manual Ed. 09-2012 F4.17...
  • Page 170 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 13 Nm H11787 Workshop Manual Ed. 09-2012 F4.18...
  • Page 171 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 140 Nm + Loctite 243 10 Nm H11788 Workshop Manual Ed. 09-2012 F4.19...
  • Page 172 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 40 Nm H11789 Workshop Manual Ed. 09-2012 F4.20...
  • Page 173 ENGINE TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 5 Nm 5 Nm + Loctite 243 4,5 Nm H12096 Workshop Manual Ed. 09-2012 F4.21...

  • Page 175: Engine Parts Wear Limits

    ENGINE PARTS WEAR LIMITS TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Workshop Manual Ed.09-2012 F5.1...
  • Page 176 ENGINE PARTS WEAR LIMITS TR 650 TERRA 2013 - TR 650 STRADA 2013 Table of Contents Engine block ....................F5.3 Cylinder head and cover................F5.3 Crankshaft and bearings ................F5.3 Connecting rods and bearings ..............F5.3 Piston with rings and bearings ..............F5.3 Countershaft ....................F5.4 Camshaft ....................F5.4...
  • Page 177 ENGINE PARTS WEAR LIMITS TR 650 TERRA 2013 - TR 650 STRADA 2013 WEAR VALUE TABLE FOR ENGINE Description Condition Engine block 100.00 + 0.025 mm New, from top edge 60 mm (2.3622 in.) 3.937 + 0.001 in. Cylinder bore diameter 100.05 mm...
  • Page 178 ENGINE PARTS WEAR LIMITS TR 650 TERRA 2013 - TR 650 STRADA 2013 WEAR VALUE TABLE FOR ENGINE Description Condition 0.015 ... 0.029 mm 0.0006 ... 0.0011 in. Radial clearance of the pin in the connecting rod max 0.050 mm Wear limit max 0.002 in.

  • Page 179: Front Suspension

    FRONT SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Workshop Manual Ed. 09-2012...
  • Page 180 FRONT SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 Sommario Front end ...................... I.3 Disassembly ....................I.4 Assembly ...................... I.6 Workshop Manual Ed. 09-2012...
  • Page 181 FRONT SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 Front end H11985 Steering nut. Fork leg retaining screws. Steering head. Ring nut. Bottom yoke. Bearings. Dust seal. Washer. Workshop Manual Ed. 09-2012...
  • Page 182 FRONT SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 Disassembly Remove the front wheel, the headlamp fairing, the headlamp, the front mudguard as described in the relevant paragraphs. Loosen the four screws (1) and move the handlebar without removing it.
  • Page 183 FRONT SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 Loosen the nut (5) and remove the steering head (6). H11989 H11990 Completely loosen the screws (3) and remove the cable ring (7). H11991 Loosen the ring nut (8) and remove the bottom yoke (9) with the related bearings and the dust seal.
  • Page 184 FRONT SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 Assembly For the reassembly of the front end, proceed as follows: Use grease to lubricate the new bearings before fitting them on the chassis. Fit the bottom yoke (1) complete with the dust seal (2) and the washer (3) Fit the upper dust seal (6) and tighten the ring nut (7) by hand.
  • Page 185 FRONT SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 Insert the fork legs (10) and adjust their withdrawal in the following manner: TERRA first notch --> GROUND version; second notch --> ROAD version. Lock them in position by tightening the lower screws (11) to torque.

  • Page 187: Rear Suspension

    REAR SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Workshop Manual Ed. 09-2012...
  • Page 188 REAR SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 Sommario Rear suspension....................J.3 Rear shock absorber removal ...............J.3 Lubrication points (grease) ................J.6 Servicing the rear suspension drop and drag link .........J.7 Removal of the chain guard................J.8 Removal of the sprocket guard casing ............J.8 Removal of the rear swinging arm ..............J.9...

  • Page 189: Rear Suspension

    REAR SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 Rear suspension The rising-rate rear suspension is made up of a shock absorber, a linkage system and a swinging arm. The spring preload of the shock absorber can be adjusted to suit riding and terrain conditions.
  • Page 190 REAR SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 Loosen the upper screw (5) fixing the shock absorber (4). H111000 Lift the rear wheel as much as possible in order to remove the shock absorber (4) from the lower part of the motorcycle.
  • Page 191 REAR SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 TERRA H111002 A= Wheelbase 341 ± 1,5 mm (13.42 ± 0.05 in.) B= Spring in its seat 201 ± 1,5 mm (7.91 ± 0.05 in.) C= Met-Met travel 74 mm (2.91 in.)

  • Page 192: Lubrication Points (Grease)

    REAR SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 Lubrication points (grease) H111004 H111005 Workshop Manual Ed. 09-2012...

  • Page 193: Servicing The Rear Suspension Drop And Drag Link

    REAR SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 Servicing the rear suspension drop and drag link With drop link and drag link still in place (connected to swinging arm and chassis, respectively), rock them both back and forth in all directions to check for radial and axial clearance.

  • Page 194: Removal Of The Chain Guard

    REAR SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 Removal of the chain guard Loosen the screws (1) and remove the chain guard (2) withdrawing it towards the rear part. H111009 Removal of the sprocket guard casing - Loosen the screws (1) and remove the sprocket guard casing (2).

  • Page 195: Removal Of The Rear Swinging Arm

    REAR SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 Removal of the rear swinging arm - Position a lift under the lower central beam of the chassis and lift the motor- cycle until the rear wheel has been lifted up off the ground.
  • Page 196 REAR SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 - Loosen the nut (8) and remove the swinging arm pin (9) from the left side. H111017 H111018 - Remove the swinging arm (10). - Manually check the wear status of the roller cages and the relative bushings;...

  • Page 197: Servicing The Swinging Arm Shaft

    REAR SUSPENSION TR 650 TERRA 2013 - TR 650 STRADA 2013 - Reassemble the swinging arm and insert the pin (9) for approx. half its length. - Using a screwdriver, turn the ring nut (11) and bring it into contact with the swinging arm, then completely insert the pin (9) and tighten the nut with the relative washer to torque from the right side.

  • Page 199: Brakes

    BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Workshop Manual Ed. 09-2012...
  • Page 200 BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Sommario Braking system (Versions without ABS) ............L.3 Braking system (Versions with ABS) ............L.4 Brake disc ..................... L.6 Removing the rear brake system (Versions without ABS) ......L.6 Front braking system removal (Versions without ABS)......... L.8 Removing the braking system (Versions with ABS)........

  • Page 201: Braking System (Versions Without Abs)

    BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Braking system (Versions without ABS) The braking system uses two independent circuits. Each circuit is equipped with a brake calliper connected to a master cylinder with a fluid reservoir. Front brake lever...

  • Page 202: Braking System (Versions With Abs)

    BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Braking system (Versions with ABS) The braking system uses two independent circuits. The master cylinders and callipers are connected to a control unit which modulates the pressure in each of the two circuits to prevent the wheels from locking up under braking.
  • Page 203 BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Front brake lever Front master cylinder Front oil reservoir Front line connecting brake calliper to ABS unit 10. Hand front brake calliper 11. Hand front brake disc H11843 H11844 12. Rear brake fluid reservoir 13.

  • Page 204: Brake Disc

    BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Brake disc Checking the brake disc is an important safety procedure; the disc must be spot- less, i.e. free from corrosion, oil or other dirt or deep scoring. Front brake disc diameter: mm 300 (11.81 in.).
  • Page 205 BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 - Loosen the screw (7) and remove the cable ring (8). - Cut the clamps that fasten the system. H11852 - Undo the screws (9) and detach the speed sensor (10).

  • Page 206: Front Braking System Removal (Versions Without Abs)

    BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Front braking system removal (Versions without ABS) To remove the front braking system from the vehicle, you must separate the var- ious components; then you should empty the liquid from the system as follows: - Remove the rubber cap (1) from the union on the brake calliper (2).

  • Page 207: Removing The Braking System (Versions With Abs)

    BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Removing the braking system (Versions with ABS) Removing the ABS unit Remove the tank, the rear chassis and the rear wheel as described in the rela- tive paragraphs. The new ABS unit is supplied pre-filled with fluid. Brake fluid is highly corrosive and may cause skin irritation; place absorbent paper around the ABS unit to absorb any spilled fluid.

  • Page 208: Replacing A Brake Line (Versions With Abs)

    BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Replacing a brake line (Versions with ABS) - Drain all the fluid from the relative braking system (front or rear). - Replace the damaged line, routing and fastening the new line (with clamps and hose guides) exactly as before and replacing all the seal washers.

  • Page 209: Removing The Front Master Cylinder

    BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Removing the front master cylinder - Loosen the drilled bolt (5) and disconnect the brake pipe (6) from the master cylinder. - Undo the two screws (7) and remove the lever complete with the master cylinder (8).

  • Page 210: Removing The Rear Master Cylinder

    BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Removing the rear master cylinder - Release the safety clip (1) and disconnect the master cylinder (2) from the lever (3). H11849 - Loosen the screw (4) and remove the oil reservoir (5).

  • Page 211: Removing The Rear Brake Calliper

    BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Removing the rear brake calliper - Loosen the screw (1) and remove the cable ring (2). - Cut the clamps that fasten the system. - Loosen the screw (3) and remove the speed sensor (4).

  • Page 212: Checking Brake Pads For Wear / Replacing The Pads

    BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Checking brake pads for wear / replacing the pads Check brake pad wear. Service limit ”A” 1 mm - (0.039 in.) (front and rear pads) A= 1 mm (0,039 in.) If said limit has been exceeded, or if even only one of the wear indicators is no longer visible, replace the pair of pads (in any case, the replacement is neces- sary when the wear indicators are no longer visible).
  • Page 213 BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 REPLACEMENT FRONT BRAKE PADS Remove safety split pin (1). Knock the pin (2) out partially. Undo the two screws (3) and remove the calliper (4). Remove the pin (2) completely.

  • Page 214: Brake Fluid Replacement

    BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Brake fluid replacement For the replacement of the braking system fluid, first of all you need to drain the existing fluid. Fluid replacement and system bleeding Brake fluid should be checked and changed as per the "Maintenance Chart"...

  • Page 215: Changing The Front Braking System Fluid

    BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Changing the front braking system fluid - Remove the rubber cap (1) from the valve (2) on the brake calliper. - Insert the end of a transparent hose in the valve (2) and the other end in a container.

  • Page 216: Changing The Rear Braking System Fluid

    BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Changing the rear braking system fluid - Remove the rubber cap (1) of the valve (2) of the calliper. - Insert the end of a transparent hose in the valve (2); insert the other end in a container.

  • Page 217: Bleeding The Front Braking System

    BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Bleeding the front braking system A long travel and mushy feel of the brake lever indicate that there is air in the system and the brake needs bleeding. Bleeding is also required after changing brake fluid.
  • Page 218 BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Remove the rubber cap (6) from the valve (7) on the brake calliper (B). Insert one end of a transparent clear tube in the valve (7) and insert the other end in a container containing fluid (the end of the tube must be completely immersed in the fluid).

  • Page 219: Bleeding The Rear Braking System

    BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Bleeding the rear braking system A long travel and mushy feel of the brake pedal indicate that there is air in the system and the brake needs bleeding. Bleeding procedure is as follows: Remove the cover (1) of the fluid reservoir (2), the rubber gaiter and fill the reservoir with fresh fluid.
  • Page 220 BRAKES TR 650 TERRA 2013 - TR 650 STRADA 2013 Periodically check the connecting hoses (C) and (D) (see Scheduled Mainte- nance Chart, Section B): if they show signs of wear or damage, replace them. H11897 H11896 Workshop Manual Ed. 09-2012...

  • Page 221: Electrical System

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Workshop Manual Ed. 09-2012...
  • Page 222 ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Wiring diagram (NON-ABS Version)............M.5 Wiring diagram (ABS Version) ..............M.6 Key to wiring diagram ................. M.7 Electrical component location ..............M.9 Generator performance ................M.11 Neutral position sensor ................M.12 Ignition and injection system ..............
  • Page 223 ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Starting system ..................M.48 Electronic ignition system ................M.48 Electrical connectors positioning ............... M.49 Important ....................M.53 Workshop Manual Ed. 09-2012...
  • Page 224 ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Workshop Manual Ed. 09-2012...

  • Page 225: Wiring Diagram (Non-Abs Version)

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Wiring diagram (NON-ABS Version) X9201 X9238 X9231 X9230 X9130 X9700 X9141 X9910 X9800 X9900 X9552 X9550 X9157 X9562 X9260 X9131 X9134 X9553 X9590S X9349B X9080B X9080 X9500 X9051 X9001...

  • Page 226: Wiring Diagram (Abs Version)

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Wiring diagram (ABS Version) X9201 X9238 X9231 X9230 X9130 X9700 X9141 X9910 X9800 X9900 X9552 X9550 X9157 X9562 X9260 X9131 X9134 X9553 X9133 X9590S X9349B X9080B X9500 X9080 X9051...

  • Page 227: Key To Wiring Diagram

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Key to wiring diagram Code Description X9001 Instrument panel X9010 Headlight X9018 Front parking light X9023 Number plate light X9030 Front LH turning indicator X9035 Rear LH turning indicator...
  • Page 228 ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Code Description X9517 Internal ignition coil X9550 Intake air temperature sensor X9552 Idle check valve X9553 Alarm system antenna X9562 Coolant temperature sensor X9570 Throttle position sensor X9572 Canister cleaning valve (USA)

  • Page 229: Electrical Component Location

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Electrical component location Generator (1) inside the right-hand cover; H111034 Electronic ignition coils (2) integrated with spark plug cap positioned on the cylinder head; Spark plugs on the cylinder head;...
  • Page 230 ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Throttle open position sensor (13) on throttle body; Idle actuator (14) on throttle body; H111038 Coolant temperature sensor (15) on RH side of cylinder head; H111039 Electric fan (16) on the rear part of the radiator;...

  • Page 231: Generator Performance

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Combined dashboard (20). H111043 Checking generator stator windings resistance (1) Disconnect the stator coil connector from the wiring and measure resistance with a meter. H111034 1) Measure across the terminals of the connector (2); correct value is about 0.1 - 1.0...

  • Page 232: Neutral Position Sensor

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Neutral position sensor Positioned in the left-hand side of the engine, under the sprocket casing. H111045 Workshop Manual Ed. 09-2012 M.12...
  • Page 233 ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Ignition and injection system H12062 Workshop Manual Ed. 09-2012 M.12a...

  • Page 234: Ignition And Injection System

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Ignition and injection system The engine ignition and injection system is controlled by the electronic control unit (ECU) which controls the status of the engine and the surrounding environ- ment at each moment with a series of sensors.

  • Page 235: Charging System

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Charging system The charging system is composed of: - Battery (1); - Voltage regulator (2); - Alternator (3). - Starter relay (4). The alternated current generated by the alternator is converted into direct cur- rent by the voltage regulator.

  • Page 236: Charging System Inspections

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Charging system inspections Battery Remove the saddle as described in the relevant paragraph to gain access to the battery. Disconnect the BLACK negative cable from the battery. Measure current across the negative terminal of the battery and the negative cable using an ammeter clamp.

  • Page 237: Electric Starting System

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Electric starting system The starting system is composed of: - ECU (1). - Battery (2); - Starter relay (3); - Starter motor (4); - Fuse box (5); - Ignition (6);...

  • Page 238: Starting System Inspection

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Starting system inspection Starter motor inspection For the inspection of the starter motor (1), proceed as follows: - connect a meter across ground (3) and starter motor contact (2).

  • Page 239: Coil Windings / Stick-Coil Inspection

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Coil windings / Stick-Coil inspection Disconnect the connector (1). Lift the coil / Stick-Coil (2) to remove it. Measure the resistance of the primary and secondary winding with a me- ter.

  • Page 240: Spark Plug

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Spark plug Check electrode gap "A" (0,6 mm) (0,02 in.). A wider gap may cause difficulties in starting the engine and overload the coil. A gap that is too narrow may cause difficulties when accelerating, when idling or poor performance at low speed.

  • Page 241: Headlight, Tail Light

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Headlight, tail light Headlight adjustment The headlamp features a twin bulb for low and high beam and a festoon bulb 9 __ for the city or parking light. When checking the proper aiming of the headlight beam: inflate tyres at the...

  • Page 242: Front Headlamp Bulb Replacement

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Front headlamp bulb replacement Proceed as follows to reach the headlamp bulbs: - Loosen the screws (1) and remove the front fairing (2); H111057 - completely loosen the top headlight adjustment screw (3);...
  • Page 243 ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 - remove the headlight (5) by turning it downwards (see illustration); H111062 - disconnect the connector (6); - remove the rubber hood(7), release the retainer clip (8) and remove the light bulb (9).

  • Page 244: Headlight Removal

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Headlight removal - Loosen the screws (1) and remove the front fairing (2); H111057 - completely loosen the top headlight adjustment screw (3); H111058 H111059 - loosen the two side headlight retention screws (4);...
  • Page 245 ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 - remove the headlight (5) by turning it downwards (see illustration); H111062 - disconnect the connector (6). H12014 Workshop Manual Ed. 09-2012 M.24...

  • Page 246: Turning Indicator Bulb Replacement

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Turning indicator bulb replacement - Loosen the screw (1); H111066 - remove lens (2) and replace bulb (3) pushing it inside, and turning it to remove Once the bulb has been replaced, reverse the above procedure to reassemble.

  • Page 247: Number Plate Bulb Replacement

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Number plate bulb replacement - Loosen screw (1) and remove the number plate bulb (2) from the mudguard. H111068 - Extract the bulb holder (3) with the bulb (4) from the housing.

  • Page 248: Left-Hand Switch

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Left-hand switch High beam flashing light. High beam switch control. Low beam switch. Left-hand turning indicators (self-cancelling) Right-hand turning indicators (self-cancelling) H111071 To deactivate the turning indicators, press the control lever after it is returned to the centre.
  • Page 249 ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 MY12 H12093 MY13 H12092 A ....Orange R ....Red AZ ....Light blue M ....Brown Gr ....Grey VI ....Violet N ....Black Bl ....Blue B ....

  • Page 250: Right-Hand Handlebar Switch

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Right-hand handlebar switch The right-hand switch features the following controls: 1) Engine start button 2) Engine KILL SWITCH. H111072 V/BL V/BL < < H10947 V ....Green Bl ....Blue N ....

  • Page 251: Right-Hand Switch Removal

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Right-hand switch removal - Remove the front fairing as described in the relevant paragraph. - Unscrew the screws (1) and move the support (2) to gain access to the con- nectors.

  • Page 252: Left-Hand Switch Removal

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Left-hand switch removal - Remove the front fairing as described in the relevant paragraph. - Unscrew the screws (1) and move the support (2) to gain access to the con- nectors.

  • Page 253: Fuses

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Fuses • When you find a blown fuse, always investigate and eliminate the cause before replacing it. • Never replace a fuse with another fuse with a different rating.

  • Page 254: Semiconductor Parts

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Semiconductor parts • Be careful to never drop parts that incorporate a semiconductor, such as the ECU or the voltage regulator/rectifier. • Closely follow the relevant instructions when inspecting these parts. An improper procedure may lead to severe damage.

  • Page 255: Relay Test

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Relay test Gain access to the relays as described in the relevant paragraph; then remove them. 1) Main relay. 2) Electric fan relay 3) Fuel pump relay H111083 A: Set the meter to the "Impedance" scale and check the energiser coil for proper operation.

  • Page 256: Combined Dashboard

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Combined dashboard H111084 The motorcycle has a combined dashboard divided into the following areas: 1. Warning lights (see “ Description of warning lights”). 2. Multifunction display (see “ Description of multifunction display”).

  • Page 257: Warning Light Description

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Warning light description “ABS” warning light. When turning the key to the “ON” position, the warning light starts blink- ing and keeps on blinking until the vehicle starts moving forward. If the system works properly, the warning light turns off;...

  • Page 258: Description Of Multifunction Display

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Description of multifunction display 1. “ICE” indicator: This appears when the external temperature is lower than 3°C or 37.4°F 2. “SERVICE” indicator: This indicates that it is time for a service.

  • Page 259: Setting Units Of Measurement

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Setting units of measurement The units of measurement must be set when the motorcycle is stationary and the key is set to ON. - Press the “S” button (1) until the word “ODO” or “TEMP” appears on the display.

  • Page 260: Setting Parameters

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Setting parameters With the dashboard on, press the “S” button (1) to display the various display functions: ODO ; TRIP ; TEMP ; CON ; CLOCK The “ODO”, “TEMP” and “CLOCK” functions are for display purposes only.

  • Page 261: Control Unit Removal

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Control unit removal - Before disconnecting the ECU, disconnect the battery cables. - Remove the saddle as described in the relevant paragraph. - Unscrew the two screws (1) and remove the ECU (2).

  • Page 262: Ignition Removal

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Ignition removal - Remove the front fairing as described in the relevant paragraph. - Unscrew the screw (1) to remove the connector bracket (2). H111095 H111096 STRADA - Unscrew the screws (3) under the mudguard and the upper screw (4).
  • Page 263 ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 - Lift the headlamp fairing (5) off the lower clips and turn it to the right. H111100 - Cut the ties (6) and open the clamp (7). - Disconnect the alarm system antenna connector (8).

  • Page 264: Rear Stop Microswitch Replacement

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Rear stop microswitch replacement - Unscrew the screw (1). H12004 - Unscrew the three screws (2) and remove the plastic cover (3). H12005 - Disconnect connector (4) and remove the microswitch (5).

  • Page 265: Clutch Microswitch Replacement

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Clutch microswitch replacement - Remove the headlight as described in the relevant paragraph. - Open the rubber clamps (1). H12064 - Disconnect the connector (2). H12065 - Unscrew the microswitch (3) and replace it.

  • Page 266: Front Stop Microswitch Replacement

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Front stop microswitch replacement - Remove the headlight as described in the relevant paragraph. - Undo the nut (1). - Disconnect the microswitch (2). H12007 - Disconnect the connector (3).

  • Page 267: Stand Rotative Switch Replacement

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Stand rotative switch replacement - Loosen the nut (1) and remove the switch (2) from the stand. H11790 - Disconnect the connector (3). - Replace the switch (2); during the reassembly, insert the switch tab (4) in the hole (5) of the stand and the upper part of the switch in the centring pin (6).

  • Page 268: Replacement Of Front Wheel Abs Sensor

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Replacement of front wheel ABS sensor - Disconnect the connector (1). H12071 - Free the cable harness from its fasteners (2). STRADA TERRA H12073 - Unscrew the screw (3) and remove the sensor (4).

  • Page 269: Troubleshooting

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Troubleshooting Charging system A battery that does not hold charge might be a symptom of: 1) current draw (see paragraph "Battery"); 2) incorrect voltage (see paragraph "Regulated voltage"); 3) no continuity in generator (see paragraph "Checking generator stator wind- ings resistance");...

  • Page 270: Electrical Connectors Positioning

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Electrical connectors positioning The following connectors are located in the front underneath the headlight: 1) Dashboard connector. 2) R.H. turning indicator connector. 3) Front stop microswitch connector. 4) Right-hand switch connector.
  • Page 271 ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 On the right-hand side of the bike, the following connectors are to be found: 10) Speed sensor/rear wheel ABS connector. H12079 11) Crankshaft position sensor connector. 12) Voltage regulator connector.
  • Page 272 ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 16)Lambda sensor connector. H12083 16A) Front wheel ABS sensor connector. H12084 The following connectors are located underneath the saddle: 17) Fuel pump connector. 18) Diagnosis connector. 19) Fuses. 20) Relay connectors.
  • Page 273 ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 The following connectors are located on the throttle body: 25) Throttle open sensor connector. 26) Idle actuator connector. H12087 The following connectors are located on the rear chassis: 27) Tail light connector.

  • Page 274: Important

    ELECTRICAL SYSTEM TR 650 TERRA 2013 - TR 650 STRADA 2013 Important Before washing the motorcycle, it is necessary to duly protect the following parts from water: a) Rear opening of the muffler; b) Clutch and front brake levers, handgrips, handlebar switches;...

  • Page 276: Engine Cooling

    ENGINE COOLING TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Workshop Manual Ed. 09-2012...
  • Page 277 ENGINE COOLING TR 650 TERRA 2013 - TR 650 STRADA 2013 Sommario Coolant level check ..................N.3 Coolant replacement ..................N.4 Cooling circuit ....................N.5 Servicing the engine cooling system ............N.6 Workshop Manual Ed. 09-2012...
  • Page 278 ENGINE COOLING TR 650 TERRA 2013 - TR 650 STRADA 2013 Coolant level check When the engine is cold, check that the level of the coolant is between the MIN and MAX marks on the expansion tank (1) on the left-hand side of the motorcycle.
  • Page 279 ENGINE COOLING TR 650 TERRA 2013 - TR 650 STRADA 2013 Coolant replacement Drainage - Place the motorcycle on its side stand. - Remove the cap (1) of the expansion tank (2). - Place a 2 litre container under the water pump and unscrew the screw (3).
  • Page 280 ENGINE COOLING TR 650 TERRA 2013 - TR 650 STRADA 2013 Cooling circuit H111025 The forced circulation cooling system uses a centrifugal pump (located to the left of the engine crankcase) and a downdraft radiator. Radiator cap Radiator Expansion tank...
  • Page 281 ENGINE COOLING TR 650 TERRA 2013 - TR 650 STRADA 2013 Servicing the engine cooling system If the coolant runs too hot, check the radiators. Any foreign matter trapped be- tween the fins (such as leaves, bugs, mud, etc.) will obstruct air flow and must be removed carefully to avoid damage to radiator. Straighten any bent fins to ensure free flow of air. If the cooling mass is clogged or damaged, no more than 20% of its surface must be affected. If damage exceeds this limit, the radiator must be replaced.

  • Page 282: Tightening Torque Figures

    TIGHTENING TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Tighten all nuts and screws to the specified torque using a torque wrench. If not tightened securely, a nut or a screw might become damaged or work itself loose, causing damage to motorcycle and injury to rider. An overtightened nut or screw might become damaged, its thread might strip, or the nut/screw might fail and work itself loose.
  • Page 283 TIGHTENING TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Description of tasks Safety Comment torque Fastening of tank assembly screw on LH side Fastening of mesh oil filter on chassis 10,0 Fastening of oil pipe clamps Fastening of plug on union for oil drainage from chassis...
  • Page 284 TIGHTENING TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Description of tasks Safety Comment torque Insert pin in swinging arm bearing seat GREASE Insert pins in seats of rear suspension kinematic mechanisms GREASE Fastening of top of shock absorber...
  • Page 285 TIGHTENING TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Description of tasks Safety Comment torque Fastening BLOW-BY tube to engine ignition cover Fastening of BLOW-BY pipe to filter box Fastening of horn Fastening of voltage regulator plate to engine...
  • Page 286 TIGHTENING TORQUE FIGURES TR 650 TERRA 2013 - TR 650 STRADA 2013 Description of tasks Safety Comment torque Fastening of turning indicators Fastening of licence plate light to number plate holder seat Fastening of tail light to number plate holder seat...

  • Page 288: Chassis And Wheels

    CHASSIS AND WHEELS TR 650 TERRA 2013 - TR 650 STRADA 2013 Section Workshop Manual Ed. 09-2012...
  • Page 289 CHASSIS AND WHEELS TR 650 TERRA 2013 - TR 650 STRADA 2013 Sommario Chassis ......................Y.3 Lubrication points (lubricant) ................ Y.3 Front wheel ....................Y.6 Front wheel ....................Y.7 Removing the front wheel ................Y.8 Reassembling the front wheel ..............Y.9 Rear wheel ....................

  • Page 290: Lubrication Points (Lubricant)

    CHASSIS AND WHEELS TR 650 TERRA 2013 - TR 650 STRADA 2013 Chassis The chassis is a tubular steel trellis type with stainless steel removable rear small chassis. In case of violent shocks or accidents, if you think that the chassis might be bent or damaged, proceed with an im- mediate inspection and, if necessary, replace it.
  • Page 291 CHASSIS AND WHEELS TR 650 TERRA 2013 - TR 650 STRADA 2013 H11746 H11723 Workshop Manual Ed. 09-2012...
  • Page 292 CHASSIS AND WHEELS TR 650 TERRA 2013 - TR 650 STRADA 2013 Check the assemblies shown in the figure for cracks or damage. If any are found, replace the part. A ENGINE MOUNTING SCREWS B REAR CHASSIS MOUNTING SCREWS C FOOTREST-PINS-SPRINGS...

  • Page 293: Front Wheel

    CHASSIS AND WHEELS TR 650 TERRA 2013 - TR 650 STRADA 2013 Front wheel STRADA 1 14 1 13 1 10 1 12 1 11 H11724 1) Tyre 2) Rim 3) Ball beraing 4) Sealing ring 5) Internal spacer 6) Spacer...
  • Page 294 CHASSIS AND WHEELS TR 650 TERRA 2013 - TR 650 STRADA 2013 Front wheel TERRA H11725 Legend 1) Tyre 2) Inner tube 3) Front wheel assy 4) Spoke 5) Nipple 6) Wheel axle 7) Sealing ring 8) Ball bearing 9) Hub...

  • Page 295: Removing The Front Wheel

    CHASSIS AND WHEELS TR 650 TERRA 2013 - TR 650 STRADA 2013 Removing the front wheel Set a stand or a block under the engine and see that the front wheel is lifted from the ground. H11726 Loosen the bolts (1) holding the wheel axle (2) to the front fork mounts.

  • Page 296: Reassembling The Front Wheel

    CHASSIS AND WHEELS TR 650 TERRA 2013 - TR 650 STRADA 2013 Reassembling the front wheel Fit the L.H. spacer (1) on the wheel hub. Fit the wheel between the fork legs so as to set the brake disc into the calliper.

  • Page 297: Rear Wheel

    CHASSIS AND WHEELS TR 650 TERRA 2013 - TR 650 STRADA 2013 Rear wheel STRADA H11734 Tyre Internal spacer Ball bearing Retaining circlip Sealing ring Spacer Tone wheel Spacer 10) Anti-vibration buffer rubber ring 11) Sprocket carrier 12) Spacer 13) Chain sprocket...
  • Page 298 CHASSIS AND WHEELS TR 650 TERRA 2013 - TR 650 STRADA 2013 Rear wheel TERRA H11735 Tyre Air chamber Spacer Ball bearing Retaining circlip Sealing ring Spacer Spacer 10) Tone wheel 11) Anti-vibration buffer rubber ring 12) Sprocket carrier 13) Spacer...

  • Page 299: Removing The Rear Wheel (Procedure Valid For All Models)

    CHASSIS AND WHEELS TR 650 TERRA 2013 - TR 650 STRADA 2013 Removing the rear wheel (procedure valid for all models) Set a stand or a block under the engine and see that the rear wheel is lifted from the ground.

  • Page 300: Wheel Axle Warpage

    CHASSIS AND WHEELS TR 650 TERRA 2013 - TR 650 STRADA 2013 Wheel axle warpage Use a feeler gauge to check the pint out-of-round; if the value of the warpage REAR exceeds the max allowed limit, replace it. Axle runout over 100 mm...

  • Page 301: Rear Chain Sprocket, Secondary Drive Sprocket And Chain

    CHASSIS AND WHEELS TR 650 TERRA 2013 - TR 650 STRADA 2013 Rear chain sprocket, secondary drive sprocket and chain The figure at the side shows the profiles of a normally worn and an exceedingly worn sprocket. 1 Normal wear...

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