Husqvarna TC 85 Owner's Manual
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Husqvarna TC 85 Owner's Manual

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OWNER'S MANUAL 2018
TC 85
Art. no. 3402163en

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Summary of Contents for Husqvarna TC 85

  • Page 1 OWNER'S MANUAL 2018 TC 85 Art. no. 3402163en...
  • Page 3 DEAR HUSQVARNA MOTORCYCLES CUSTOMER Congratulations on your decision to purchase a Husqvarna motorcycle. You are now the owner of a state-of- DEAR HUSQVARNA MOTORCYCLES CUSTOMER the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS PREPARING FOR USE........21 MEANS OF REPRESENTATION......5 Advice on first use ......21 Symbols used ........5 Running in the engine ......23 Formats used ........5 Preparing the vehicle for difficult SAFETY ADVICE ..........6 riding conditions .........
  • Page 5 TABLE OF CONTENTS 10.10 Adjusting the spring preload of the 11.32 Removing the fuel tank ....60 shock absorber ....... 39 11.33 Installing the fuel tank ..... 61 10.11 Adjusting the riding sag ....40 11.34 Checking for chain dirt 10.12 Checking the basic setting of the accumulation ........
  • Page 6 TABLE OF CONTENTS 14.3 Installing the radiator cover ....90 20.6 Tires ..........118 14.4 Removing the radiator cover ....92 20.7 Fork........... 118 14.5 Checking the antifreeze and coolant 20.8 Shock absorber ........ 118 level............. 92 20.9 Chassis tightening torques ....119 14.6 Checking the coolant level....

  • Page 7: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interests of your own safety, have these jobs performed by an authorized Husqvarna Motorcycles workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations. Info Only operate this vehicle in closed-off areas remote from public road traffic.

  • Page 9: Tampering Warning

    Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. Have malfunctions that impair safety promptly eliminated by an authorized Husqvarna Motorcycles workshop. Adhere to the information and warning labels on the vehicle.

  • Page 10: Protective Clothing

    – When you ride a motorcycle, set an example for your child and wear suitable protective clothing. In the interest of your child’s safety, Husqvarna Motorcycles recommends that only operating the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the number in parentheses.
  • Page 11 2 SAFETY ADVICE The Owner's Manual is also available for download from your authorized Husqvarna Motorcycles dealer and on the Husqvarna Motorcycles website. International Husqvarna Motorcycles website: www.husqvarna-motorcycles.com...

  • Page 12: Important Notes

    The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles workshop only and confirmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motor- cycles Dealer.net; otherwise, all warranty claims will be void. Damage or secondary damage caused by tam- pering with and/or conversions on the vehicle are not covered by the warranty.

  • Page 13: Customer Service

    3 IMPORTANT NOTES Customer service Your authorized Husqvarna Motorcycles dealer will be happy to answer any questions you may have regarding your vehicle and Husqvarna Motorcycles. A list of authorized Husqvarna Motorcycles dealers can be found on the Husqvarna Motorcycles website.

  • Page 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) H02526-10 Hand brake lever ( p. 16) Clutch lever ( p. 16) Filler cap Air filter box cover Shift lever ( p. 18) Choke ( p. 18) Fuel tap ( p.

  • Page 15: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) H02527-10 Kill switch ( p. 16) Throttle grip ( p. 16) Fork article number Foot brake lever ( p. 19) Kick starter ( p. 19) Level viewer for brake fluid, rear...

  • Page 16: Serial Numbers

    5 SERIAL NUMBERS Chassis number Chassis number is stamped on the right side of the steering head. 401945-10 Type label Type label is located on the front frame tube. 402154-10 Engine number The engine number is located on the left side of the engine under the engine sprocket.

  • Page 17: Shock Absorber Article Number

    5 SERIAL NUMBERS Shock absorber article number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. H02222-10...

  • Page 18: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. K00953-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar. The front brake is engaged using the hand brake lever.

  • Page 19: Opening The Filler Cap

    6 CONTROLS Opening the filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 20: Fuel Tap

    6 CONTROLS Fuel tap The fuel tap is on the left side of the fuel tank. Using the tap handle on the fuel tap, you can open or close the fuel supply to the carburetor. Possible states Fuel supply closed OFF – Fuel cannot flow from the fuel •...

  • Page 21: Kick Starter

    6 CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.10 Kick starter Kick starter is fitted on the right side of the engine. The kick starter can be swiveled. Info 0 0 1 Before riding, swing the kickstarter inwards towards the...

  • Page 22: Service Hour Counter

    6 CONTROLS 6.13 Service hour counter The service hour counter is attached below the seat. It shows the total number of service hours of the engine. The service hour counter begins counting when the engine is started and stops when the engine is switched off. Info The value indicated by the service hour counter cannot be cleared or adjusted.

  • Page 23: Preparing For Use

    7 PREPARING FOR USE Advice on first use Warning Danger of accidents A lack of physical and mental readiness on the part of the child poses a major risk. Children often underestimate or fail to recognize dangerous situations. – Your child must already be able to ride a bicycle. –...
  • Page 24 When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized Husqvarna Motorcy- cles workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.

  • Page 25: Running In The Engine

    7 PREPARING FOR USE Running in the engine – During the running-in phase, do not exceed the specified engine performance. Guideline Maximum engine performance During the first 3 operating hours < 70 % During the first 5 operating hours < 100 % –...
  • Page 26 Change the radiator cap. – Mount a dust cover on the air filter. Dust cover for air filter (47206920000) Info See the Husqvarna Motorcycles accessories fitting instructions. M01104-01 – Mount a sand cover on the air filter. Sand cover for air filter (79006922000)

  • Page 27: Preparing Vehicle For Rides On Wet Sand

    – Change the radiator cap. – Adjust the carburetor jetting and setting. Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop. – Clean the chain. – Grease the chain. Universal oil spray ( p. 123) M01107-01 –...

  • Page 28: Preparing Vehicle For High Temperatures Or Slow Riding

    7 PREPARING FOR USE – Adjust the carburetor jetting and setting. Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop. – Clean the motorcycle. ( p. 107) – Straighten bent radiator fins carefully. M01107-01 Preparing vehicle for high temperatures or slow riding –...

  • Page 29: Preparing Vehicle For Low Temperatures Or Snow

    7 PREPARING FOR USE Preparing vehicle for low temperatures or snow – Adjust the carburetor jetting and setting. Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop. M01107-01...

  • Page 30: Riding Instructions

    8 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 31: Starting Off

    Make it clear to your child that he or she must not change into a low gear at high engine speed. Info If unusual noises occur while riding, stop immediately, switch off the engine, and contact an authorized Husqvarna Motorcycles workshop. First gear is used for starting off and for steep inclines. –...

  • Page 32: Applying The Brakes

    – Check the brake system and do not allow your child to continue riding until the problem is elimi- nated. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 33: Transporting

    8 RIDING INSTRUCTIONS – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. Note Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over.
  • Page 34 8 RIDING INSTRUCTIONS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –...

  • Page 35: Service Schedule

    9 SERVICE SCHEDULE Additional information Any further work that results from the required work or from the recommended work must be ordered sepa- rately and can be invoiced separately. Different service intervals may apply in your country, depending on the local operating conditions. Required work after every race Every 40 operating hours...

  • Page 36: Recommended Work

    ● Final check: Check the vehicle for operating safety and take a test ride. ○ ● ● ● Make the service entry in the Husqvarna Motorcycles Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval...

  • Page 37: Tuning The Chassis

    – As delivered, Husqvarna motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 45 …...

  • Page 38: Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 39: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber.

  • Page 40: Measuring Rear Wheel Sag Unloaded

    10 TUNING THE CHASSIS Guideline Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping; turn counter- clockwise to reduce damping. 10.7 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p.

  • Page 41: Checking The Riding Sag Of The Shock Absorber

    Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor- rectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Preparatory work –...

  • Page 42: Adjusting The Riding Sag

    10 TUNING THE CHASSIS Main work – Measure the full spring length while it is under tension and note down the value. – Loosen screw – Turn adjusting ring until the spring is no longer under ten- sion. Holding wrench (90129051000) –...

  • Page 43: Checking The Basic Setting Of The Fork

    10 TUNING THE CHASSIS – Check the static sag of the shock absorber. ( p. 38) – Check the riding sag of the shock absorber. ( p. 39) – Adjust the rebound damping of the shock absorber. ( p. 37) 10.12 Checking the basic setting of the fork Info...

  • Page 44: Adjusting The Compression Damping Of The Fork

    Info This is due to the volume of the hose and not due to a defect in the fork pump or the fork. Read the accompanying instructions for Husqvarna Motorcycles accessories. – Adjust the air pressure as specified. Guideline Air pressure...

  • Page 45: Adjusting The Rebound Damping Of The Fork

    10 TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counter- clockwise to reduce damping. – Mount protection cap 10.15 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. – Turn red adjusting screw clockwise as far as it will go.

  • Page 46: Adjusting The Handlebar Position

    10 TUNING THE CHASSIS 10.17 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result. – Change the handlebar if the handlebar is damaged or bent. –...

  • Page 47: Service Work On The Chassis

    11 SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (80329955100) Neither wheel is in contact with the ground.

  • Page 48: Cleaning The Dust Boots Of The Fork Legs

    11 SERVICE WORK ON THE CHASSIS 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) – Remove the fork protector. ( p. 48) Main work – Push dust boots of both fork legs downward.

  • Page 49: Installing The Fork Legs

    11 SERVICE WORK ON THE CHASSIS – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. A00144-11 11.6 Installing the fork legs Main work – Position the fork legs. Air release screw of the right fork leg is positioned to the front.

  • Page 50: Removing The Fork Protector

    11 SERVICE WORK ON THE CHASSIS 11.7 Removing the fork protector – Remove screws and take off the clamp. – Remove screws on the left fork leg. Take off the fork pro- tector. – Remove screws on the right fork leg. Take off the fork protector.

  • Page 51: Installing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS – Remove protective ring – Take off the lower triple clamp with the steering stem in a downward direction. – Remove the upper steering head bearing. A00146-10 11.10 Installing the lower triple clamp Main work –...
  • Page 52 11 SERVICE WORK ON THE CHASSIS – Position the fork legs. Air release screw of the right fork leg is positioned to the front. Valve of the left fork leg faces the front. Info Grooves are milled into the side of the upper end of the fork legs.

  • Page 53: Checking The Play Of The Steering Head Bearing

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become damaged over time.

  • Page 54: Greasing The Steering Head Bearing

    11 SERVICE WORK ON THE CHASSIS Main work – Pull fuel tank breather out of the steering stem. – Loosen screws – Loosen screw – Loosen and retighten nut Guideline Nut, steering stem M20x1.5 10 Nm (7.4 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp A00149-10 to avoid stresses.

  • Page 55: Installing The Start Number Plate

    11 SERVICE WORK ON THE CHASSIS 11.15 Installing the start number plate – Attach the start number plate to the brake line. – Position the start number plate. Holding lugs engage in the fender. A00151-10 – Mount and tighten screw Guideline Start number plate 4 Nm (3 lbf ft)

  • Page 56: Installing Front Fender

    11 SERVICE WORK ON THE CHASSIS 11.17 Installing front fender Main work – Position front fender. – Mount and tighten screws Guideline Screw, front fender 10 Nm (7.4 lbf ft) – Mount and tighten screws Guideline Screw, front fender 10 Nm (7.4 lbf ft) A00138-10 Finishing work –...

  • Page 57: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 45) 11.20 Removing the seat – Remove screw – Raise the rear of the seat, pull the seat back, and lift it off. K00964-10 11.21 Mounting the seat...

  • Page 58: Installing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS 11.23 Installing the air filter box cover – Position air filter box cover on collar bushings and push toward the rear. – Engage the air filter box cover in areas K00966-10 11.24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine.

  • Page 59: Installing The Air Filter

    11 SERVICE WORK ON THE CHASSIS 11.25 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 123) V00839-10 – Insert the air filter and position top retaining pin in bush- The air filter is correctly positioned.

  • Page 60: Removing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS Finishing work – Install the air filter. p. 57) – Install the air filter box cover. ( p. 56) 11.27 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. –...

  • Page 61: Removing The Right Side Cover

    11 SERVICE WORK ON THE CHASSIS Main work – Remove screws – Take off outer tube – Remove glass fiber yarn filling from inner tube – Clean the parts that need to be reinstalled and check for damage. – Mount the new glass fiber yarn filling on the inner tube. Info Mount the glass fiber yarn filling so that the thermal protection foil is positioned on the right in the direction...

  • Page 62: Installing The Right Side Cover

    11 SERVICE WORK ON THE CHASSIS 11.31 Installing the right side cover – Position side cover with catch on the cut-out – Position the side cover on collar bushings , and push toward the rear. – Engage the side cover in areas K00979-10 11.32 Removing the fuel tank...

  • Page 63: Installing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS Main work – Pull off the fuel hose. Info Remaining fuel may flow out of the fuel hose. – Remove screws K00968-10 – Remove screw with the rubber bushing. – Remove the hose from the fuel tank breather. K00969-10 –...

  • Page 64: Checking For Chain Dirt Accumulation

    11 SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. ( p. 67) – Position the fuel tank and fit the two spoilers to the sides of the radiator bracket. – Make sure that no cables or throttle cables are trapped or damaged.

  • Page 65: Cleaning The Chain

    11 SERVICE WORK ON THE CHASSIS 11.35 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. – Remove the lubricant from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...

  • Page 66: Adjusting The Chain Tension

    11 SERVICE WORK ON THE CHASSIS Main work – Pull the chain at the end of the chain sliding guard upward to measure chain tension Info The lower chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 67: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    11 SERVICE WORK ON THE CHASSIS Guideline Nut, rear wheel spin- M20x1.5 80 Nm (59 lbf ft) Info The wide adjustment range of the chain adjusters (32 mm (1.18 in)) enables different secondary ratios with the same chain length. Chain adjusters can be turned by 180°.
  • Page 68 11 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with, or below, the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.

  • Page 69: Checking The Frame

    – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by Husqvarna V00858-01 Motorcycles. 11.40 Checking the swingarm – Check the swingarm for damage, cracking, and deformation.

  • Page 70: Checking The Rubber Grip

    11 SERVICE WORK ON THE CHASSIS – Turn the tap handle of the fuel tap to the OFF position. – Remove the fuel tank. p. 60) Main work – Check the throttle cable routing. The throttle cable must be routed along the back of the handlebar, to the right of the frame, above the fuel tank bracket, and to the carburetor.

  • Page 71: Checking The Fluid Level Of The Hydraulic Clutch

    11 SERVICE WORK ON THE CHASSIS Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply force.

  • Page 72: Changing The Hydraulic Clutch Fluid

    11 SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Correct the fluid up to level Guideline 4 mm (0.16 in) Level (fluid level below container rim)
  • Page 73 11 SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane K00989-11 – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 ( p.

  • Page 74: Brake System

    Do not make any adjustments while riding! 12.3 Checking the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.)

  • Page 75: Checking The Front Brake Fluid Level

    – Check the brake system and ensure that nobody drives the vehicle before the problem is elimi- nated. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect.

  • Page 76: Adding Front Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 77: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 78 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 79 12 BRAKE SYSTEM – Remove pin – Take off retainer spring and remove the brake linings. – Clean the brake caliper. – Position new brake linings. Info Always change the brake linings in pairs. – Position retaining spring E00239-10 – Mount pin but do not tighten yet.

  • Page 80: Checking The Free Travel Of Foot Brake Lever

    12 BRAKE SYSTEM 12.8 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

  • Page 81: Checking The Rear Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Stand the vehicle upright.
  • Page 82 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 83: Checking The Rear Brake Linings

    Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 84 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 85 12 BRAKE SYSTEM – Position retaining spring – Mount and tighten pin Guideline Pin, rear brake 4 Nm (3 lbf ft) Info To make it easier to mount the pin, push the retainer spring down. K00999-10 Make sure the retaining spring is seated correctly. –...

  • Page 86: Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) Main work – Loosen screw by several rotations. – Loosen screws – Press on screw to push the wheel spindle out of the axle clamp.

  • Page 87: Removing The Rear Wheel

    13 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the front wheel bearing. – Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p.

  • Page 88: Installing The Rear Wheel

    13 WHEELS, TIRES Main work – Remove nut – Remove chain adjuster . Pull out wheel spindle enough to allow the rear wheel to be pushed forward. – Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket. Info Cover the components to protect them against dam- age.

  • Page 89: Checking The Tire Condition

    Checking the tire condition Info Only mount tires approved and/or recommended by Husqvarna Motorcycles. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcy- cle.

  • Page 90: Checking The Tire Air Pressure

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. Husqvarna Motorcycles recommends that the tires be H01144-01 changed after 5 years at the latest, regardless of the actual state of wear.

  • Page 91: Checking Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) –...

  • Page 92: Cooling System

    14 COOLING SYSTEM 14.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
  • Page 93 14 COOLING SYSTEM – Remove screws – Remove right radiator shield – Remove screws – Remove left radiator shield H02536-10 – Position the matching radiator cover ( p. 90). The projections point towards the frame. H02356-01 – Position left radiator shield –...

  • Page 94: Removing The Radiator Cover

    14 COOLING SYSTEM 14.4 Removing the radiator cover Info Only remove left radiator shield if both radiator covers are mounted. – Remove screws – Remove right radiator shield – Remove screws – Remove left radiator shield – Remove corresponding radiator cover. –...

  • Page 95: Checking The Coolant Level

    14 COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...

  • Page 96: Draining The Coolant

    14 COOLING SYSTEM 14.7 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
  • Page 97 14 COOLING SYSTEM Main work – Make sure that screw is tightened. – Position the motorcycle upright. – Take off radiator cap – Completely fill the radiator with coolant. Coolant ( p. 121) K00973-10 – Loosen screw until coolant escapes without bubbles. –...

  • Page 98: Tuning The Engine

    15 TUNING THE ENGINE 15.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain play the throttle cable. Throttle cable play 2 …...

  • Page 99: Carburetor Setting

    15 TUNING THE ENGINE – Turn adjusting screw in such a way there is throttle cable play in the throttle grip. Guideline Throttle cable play 2 … 3 mm (0.08 … 0.12 in) – Tighten nut – Slide on sleeve 400192-11 Finishing work –...
  • Page 100 15 TUNING THE ENGINE Cylindrical part of the needle CYL The cylindrical part of the needle has the greatest influence when the throttle slide is almost closed. Idling jet IJ The idling jet has the greatest influence in the low to mid throttle slide range. If the engine stutters when idling or accelerating with a partially open throttle slide, a smaller idling jet must be used.

  • Page 101: Carburetor - Idle

    15 TUNING THE ENGINE 402797-01 Column 2 corresponds to a needle in the standard position. Column 1 corresponds to a needle which is half a clip leaner. Column 3 specifies the diameter of the first cylindrical part of the needle. The smaller the diameter of the first cylindrical part of the needle, the richer the carburation.

  • Page 102: Carburetor - Adjusting The Idle Speed

    15 TUNING THE ENGINE Carburetor – adjusting the idle speed 15.5 – Screw in idle air adjusting screw all the way and turn it to the specified basic position. Guideline Idle air adjusting screw open 2 turns – Run the engine until warm. Guideline ≥...

  • Page 103: Emptying The Carburetor Float Chamber

    15 TUNING THE ENGINE 15.6 Emptying the carburetor float chamber Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 104: Plug-In Connector Of Ignition Timing Map Adjustment

    15 TUNING THE ENGINE 15.7 Plug-in connector of ignition timing map adjustment Plug-in connector of the ignition timing map adjustment is located on the frame under the fuel tank. Possible states Soft – The plug-in connector of the ignition timing map •...
  • Page 105 15 TUNING THE ENGINE – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.

  • Page 106: Service Work On The Engine

    16 SERVICE WORK ON THE ENGINE 16.1 Checking the gear oil level Condition The engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Remove screw – Check the gear oil level. Gear oil must not run out of the hole. The gear oil level is at the lower edge of the hole.

  • Page 107: Adding Gear Oil

    16 SERVICE WORK ON THE ENGINE Guideline Oil drain plug with 20 Nm (14.8 lbf ft) magnet – Remove filler plug and fill up with gear oil. Gear oil 0.50 l Engine oil (0.53 qt.) (SAE 10W/40) p. 121) – Mount and tighten filler plug Danger Danger of poisoning Exhaust gases are toxic and...
  • Page 108 16 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 109: Cleaning, Care

    17 CLEANING, CARE 17.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 110 17 CLEANING, CARE – Push back the protection caps on the handlebar controls to allow water to evaporate. – After the motorcycle has cooled off, lubricate all moving parts and bearings. – Clean the chain. ( p. 63) – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor.

  • Page 111: Storage

    101) 401058-01 – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info Husqvarna Motorcycles recommends raising the motorcycle. – Raise the motorcycle with a lift stand. ( p. 45) – Cover the vehicle with a tarp or similar cover that is perme- able to air.

  • Page 112: Preparing For Use After Storage

    18 STORAGE 18.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 45) – Perform checks and maintenance measures when preparing for use. ( p. 28) – Take a test ride. 401059-01...

  • Page 113: Troubleshooting

    19 TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start Operating error Carry out the start procedure. p. 28) – Motorcycle was out of use for Empty the carburetor float cham- a long time and there is old ber.
  • Page 114 19 TROUBLESHOOTING Faults Possible cause Action – Engine has too little power Membrane or reed valve hous- Check the membrane and reed valve ing is damaged housing. – Engine stalls or is popping into Lack of fuel Turn handle of the fuel tap to the the carburetor ONposition.

  • Page 115: Technical Data

    20 TECHNICAL DATA 20.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 84.93 cm³ (5.1828 cu in) Stroke 48.95 mm (1.9272 in) Bore 47 mm (1.85 in) Idle speed 1,400 … 1,500 rpm Crankshaft bearing 1 grooved ball bearing / 1 roller bearing Conrod bearing Needle bearing...
  • Page 116 20 TECHNICAL DATA Screw, locking lever 6 Nm (4.4 lbf ft) ® Loctite 243™ Screw, power valve stop plate M5x12 6 Nm (4.4 lbf ft) ® Loctite 243™ Screw, water pump wheel 6 Nm (4.4 lbf ft) ® Loctite 243™ Coolant drain plug 8 Nm (5.9 lbf ft) Nut, adjusting screw, power valve...

  • Page 117: Carburetor

    20 TECHNICAL DATA 20.3 Carburetor Carburetor type KEIHIN PWK 28 Needle position 3rd position from top Idle air adjusting screw open 2 turns Main jet 142 (140, 145, 148) Jet needle NRKC (NRJC) Idling jet 48 (45, 50) Throttle slide Cold start jet 20.3.1 Basic carburetor setting for sandy surfaces...

  • Page 118: Carburetor Tuning

    20 TECHNICAL DATA 20.3.2 Carburetor tuning 402814-01 M/FT ASL Above sea level TEMP Temperature Open (rotations) idle air adjusting screw Idling jet Jet needle Needle position from top Main jet...

  • Page 119: Capacities

    44, 45, 46, 47, 48, 49, 50, 51 Steering head angle 66° Wheelbase 1,290±10 mm (50.79±0.39 in) Seat height, unloaded (TC 85 17/14) 855 mm (33.66 in) Seat height, unloaded (TC 85 19/16) 890 mm (35.04 in) Ground clearance, unloaded (TC 85 17/14) 352 mm (13.86 in)

  • Page 120: Tires

    20 TECHNICAL DATA Weight without fuel, approx. (TC 85 17/14) 67 kg (148 lb.) Weight without fuel, approx. (TC 85 19/16) 68 kg (150 lb.) Maximum rider weight 75 kg (165 lb.) 20.6 Tires Validity Front tire Rear tire (TC 85 17/14)

  • Page 121: Chassis Tightening Torques

    20 TECHNICAL DATA Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload 11 mm (0.43 in) Spring rate Weight of rider: ≤ 45 kg (≤ 99 lb.) 35 N/mm (200 lb/in) Weight of rider: 45 … 55 kg (99 … 121 lb.) 40 N/mm (228 lb/in) Weight of rider: ≥...
  • Page 122 20 TECHNICAL DATA Screw, subframe 35 Nm (25.8 lbf ft) ® Loctite 2701™ Screw, top triple clamp 20 Nm (14.8 lbf ft) Engine carrying screw 45 Nm (33.2 lbf ft) Nut, foot brake lever 45 Nm (33.2 lbf ft) ® Loctite 243™...

  • Page 123: Substances

    21 SUBSTANCES Brake fluid DOT 4 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties. Recommended supplier Bel‑Ray ® – Super DOT 4 Brake Fluid Coolant Guideline –...
  • Page 124 21 SUBSTANCES Recommended supplier ® Bel‑Ray – Si‑7 Synthetic 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 124) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 125: Auxiliary Substances

    22 AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel‑Ray – Foam Filter Cleaner & Degreaser Grip adhesive (00062030051) Recommended supplier KTM AG – GRIP GLUE High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier ®...

  • Page 126: Standards

    23 STANDARDS JASO T903 MA Different technical development directions required a separate specification for motorcycles – the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 127: List Of Abbreviations

    24 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 128: Index

    INDEX INDEX Chain tension adjusting ......64 Accessories ......10 checking .
  • Page 129 INDEX free travel, checking ....78 Fork Kick starter ......19 air pressure, adjusting .
  • Page 130 INDEX removing ......59 Throttle cable play adjusting ......96 Rubber grip checking .
  • Page 131 *3402163en* 3402163en 06/2017 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer, www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...

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