Related Manuals for HUSABERG TE 125 EU
Summary of Contents for HUSABERG TE 125 EU
- Page 1 OWNER'S MANUAL TE 125 EU TE 250 EU TE 250 AUS TE 250 USA TE 300 EU TE 300 AUS TE 300 USA 2013 Art. no. 3802032en...
- Page 3 DEAR HUSABERG CUSTOMER Congratulations on your decision to purchase a HUSABERG motorcycle. You are now the owner of a state-of-the-art sports motorcycle DEAR HUSABERG CUSTOMER that will give you enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle.
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Page 4: Table Of Contents
TABLE OF CONTENTS 6.14.17 Display mode SPEED/S1 (stop watch 1)..21 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 6.14.18 Display mode SPEED/S2 (stop watch 2)..21 Symbols used ........... 5 6.14.19 Table of functions........22 Formats used............ 5 6.14.20 Table of conditions and menu activation .. - Page 5 TABLE OF CONTENTS 11 SERVICE WORK ON THE CHASSIS......44 12.3 Adjusting the basic position of the hand brake lever (TE USA)..........69 11.1 Raising the motorcycle with the lift stand ..44 12.4 Checking the brake discs ......... 70 11.2 Removing the motorcycle from the lift stand..
- Page 6 TABLE OF CONTENTS 18 CLEANING, CARE ............ 101 18.1 Cleaning the motorcycle ........ 101 18.2 Checks and maintenance steps for winter operation............102 19 STORAGE ..............103 19.1 Storage ............103 19.2 Preparing for use after storage......103 20 TROUBLESHOOTING ..........104 21 TECHNICAL DATA............
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Page 7: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized HUSABERG workshop. There, your motorcycle will be optimally maintained by specially trained experts using the specialist tools required. -
Page 8: Safety Advice
Use definition - intended use (TE EU/AUS) HUSABERG sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motor- cycles comply with currently valid regulations and categories of the top international motorsport organizations. -
Page 9: Safe Operation
Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. In the interest of your own safety, HUSABERG recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are needed for certain tasks. -
Page 10: Owner's Manual
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized HUSABERG dealer. -
Page 11: Important Notes
Warranty The work prescribed in the service schedule must be carried out by an authorized HUSABERG workshop only and confirmed in the customer's service booklet and in the HUSABERG dealer.net; otherwise, all manufacturer warranty claims shall be void. No manufac- turer warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle. -
Page 12: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) L00311-10 Filler cap Air filter box lid Fuel tap ( p. 23) Choke ( p. 23) Shift lever ( p. 24) Side stand ( p. 24) -
Page 13: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) L00312-10 Fork compression adjustment Clutch lever ( p. 14) Kill switch ( p. 14) Horn button ( p. 15) Light switch ( p. 15) Turn signal switch ( p. 15) Speedometer overview ( p. -
Page 14: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. L00307-11 Type label The type label is fixed to the front of the steering head. L00307-10 Key number (TE EU/AUS) The key number is stamped on the key strap. -
Page 15: Shock Absorber Part Number
SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the upper part of the shock absorber above the adjusting ring. L00306-10... -
Page 16: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. L00165-10 Hand brake lever The hand brake lever is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. L00305-11 Throttle grip The throttle grip... -
Page 17: Horn Button (Te Eu/Aus)
CONTROLS Horn button (TE EU/AUS) The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – The horn is operated in this position. • Horn button L00166-11 Light switch (TE EU/AUS) The light switch is fitted on the left side of the handlebar. -
Page 18: Electric Starter Button (Te 250/300 Eu/Usa)
CONTROLS 6.11 Electric starter button (TE 250/300 EU/USA) The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in the basic position pressed – The electric starter is actuated in this position. •... -
Page 19: Tripmaster Switch
CONTROLS WS (wheel size) After the display function check, the wheel size WS is displayed briefly. Info The number 2205 equals the circumference of the 21" front wheel with stan- dard tires. The display then changes to the last selected mode. 400314-01 6.14.3 Tripmaster switch... -
Page 20: Setting The Clock
CONTROLS Deactivating the function – Press the button The symbol on the screen goes out and the display changes to the next function. – All desired functions are activated or deactivated accordingly. – Press the button for 3 - 5 seconds. The settings are stored and the Setup menu is closed. -
Page 21: Display Mode Speed (Speed)
CONTROLS 6.14.8 Display mode SPEED (speed) – Press the button briefly and repeatedly until SPEED appears on the left side of the display. The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph. Info Making the setting according to the country. -
Page 22: Display Mode Speed/Odo (Odometer)
CONTROLS Press the button Next display mode briefly. 6.14.12 Display mode SPEED/ODO (odometer) – Press the button briefly and repeatedly until ODO appears at the bottom right of the display. The total distance traveled is displayed in the ODO display mode. Press the button . -
Page 23: Display Mode Speed/A1 (Average Speed 1)
CONTROLS 6.14.15 Display mode SPEED/A1 (average speed 1) – Press the button briefly and repeatedly until A1 appears at the top right of the display. A1 (average speed 1) shows the average speed calculated on the basis of TR1 (trip mas- ter 1) and S1 (stop watch 1). -
Page 24: 6.14.19 Table Of Functions
CONTROLS 6.14.19 Table of functions Display Press the button Press the button Press the button for 3 - Press the button 5 seconds. briefly. Display mode SPEED/H No function No function The display changes to Next display mode (operating hours) the Setup menu of the speedometer functions. -
Page 25: Closing The Filler Cap
CONTROLS Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. – Press release button , turn the filler cap counterclockwise, and lift it free. L00308-10 6.16 Closing the filler cap... -
Page 26: Shift Lever
CONTROLS 6.19 Shift lever Shift lever is mounted on the left side of the engine. 602501-11 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 602501-10 6.20 Kick starter The kick starter is fitted on the right side of the engine. -
Page 27: Steering Lock (Te Eu/Aus)
CONTROLS The side stand is used to park the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber band 602503-10 6.23 Steering lock (TE EU/AUS) The steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering. -
Page 28: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized HUSABERG workshop. You will receive a delivery certificate and the service booklet at vehicle handover. -
Page 29: Running In The Engine
PREPARING FOR USE – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis- tribution between the front and rear wheels. -
Page 30: Preparing For Rides On Dry Sand
Change the radiator cap. – Fit a dust cover on the air filter. Dust cover for air filter (59006019000) Info See the HUSABERG Pure Tech fitting instructions. 600869-01 – Fit a sand cover on the air filter. Sand cover for air filter (59006022000) Info See the HUSABERG Pure Tech fitting instructions. -
Page 31: Preparing For Rides On Wet And Muddy Surfaces
Preparing for rides on wet and muddy surfaces – Mount a rain cover on the air filter. Rain cover for air filter (59006021000) Info See the HUSABERG Pure Tech parts fitting instructions. – Adjust the carburetor jetting and setting. Info 600870-01 The recommended carburetor tuning is available from your authorized HUS- ABERG workshop. -
Page 32: Preparing For Rides At Low Temperature And In Snow
Preparing for rides at low temperature and in snow – Mount a rain cover on the air filter. Rain cover for air filter (59006021000) Info See the HUSABERG Pure Tech fitting instructions. – Adjust the carburetor jetting and setting. Info 600870-01 The recommended carburetor tuning is available from your authorized HUS- ABERG workshop. -
Page 33: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance steps when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the gear oil level. ( p. 97) –... -
Page 34: Starting Off
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized HUSABERG work- shop. -
Page 35: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –... -
Page 36: Refueling
RIDING INSTRUCTIONS Refueling Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 37: Service Schedule
• Final check: Check the vehicle for safe operation and take a test ride. • • Make the service entry in HUSABERG DEALER.NET and in the service record. • • S20A: Every 20 operating hours S40A: Every 40 operating hours/after every race... -
Page 38: Service Work (As Additional Order)
SERVICE SCHEDULE Service work (as additional order) S40A S80A Change the front brake fluid. • Change the rear brake fluid. • Change the hydraulic clutch fluid. p. 66) • Grease the steering head bearing. p. 50) • Check/set the carburetor components. •... -
Page 39: Tuning The Chassis
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized HUSABERG workshop would be pleased to help you.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 40: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized HUSABERG workshop would be pleased to help you.) Info The high-speed setting can be seen during the fast compression of the shock absorber. -
Page 41: Measuring The Sag Of The Unloaded Rear Wheel
TUNING THE CHASSIS – Turn adjusting screw clockwise up to the last perceptible click. Info Do not loosen nut – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping (TE 125) L00191-10 Comfort 28 clicks Standard... -
Page 42: Checking The Riding Sag Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized HUSABERG workshop would be pleased to help you.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 43: Adjusting The Riding Sag
TUNING THE CHASSIS 10.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p. 44) – Remove the shock absorber. p. 51) – After removing the shock absorber, clean it thoroughly. Main work – Choose and mount a suitable spring. -
Page 44: Adjusting The Compression Damping Of The Fork
TUNING THE CHASSIS 10.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn the white adjusting screw all the way clockwise. Info Adjusting screw is located at the upper end of the left fork leg. The compression damping is located in the left fork leg COMP (white adjust- ing screw). -
Page 45: Handlebar Position
TUNING THE CHASSIS 10.14 Handlebar position On the upper triple clamp, there are two holes a distance of apart. Hole distance A 15 mm (0.59 in) The holes on the handlebar support are placed at a distance of from the center. Hole distance B 3.5 mm (0.138 in) The handlebar can be mounted in four different positions. -
Page 46: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with the lift stand (TE 125) Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (81229055100) The wheels must no longer touch the ground. -
Page 47: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 44) – Loosen the fork protection. ( p. 45) Main work – Push dust boots of both fork legs downwards. -
Page 48: Removing The Fork Legs
SERVICE WORK ON THE CHASSIS 11.7 Removing the fork legs Preparatory work – Switch off all power consumers and switch off the engine. – Remove the headlight mask with the headlight. ( p. 84) – Raise the motorcycle with the lift stand. ( p. -
Page 49: Removing The Fork Protector
SERVICE WORK ON THE CHASSIS – Install the headlight mask with the headlight. ( p. 84) 11.9 Removing the fork protector Preparatory work – Switch off all power consumers and switch off the engine. – Remove the headlight mask with the headlight. ( p. -
Page 50: Installing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS – Remove O-ring . Remove protective ring – Take out the lower triple clamp with the steering stem. – Take out the upper steering head bearing. 602534-10 11.12 Installing the lower triple clamp Main work –... -
Page 51: Checking The Play Of The Steering Head Bearing
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized HUSABERG workshop would be pleased to help you.) Info If the bike is ridden with play in the steering head bearing, the bearing, and the bearing seats in the frame can become dam- aged over time. -
Page 52: Adjusting The Play Of The Steering Head Bearing
SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: –... -
Page 53: Removing The Front Fender
SERVICE WORK ON THE CHASSIS 11.16 Removing the front fender Preparatory work – Switch off all power consumers and switch off the engine. – Remove the headlight mask with the headlight. ( p. 84) Main work – Remove screws – Take the brake line and wiring harness out of the brake line guide. -
Page 54: Installing The Shock Absorber
SERVICE WORK ON THE CHASSIS Main work (TE 125) – Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in this position. – Remove screw , push splash protector to the side, and remove the shock absorber. -
Page 55: Removing The Seat
SERVICE WORK ON THE CHASSIS 11.20 Removing the seat – Remove screws in the recessed grips on the left and right. – Lift up the seat at the rear, pull it back, and then lift it off. 602510-10 11.21 Mounting the seat –... -
Page 56: Installing The Air Filter
SERVICE WORK ON THE CHASSIS Main work – Push air filter holder toward the air filter at position and detach it at end Swing the air filter holder to one side and remove the air filter with the air filter support. -
Page 57: Sealing The Air Filter Box
SERVICE WORK ON THE CHASSIS – Check the carburetor connection boot for damage and tightness. Finishing work – Install the air filter. p. 54) – Install the air filter box lid. ( p. 53) 11.27 Sealing the air filter box –... -
Page 58: Changing The Glass Fiber Yarn Filling Of The Main Silencer
SERVICE WORK ON THE CHASSIS 11.30 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Info Over time, the fibers of the glass fiber yarn filling escape and the damper "burns"... -
Page 59: Installing The Right Side Cover
SERVICE WORK ON THE CHASSIS 11.32 Installing the right side cover – Position the side cover and engage in area – Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 602516-10 11.33 Removing the fuel tank Danger Fire hazard Fuel is highly flammable. -
Page 60: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS 11.34 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 61: Checking The Chain For Dirt
SERVICE WORK ON THE CHASSIS 11.35 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 59) 400678-01 11.36 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. –... -
Page 62: Adjusting The Chain Tension
SERVICE WORK ON THE CHASSIS Main work – Press the chain upward at the end of the chain sliding piece and determine chain tension Info The lower chain section must be taut. When the chain guard is mounted, it must be possible to pull up the chain at least to the point where it makes contact with chain guard Because chain wear is not always even, repeat this measurement at differ- ent chain positions. -
Page 63: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide
SERVICE WORK ON THE CHASSIS 11.39 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. 44) Main work – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear. »... - Page 64 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check the chain sliding piece for tightness. »...
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Page 65: Adjusting The Chain Guide
Check the swingarm for damage, cracking, and deformation. » If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info A damaged swingarm must always be changed. Repair of the swingarm is not authorized by HUSABERG. 401341-01... -
Page 66: Checking The Throttle Cable Routing
SERVICE WORK ON THE CHASSIS 11.43 Checking the throttle cable routing Preparatory work – Remove the seat. ( p. 53) – Remove the fuel tank. p. 57) Main work (TE 125) – Check the throttle cable routing. The throttle cable must be routed to the carburetor on the left side of the upper frame tube behind the handlebars. -
Page 67: Additionally Securing The Rubber Grip
SERVICE WORK ON THE CHASSIS 11.45 Additionally securing the rubber grip Preparatory work – Check the rubber grip. ( p. 64) Main work – Secure the rubber grip at two points using the securing wire. Securing wire (54812016000) Wire twister forceps (U6907854) The twisted wire ends face away from the hands and are bent toward the rub- ber grip. -
Page 68: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS (TE 250/300) – Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi- tion. – Remove screws – Remove cover with membrane – Check the fluid level. Fluid level below container rim 4 mm (0.16 in) »... -
Page 69: Removing The Engine Guard
SERVICE WORK ON THE CHASSIS – Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 119) – On the slave cylinder, remove bleeder screw and mount bleeding syringe L00323-10 –... - Page 70 SERVICE WORK ON THE CHASSIS (TE 250/300) – Turn quick release clockwise all the way. – Attach the engine guard on the frame at the rear and swing up at the front. L00328-10...
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Page 71: Brake System
BRAKE SYSTEM 12.1 Checking the free travel of the hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating. -
Page 72: Checking The Brake Discs
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized HUSABERG workshop would be pleased to help you.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. -
Page 73: Checking The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized HUSABERG work- shop would be pleased to help you.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 74: Changing The Front Brake Linings
HUSABERG brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid. -
Page 75: Checking The Free Travel Of The Foot Brake Lever
BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 0 0 6 100397-01 – Insert the brake linings, insert the pin, and mount the cotter pin. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. -
Page 76: Checking The Rear Brake Fluid Level
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized HUSABERG workshop would be pleased to help you.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. -
Page 77: Checking The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized HUSABERG work- shop would be pleased to help you.) Warning Environmental hazard Hazardous substances cause environmental damage. - Page 78 BRAKE SYSTEM Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.
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Page 79: Wheels, Tires
WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 44) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 80: Removing The Rear Wheel
WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly against on the brake disc. -
Page 81: Checking The Tire Condition
Checking the tire condition Info Only mount tires approved or recommended by HUSABERG. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have an important impact on the handling characteristics of the motorcy- cle. -
Page 82: Checking The Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized HUSABERG workshop would be pleased to help you.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. - Page 83 WHEELS, TIRES Guideline Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Spoke nipple, rear wheel 5… 6 Nm (3.7… 4.4 lbf ft) Torque wrench with various accessories in set (58429094000)
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Page 84: Electrical System
ELECTRICAL SYSTEM 14.1 Removing the battery (TE 250/300) Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –... -
Page 85: Changing The Main Fuse (Te 250/300)
– Do not dispose of batteries with the regular garbage. Dispose of defective batteries in an environmentally responsible man- ner. Take the batteries to your HUSABERG dealer or to a collection point for old batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 86: Removing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM Main work – Remove protection caps – Remove the faulty main fuse Info A defective fuse can be identified by the burned-out fuse wire A reserve fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109110) –... -
Page 87: Changing The Headlight Bulb
ELECTRICAL SYSTEM 14.7 Changing the headlight bulb Note Damage to reflector Reduced luminance. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. Preparatory work –... -
Page 88: Checking The Headlight Setting
ELECTRICAL SYSTEM Finishing work – Check that the turn signal system is functioning properly. 14.9 Checking the headlight setting – Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. –... - Page 89 ELECTRICAL SYSTEM – Using a coin, turn protection cap all the way counterclockwise and remove it. – Remove speedometer battery – Insert the new battery with the lettering facing up. Speedometer battery (CR 2430) ( p. 110) – Check the O-ring of the protection cap for correct seating. L00252-10 –...
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Page 90: Cooling System
COOLING SYSTEM 15.1 Cooling system (TE 125) Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. -
Page 91: Checking The Coolant Level
COOLING SYSTEM 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. -
Page 92: Refilling With Coolant
COOLING SYSTEM (TE 250/300) – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) 602531-11 15.5 Refilling with coolant Warning... - Page 93 COOLING SYSTEM – Fill the radiator completely with coolant. – Mount radiator cap – Run the engine until it is warm. – Check the coolant level. ( p. 89) L00333-10...
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Page 94: Tuning The Engine
TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…... -
Page 95: Carburetor - Adjusting The Idle Speed
TUNING THE ENGINE The idle speed is adjusted with adjusting screw The idle mixture is adjusted with the idle air adjusting screw Idle range A Operation with the throttle slide closed. This range is influenced by adjusting screw and the idle air adjusting screw Transition range B Behavior of the engine when the throttle slide is being opened. -
Page 96: Emptying The Carburetor Float Chamber
TUNING THE ENGINE – Note the position and turn the idle air adjusting screw slowly counterclockwise until the idle speed falls again. – Adjust to the point between these two positions with the highest idle speed. Info If there is a large engine speed rise, reduce the idle speed to a normal level and repeat the above steps. -
Page 97: Checking The Basic Position Of The Shift Lever
TUNING THE ENGINE 16.6 Checking the basic position of the shift lever – Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10…... - Page 98 TUNING THE ENGINE Main work – Remove screws B00496-10 – Take cap , adjusting spring , auxiliary spring , and spring insert out of the 0 0 2 clutch cover. – Pull both springs off of the spring insert. 0 0 3 0 0 0 4 0 0 5 B00056-11...
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Page 99: Service Work On The Engine
SERVICE WORK ON THE ENGINE 17.1 Checking the gear oil level Info The gear oil level must be checked while the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work (TE 125) – Remove screw from the opening used to check the gear oil level. -
Page 100: Draining The Gear Oil
SERVICE WORK ON THE ENGINE 17.3 Draining the gear oil Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 101: Adding Gear Oil
SERVICE WORK ON THE ENGINE Main work – Remove screw cap and fill up gear oil. Gear oil (TE 125) 0.70 l (0.74 qt.) Engine oil (15W/50) ( p. 119) Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. - Page 102 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
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Page 103: Cleaning, Care
CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts. -
Page 104: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 18.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt. -
Page 105: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info HUSABERG recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 44) – Cover the vehicle with an air-permeable cover or blanket. -
Page 106: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Go through the steps of starting the engine. tric starter) p. 31) Battery discharged (TE 250/300) – Recharge the battery. p. 82) – Check the charging voltage. –... - Page 107 TROUBLESHOOTING Faults Possible cause Action – Engine has too little power Diaphragm or reed valve housing Check the diaphragm and reed valve housing. damaged – Engine stalls or is popping into the Lack of fuel Turn tap handle on the fuel tap to position ON.
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Page 108: Technical Data
TECHNICAL DATA 21.1 Engine 21.1.1 TE 125 Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing... -
Page 109: All Te 300
TECHNICAL DATA 1st gear 14:32 2nd gear 16:26 3rd gear 20:25 4th gear 22:23 5th gear 25:22 6th gear 26:20 Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Ignition point (BTDC) 1.9 mm (0.075 in) Spark plug NGK BR 7 ES Spark plug electrode gap... -
Page 110: Engine Tightening Torques
TECHNICAL DATA 21.2 Engine tightening torques 21.2.1 TE 125 ® Screw, membrane 2 Nm (1.5 lbf ft) Loctite 243™ ® Locking screw for bearing 6 Nm (4.4 lbf ft) Loctite 243™ – Screw, alternator cover 5 Nm (3.7 lbf ft) ®... -
Page 111: Capacities
TECHNICAL DATA ® Screw, water pump wheel 6 Nm (4.4 lbf ft) Loctite 243™ – Screw, alternator cover 8 Nm (5.9 lbf ft) – Screw, clutch cover 10 Nm (7.4 lbf ft) – Screw, clutch spring 10 Nm (7.4 lbf ft) ®... -
Page 112: Chassis
TECHNICAL DATA 21.4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 4CS Suspension travel Front 292 mm (11.5 in) Rear 335 mm (13.19 in) Fork offset 22 mm (0.87 in) Shock absorber WP Suspension PDS 5018 DCC Brake system... -
Page 113: Tires
Michelin ENDURO COMPETITION (TE USA) 80/100 - 21 M/C 51M TT 110/100 - 18 M/C 64M TT Dunlop GEOMAX MX51 Dunlop GEOMAX MX51 Additional information is available in the Service section under: www.husaberg.com 21.7 Fork 21.7.1 TE 125 Fork part number 24.18.7M.61... -
Page 114: Shock Absorber
TECHNICAL DATA 21.8 Shock absorber 21.8.1 TE 125 Shock absorber part number 12.45.7M.61 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 turns Rebound damping... -
Page 115: Chassis Tightening Torques
TECHNICAL DATA Riding sag 105… 115 mm (4.13… 4.53 in) Fitted length 417 mm (16.42 in) Shock absorber oil ( p. 120) SAE 2.5 21.9 Chassis tightening torques – Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) –... -
Page 116: Carburetor
TECHNICAL DATA 21.10 Carburetor 21.10.1 TE 125 Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK125 Needle position 4th position from top Jet needle N84I (NOZF / NOZG / NOZH) Main jet 100 (168/170/172) Idling jet 38X38 (45) Starting jet 50 (85) Idle air adjusting screw Open... -
Page 117: 21.10.5 Te 300 Eu
TECHNICAL DATA Throttle slide 7 with cut-out Slide stop 21.10.5 TE 300 EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK029 Needle position 2nd position from top Jet needle N84K (N2ZJ / N2ZK / N2ZL) Main jet 115 (162 / 165) Idling jet 38X38 (35) Starting jet... -
Page 118: Carburetor Tuning (All Te 250)
TECHNICAL DATA 401348-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from above Main jet Does not apply to sand surfaces! 21.10.8 Carburetor tuning (All TE 250) Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. -
Page 119: Carburetor Tuning (All Te 300)
TECHNICAL DATA 401043-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from above Main jet Does not apply to sand surfaces! 21.10.9 Carburetor tuning (All TE 300) Danger Loss of approval for road use and insurance coverage The motorcycle is authorized for public road traffic in the homologous (reduced) version only. -
Page 120: General Carburetor Tuning
TECHNICAL DATA 401044-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from above Main jet Does not apply to sand surfaces! 21.10.10 General carburetor tuning 1... 5 Needle position from above The five possible needle positions are shown here. 0 0 1 The carburetor tuning depends on the defined ambient and operating conditions. -
Page 121: Substances
SUBSTANCES 2-stroke engine oil According to – JASO FC ( p. 123) Guideline – Only use high quality 2-stroke engine oil of a well-known brand. HUSABERG recommends Motorex ® products. Fully synthetic Supplier Motorex ® – Cross Power 2T Brake fluid DOT 4 / DOT 5.1 According to –... - Page 122 Hydraulic oil (15) According to – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standards (see specifications on the container) and that possesses the cor- responding properties. HUSABERG recommends Motorex ® products. Supplier Motorex ® –...
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Page 123: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaning agent Guideline – HUSABERG recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Guideline – HUSABERG recommends Motorex ® products. Supplier Motorex ® – Chain Clean Chain spray Guideline –... - Page 124 AUXILIARY SUBSTANCES Rubber grip adhesive (00062030051) Supplier KTM-Sportmotorcycle AG / Division HUSABERG – GRIP GLUE Universal oil spray Guideline – HUSABERG recommends Motorex ® products. Supplier Motorex ® – Joker 440 Synthetic...
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Page 125: Standards
STANDARDS JASO FC JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions. JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles –... -
Page 126: Index
INDEX Clutch INDEX fluid level, checking/rectifying ....65 Accessories ........9 fluid, changing . - Page 127 INDEX Fork basic setting, checking ..... . . 41 Light switch ........15 Fork legs Lower triple clamp bleeding .
- Page 128 INDEX basic position, checking ..... . 95 Type label ........12 Shock absorber compression damping, general .
- Page 129 KTM-Sportmotorcycle AG / Division HUSABERG Stallhofnerstraße 3 5230 Mattighofen, Austria www.husaberg.com *3802032en* 3802032en...
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