Husqvarna TE 250 - 310 2011 I.E. Workshop Manual
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Husqvarna TE 250 - 310 2011 I.E. Workshop Manual

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Workshop Manual
TE 250 - 310 2011 I.E.
TEi 250 2011 I.E. USA
TC 250 2011 - TC 250i 2011 I.E. USA
TXCi 250 2011 I.E. USA
Ed. 07-2010

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  • Page 1 Workshop Manual TE 250 - 310 2011 I.E. TEi 250 2011 I.E. USA TC 250 2011 - TC 250i 2011 I.E. USA TXCi 250 2011 I.E. USA Ed. 07-2010...
  • Page 2 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 ma- nual may differ from actual components. No reproduction in full or in part without written authorisation.

  • Page 3: Foreword, Table Of Contents

    TE 250 - 310 2011 I.E. TEi 250 2011 I.E. USA TC 250 2011 - TC 250i 2011 I.E. USA TXCi 250 2011 I.E. USA Copyright by HUSQVARNA MOTORCYCLES S.R.L. BMW Group Technical Service Via Nino Bixio, 8 21024 (Varese) - Italy tel.
  • Page 4 FOREWORD, TABLE OF CONTENTS 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 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 Engine Disassembly ....................F Engine Overhaul ....................G Engine Reassembly....................

  • Page 7: Important Notices

    IMPORTANT NOTICES Section Ed. 07-2010...
  • Page 8 * In order to maintain the vehicle’s “Guarantee of Functionality”, the client must follow the maintenance programme indicated in Section B by having the required maintenance inspections carried out at authorised HUSQVARNA dealers. The cost for changing parts and for the labour necessary in order to comply with the maintenance plan is charged to the Client.

  • Page 9: General Information

    GENERAL INFORMATION Section Ed. 07-2010...
  • Page 10 GENERAL INFORMATION ENGINE ......................A.3 Cooling ......................A.3 Starting ......................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 (TE-TXCi) ...............A.3 Transmission ratio (TC) ................A.4 SECONDARY DRIVE ...................A.4 FINAL RATIOS (TE-TXCi) ................A.4 FINAL RATIOS (TC) ..................A.4 FRAME ......................A.4 FRONT SUSPENSION .................A.4...

  • Page 11: Engine

    GENERAL INFORMATION ENGINE Type ................single cylinder, 4 stroke COOLING Type ..........liquid, with electric fan on TE-TXCi models (TC-TE-TXCi 250) Bore ..................mm 79 (3,11 in.) Stroke ................... mm 50,9 (2.00 in.) Displacement .............. cm 249,5 (15,22 cu. in.) Compression ratio ..................13,6:1 (TE 310) Bore ..................

  • Page 12: Transmission Ratio (Tc)

    GENERAL INFORMATION Transmission ratio (TC) 1st gear..................2,142 (z 30/14) 2nd gear ..................1,750 (z 28/16) 3rd gear ..................1,450 (z 29/26) 4th gear..................1,227 (z 27/22) 5 th gear..................1,041 (z 25/24) SECONDARY DRIVE Transmission sprocket- Rear wheel sprocket (TC) ....................

  • Page 13: Tires

    GENERAL INFORMATION TIRES Front (TE -TXCi) ..................90/90x21” (TC) ....................80/100 x 21” Rear (TE-TXCi ...................120/90x18” (TC) ....................100/90x19” Cold tire pressure (front TC) ............0,9÷1,0 Kg/cm (12,8÷14,2 Psi) (front TE-TXCi) (*) ...........0,9÷1,0 Kg/cm (12,8÷14,2 Psi) (front TE) (%) ..............1,1 Kg/cm (15,6 Psi) (rear TC) ............0,8÷0,9 Kg/cm (11,4÷12,8 Psi) (rear TE-TXCi) (*) ..........

  • Page 14: Overall Dimensions

    GENERAL INFORMATION The electrical system includes the following elements: 12V-6Ah battery under the saddle; Turning indicator flasher on left side of rear chassis; Relay for electric fan, fuel injection system and lights on right side of chassis: Electric fan; Two 15A fuses and one 20A fuse on right side of rear chassis; Coolant temperature sensor;...

  • Page 15: Weight

    GENERAL INFORMATION Saddle height E (TC) ..................mm 985 (38.77 in.) (TE-TXCi) ................mm 950 (37.40 in.) Minimum ground clearance F (TE-TXCi) ................mm 290 (11.41 in.) (TC) ..................mm 325 (12.79 in.) Weight Kerb weight, without fuel (TC): ..........97 Kg (213,8 lb) Kerb weight, without fuel (TE): ..........102,5 Kg (225,9 lb) Kerb weight, without fuel (TXCi): ..........99,7 Kg (219,7 lb) Capacities...

  • Page 17: Maintenance

    MAINTENANCE Section Ed. 07-2010...
  • Page 18 MAINTENANCE SCHEDULED MAINTENANCE CHART TC - TE - TXCi (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING SERVICE SERVICE SERVICE SERVICE SERVICE COUPON COUPON COUPON COUPON COUPON PART AFTER FIRST EVERY EVERY...
  • Page 19 MAINTENANCE SCHEDULED MAINTENANCE CHART TC - TE - TXCi (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING SERVICE SERVICE SERVICE SERVICE SERVICE COUPON COUPON COUPON COUPON COUPON PART AFTER FIRST EVERY EVERY...
  • Page 20 MAINTENANCE SCHEDULED MAINTENANCE CHART TC - TE - TXCi (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING SERVICE SERVICE SERVICE SERVICE SERVICE COUPON COUPON COUPON COUPON COUPON PART AFTER FIRST EVERY EVERY...
  • Page 21 MAINTENANCE SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) AFTER FIRST EVERY EVERY REPLACE - STANDARD MOTORCYCLE, FOR ROAD USE 1000 KM 5000 KM 10000 KM REQUIRED (DERATED) VALVES C (•) C (•) S (#) VALVE SPRINGS...
  • Page 22 MAINTENANCE SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) AFTER FIRST EVERY EVERY REPLACE - STANDARD MOTORCYCLE, FOR ROAD USE 1000 KM 5000 KM 10000 KM (DERATED) REQUIRED SERVICE SERVICE SERVICE PART COUPON COUPON COUPON KICK START PEDAL...
  • Page 23 MAINTENANCE SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) REPLACE EVERY EVERY AFTER FIRST - STANDARD MOTORCYCLE, FOR ROAD USE 5000 KM 10000 KM 1000 KM REQUIRED (DERATED) SERVICE SERVICE SERVICE PART COUPON COUPON COUPON REAR BRAKE DISC...

  • Page 25: Troubleshooting

    TROUBLESHOOTING Section Ed. 07-2010...
  • Page 26 TROUBLESHOOTING ENGINE Trouble Cause Remedy Engine does not start or Insufficient compression has starting trouble 1. Piston seized Replace 2. Connecting rod small or big end seized Replace 3. Worn piston rings Replace 4. Worn cylinder Replace 5. Cylinder head loosely tightened Tighten 6.
  • Page 27 TROUBLESHOOTING Trouble Cause Remedy Clutch slips 1. Weak clutch springs Replace 2. Worn clutch plates Replace Clutch is hard to operate 1. Uneven spring load Replace 2. Bent clutch plates Replace Gears do not engage 1. Bent or seized shifter forks Replace 2.
  • Page 28 TROUBLESHOOTING CHASSIS Trouble Cause Remedy Handlebar turns hard 1. Insufficient tyre pressure Inflate 2. Bearing adjuster ring nut or steering stem nut overtightened Adjust 3. Bent steering stem Replace bottom yoke 4. Worn or seized steering bearings Replace Handlebar vibration 1.
  • Page 29 TROUBLESHOOTING ELECTRICAL SYSTEM (see also Section M) Trouble Cause Remedy Spark plug fouls 1. Dirty air filter Clean easily 2. Worn piston rings Replace 3. Worn piston or cylinder liner Replace Spark plug electrodes 1. Spark plug electrode gap too close Adjust overheat 2.

  • Page 31: Settings And Adjustments

    SETTINGS AND ADJUSTMENTS Section Ed. 07-2010...
  • Page 32 SETTINGS AND ADJUSTMENTS Saddle removal.....................D.4 Tank removal ....................D.4 Valve clearance adjustment ................D.6 Throttle cable adjustment ................D.7 Enrichener lever play adjustment ..............D.7 Idle adjustment .....................D.8 Clutch plate replacement ................D.9 Hydraulic clutch lever adjustment and fluid level check ......D.10 Front brake lever adjustment and fluid level check ........D.11 Rear brake pedal position adjustment ............D.12 Rear brake pedal free play adjustment............D.13 Rear brake fluid level check ..............D.13...
  • Page 33 SETTINGS AND ADJUSTMENTS H02176 H02177 TXCi H02178 Ed. 07-2010...

  • Page 34: Saddle Removal

    SETTINGS AND ADJUSTMENTS Saddle removal Turn the rear fixing (1) counter clockwise, remove it and extract the saddle. Tank removal Remove the screws (1) and the side panels. Remove the tank retaining screw (2). (TE-TXCi) Close the two taps (3) and (4) and connect the hose (5). Disconnect connector (6) of the reserve sensor.
  • Page 35 SETTINGS AND ADJUSTMENTS Lift the tank and disconnect the fuel pump connector (7) from the main wiring harness. H02184 Disconnect the supply hose (8) from the outlet fitting (9) on the fuel pump, located in the rear bottom section of the tank. H02182 H02185 Remove the tank (10) together with the scoops.

  • Page 36: Valve Clearance Adjustment

    SETTINGS AND ADJUSTMENTS Valve clearance adjustment Remove saddle and tank as outlined in the relevant paragraphs. Remove spark plug (1), both head cover screws (2) and head cover (3). Engage the 2nd gear and push and pull the motorcycle back and forth to bring the piston to Top Dead Centre.

  • Page 37: Throttle Cable Adjustment

    SETTINGS AND ADJUSTMENTS Throttle cable adjustment To check the correct adjustment of the throttle cable, operate as follows: Loosen the screw and remove the cover (1). Make sure the cables protrude by 10 mm (length A). If they need adjusting, loosen the check nuts (2) and turn the adjuster screws (3).

  • Page 38: Idle Adjustment

    SETTINGS AND ADJUSTMENTS Idle adjustment Adjust the carburettor with warm engine and with the throttle control in closed position. Proceed as follows: - Turn the idle speed adjuster screw (3) located on the throttle body on the right- hand side of the vehicle, until setting idle speed to 1,600 RPM (turn clockwise to increase the speed and counter clockwise to reduce it).

  • Page 39: Clutch Plate Replacement

    SETTINGS AND ADJUSTMENTS Clutch plate replacement This procedure can be performed with the motorcycle leaning to the left - there is no need to drain engine oil. Remove the brake pedal (1). Remove the six retaining screws (2) and the clutch cover (3). Using an 8 mm wrench, unscrew the six screws (4) securing the clutch springs.

  • Page 40: Hydraulic Clutch Lever Adjustment And Fluid Level Check

    SETTINGS AND ADJUSTMENTS Remove the plates (8), lubricate the new plates with engine oil and install them (always start with a friction plate). Refit clutch actuator plate, bearing and pressure plate. Tighten the spring screws gradually in a cross pattern (8 Nm - 0.8 Kgm - 5.8 ft/ lb).

  • Page 41: Front Brake Lever Adjustment And Fluid Level Check

    SETTINGS AND ADJUSTMENTS Front brake lever adjustment and fluid level check The adjuster (1) located on the control lever, allows adjusting of the free play (a). Free play (a) must be at least 3 mm. The level of the fluid in master cylinder reservoir must never be below the mini- mum value (2), which can be checked from the inspection window on the rear of the master cylinder body.

  • Page 42: Rear Brake Pedal Position Adjustment

    SETTINGS AND ADJUSTMENTS Rear brake pedal position adjustment The position of the rear brake pedal with respect to the footrest may be adjusted according to individual needs. For adjusting, proceed as follows: Loosen the screw (1). Turn the cam (2) in order to raise or lower the brake pedal within the range available (A).

  • Page 43: Rear Brake Pedal Free Play Adjustment

    SETTINGS AND ADJUSTMENTS Rear brake pedal free play adjustment The rear brake pedal should have 5 mm free play (B) before the brake begins to bite. Should this not happen, operate as follows: Loosen the nut (3); Operate the master cylinder linkage (4) to increase or decrease free play; Tighten the nut (3) at the end of the operation.

  • Page 44: Engine Oil Level Check

    SETTINGS AND ADJUSTMENTS Engine oil level check Keeping the motorcycle level and upright, check the oil level through the inspec- tion window (1) on the right crankcase. Make sure level is up to window midline (1). To top up, remove the filler cap (2). Have this operation made with warmed-up engine.

  • Page 45: Engine Oil Replacement And Mesh Filters-Filter Cartridge Cleaning Or Replacement

    SETTINGS AND ADJUSTMENTS Engine oil replacement and mesh filters-filter cartridge cleaning or replace- ment Drain the oil with WARM ENGINE; proceed as follows: Remove the oil filler cap (2). The oil sump guard (A) may be left in place. However, the procedure will be easier with the guard removed.

  • Page 46: Coolant Level Check

    SETTINGS AND ADJUSTMENTS Coolant level check Check level (1) in right-hand radiator when engine is cold (place the motorcycle so that it is perpendicular to the ground). The coolant should be approximately 0.39 in. above the cells. The radiator cap features two locking positions: the first one is for prior discharge of pressure from the cooling system.

  • Page 47: Air Filter Check (Tc)

    SETTINGS AND ADJUSTMENTS Air filter check (TC) Turn the rear fixing (1) counter clockwise, remove it and extract the saddle re- leasing it from the front retaining screw. Remove the screw (3), remove the complete air filter (4) and separate filter (5) from rear chassis (6).

  • Page 48: Air Filter Check (Te - Txci)

    SETTINGS AND ADJUSTMENTS Air filter check (TE - TXCi) Turn the rear fixing (1) counter clockwise, remove it and extract the saddle releasing it from the front retaining screw. Take out the battery (A) and leave it hanging on the side of the motorcycle. Remove the screw (3), remove the complete air filter (4) and separate filter (5) from intake silencer (6).

  • Page 49: Assembly

    SETTINGS AND ADJUSTMENTS Assembly Grease the edge (C) of the filter face that goes into the housing to ensure proper sealing. When refitting the filter into its housing, make sure to position it with the tab (A) pointing upwards and edge (B) at the left bottom corner of the filter housing.

  • Page 50: Secondary Drive Chain Adjustment

    SETTINGS AND ADJUSTMENTS Secondary drive chain adjustment Chain should be checked, adjusted and lubricated as per the "Maintenance Chart" (see Section B) to ensure safety and prevent excessive wear. If the chain becomes badly worn or is poorly adjusted (i.e., if it is too loose or too taut), it could escape from sprocket or break.

  • Page 51: Chain Lubrication

    SETTINGS AND ADJUSTMENTS Chain lubrication Lubricate the chain following these instructions. Never use grease to lubricate the chain. Grease helps to accumulate dust and mud, which act as abrasive and help to rapidly wear out the chain, the front and rear sprockets. Disassembling and cleaning When particularly dirty, remove and clean the chain before lubrication.

  • Page 52: Suspension Setup According To Track Condition

    SETTINGS AND ADJUSTMENTS Suspension setup according to track condition Following are a few guidelines to find the right suspension setup for different types of terrain. Always start from the suspensions standard set- ting before making any change. Afterwards, increase or decrease the adjusting clicks, one at a time.

  • Page 53: Shock Absorber Adjustment

    SETTINGS AND ADJUSTMENTS Shock absorber adjustment The rear shock absorber must be adjusted to suit rider weight and terrain condi- tions. Proceed as follows: 1. Place the motorcycle on the stand and measure distance (A). 2. Sit on the motorcycle in normal riding position with full riding gear on. 3.

  • Page 54: Shock Absorber Spring Preload Adjustment

    SETTINGS AND ADJUSTMENTS Shock absorber spring preload adjustment Proceed as follows: 1. Turn the rear fixing (1) counter clockwise and remove the saddle, unscrew the retaining screws (2) and remove the right-hand side panel (3). 2. Clean lock ring nut (4) and adjuster ring nut (5) of the spring (6). 3.

  • Page 55: Shock Absorber Compression And Rebound Damping Adjustment

    SETTINGS AND ADJUSTMENTS Shock absorber compression and rebound damping adjustment Adjustment of the compression stroke is independent from the rebound stroke. A) COMPRESSION - Standard setting: 1) Low damping speed: -15 clicks (± 2 clicks) (adjuster 1) 2) High damping speed: -15 clicks (±...

  • Page 56: Kayaba Front Fork Adjustment

    SETTINGS AND ADJUSTMENTS KAYABA front fork adjustment COMPRESSION (Fig. a) (TC - TXCi: TOP ADJUSTER; TE: LOWER ADJUSTER) KAYABA: -13 clicks (TC - TXCi); KAYABA: -10 clicks (TE); To reset the standard setting, turn cap nut (A) clockwise to reach the fully closed position;...

  • Page 57: Kayaba Front Fork Springs

    SETTINGS AND ADJUSTMENTS KAYABA front fork springs STANDARD (TC - TXCi): K=4.4 N/mm (spring part no. 8000 H2669) TC - TXCi H02190 (TE): K=4.2 N/mm (spring part no. 8000 H2690) H02191 Ed. 07-2010 D.27...

  • Page 58: Steering Bearing Clearance Adjustment

    SETTINGS AND ADJUSTMENTS Steering bearing clearance adjustment For safety reasons, the steering should always be adjusted so that the handlebar turns freely and without play. To check steering adjustment, set a stand or a block under the engine and see that the front wheel is lifted from the ground. Press lightly on the handlebar grips to cause the front end to rotate;...

  • Page 59: Changing Handlebar Position And Height

    SETTINGS AND ADJUSTMENTS Changing handlebar position and height Handlebar position (a) and height (b) can be modified to better suit your personal preferences. To perform these adjustments, remove the handlebar clamp bolts (3) and (4), and then remove the handlebar upper (1) and lower (2) clamps. a) Changing handlebar position Rotate the lower clamp by 180°...

  • Page 60: Supply Hose Check

    SETTINGS AND ADJUSTMENTS Supply hose check Remove saddle and side panels as described in Section "E". Remove the tank (1) retaining screw (2). Lift the tank (2) and check the hose (3) running from the pump (4) to the throttle body (5).

  • Page 61: Exhaust System Check

    SETTINGS AND ADJUSTMENTS Exhaust system check Remove exhaust system components as described in Section "E". Check pipes (1) and (2) silencer (3) for cracks or damage: replace if cracked or damaged. H02196 Ed. 07-2010 D.31...

  • Page 63: General Procedures

    GENERAL PROCEDURES Section Ed. 07-2010...
  • Page 64 GENERAL PROCEDURES Foreword ......................E.3 Saddle removal.....................E.4 Side panel removal ..................E.4 Battery removal (TE - TCXi) .................E.4 Removing the rear chassis complete with mudguard and air box (TC) ..............E.5 Removing the rear chassis complete with mudguard and air box (TE – TXCi) ............E.5 Exhaust system removal ................E.8 Fuel tank, scoops and spoiler removal ............E.10 Fuel pump removal (TC)................E.14...

  • Page 65: Foreword

    GENERAL PROCEDURES Foreword This section describes the operations preliminary to engine removal. Please note that, in order to gain access to certain motorcycle components (rear shock absorber, electrical parts, wiring, etc.), it may be necessary to partially remove some parts. H02198 H02199 H02200...

  • Page 66: Saddle Removal

    GENERAL PROCEDURES Saddle removal - Turn the rear fixing (1) counter clockwise and remove the saddle. Side panel removal Remove the saddle as described in the relevant paragraph. Loosen the retaining screws (1) and remove the side panels (2) and (3). H02201 Battery removal (TE - TCXi) Remove the saddle as described in the relevant paragraph. First remove the BLACK negative cable (8 mm Allen wrench), then the RED positive cable (when reassembling, first connect the RED positive cable, then the BLACK negative cable);...

  • Page 67: Removing The Rear Chassis Complete With Mudguard And Air Box (Tc)

    GENERAL PROCEDURES Removing the rear chassis complete with mudguard and air box (TC) Remove the saddle as described in the relevant paragraph. Remove the side panels as described in the relevant paragraph. Lift the tank at the rear end. Remove the exhaust silencer as described in the relevant paragraph. Slacken clamp (1) that secures the rubber coupling (2) of the air box (3) to the throttle body.
  • Page 68 GENERAL PROCEDURES Disconnect the connector (4) of the tail light unit (TE). Detach relays (5) and fuses (6) on the right-hand side of the motorcycle. - Detach the breather hose (7) from the air filter (8). H00621 Ed. 07-2010...
  • Page 69 GENERAL PROCEDURES - Unscrew the clamp (9) connecting air filter (8) to throttle body (10). Remove the four screws (11) of the rear chassis (12) using a 10 mm ring wrench. Pull the rear chassis (12) rearwards together with mudguard and air box , and detach it from the main chassis. Ed.

  • Page 70: Exhaust System Removal

    GENERAL PROCEDURES Exhaust system removal H02205 TE-TXCi H02338 Ed. 07-2010...
  • Page 71 GENERAL PROCEDURES Remove the saddle as described in the relevant paragraph. Remove the left-hand side panel as described in the relevant paragraph. Using an 8 mm T-wrench on the outside and a 10 mm T-wrench on the inside, remove the silencer (4) retaining screw (1). Remove the spring (2) (TC) and the screw (3) using an 8 mm T-wrench;...

  • Page 72: Fuel Tank, Scoops And Spoiler Removal

    GENERAL PROCEDURES (TE-TXCi) TE-TXCi Loosen the two bolts (5) and remove the exhaust pipe (6). (TC) Detach springs (7) and remove exhaust pipe (6). H02209 H02208 Fuel tank, scoops and spoiler removal H02211 E.10 Ed. 07-2010...
  • Page 73 GENERAL PROCEDURES TE-TXCi H00630 H02210 Remove the saddle as described in the relevant paragraph. Remove the side panels as described in the relevant paragraph. Remove the breather hose (1). Loosen the fuel tank retaining screw (2). Ed. 07-2010 E.11...
  • Page 74 GENERAL PROCEDURES Remove the screws (3) retaining the scoops to the fuel tank. Remove the scoops (4) and the screws (5) retaining the spoilers (6) to the radiators and then remove the spoilers. H02212 E.12 Ed. 07-2010...
  • Page 75 GENERAL PROCEDURES (TC) Disconnect the fuel pump connector (7) from the main wiring harness. - Lift the tank and disconnect the hose (8) from the fuel pump outlet fitting (9) in the bottom section of the tank. H00645 (TE-TXCi) TE-TXCi Close the two taps (7) and (8) and connect the hose (9). Disconnect connector (6) of the reserve sensor. - Lift the tank and disconnect the hose (10) from the fuel pump outlet fitting (11) in the bottom section of the tank.

  • Page 76: Fuel Pump Removal (Tc)

    GENERAL PROCEDURES Fuel pump removal (TC) Remove the fuel tank as described in the relevant paragraph. - Remove the tank filler cap and pour the fuel contained in the tank into a ves- sel of adequate capacity. Use an Allen wrench to loosen the 6 screws (1) and remove the pump (2). H00648 WARNING On assembly, make sure that the pump O-ring (3) is correctly po- sitioned in its seat.
  • Page 77 GENERAL PROCEDURES Fuel pump removal (TE – TXCi) Remove the fuel tank as described in the relevant paragraph. - Remove the tank filler cap and pour the fuel contained in the tank into a vessel of adequate capacity. - Make use of a 10 mm wrench to slacken the 4 screws (1) of the pump flange (2) and the four screws (3) of the fitting flange (4).

  • Page 78: Solenoid Starter Removal (Te - Txci)

    GENERAL PROCEDURES Solenoid starter removal (TE – TXCi) Remove saddle and left-hand side panel (in this order) as outlined in the relevant paragraphs. Disconnect the negative and positive cables of the battery. Disconnect the starter motor positive cable (1) from the solenoid starter. Disconnect the connector (2) and remove the solenoid starter (3) from its mount.

  • Page 79: Cdi Electronic Control Unit Removal

    GENERAL PROCEDURES CDI electronic control unit removal TE-TXCi Remove: saddle and fuel tank as described in the relevant paragraphs. Detach the connector (1) from the CDI electronic control unit (2) and take the control unit together with its vibration mount out of the chassis. TE-TXCi H02221 H02343...

  • Page 80: Ignition Coil Removal

    GENERAL PROCEDURES Loosen the two retaining screws (2) and remove the regulator (3). TE-TXCi H02224 H02223 Ignition coil removal Remove: saddle and fuel tank as described in the relevant paragraphs. Remove the spark plug cap (1). Remove the retaining screws (2) and then the coil (3). TE-TXCi H02225 E.18...

  • Page 81: Clutch Hose Removal

    GENERAL PROCEDURES Clutch hose removal - Loosen the fitting (1) of the clutch hose (2) on the left-hand of the engine. Drain any oil left in the hose. On assembly, bleed the clutch system as de- scribed in Section "P". Horn removal (TE) Remove saddle and fuel tank (in this order) as outlined in the relevant para- graphs.

  • Page 82: Electric Cooling Fan Removal (Te - Txci)

    GENERAL PROCEDURES Electric cooling fan removal (TE – TXCi) Remove saddle, fuel tank and scoops (in this order) as outlined in the relevant paragraphs. Disconnect the connector (1). Loosen the screw (2) and remove the electric fan (3). E.20 Ed. 07-2010...

  • Page 83: Secondary Drive Chain Removal

    GENERAL PROCEDURES Secondary drive chain removal The following procedure applies to both O-ring chains and chains without O- rings: Remove: screws (1), sprocket guard (2), clip (3), master link (4) and chain (5). H02226 H02344 Engine removal Remove the saddle as described in the relevant paragraph. Remove the side panels as described in the relevant paragraph.
  • Page 84 GENERAL PROCEDURES Disconnect connectors (1) and (2) and MAQS connector (3) from the throttle body (4). Loosen the clamps (5) and (6). Push the intake coupling (7) towards the rear end of the motorcycle to re- lease the throttle body (4) and then extract it from the right-hand side of the motorcycle.
  • Page 85 GENERAL PROCEDURES Slacken the clamp (11) and disconnect the hose (12) connecting the radiators to the engine. Drain all fluid. Slacken the clamp (13) and disconnect the hose (14) connecting the radiator to the water pump. Drain engine oil as described in the relevant paragraph. Ed.
  • Page 86 GENERAL PROCEDURES Remove the spark plug cap (17). Remove the clamp (18) and disconnect the hose (19) from the cylinder head cover. Remove the chain as described in the relevant paragraph. H02230 Remove the chain guide plate (20) unscrewing the screw (21) with an 8 mm wrench.
  • Page 87 GENERAL PROCEDURES Loosen the three screws (22) and remove the clutch actuator (23). H02231 Remove the clip (24) that holds clutch hose and wiring harness together. H02232 Disconnect connectors (25) and (26) that connect generator and gear sensor connector (27). H02233 Remove the water temperature sensor connector (27).
  • Page 88 GENERAL PROCEDURES Remove the positive power supply cable (29) of the starter motor TE-TXCi (TE-TXCi). H02347 To remove the brake lever (32), use an 8 mm wrench to loosen the master cylinder linkage (33) and a 6 mm Allen wrench to loosen the central screw (34).
  • Page 89 GENERAL PROCEDURES Loosen the upper retaining screw (35) of the shock absorber (36) with a 14 mm wrench. H02349 Remove the guards (37) on both sides shearing the clips (38). H02348 TE-TXCi (TE-TXCi) Loosen clamp (39) and disconnect the Blow-by tube (40). H02236 Ed.
  • Page 90 GENERAL PROCEDURES Remove the engine mounting bolts (41) using a 12 mm wrench on the left- hand side and a 10 mm wrench on the right-hand side. H02237 Loosen the swinging arm axle nut (42) using a 22 mm wrench; pull out the axle (43) from the right-hand side of the engine and pull the swinging arm rearwards to facilitate engine removal.

  • Page 91: Radiator Removal

    GENERAL PROCEDURES Radiator removal Remove the fuel tank together with scoops and spoilers as outlined in the relevant paragraphs. Remove the electric cooling fan (TE – TXCi) as described in the relevant paragraph. Place a pan under the hose (1) to collect coolant, then loosen the clamp (2), detach the hose (1) and drain all coolant.

  • Page 92: Thermostat Removal (Te - Txci)

    GENERAL PROCEDURES Loosen the screws (12) and remove the left-hand radiator (5). Loosen the screws (13) and remove the right-hand radiator (8). Thermostat removal (TE – TXCi) Remove the fuel tank and the left-hand spoiler as outlined in the relevant paragraph.

  • Page 93: Engine Disassembly

    ENGINE DISASSEMBLY Section Ed. 07-2010...
  • Page 94 ENGINE DISASSEMBLY Layout of engine components ..............F.3 Cylinder head cover removal ................ F.4 Camshaft removal ..................F.4 Water pump body removal ................F.8 Water pump disassembly ................F.8 Cylinder head removal................F.10 Valve removal ..................... F.12 Cylinder removal..................F.14 Piston removal ...................

  • Page 95: Layout Of Engine Components

    ENGINE DISASSEMBLY Layout of engine components Throttle body Cylinder head cover Cylinder head Chain tensioner Cylinder Starter motor (TE - TXCi) Head lubrication pipe Oil filter Clutch cover Kick start lever Water pump Alternator cover Sprocket H02240 H02241 Ed. 07-2010...

  • Page 96: Cylinder Head Cover Removal

    ENGINE DISASSEMBLY Cylinder head cover removal Remove the two retaining screws (1) (10 mm wrench) and remove the head cover (2) with its gasket. Camshaft removal Remove the six retaining screws (1) of the alternator cover (2) (4 mm Allen wrench) and remove the cover with its gasket.
  • Page 97 ENGINE DISASSEMBLY To remove the gear sensor (3), loosen the two screws (4) (8 mm wrench) and its pushrod and spring. TE-TXCi H02244 Ed. 07-2010...
  • Page 98 ENGINE DISASSEMBLY Using a 17 mm wrench, bring the piston to T.D.C. at the end of the compres- sion stroke (in this condition, the two holes (5) and the two marks (6) on the gears must be positioned as shown in the figure). TE-TXCi Cover parting line "A"...
  • Page 99 ENGINE DISASSEMBLY Remove the spark plug (7) (16 mm wrench) and the head lubrication pipe (8) unscrewing the drilled screw (9) (12 mm wrench). Remove the screws (10) (4 mm wrench) and the screws (11) (5 mm wrench) from both clamps (12) and (13) and remove them. Remove the intake camshaft (14) and the exhaust camshaft (15).

  • Page 100: Water Pump Body Removal

    ENGINE DISASSEMBLY Water pump body removal Remove the four screws (1) securing pump body (2) to head (4 mm Allen wrench) and remove pump body. Water pump disassembly Loosen the screw (1) to disassemble the pump. Loosen the nut (2) to remove the impeller (3). Ed.
  • Page 101 ENGINE DISASSEMBLY Remove the oil seal (4) and slide off the gear (5) together with the bearing (6). Remove the circlip (7) and remove the bearing (6) from the gear (5). On assembly, make sure the centring pins (8) are correctly located in their seats.

  • Page 102: Cylinder Head Removal

    ENGINE DISASSEMBLY Cylinder head removal Remove the head cover as described in the relevant paragraph. Remove the camshafts as described in the relevant paragraph. Remove the chain tensioner (1) as follows: • Loosen the screw (2) with an 8 mm wrench. •...
  • Page 103 ENGINE DISASSEMBLY Remove the timing gear retaining clip (5) using a screwdriver. Loosen the two screws (6) using a Phillips screwdriver and remove the timing drive shaft (7) while holding the gear (8) with your hand. Support the gear (8) using a screwdriver or a punch, unwrap the chain (9) and remove the gear.

  • Page 104: Valve Removal

    ENGINE DISASSEMBLY Loosen the four head bolts (10) using a 12 mm socket wrench. Mark each bolt with its position to avoid confusing them on assembly (three bolts are 112.5 mm long, one (10A) is 104.5 mm long). Remove the cylinder head (11) and its gasket (12). Be careful not to lose the locating pins positioned between head and cylinder.
  • Page 105 ENGINE DISASSEMBLY Use a valve spring compressor to compress the valve springs. Be careful not too damage the mating surfaces that contact the gasket or those of the combustion chamber. Make sure the valve spring compressor is aligned straight on the spring, or you might bend the valve stem. Do not compress the springs too much or they will weaken.

  • Page 106: Cylinder Removal

    ENGINE DISASSEMBLY Cylinder removal Remove the front slider (1) of the timing chain pulling it upwards. Remove the cylinder (2) with its gasket (3). Piston removal Remove the piston pin retaining rings (1), slide out the piston pin (2) and remove the piston (3).

  • Page 107: Flywheel Removal

    ENGINE DISASSEMBLY Flywheel removal Loosen the rotor (2) nut (1) (17 mm wrench). H02350 Remove the rotor (2) using the puller (3A) (part no. 8000 H2146) H02243 Ed. 07-2010 F.15...

  • Page 108: Kick Start Pedal Removal

    ENGINE DISASSEMBLY Remove the key (4) from the crankshaft. Kick start pedal removal Remove the pedal retaining bolt (1) (12 mm wrench), the washer and the pedal (2). Sprocket removal Lift the tab of the lock washer (1) using a chisel. F.16 Ed.
  • Page 109 ENGINE DISASSEMBLY Loosen the nut (2) using a 22 mm wrench and remove sprocket (3) and spacer (4). Ed. 07-2010 F.17...

  • Page 110: Oil Filter Removal

    ENGINE DISASSEMBLY Oil filter removal Loosen the drilled nut (1) and disconnect the hose (2) from the oil pump cover (3). Loosen the three screws (4) using an 8 mm wrench. Remove the cover (3) together with its filter (5) and Belleville washer (6). F.18 Ed.

  • Page 111: Clutch Cover Removal

    ENGINE DISASSEMBLY Clutch cover removal Remove the nine screws (1) and the screw (2) securing the cover (3) (8 mm wrench) and remove the cover (3). Remove the gasket (4) and the bushings (5). Ed. 07-2010 F.19...

  • Page 112: Clutch Disassembly

    ENGINE DISASSEMBLY Clutch disassembly Remove the six retaining screws (2) and the clutch cover (3). Using an 8 mm wrench, unscrew the six screws (4) securing the clutch springs. Remove springs, pressure plate (5) with bearing (6) and clutch actuator plate (7).
  • Page 113 ENGINE DISASSEMBLY Remove the plates (8), lubricate the new plates with engine oil and install them (always start with a friction plate). Remove the clutch pushrod (9) from the opposite side of the engine. Straighten the tab of the lock washer (10). Ed.
  • Page 114 ENGINE DISASSEMBLY Remove the nut (11) (22 mm wrench) using the clutch removal tool (A) (part no. 8000 79015 ). Remove the washer (10). Remove hub (12), washer (13) and clutch housing (14). Remove the bushing (15). F.22 Ed. 07-2010...

  • Page 115: Slider Removal

    ENGINE DISASSEMBLY Slider removal Use a 5 mm Allen wrench to loosen the screw (1) and remove the slider (2). Kick start disassembly Release the spring (1) from the casing (2) and remove the complete shaft assembly (3). Be careful not to lose the washer (11) located on the crank- case.
  • Page 116 ENGINE DISASSEMBLY Remove the snap ring (4), the washer (5) and the timing drive gear (6). Disassemble the shaft as shown in the diagram. On assembly, make sure that the dot (7) on shaft end (8) and the dot (9) on the ratchet (10) are aligned. F.24 Ed.

  • Page 117: Starter Motor Removal (Te-Txci)

    ENGINE DISASSEMBLY Starter motor removal (TE – TXCi) Remove the exhaust pipe as described in the relevant paragraph. Disconnect the positive power supply cable (1) loosening the hexagonal-head screw (8 mm wrench). H00753 Unscrew the four screws (2) using a 4 mm Allen wrench. H00757 H00759 Ed.
  • Page 118 ENGINE DISASSEMBLY Slide the starter motor (3) towards the rear end of the motorcycle to remove H00756 H00758 WARNING Upon assembly, check the gasket (4) for damage and replace it if needed. Make sure to position it correctly with the gasket hole (5) matching the hole (6) in the starter motor flange.

  • Page 119: Starter Motor Disassembly (Te-Txci)

    ENGINE DISASSEMBLY Starter motor disassembly (TE – TXCi) Separate the starter motor (1) from the starter drive (2). Starter drive disassembly (TE – TXCi) Ed. 07-2010 F.27...
  • Page 120 ENGINE DISASSEMBLY Remove flywheel and starter motor as outlined in the relevant paragraph. Disassemble the starter motor as outlined in the relevant paragraph. Remove the cap (1) using a 10 mm Allen wrench. Remove the circlip (2) and the bearing (3) with the bevel gear. F.28 Ed.
  • Page 121 ENGINE DISASSEMBLY Place the wormshaft (4) assembly in a vice with aluminium jaws, loosen the nut (5) using a 10 mm T-wrench and slide out the wormshaft (4). H00772 Remove the freewheel (6). Remove the needle roller bearing (7) and the thrust ring (8). Ed.

  • Page 122: Oil Pump Disassembly

    ENGINE DISASSEMBLY Oil pump disassembly Loosen the screws (1) using a 4 mm Allen wrench and remove pump body (2) and gasket. Remove the pump rotors (3) and (4) and extract the drive pin (5) to release the gear (6). Remove drive gear (7) and oil suction stub (8).
  • Page 123 ENGINE DISASSEMBLY To facilitate assembly, mark the position of the gear shift pedal (1) on the shaft. Remove the retaining screw (2) of the gear shift pedal (1) (8 mm wrench) and slide the pedal from the selector shaft. Remove the selector shaft (3) from the right-hand side. Remove the two screws (4) (4 mm Allen wrench and 8 mm wrench) secur- ing the selector retaining plate (5) and remove retaining plate and ratchet mechanism (6).
  • Page 124 ENGINE DISASSEMBLY Remove the bolt (7) of the selector drum (8) (12 mm wrench). Release the ratchet (10) spring (9) and remove retaining ring (11), washer (12) and ratchet (10). Be careful not to lose the roller (13). F.32 Ed. 07-2010...

  • Page 125: Primary Drive Gear Removal

    ENGINE DISASSEMBLY Primary drive gear removal Loosen the central nut (1) using a 22 mm wrench. Remove primary gear (2) and water pump drive gear (3). Ed. 07-2010 F.33...

  • Page 126: Crankcase Disassembly

    ENGINE DISASSEMBLY Crankcase disassembly Remove the nine screws (1) from the left crankcase (2) (8 mm wrench). Important: the screws (1) are not all the same length. Refer to figure "A" on assembly to ensure correct installation. FIG. "A" a1= 6x60 mm a2= 6x55 mm a3= 6x70 mm a4= 6x90 mm...

  • Page 127: Gearbox Disassembly

    ENGINE DISASSEMBLY Install the crankcase puller (3) (part no. 8000 A7015) using the flywheel cover holes and remove the left crankcase half (4). Tap the output shaft (5) with a rubber hammer at intervals during removal to keep the crankcase half from getting stuck. Gearbox disassembly Remove the shaft (1) of the output shaft shifter forks.
  • Page 128 ENGINE DISASSEMBLY Remove the retaining ring (5) and then the shaft (6) of the input shaft shifter fork (7). Remove the input shaft (8) and output shaft (9) being careful not to lose any shims (if fitted). F.36 Ed. 07-2010...

  • Page 129: Crankshaft Disassembly

    ENGINE DISASSEMBLY Crankshaft disassembly Slide the puller (1) (part no. 8000 A7015) over the right end of the crank- shaft. Secure the puller to the crankcase half and remove the crankshaft (2) from the opposite side. In case crankshaft and/or connecting rod are worn it is necessary to replace the whole crankshaft assembly and the connecting rod.

  • Page 131: Engine Overhaul

    ENGINE OVERHAUL Section Ed. 07-2010...
  • Page 132 ENGINE OVERHAUL Cleaning parts ..................... G.3 Clearances ....................G.3 Cylinder head ....................G.3 Valve seat refacing ..................G.4 Valve guide ....................G.5 Valve guide replacement ................G.5 Valve ......................G.7 Valve spring ....................G.7 Valve bucket inspection ................G.8 Valve installation ..................G.8 Valve leak check ..................

  • Page 133: Cleaning Parts

    ENGINE OVERHAUL Cleaning parts All parts must be cleaned with gasoline and dried with compressed air. Flammable vapours develop during this procedure and metal filings blown by compressed air may get into your eyes. Perform this procedure away from open flames or sources of ignition and wear an eye protection. Clearances To ensure the best operating conditions and maximum performance, all clearances must be within the specified tolerance.

  • Page 134: Valve Seat Refacing

    ENGINE OVERHAUL Valve seat refacing Clean off any fouling deposits from the valve. Apply Prussian Blue to the valve and rotate it in its seat using a rubber hose or other similar tool. Remove the valve and measure the width “X” of the seating face. If width is greater than 1.2 mm (0.0472 in.), the seat needs to be refaced.

  • Page 135: Valve Guide

    ENGINE OVERHAUL Valve guide Perform a careful visual inspection of the valve guide. To determine wear, measure valve to valve guide clearance in the “x” and “y” di- rections (at right angles to each other) using a suitably positioned dial gauge. Intake valve: normal clearance: 0.008 - 0.035 mm Service limit: 0.05 mm (0.0019 in.).
  • Page 136 ENGINE OVERHAUL Install the new guide from the top of the head using a suitable punch. Smear the guide with oil before installation. Ream the valve guide using a suitable reamer and lubricate with cutting fluid. Rotate the reamer when extracting it to avoid scoring the valve guide. When a valve guide is changed, the valve seat must be refaced.

  • Page 137: Valve

    ENGINE OVERHAUL Valve Inspect valve stem and valve seating face to make sure they are in good condi- tion. There should be no signs of pitting, cracking, distortion or wear. Check for the following: Valve stem runout: place valve on a V block and measure runout with a dial gauge.

  • Page 138: Valve Bucket Inspection

    ENGINE OVERHAUL Check the valve springs for proper squareness. Maximum acceptable deviation is 1.5 mm on each side. Valve bucket inspection Check that the valve buckets (1) slides freely in their seats. If not so, replace them. Valve installation Smear valve guides and stems with oil before installation. Install spring seat (1) and springs (2) - place spring (a) at head end - and finally the spring retainer (3).

  • Page 139: Valve Leak Check

    ENGINE OVERHAUL Tap valve stem lightly with a plastic hammer and an aluminium punch to help the valve collets become seated. Tap the valve stem tip to avoid pushing the valve off centre. Valve leak check Check the valves for proper sealing before assembling the cylinder head to the engine.

  • Page 140: Camshaft

    ENGINE OVERHAUL Camshaft Check the contact faces of the lobes for streaks, scoring, dents and waviness. Clamp the camshaft between centres and check deviation using two dial gauges. Service limit: 0.1 mm. Check that the lobes are in pristine conditions, without signs of scoring or distortion.

  • Page 141: Cylinder

    ENGINE OVERHAUL Cylinder Check the walls for dents or scuffing. Measure cylinder bore diameter at three different positions. Measure each diameter in two directions at right angles to each other to determine taper and out-of-round. Max. taper (wear limit): 0.05 mm. Max.

  • Page 142: Cylinder To Piston Clearance

    ENGINE OVERHAUL Cylinder to piston clearance Cylinder diameter Measure inside diameter (Dc) with an internal bore micrometer 25 mm (0.9842 in.) below the edge (distance “A”). Piston diameter Measure piston diameter (Dp) 7 mm (0.2755 in.) above skirt edge (distance “B”). Clearance is calculated as follows = Dc-Dp.

  • Page 143: Piston Rings

    ENGINE OVERHAUL Piston rings They should show no signs of forcing or scoring. Replacement pistons come with piston rings and piston pin. Piston ring to cylinder clearance Insert the piston ring at the bottom of the bore (where minimum wear occurs) taking care to position it squarely and measure end gap.

  • Page 144: Piston Ring To Groove Clearance

    ENGINE OVERHAUL Piston ring to groove clearance Use a feeler gauge to measure the axial clearance (H) of piston rings. If the piston ring is marked on one side, that side must be facing up. PISTON RING END GAP ALIGNMENT PISTON MOUNTING CLEARANCE (H) SERVICE LIMIT...

  • Page 145: Crankshaft

    ENGINE OVERHAUL Crankshaft Main journals should show no scoring or scuffing. Threads, keyways and splines must be in good condition. Crankshaft straightness Place the crankshaft (1) on a stand (2) with two dial gauges (3) positioned on the journals. Turn the crankshaft and measure runout. STANDARD SERVICE LIMIT <...

  • Page 146: Clutch

    ENGINE OVERHAUL Clutch Inspect all clutch components to make sure they are in the best conditions. Clutch plates should show no signs of bluing, scoring or distortion. Measure the thickness of friction plates. Plate thickness when new: 3.0 mm (0.1181 in.). Service limit: 2.9 mm (0.1141 in.).

  • Page 147: Friction Plate To Clutch Housing Clearance

    ENGINE OVERHAUL Friction plate to clutch housing clearance Measure clearance "A" between clutch housing (2) and plate (1) with a feeler gauge and compare measured clearance with the table below. STANDARD SERVICE LIMIT 0.30-0.50 mm 0.6 mm (0.012-0.020 in.) (0.024 in.) If measured clearance exceeds the service limit, replace clutch plates or housing and repeat measurement.
  • Page 148 ENGINE OVERHAUL 1- Pressure plate, 2- Clutch actuator plate, 3- Pushrod, 4- Piston assembly: Check these parts for signs of wear or failure. If any are found, replace the part. 5- Clutch hub: Check the steel plate slots for signs of wear or failure. If any are found, replace the part. 6- Clutch housing: Check the friction plate slots for signs of wear or failure.

  • Page 149: Oil Pump

    ENGINE OVERHAUL Oil pump Loosen the screws (1) using a 4 mm Allen wrench and remove pump body (2) and gasket. Remove the pump rotors (3) and (4), and extract the drive pin (5) to release the gear (6). Check gear (6) and rotors (4) for wear. Replace if worn. Smear the rotors with oil and make sure to align the rotor dots (9) on assembly.

  • Page 150: Shifter Forks And Gears

    ENGINE OVERHAUL Shifter forks and gears Visually inspect the shifter forks (1) and replace any bent forks. A bent fork will make gears hard to engage or let the transmission jump out of gear unexpect- edly under loading. Check the clearance of the each shifter fork in its gear groove using a feeler gauge.

  • Page 151: Engine Reassembly

    ENGINE REASSEMBLY Section Ed. 07-2010...
  • Page 152 ENGINE REASSEMBLY General ......................H.3 Assembly and lubrication instructions .............H.4 CRANK- ALTERNATOR- LUBRICATION- LEFT CRANKCASE HALF ..H.4 Tightening torque figures ................H.5 Assembly and lubrication instructions .............H.6 GEARBOX - GEAR SHIFT CONTROL ............H.6 Tightening torque figures ................H.7 Assembly and lubrication instructions .............H.8 GEARBOX - GEAR SHIFT CONTROL ............H.8 Tightening torque figures ................H.9 Assembly and lubrication instructions ............H.10...

  • Page 153: General

    ENGINE REASSEMBLY General To reassemble, reverse the disassembly procedure. Any special instructions concerning reassembly are expressly highlighted in the text. Always replace gaskets, oil seals, metal retainers, sealing washers made from deformable material (copper, aluminium, fibre, etc.) and self-locking nuts after removal. Bearing specifications and dimensions have been calculated for a certain life.

  • Page 154: Assembly And Lubrication Instructions

    ENGINE REASSEMBLY Assembly and lubrication instructions CRANK- ALTERNATOR- LUBRICATION- LEFT CRANKCASE HALF Ed. 07-2010...

  • Page 155: Tightening Torque Figures

    ENGINE REASSEMBLY Tightening torque figures M5 - L20 (Loctite 272) 6 Nm- 0.6 Kgm- 4.43 ft/lb M5 - L12 (Loctite 272) 6 Nm- 0.6 Kgm- 4.43 ft/lb M5 - L18 6 Nm- 0.6 Kgm- 4.43 ft/lb M5 - L35 6 Nm- 0.6 Kgm- 4.43 ft/lb TXCi M5 - L25 6 Nm- 0.6 Kgm- 4.43 ft/lb...

  • Page 156: Assembly And Lubrication Instructions

    ENGINE REASSEMBLY Assembly and lubrication instructions GEARBOX - GEAR SHIFT CONTROL Ed. 07-2010...

  • Page 157: Tightening Torque Figures

    ENGINE REASSEMBLY Tightening torque figures M8x1.25 (+LOCTITE Alt. 243) 25 Nm- 2.55 Kgm- 18.44 ft/lb M6 - L13 (+LOCTITE 243) 8 Nm- 0.8 Kgm- 5.9 ft/lb M6 - L14 (+LOCTITE 243) 8 Nm- 0.8 Kgm- 5.9 ft/lb M5x0.8 - L12 6 Nm- 0.6 Kgm- 4.43 ft/lb M6 - L20 8 Nm- 0.8 Kgm- 5.9 ft/lb...

  • Page 158: Assembly And Lubrication Instructions

    ENGINE REASSEMBLY Assembly and lubrication instructions GEARBOX - GEAR SHIFT CONTROL Ed. 07-2010...

  • Page 159: Tightening Torque Figures

    ENGINE REASSEMBLY Tightening torque figures M8x1.25 (+LOCTITE Alt. 243) 25 Nm- 2.55 Kgm- 18.44 ft/lb M6 - L13 (+LOCTITE 243) 8 Nm- 0.8 Kgm- 5.9 ft/lb M6 - L14 (+LOCTITE 243) 8 Nm- 0.8 Kgm- 5.9 ft/lb M5x0.8 - L12 6 Nm- 0.6 Kgm- 4.43 ft/lb M6 - L20 8 Nm- 0.8 Kgm- 5.9 ft/lb...

  • Page 160: Assembly And Lubrication Instructions

    ENGINE REASSEMBLY Assembly and lubrication instructions CLUTCH- KICK START- LUBRICATION- RIGHT CRANKCASE HALF H.10 Ed. 07-2010...

  • Page 161: Tightening Torque Figures

    ENGINE REASSEMBLY Tightening torque figures M5 - L12 (+LOCTITE 270 or 272) 6 Nm- 0.6 Kgm- 4.43 ft/lb M8 X 1.25 (Al) 8 Nm- 0.8 Kgm- 5.9 ft/lb M5 - L16 8 Nm- 0.8 Kgm- 5.9 ft/lb M5 x 0.8 - L20 6 Nm- 0.6 Kgm- 4.43 ft/lb M6 x 1 (+LOCTITE 243) 8 Nm- 0.8 Kgm- 5.9 ft/lb...

  • Page 162: Assembly And Lubrication Instructions

    ENGINE REASSEMBLY Assembly and lubrication instructions RIGHT CRANKCASE COVER H.12 Ed. 07-2010...

  • Page 163: Tightening Torque Figures

    ENGINE REASSEMBLY Tightening torque figures M5 - L16 6 Nm- 0.6 Kgm- 4.43 ft/lb M6 - L22 8 Nm- 0.8 Kgm- 5.9 ft/lb M6 x 1 - L50 8 Nm- 0.8 Kgm- 5.9 ft/lb M6 x 1 - L20 8 Nm- 0.8 Kgm- 5.9 ft/lb LUBRICATION POINTS-NOTES LUBRICANT-INSTALLATION INSTRUCTIONS Engine oil...

  • Page 164: Assembly And Lubrication Instructions

    ENGINE REASSEMBLY Assembly and lubrication instructions HEAD - CYLINDER - PISTON - TIMING SYSTEM - WATER PUMP - SPARK PLUG H.14 Ed. 07-2010...

  • Page 165: Tightening Torque Figures

    ENGINE REASSEMBLY Tightening torque figures Special flanged screw L.23.4 8 Nm- 0.8 Kgm- 5.9 ft/lb Special flanged screw L.31.3 8 Nm- 0.8 Kgm- 5.9 ft/lb M5 x 0.8 - L8 (+LOCTITE 243) 6 Nm- 0.6 Kgm- 4.43 ft/lb M10 x 1.25 5 Nm- 0.5 Kgm- 3.69 ft/lb M10 - L104.5 40 Nm- 4 Kgm- 29.5 ft/lb...

  • Page 166: Input Shaft (5 Speed)

    ENGINE REASSEMBLY Input shaft Output shaft H.16 Ed. 07-2010...
  • Page 167 ENGINE REASSEMBLY Input shaft (5 SPEED) Fit roller cage (1) and 5th gear (2) on the bushing and then install the washer (3) and the retaining ring (4). The washer must be placed between gear and retaining ring. Fit 3rd gear (5), retaining ring (6) and washer (7). Fit the roller cage (8).
  • Page 168 ENGINE REASSEMBLY Output shaft (5 SPEED) Fit the roller cage (1). Fit 2nd gear (2), washer (3) and retaining ring (4). Fit 4th gear (5) and retaining ring (6). Fit the washer (7). Fit roller cage (8) and 3rd gear (9). Fit washer (10) and retaining ring (11).

  • Page 169: Input Shaft (6 Speed)

    ENGINE REASSEMBLY Input shaft Output shaft Ed. 07-2010 H.19...
  • Page 170 ENGINE REASSEMBLY Input shaft (6 SPEED) Fit roller cage (1) and 5th gear (2) on the bushing and then install the washer (3) and the retaining ring (4). The washer must be placed between gear and retaining ring. Fit 3rd/4th gear (5), retaining ring (6) and washer (7). Fit the roller cage (8).
  • Page 171 ENGINE REASSEMBLY Output shaft (6 SPEED) Fit the roller cage (1). Fit 2nd gear (2), washer (3) and retaining ring (4). Fit 6th gear (5) and retaining ring (6). Fit the washer (7). Fit roller cage (8) and 3rd gear (9). Fit washer (10) and 4th gear (11).

  • Page 172: Crankcase Assembly

    ENGINE REASSEMBLY Crankcase assembly Clean the crankcase half mating faces and place crankcase half on tool no. 8A00 90662. Heat up to around 125 °C and drive the ball bearings into each crankcase half using a suitable driver tool. Fit the retaining plates (1) and (2) to the crankcase bearings. (5 Nm, 0.5 Kgm, 3.6 ft/lb + Loctite 272) for crankshaft bearing retaining plate (1).
  • Page 173 ENGINE REASSEMBLY Install the input and output shaft assembly making sure the output shaft (3) shim is in place. Lubricate the three shifter forks (4) with engine oil and install them. Make sure the bushings (5) are correctly in place (grease the bushings). Ed.
  • Page 174 ENGINE REASSEMBLY Insert the selector drum (6) into its seat. Install the fork shafts (7) and (8) and make sure the forks move freely. Make sure the fork bushings (5) are correctly located in the drum grooves (6). Insert the circlip (9) of the input shaft fork shaft. Rotate the selector drum to test operation.
  • Page 175 ENGINE REASSEMBLY Heat up the crankshaft bearing (10) and install the crankshaft (11). Make sure both crankcase locating bushings (12) are in place. Apply a layer of “LOCTITE 5205” on the right crankcase mating surface (13), making sure not to obstruct the oil passage hole (14). Ed.
  • Page 176 ENGINE REASSEMBLY Heat up the left crankcase bearing housings and install the crankcase. To join the crankcase halves, tap with a plastic hammer. Tighten the screws (15) using an 8 mm wrench (10 Nm, 1Kgm, 7.25 ft/lb). Make sure to fit the screws in the correct positions according the specified pattern (see Section F, paragraph "Crankcase disassembly").

  • Page 177: Gear Shift Control Assembly

    ENGINE REASSEMBLY Gear shift control assembly Refit the spring abutment pin (1) using a 12 mm wrench (apply Loctite 243 and tighten to 20 Nm, 2.0 Kgm, 14.5 ft/lb). Install ratchet (2), spring (3), washer (4) and circlip (5). Install the selector drum (6) making sure the tab (7) locates in the recess (8) and secure drum with its screw (9).
  • Page 178 ENGINE REASSEMBLY Operate shifter and transmission shaft to test gearbox for proper operation. Refit the ratchet assembly (10) together with the plate, making sure ratchets and springs are in the correct positions. Tighten the upper screw (11) using a 4 mm Allen wrench (Loctite 243, 10 Nm, 1.0 Kgm, 7.2 ft/lb).
  • Page 179 ENGINE REASSEMBLY Turn the engine over. Make sure the spring (15) of the gear shift lever shaft is positioned correctly. Check the gear shift lever shaft (16) and the slot of the gear selector mechanism for signs of wear. Lubricate the shaft with engine oil and insert the shaft (16) into the crankcase so that the fork (17) slides over the ratchet detent and the spring (18) locates to its abutment pin.
  • Page 180 ENGINE REASSEMBLY Install the gear shift lever (19) and operate the gearbox manually (8 mm wrench, 8 Nm, 0.8 Kgm, 5.8 ft/lb). H.30 Ed. 07-2010...

  • Page 181: Kick Start Assembly

    ENGINE REASSEMBLY Kick start assembly Refit the starter ratchet release plate (1) (use a 4 mm wrench, 8 Nm, 0.8 Kgm, 5.8 ft/lb, Loctite 243). Fit the complete shaft assembly (2) to its seat (B) in the crankcase, making sure the ratchet is correctly positioned on the shaft (marks lined up) and insert the spring end (3) into the hole (D).

  • Page 182: Timing Chain And Primary Drive Assembly

    ENGINE REASSEMBLY Timing chain and primary drive assembly Install the timing chain slider (1), tighten the screw (2) using a 5 mm wrench (10 Nm, 0.1 Kgm, 7.3 ft/lb, Loctite 243) and make sure the slider moves freely. Fit the oil pump drive gear (3) making sure the side with the dot is facing out- side.
  • Page 183 ENGINE REASSEMBLY Install the timing chain (5). Refit the bushing (6). Refit the clutch housing (7). Ed. 07-2010 H.33...
  • Page 184 ENGINE REASSEMBLY Place a dummy gear (8) or an aluminium shim between clutch housing (7) gear and double gear (4), and then tighten the primary drive shaft nut (9) (use a 22 mm wrench, 100 Nm, 10 Kgm, 72.50 ft/lb). H.34 Ed.

  • Page 185: Clutch Assembly

    ENGINE REASSEMBLY Clutch assembly Install washer (1), hub (2), lock washer (3) and nut (4). Use the suitable tool (5) to prevent rotation and tighten to 60 Nm, 6 Kgm, 43.5 ft/lb (use a 22 mm wrench). Ed. 07-2010 H.35...
  • Page 186 ENGINE REASSEMBLY Refit the plates (6) (install a friction plate first and then a steel plate and keep alternating between friction and steel plates; the last to go in should be a steel plate). Fit actuator plate (7), thrust bearing (8), thrust washer (9), pressure plate (10) and springs (11).

  • Page 187: Sprocket Installation

    ENGINE REASSEMBLY Sprocket installation Install the oil seal retaining plate (1) and tighten the screws (2) (use an 8 mm wrench , 5.5 Nm, 0.55 Kgm, 4 ft/lb). Fit the spacer (3) with the grooved side facing inwards. Install sprocket (4), lock washer (5) and nut (6). Hold the sprocket (4) with the suitable tool (7) to prevent rotation and tighten the nut (6) (use a 22 mm wrench, 100 Nm, 10 Kgm, 72.5 ft/lb).

  • Page 188: Flywheel And Starter Motor Installation

    ENGINE REASSEMBLY Flywheel and starter motor installation Clean flywheel rotor to remove any debris suspended in swirling oil and captured by the magnets. Fit the tab (1) to the crankshaft. (TE-TXCi) TE-TXCi Lubricate needle roller bearing (2) and thrust ring (3) with engine oil and install them, making sure the thrust ring slots are pointing outwards.

  • Page 189: Assemble The Starter Motor (7)

    ENGINE REASSEMBLY Refit the rotor (5). Hold the rotor (5) to prevent rotation and place an aluminium shim or dummy gear between the primary drives gears on the right side, again to prevent rotation. Tighten the nut (6) to 75 Nm, 7.5 Kgm, 54.3 ft/lb. Use a 17 mm wrench.

  • Page 190: Piston Ring Installation

    ENGINE REASSEMBLY Piston ring installation Fit the piston rings as shown in the diagram. If the piston ring is marked on one side, that side must be facing up. A= Compression ring C= Oil control ring *C1= Top oil rail end gap position *C1= Oil rail spacer end gap position *C1= Bottom oil rail end gap position Piston and cylinder installation...
  • Page 191 ENGINE REASSEMBLY Lubricate the cylinder liner (7) with engine oil and slide it over the piston rings. Make sure to collect the timing chain (8). Position the slider (9). Ed. 07-2010 H.41...

  • Page 192: Cylinder Head Gasket Selection Table

    ENGINE REASSEMBLY Fit screws and spacers (10) to temporarily secure the cylinder liner (7). (3 spacers 10a, h= 44.2 mm; 1 spacer 10b, h= 29.2 mm) Use a 12 mm wrench - 40 Nm, 4 Kgm, 29 ft/lb. Make sure that the piston is at Top Dead Centre. Measure distance "A"...

  • Page 193: Cylinder Head Installation

    ENGINE REASSEMBLY Cylinder head installation For valve installation instructions, please see Section "G". Always use a new head gasket on assembly: see the "Cylinder head gasket selection table". Install the head (1) while supporting the timing chain (2) with a screwdriver. Tighten the head bolts (3) gradually in a cross pattern to 40 Nm, 4 Kgm, 29 ft/ lb (use a 12 mm wrench).
  • Page 194 ENGINE REASSEMBLY Refit the four shim (5) on the valves and the valve buckets (6) as marked on removal. Check the bearings of the timing drive upper gear (7) and replace them if needed. The gear (7) requires no timing. Refit the gear (7) with its shaft (8) and gasket (9).

  • Page 195: Timing Chain Tensioner Installation

    ENGINE REASSEMBLY Timing chain tensioner installation Refit the chain tensioner (12) and its gasket. Tighten the two screws (13) using an 8 mm wrench (10, Nm, 1.0 Kgm, 7.25 ft/lb). WARNING On TE and TCX models, the two retaining screws feature two different lengths.

  • Page 196: Camshaft Installation

    ENGINE REASSEMBLY Camshaft installation Secure a dial gauge (1) to the spark plug hole. Turn the crankshaft manually until bringing the piston to Top Dead Centre. Refit intake camshaft (2) and exhaust camshaft (3) with the gears positioned as shown in the figure. Cover parting line "A"...
  • Page 197 ENGINE REASSEMBLY Refit the camshaft covers (6) and tighten the screws (7) in a cross sequence and shown in diagram "B". Make sure to fit the screws in the correct position according to their length (see diagrams "A" and "B"). M6x35 Allen screw M6x30 Allen screw M6x25 Allen screw...

  • Page 198: Flywheel Cover Installation

    ENGINE REASSEMBLY Flywheel cover installation Install the stator (1) with its mark lined up with the flywheel cover mark and tighten the two retaining screws (2) (use a 4 mm Allen wrench, 6 Nm, 0.6 Kgm, 4.3 ft/lb + Loctite 272). Insert the cable guide (3) into its seat in the cover and tighten the two retaining screws (4) of the pick-up sensor (5) with its plate (6 Nm, 0.6 Kgm, 4.3 ft/lb + Loctite 272).

  • Page 199: Neutral Sensor Installation

    ENGINE REASSEMBLY Neutral sensor installation Refit pin (1) and spring (2). Check the O-ring (3) of the sensor (4). Refit the sensor (4) and tighten the screws (5) using an 8 mm wrench (5.5 Nm, 0.55 Kgm, 4 ft/lb, Loctite 243). Ed.

  • Page 200: Starter Motor Seat Cover Installation (Tc)

    ENGINE REASSEMBLY Starter motor seat cover installation (TC) Refit the cover (1) with its gasket making sure the arrow is pointing "UP". Tighten the screws (2) with the wire clip (3) placed on the upper screw. Cylinder head cover, spark plug, oil feed hose installation Position the central seal (1).

  • Page 201: Right Crankcase Assembly

    ENGINE REASSEMBLY Right crankcase assembly Refit the oil pump drive gear (1) and its shaft (2). Check the O-rings of the oil suction stub (3) and replace them if needed. Refit the oil suction stub (3). Refit the centring bushings (4). Refit the gasket (5).
  • Page 202 ENGINE REASSEMBLY Install the crankcase (8) and tighten the screws (9) following a cross pattern (use an 8 mm wrench , 10 Nm, 1.0 Kgm, 7.25 ft/lb). Make sure pump gear and drive gear engage correctly. Check the O-ring (10) for damage and replace it if needed. Refit the spring (11) of the oil filter (12).

  • Page 203: Filter And Drain Plug

    ENGINE REASSEMBLY Filter and drain plug Fit the oil filter (1) and tighten the cap (2) into place with its gasket using a 12 mm wrench (25 Nm, 2.5 Kgm, 18.44 ft/lb). Blow-by tube fitting/filter (310) Insert the oil filter (1), screw the hose fitting (2), insert hose (3) and screw clamp (4).

  • Page 204: Gear Shift And Kick Start Pedal Installation

    ENGINE REASSEMBLY Gear shift and kick start pedal installation Install the gear shift pedal (1) and tighten the screw (2) using an 8 mm wrench (8 Nm, 0.8 Kgm, 5.8 ft/lb). Check the pedal (1) for damage. Refit the kick start pedal (3) and tighten the screw (4) using a 12 mm wrench (25 Nm, 2.5 Kgm, 18.44 ft/lb + Loctite 272).

  • Page 205: Installing The Engine And Assembling The Motorcycle

    ENGINE REASSEMBLY Installing the engine and assembling the motorcycle Install the engine and any parts you had removed in the order given below. Place the engine in the chassis. Insert the swinging arm shaft from the right-hand side and tighten its nut using a 22 mm wrench (122.5 Nm, 12.5 Kgm, 90.3 ft/lb).

  • Page 207: Front Suspension

    FRONT SUSPENSION Section Ed. 07-2010...
  • Page 208 FRONT SUSPENSION Front fork removal ..................I.4 Service instructions for Ø48USD Kayaba fork - TC-TXCi ......I.6 Front suspension (TC - TXCi) ............... I.7 Front fork disassembly (TC - TXCi) .............. I.8 Front suspension (TE) ................I.18 Ed. 07-2010...
  • Page 209 FRONT SUSPENSION H02176 H02177 TXCi H02178 Ed. 07-2010...
  • Page 210 FRONT SUSPENSION Front fork removal Measure height "A" (it will need to be restored to original value on assembly). Set a block under the engine and see that the front wheel is lifted from the ground and then proceed as follows: remove the screws (1) and the brake line clamp on the left-hand side;...
  • Page 211 FRONT SUSPENSION loosen the bolts (4) that secure the fork legs to steering head and bottom yoke; remove the fork legs. Refit fork legs and front wheel as described in Section "Y". Set height "A" back to original value. Ed. 07-2010...
  • Page 212 FRONT SUSPENSION Front suspension Mod. TC-TXCi Service instructions for Ø48USD Kayaba fork - TC-TXCi GENERAL The fork uses a multi-valve damping system with rebound and compression adjustment and spring preload adjustment for static load. Compression damping is controlled by a special valve located at the top of each fork leg.
  • Page 213 FRONT SUSPENSION TC - TXCi H02255 Front suspension (TC - TXCi) Front suspension is handled by a KAYABA upside-down telescopic hydraulic fork with advanced axle and 48 mm legs. Wheel travel is 300 mm. Ed. 07-2010...
  • Page 214 FRONT SUSPENSION Front fork disassembly (TC - TXCi) TC - TXCi Loosen the cap nut at the top of each outer tube. (Note: it is good practice to moderately slacken the cap nuts before removing the fork legs from the motorcycle). H02256 Drain oil from the damper unit.
  • Page 215 FRONT SUSPENSION Take the cartridge out of the outer tube. TC - TXCi H02260 Do not remove the nut at the bottom end of the cartridge. TC - TXCi H02261 TC - TXCi Remove the bottom valve assembly from the cartridge. Hold the cartridge octagonal nut with the suitable tool to prevent rotation.
  • Page 216 FRONT SUSPENSION If outer tube and inner tube are still assembled together, place the fork leg upside TC - TXCi down and allow at least 20 minutes for oil to drain. H02264 Remove the dust seal using a flat head screwdriver. TC - TXCi H02265 Remove the retaining ring using a flat head screwdriver.
  • Page 217 FRONT SUSPENSION Remove the sealing rings and the metal rings mounted on the inner tube. TC - TXCi Do not reuse any metal parts after removal. Replace them with new components. Replace damaged sealing rings. Washer and retaining ring may be reused if they are not damaged. H02268 Check the rebound adjuster rod for distortion or damage.
  • Page 218 FRONT SUSPENSION Mount sealing rings and metal parts on the inner tube. TC - TXCi See the figure below for the installation sequence. Note 1: Grease the edge of the sealing ring. Note 2: Before sliding the sealing ring over the inner tube, cover tube edge with plastic as shown in the figure.
  • Page 219 FRONT SUSPENSION Fit the dust seal to the outer tube. TC - TXCi Make sure that there is not play between dust seal and outer tube. H02277 TC - TXCi Refit the cartridge. Tighten the nut all the way onto the rebound adjuster rod. Make sure rebound adjuster rod thread length is at least 15 mm (0.6 in.).
  • Page 220 FRONT SUSPENSION Pull the piston rod until fully extended. TC - TXCi Check oil level. It should be about 145 mm (5.7 in.). H02281 Push the piston rod all the way down and install the bottom valve assembly. TC - TXCi With the bottom valve assembly installed, check that the piston rod is fully extended.
  • Page 221 FRONT SUSPENSION Drain excess oil from the cartridge pushing the damper unit all the way home. TC - TXCi Be careful not to distort or damage the piston rod or any other parts. Please note that excess oil may flow out from the hole located before the res- ervoir.
  • Page 222 FRONT SUSPENSION Push down the inner tube. TC - TXCi Slip the tool shown in the figure between wheel axle carrier and cartridge nut. Insert the rebound adjuster rod into the piston rod and tighten the adjuster screw. Be careful not to hurt your fingers. H02289 Tighten the adjuster screw all the way in.
  • Page 223 FRONT SUSPENSION Clamp the wheel axle carrier in a vice and tighten the adjuster screw onto the TC - TXCi carrier to 55 Nm (40.5 ft/lb). H02258 Fill the outer tube with the specified quantity of oil. TC - TXCi H02292 Tighten the cylinder onto the outer tube to 29 Nm (21.4 ft/lb).
  • Page 224 FRONT SUSPENSION Front suspension Mod. TE Front suspension (TE) Front suspension is handled by a KAYABA upside-down telescopic hydraulic fork with advanced axle and 48 mm legs. Wheel travel is 300 mm. I.18 Ed. 07-2010...
  • Page 225 FRONT SUSPENSION Loosen the cap nut at the top of each outer tube. (Note: it is good practice to moderately slacken the cap nuts before removing the fork legs from the motorcycle). Loosen the fork cap nut and the nut with a wrench. Remove top cap nut, spring retainer, spring and rebound adjuster rod.
  • Page 226 FRONT SUSPENSION Remove nut, spring guide, O-ring and collar bushing. Hold the cartridge top end steady. Loosen and remove the bottom valve assembly. I.20 Ed. 07-2010...
  • Page 227 FRONT SUSPENSION Take the cartridge out of the outer tube. Remove the dust seal using a flat head screwdriver. I.21 Ed. 07-2010...
  • Page 228 FRONT SUSPENSION Remove the retaining ring using a flat head screwdriver. Pull the inner tube until separating it from the outer tube. Note: to facilitate removal, quickly (but carefully) pump the tubes back and forth until separating them. Remove the sealing rings and the metal rings mounted on the inner tube. Do not reuse any metal parts after removal.
  • Page 229 FRONT SUSPENSION Check the spring. Replace it if: outside diameter is damaged or exceedingly worn. Free length is 457 mm (18 in.) or less. Check the inner tube. Replace if distorted. (Never attempt to repair or reuse a distorted fork tube). If the tube shows surface defects, sand the surface.
  • Page 230 FRONT SUSPENSION Fit metal bushing and washer to outer tube using an appropriate installer. Fit the oil seal to the outer tube and push it home using an appropriate in- staller. Make sure that the retaining ring groove inside the outer tube is fully visible. Install the retaining ring.
  • Page 231 FRONT SUSPENSION Insert the cartridge into the outer tube. Hold the cartridge top end into place. Tighten the bottom valve assembly to 55 Nm (40.5 ft/lb). I.25 Ed. 07-2010...
  • Page 232 FRONT SUSPENSION Fit collar bushing, O-ring, spring guide and nut onto piston rod. Insert the rebound adjuster rod into the piston rod. Make sure that at least an 18 mm (0.71 in.) portion of the rebound adjuster rod protrudes from the piston rod. Oil filling.
  • Page 233 FRONT SUSPENSION Filling oil to specific level Fill the damper unit with oil up to the top edge of the outer tube. Slowly pump the outer tube up and down to help oil flow equally into both inner and outer tube. Now slowly pump the piston rod up and down to help oil reach all points of the cartridge.

  • Page 235: Rear Suspension

    REAR SUSPENSION Section Ed. 07-2010...
  • Page 236 REAR SUSPENSION Rear shock absorber ..................J.3 Lubrication points (grease) ................J.3 Rear suspension....................J.4 Rear shock absorber removal ...............J.5 Disassembling, servicing and assembling the rear shock absorber ....J.6 Spring servicing .....................J.6 Shock absorber inspection ................J.6 Reservoir cap with its valve removal .............J.7 Piston assembly inspections .................J.9 Seal replacement...................J.9 Checking the setting ..................J.10...

  • Page 237: Rear Shock Absorber

    REAR SUSPENSION Rear shock absorber TIGHTENING TORQUE FIGURES 1, 2: 52.4 Nm/ 5.35 Kgm/ 38.6 ft/lb Lubrication points (grease) Ed. 07-2010...
  • Page 238 REAR SUSPENSION 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. Hydraulic damping is also adjustable using outer adjuster screws.

  • Page 239: Rear Shock Absorber Removal

    REAR SUSPENSION Rear shock absorber removal Set a block under the engine and see that the rear wheel is lifted from the ground. Remove saddle, side panels, silencer and rear chassis (see Section "E" - General Procedures). Loosen the front clamp (1) of the intake coupling. H02293 Remove the front bolt (2) securing the suspension linkage to the chassis, the bottom (3) and top (4) shock absorber mounting bolts and remove the shock...

  • Page 240: Disassembling, Servicing And Assembling The Rear Shock Absorber

    REAR SUSPENSION Disassembling, servicing and assembling the rear shock absorber Clean the shock absorber before disassembly. Spring servicing Measure the spring in place before removal. Spring removal: clamp the shock absorber in a vice taking care to avoid distorting it. Slacken lock ring nut and ring nut, spring retainer and spring. Measure spring free length.
  • Page 241 REAR SUSPENSION Push on the reservoir valve to discharge the gas. Aim valve away from you to prevent any debris from getting into your eyes. Reservoir cap and valve removal Locate a suitable tool to reservoir cap and push down on cap until gaining ac- cess to the retaining ring.
  • Page 242 REAR SUSPENSION Place the shock absorber on a bench. Unscrew or knock out the cover (depend- ing on the model). Once the tank cap is removed, push the rod guide down into the body so as to expose the circlip groove and remove the circlip with a screwdriver. Ed.

  • Page 243: Piston Assembly Inspections

    REAR SUSPENSION Clamp the top section of the shock absorber in a vice with aluminium or bronze jaws. Insert a rod or a screwdriver into the mounting hole and extract the rod guide and piston assembly from the shock absorber body. Before extracting the assembly, cover the end of the shock body with a cloth to capture leaking oil.

  • Page 244: Checking The Setting

    REAR SUSPENSION Checking the setting If the suspension is not operating properly and you need to adjust compression damping, loosen the knob dowel (heat with an air gun before loosening). Proceed as follows: loosen the ring nut with the suitable key, slide off all parts noting their positions to ensure correct assembly.

  • Page 245: Reservoir Replacement

    REAR SUSPENSION After the inspection, refit piston, disc, spring and slotted ring. Slide the needle shaft off the cap, tighten the ring, insert into slot pressing lightly and secure in place tightening the cap to 30 Nm (3 kgm; 29.2 ft/lb). It is strictly forbidden to change the compression washers.

  • Page 246: Floating Piston Removal

    REAR SUSPENSION Apply Loctite and screw on the reservoir being careful not to damage the O-ring. Tighten to 40 Nm (4 kgm; 39.2 ft/lb). NOTE: Perform these procedures in a clean environment and clean any com- ponents to be reused. Floating piston removal If you have drained the shock oil, you will need to remove the floating piston.
  • Page 247 REAR SUSPENSION Push the floating piston quickly down to reservoir bottom while holding the rod steady in the appropriate position for top-up. The oil inside the reservoir will flow into the shock absorber body and fill it up to a certain level as it seeps through the piston washers.
  • Page 248 REAR SUSPENSION Refit the reservoir cap with its valve. Fit it into the reservoir and fit the circlip into the groove. Fill nitrogen (or air) through the valve and pressurise to 10-12 bar. Refit the cap to the valve and check for oil or air leaks. Drive the cap onto the body.

  • Page 249: Shock Absorber Damping Adjustment

    REAR SUSPENSION Shock absorber damping adjustment Adjustment of the compression stroke is independent from the rebound stroke. A) COMPRESSION - Standard setting: 1) Low damping speed: -15 clicks (± 2 clicks) (adjuster screw 1) 2) High damping speed: -15 clicks (± 2 clicks) (adjuster screw 3) To reset the standard setting, turn upper adjuster screws (1) and (3) clockwise until reaching fully closed position.

  • Page 250: Disassembling And Servicing The Swinging Arm

    REAR SUSPENSION Disassembling and servicing the swinging arm Set a stand or a block under the engine and see that the rear wheel is lifted from the ground. Remove the secondary drive chain (1) and detach the rear brake line (2) from the swinging arm (A). Remove both chassis side guards (3). Dis- engage the return spring (4) of the rear brake pedal from the chassis.

  • Page 251: Servicing The Swinging Arm Shaft

    REAR SUSPENSION Servicing the swinging arm shaft Check shaft taper using a dial gauge. Place the shaft on two identical reference blocks. Turn the shaft and move the dial gauge horizontally to determine the amount of distortion. Service limit: 0.30 mm. Servicing the rear suspension drop and drag link With drop link (1) and drag link (2) still in place (connected to swinging arm and chassis, respectively), rock them both back and forth in all directions to check for...

  • Page 252: Chain Roller, Chain Guide, Chain Slider

    REAR SUSPENSION Chain roller, chain guide, chain slider Check the wear of the above-mentioned elements and replace them when necessary. Check the chain guide alignment, and remember that a bent element can cause chain early wear. In this case, chain might unwrap from the sprocket.

  • Page 253: Brakes

    BRAKES Section Ed. 07-2010...
  • Page 254 BRAKES Braking system ..................... L.3 Brake disc ..................... L.4 Checking brake pads for wear / replacing the pads ........L.5 Bleeding the front braking system ..............L.6 Bleeding the rear braking system ..............L.7 Changing the fluid..................L.8 Ed. 07-2010...

  • Page 255: Braking System

    BRAKES Braking system The braking system uses two independent circuits. Each system is equipped with a brake calliper connected to a master cylinder with a fluid reservoir. 1. Front brake lever 2. Front brake master cylinder with fluid reservoir 3. Front brake line 4.

  • Page 256: Brake Disc

    BRAKES 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: 260 mm Front brake disc thickness (when new): 3.0 mm Wear limit: 2.5 mm Rear brake disc diameter: 240 mm Rear brake disc thickness (when new): 4.0 mm...

  • Page 257: Checking Brake Pads For Wear / Replacing The Pads

    BRAKES Checking brake pads for wear / replacing the pads Check brake pad wear. Service limit ”A” 3.8 mm (front and rear pads) If service limit is exceeded, always replace the pads in pairs. Be careful that no brake fluid or any oil gets on brake pads or discs. Clean off with alcohol any fluid or oil that inadvertently gets on the pads or disc.

  • Page 258: Bleeding The Front Braking System

    BRAKES 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 procedure is as follows: Take the rubber cap off the bleed valve (1). Attach a clear plastic hose to the calliper bleed valve and place the other end of the hose in a vessel (make sure the hose end stays dipped in the fluid throughout the procedure).

  • Page 259: Bleeding The Rear Braking System

    BRAKES 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 reservoir cap (A) (21 mm wrench) and diaphragm and fill with fluid (DOT 4).

  • Page 260: Changing The Fluid

    BRAKES Changing the fluid Brake fluid should be checked and changed as per the "Maintenance Chart" (see Section B), or earlier if contaminated with debris or water. Do not change brake fluid in the rain or with a strong wind. Use only fluid taken from a sealed container (DOT 4).
  • Page 261 BRAKES Remove the reservoir cap (2) or (2A) 21 mm wrench and the rubber gaiter. Loosen the bleed valve on the calliper. Pump the brake lever (3) or the brake pedal (3A) until draining all fluid. Tighten the bleed valve and fill the reservoir with fresh fluid. Loosen the bleed valve, operate lever or pedal, tighten the valve keeping lever or pedal pressed and then release quickly.
  • Page 262 BRAKES Periodically check the connecting hoses (C) and (D) (see Scheduled Maintenance Chart, Section B): replace worn or cracked hoses. L.10 Ed. 07-2010...

  • Page 263: Electrical System

    ELECTRICAL SYSTEM Section Ed. 07-2010...
  • Page 264 ELECTRICAL SYSTEM Wiring diagram (TC) ..................M.5 Key to wiring diagram .................. M.5 Colour coding key ..................M.5 Wiring diagram (TE) ..................M.6 Key to wiring diagram .................. M.6 Colour coding key ..................M.6 Wiring diagram (TXCi) ................. M.7 Key to wiring diagram .................. M.7 Colour coding key ..................
  • Page 265 ELECTRICAL SYSTEM STARTING SYSTEM (TE - TXCi) .............. M.38 ELECTRONIC IGNITION SYSTEM ............M.38 Wiring (TC) ....................M.39 Cable routing and electrical parts installation instructions (TC)....M.40 • HT coil position (1) (TC) ................. M.40 • Fuel injection control unit position (2) (TC) ..........M.40 •...
  • Page 266 ELECTRICAL SYSTEM • Securing the wiring harness..............M.53 • Securing the wiring harness..............M.53 • Securing the wiring harness..............M.53 IMPORTANT ....................M.54 Ed. 07-2010...

  • Page 267: Wiring Diagram (Tc)

    ELECTRICAL SYSTEM Wiring diagram (TC) H02353 Key to wiring diagram Colour coding key W ....White W/Bk ..... White/Black 1. Electronic control unit B ....Blue W/G ....White/Green 2. Gear sensor Bk ....Black W/R ....White/Red 3. R.H. switch Br ....

  • Page 268: Colour Coding Key

    ELECTRICAL SYSTEM Wiring diagram (TE) H02299 Key to wiring diagram 31. Rear R.H. turning indicator 32. Tail light 1. Electronic control unit 33. Rear L.H. turning indicator 2. Control unit interface 34. Front R.H. turning indicator 3. Coolant temperature sensor 35.

  • Page 269: Wiring Diagram (Txci)

    ELECTRICAL SYSTEM Wiring diagram (TXCi) TXCi H02300 Key to wiring diagram Colour coding key Y/G ....Yellow/Green 1. Electronic control unit B ....Blue Y/Sb ....Yellow/Sky blue 2. Control unit interface Bk ....Black Y/R....Yellow/Red 3. Coolant temperature sensor Br ....

  • Page 270: Electrical Components Location (Tc)

    ELECTRICAL SYSTEM Electrical components location (TC) The ignition system includes the following elements: Generator (1), on the inner side of L.H. crankcase half cover; H02302 Electronic ignition coil (2) under the fuel tank; Electronic control unit (3) under the fuel tank; Voltage regulator (4) on the electronic control unit;...

  • Page 271: Electrical Components Location (Te)

    ELECTRICAL SYSTEM Electrical components location (TE) The ignition system includes the following elements: Generator (1), on the inner side of L.H. crankcase half cover; H02307 Electronic ignition coil (2) under the fuel tank; Electronic control unit (3) under the fuel tank; Spark plug (4) on cylinder head;...
  • Page 272 ELECTRICAL SYSTEM 12V-350W starter motor (6) behind the cylinder; Solenoid starter (7) on left side of rear chassis; M.A.Q.S. sensor (air temperature, pressure, throttle position) (8) on throttle body. The electrical system includes the following elements: 12V-6Ah battery (9) under the saddle; Turning indicators flasher (10) on left side of rear chassis;...
  • Page 273 ELECTRICAL SYSTEM Power Relay (11): coil, injection system, fuel pump, on right side of rear chassis; Fan Relay (12): electric fan, on right side of rear chassis; DC Relay (13): light system, turning indicators, horn, on right side of rear chassis;...
  • Page 274 ELECTRICAL SYSTEM Headlamp (20) with 12V-35/35W twin halogen bulb and 12V-5W parking light bulb; LED tail light (21); Turning indicators (22), 12V-10W bulbs; Fuel pump (23) inside the fuel tank. H02304 M.12 Ed. 07-2010...

  • Page 275: Electrical Components Location (Txci)

    ELECTRICAL SYSTEM Electrical components location (TXCi) The ignition system includes the following elements: Generator (1), on the inner side of L.H. crankcase half cover; H02307 Electronic ignition coil (2) under the fuel tank; Electronic control unit (3) under the fuel tank; Spark plug (4) on cylinder head;...
  • Page 276 ELECTRICAL SYSTEM 12V-350W starter motor (6) behind the cylinder; Solenoid starter (7) on left side of rear chassis; M.A.Q.S. sensor (air temperature, pressure, throttle position) (8) on throttle body. M.14 Ed. 07-2010...
  • Page 277 ELECTRICAL SYSTEM The electrical system includes the following elements: 12V-6Ah battery (9) under the saddle; Relay (10): coil, injection system, fuel pump, on right side of rear chassis; Relay (11): solenoid valve, on right side of rear chassis; Fuses (12), (13), (14): on rear mudguard, right side: Fuse 12 (15A): coil, injection system, fuel pump;...

  • Page 278: Checking Generator Stator Windings Resistance

    ELECTRICAL SYSTEM Coolant temperature sensor (16); Lambda sensor (17); Fuel pump (18) inside the fuel tank. H02356 Checking generator stator windings resistance Disconnect the stator coil connector from the wiring and measure resistance with a meter. H02308 M.16 Ed. 07-2010...

  • Page 279: Generator No-Load Performance

    ELECTRICAL SYSTEM 1) Measure across the terminals of the connector (1); correct value is about If resistance is outside the specified limits, replace the complete generator. H02357 H02309 Generator no-load performance A D.C. (typical) 1200 2000 13.8 3000 15.5 5000 16.4 6000 16.6...

  • Page 280: Key To Wiring Diagram

    ELECTRICAL SYSTEM Ignition system (TC) The ignition system is controlled by the ECU (1). The ignition is an integrated digital electronic ignition system with static timing and advance using intermittent sequential phased electronic injection feed. This ignition system is composed of a crankshaft position (pick-up) sensor, an ECU, an ignition coil and an intake manifold pressure sensor.

  • Page 281: Ignition System (Te - Txci)

    ELECTRICAL SYSTEM Ignition system (TE - TXCi) The ignition system is controlled by the ECU (1). The ignition is an integrated digital electronic ignition system with static timing and advance using intermittent sequential phased electronic injection feed. This ignition system is composed of a crankshaft position (pick-up) sensor, an ECU, an ignition coil and an intake manifold pressure sensor.

  • Page 282: Key To Wiring Diagram

    ELECTRICAL SYSTEM TXCi H02359 Key to wiring diagram 1. Electronic control unit 2. Control unit interface 3. Coolant temperature sensor 4. HT coil 6. Fuel pump 7. Electric fan relay 8. Lambda sensor 9. Cooling fan 11. Battery 12. Solenoid starter 13.

  • Page 283: Charging System (Te - Txci)

    ELECTRICAL SYSTEM CHARGING SYSTEM (TE - TXCi) The charging system is composed of: - Alternator (1); - Voltage regulator/rectifier (2); - Solenoid starter (3); - Battery (4). The alternated current generated by the alternator is converted into direct cur- rent by the voltage regulator/rectifier. The voltage regulator/rectifier serves a dual purpose: it provides overvoltage protection for the battery and converts alternated current into direct current.

  • Page 284: Charging System Inspections

    ELECTRICAL SYSTEM CHARGING SYSTEM INSPECTIONS Current loss at the battery (TE - TXCi) Remove the saddle (as described in the relevant paragraph) to gain access to the battery (1). Disconnect the BLACK negative cable from the battery. Measure current across the negative terminal of the battery and the negative cable using a meter.

  • Page 285: Wiring Diagram

    ELECTRICAL SYSTEM ELECTRICAL STARTING SYSTEM (TE - TXCi) The starting system is composed of: - Battery (16); - Solenoid starter (17); - Starter motor (18); - R.H. switch (25); - Clutch microswitch (27) (TE); - Ignition switch (26) (TE); - Fuses (37). For a description of wires and components, please see the key to the wiring diagram TXCi...

  • Page 286: Starting System Inspection

    ELECTRICAL SYSTEM STARTING SYSTEM INSPECTION Starter motor inspection (TE - TXCi) Remove the starter motor (1) as described in the relevant paragraph. Whenever a starter motor fault is detected, check the starter motor as follows: - connect a meter across ground and starter motor contact. - Check for continuity between the positive pole and motor ground.

  • Page 287: Checking Coil Windings Resistance

    ELECTRICAL SYSTEM Checking coil windings resistance Remove saddle and fuel tank (see relevant paragraph) to gain access to the coil (1). Disconnect the coil connector from the wiring, remove retaining screws and coil and measure resistance in the primary and secondary windings with a meter. Inductive coil: Primary winding resistance: 4.5 ±15% at 20°C.

  • Page 288: Electronic Control Unit (Ecu)

    ELECTRICAL SYSTEM Electronic control unit (ECU) TE-TXCi Remove saddle and fuel tank (see Section E) to gain access to the electronic control unit (1). It is composed of a capacitor, a rectifier circuit that handles input signals received from the pick-up sensor, a circuit that controls ignition timing advance in accordance with pick-up sensor inputs and a switching circuit for capacitor discharge.

  • Page 289: Gear Position Sensor Inspection (Gps: Gear Position Sensor)

    ELECTRICAL SYSTEM Gear position sensor inspection (GPS: Gear Position Sensor) Set the meter to the “Ohm” scale and disconnect the six-way connector (1) of the alternator from the main wiring harness (the gear sensor wiring is secured to the alternator wiring with a clip). Touch one meter probe to engine ground and insert the other probe into the connector hole for the WHITE/BLACK gear sensor wire (2).

  • Page 290: Battery (Te - Txci)

    ELECTRICAL SYSTEM BATTERY (TE - TXCi) The battery (1) is a sealed-for-life, maintenance-free battery. If the vehicle remains unused for long periods, it is recommended to disconnect the battery from the electrical system and store it in a dry place. After an intensive use of the battery, it is advisable to carry out a standard slow charging cycle (12V-6Ah battery: 0.6A for 8 hours).

  • Page 291: Headlamp, Tail Light (Te)

    ELECTRICAL SYSTEM HEADLAMP, TAIL LIGHT (TE) Headlamp adjustment The headlamp features a twin bulb for low and high beam and a festoon bulb for the city or parking light. Beam setting needs to be performed accurately; proceed as follows: Place the motorcycle 10 metres away from a vertical wall; The motorcycle must be on level ground and the optical axis of the headlamp must be perpendicular to the wall;...

  • Page 292: Tail Light Replacement

    ELECTRICAL SYSTEM Tail light replacement Remove the tail light as follows: - Loosen the two screws (1) under the rear mudguard. - Extract the tail light (2) and disconnect the connector (3). Once the tail light has been replaced, reverse the above procedure to reas- semble.

  • Page 293: Handlebar Switches

    ELECTRICAL SYSTEM Handlebar switches Measure continuity on the different switches using a meter. Replace any part found to be faulty. Left-hand switch (TC) 1 Engine stop switch (TC) COLOUR POSITION Left-hand switch (TE) High beam flasher (self-cancelling) High beam switch Low beam switch Left-hand turning indicators (self-cancelling) Right-hand turning indicators (self-cancelling)

  • Page 294: Colour Coding Key

    ELECTRICAL SYSTEM Right-hand switch (TE - TXCi) 1. Engine start button 2. Engine start/stop switch H01040 Bk-Br Y-Sb H01041 Colour coding key B ....Blue Br ....Brown Br-Bk ..... Brown-Black Y-Sb ....Yellow-Sky blue M.32 Ed. 07-2010...

  • Page 295: Fuses

    ELECTRICAL SYSTEM FUSES • When you find a blown fuse (1), always investigate and eliminate the cause before replacing it. • Never replace a fuse with another fuse with a different rating. • Never use a wire or other makeshift repair techniques instead of installing a new fuse.

  • Page 296: Relay Test (Te - Txci)

    ELECTRICAL SYSTEM Relay test (TE - TXCi) Remove saddle and fuel tank as described in "Section E". Remove the relays (1) located on the R.H. side of the chassis. A: Set the meter to the "Impedance" scale and check the energiser coil for proper operation.

  • Page 297: Digital Dashboard, Warning Lights (Te)

    IMPORTANT: In the event of a FUEL INJECTION SYSTEM MALFUNCTION, the word FAIL appears on the right side of the dashboard display (see page 14). When this is the case, contact your HUSQVARNA dealer. 1- SPEED (Km/h or mph) / ODO (figure 1) - SPEED: vehicle speed - maximum value: 299 Km/h or 299 mph;...
  • Page 298 ELECTRICAL SYSTEM 2 - SPEED / CLOCK (figure 2) - SPEED: speed - maximum value: 299 Km/h or 299 mph; - CLOCK: clock - reading from 0:00 to 23:59:59. To reset the clock, push the SCROLL button (A) and hold for more than 3 sec- onds in order to increase the hour value;...

  • Page 299: Warning Lights Panel (Txci)

    ELECTRICAL SYSTEM 5 - SPEED / NUMBER of RPM (figure 5) - SPEED: speed - maximum value: 299 Km/h or 299 mph - NUMBER OF RPM: MIN. 500, MAX 14250 The display also provides a fuel injection “Fail” indication; the latter takes prior- ity over any other indication.

  • Page 300: Dashboard Replacement (Te)

    ELECTRICAL SYSTEM Dashboard replacement (TE) - Remove the upper retaining screw securing headlamp fairing to dashboard bracket (A); - slide the headlamp fairing (B) forward and pull upwards (C) to ease it off the two lower mounts; - disconnect the connector (2) and remove the headlamp fairing (1); Remove the two retaining screws (3) securing the dashboard to its bracket, disconnect the connector (4) and remove the dashboard (5).
  • Page 301 ELECTRICAL SYSTEM Wiring (TC) H02334 1 Engine stop button 2 Coil 3 Control unit 4 Voltage regulator 5 Main wiring harness 6 MAQS sensor 7 Gear sensor 8 Condenser Ed. 07-2010 M.39...

  • Page 302: Cable Routing And Electrical Parts Installation Instructions (Tc)

    ELECTRICAL SYSTEM Cable routing and electrical parts installation instructions (TC) • HT coil position (1) (TC) Connect the HT coil as shown in the figure. H02315 • Fuel injection control unit position (2) (TC) Electronic control unit installed with the flat side down. H02365 •...

  • Page 303: Control Unit Connection (Tc)

    ELECTRICAL SYSTEM • Control unit connection (TC) Connect the control unit connector (4) as shown. H02366 • Ignition coil connection (TC) Connect the ignition coil connectors (5) as shown. • Gear sensor cable connection (TC) Connect the gear sensor connector (6) as shown. H02319 •...

  • Page 304: Securing The Wiring (Tc)

    ELECTRICAL SYSTEM • Securing the wiring (TC) Strap wiring to chassis with three clips (7) as shown in the figure. H02321 • Securing the engine stop button cable (TC) Secure the engine stop button cable (8) with two clips (9). •...

  • Page 305: Wiring (Te - Txci)

    ELECTRICAL SYSTEM Wiring (TE - TXCi) H00973 TXCi H02324 Ed. 07-2010 M.43...

  • Page 306: Cable Routing And Electrical Parts Installation Instructions "Te - Txci

    ELECTRICAL SYSTEM CABLE ROUTING AND ELECTRICAL PARTS INSTALLATION INSTRUC- TIONS "TE - TXCi" • Coil position TE -TXCi Connect the HT coil as shown in the figure. H02367 • Relay (1) and fuses (2) position (TE - TXCi) On right side of motorcycle. •...

  • Page 307: Electronic Control Unit (5) And Voltage Regulator (6) Position (Te - Txci)

    ELECTRICAL SYSTEM • Electronic control unit (5) and voltage regulator (6) position (TE - TXCi). Electronic control unit installed with the flat side down. Voltage regulator installed over the electronic control unit. Coat voltage regulator with heat grease. • Securing the starter motor/solenoid starter cable (TE - TXCi) Connect the starter motor/solenoid starter cable (7) as shown in the figure.

  • Page 308: Securing The Voltage Regulator Ground Cable (9) (Te - Txci)

    ELECTRICAL SYSTEM • Securing the voltage regulator ground cable (9) (TE - TXCi) Secure the regulator ground cable to the right-hand screw of the injection coil. • Securing the engine ground / chassis ground cables (10). Electrical system ground Secure the engine ground / chassis ground cable and the wiring harness ground eye terminal to the coil retaining screw.

  • Page 309: Connection Of Relays And Fuses (Te - Txci)

    ELECTRICAL SYSTEM • Connection of relays and fuses (TE - TXCi) RELAYS Connect the cable marked “POW” to relay (12) Connect the cable marked “FAN” to relay (13) Connect the cable marked “DC” to relay (14) (TE only) FUSES Connect the cable marked “POW” to fuse (15) Connect the cable marked “MAN”...

  • Page 310: Fuel Pump Connector Position (Te -Txci)

    ELECTRICAL SYSTEM • Fuel pump connector position (TE -TXCi) Position the fuel pump connector (21) as shown. H02325 • MAQS connector (TE - TXCi) Connect the connector (22) as shown. H02326 • Engine water temperature connector (TE - TXCi) Connect the engine water temperature connectors (23) to the thermostat.

  • Page 311: Ignition And Gear Sensor Cable Connection

    ELECTRICAL SYSTEM • Ignition and gear sensor cable connection Connect the ignition (26) and gear sensor (27) connectors as shown. • Routing of rear chassis cables, tail light connection, flasher contactor. Route the rear end of the wiring (28) as shown in the figure. Connect the tail light/turning indicators connector (29) (TE).

  • Page 312: Rear Stop Connection

    ELECTRICAL SYSTEM • Clip installation on fuse holders Secure the three fuses to the suitable perforated panel of the rear mudguard. • Rear stop connection Connect the wiring connector (A) to the rear STOP sensor. • Routing of steering head tube wiring Secure the wiring harness with the suitable clip (34).

  • Page 313: Speed Sensor And Ignition Switch Connectors (Te)

    ELECTRICAL SYSTEM • Double map connector (TE) Connect the connector (40). H02328 • Speed sensor and ignition switch connectors (TE) Connect the speed sensor connector. Connect the connector (41) of the ignition switch (42). H03072 • Horn connector (TE) Connect the connector (43) to the horn. Ed.

  • Page 314: Securing The Wiring Harness To Rear Chassis Right Side

    ELECTRICAL SYSTEM • Securing the wiring harness to rear chassis right side Strap wiring to rear chassis with clips as shown in the figure. • Securing the wiring harness to rear chassis left side Secure wiring harness with a clip as shown in the figure. •...
  • Page 315 ELECTRICAL SYSTEM • Securing the wiring harness Secure the generator connector as shown (26). • Securing the wiring harness Secure the ignition, gear sensor and Lambda sensor wiring loom to the clutch hose with two clips. • Securing the wiring harness Secure the ignition and gear sensor wiring loom to the clutch hose.
  • Page 316 ELECTRICAL SYSTEM 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; c) Air filter intake; d) Steering head, wheel bearings; e) Rear suspension drag drop link.

  • Page 317: Engine Cooling

    ENGINE COOLING Section Ed. 07-2010...
  • Page 318 ENGINE COOLING Coolant level check ..................N.3 Cooling circuit (TC) ..................N.4 Engine cooling system overhaul (TC)............N.5 Cooling circuit (TE-TXCi) ................N.6 Engine cooling system overhaul (TE-TXCi)..........N.7 Ed. 07-2010...

  • Page 319: Coolant Level Check

    ENGINE COOLING Coolant level check Coolant takes the heat from the piston-cylinder-and-head assembly and transfers it to the radiator, where it is released to the atmosphere. Checking coolant level at regular periods is critical to ensuring proper operation of the cooling system. Without cooling medium (water), no heat exchange occurs between cylinder head and radiator.

  • Page 320: Cooling Circuit (Tc)

    ENGINE COOLING Cooling circuit (TC) The forced circulation cooling system uses a centrifugal pump (located to the left of the head) and two down-draft radiators. Radiator cap Right-hand radiator Left-hand radiator Fitting Water pump Breather hose Radiator connecting pipe Radiators to cylinder head pipe Water pump to fitting pipe 10 Fitting to left-hand radiator pipe 11 Fitting to right-hand radiator pipe...

  • Page 321: Engine Cooling System Overhaul (Tc)

    ENGINE COOLING Engine cooling system overhaul (TC) If the coolant runs too hot, check the radiators. Any foreign matter trapped between 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.

  • Page 322: Cooling Circuit (Te-Txci)

    ENGINE COOLING Cooling circuit (TE-TXCi) TE-TXCi H02329 The forced circulation cooling system uses a centrifugal pump (located to the left of the head) and two down-draft radiators. Radiator cap Right-hand radiator Left-hand radiator Thermostat Water pump Breather hose Radiator connecting pipe Radiators to cylinder head pipe Water pump to fitting pipe 10 Thermostat to radiators pipe...

  • Page 323: Engine Cooling System Overhaul (Te-Txci)

    ENGINE COOLING Engine cooling system overhaul (TE-TXCi) If the coolant runs too hot, check the radiators. Any foreign matter trapped between 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.

  • Page 325: Hydraulically Controlled Clutch

    HYDRAULICALLY CONTROLLED CLUTCH Section Ed. 07-2010...
  • Page 326 HYDRAULICALLY CONTROLLED CLUTCH Hydraulic clutch system ................P.3 Draining clutch fluid ..................P.4 Clutch master cylinder servicing ..............P.5 Bleeding the clutch system ................P.6 Ed. 07-2010...

  • Page 327: Hydraulic Clutch System

    HYDRAULICALLY CONTROLLED CLUTCH Hydraulic clutch system The hydraulic circuit is composed of a master cylinder with its reservoir located on the left side of the handlebar, and a piston installed on the left crankcase half. The clutch is disengaged by the piston (5) that actuates the pushrod (4) to operate the pressure plate (6).

  • Page 328: Draining Clutch Fluid

    HYDRAULICALLY CONTROLLED CLUTCH Draining clutch fluid Connect a plastic hose to the bleed valve (1) and the loosen the valve turning it back 1 or 2 turns. Remove reservoir cap (2) and gasket (3) and operate the control lever (4) until draining all fluid. Ed.

  • Page 329: Clutch Master Cylinder Servicing

    HYDRAULICALLY CONTROLLED CLUTCH Clutch master cylinder servicing Drain the circuit, detach the master cylinder from the left side of the handlebar and take it apart. Replace all seals, reassemble the master cylinder and refit it to the handlebar. Reconnect the hose and fill fresh fluid into the reservoir; bleed the system as described in the relevant paragraph.

  • Page 330: Bleeding The Clutch System

    HYDRAULICALLY CONTROLLED CLUTCH Bleeding the clutch system A long travel and mushy feel of the clutch lever indicate that there is air in the system and the clutch hydraulic system needs bleeding. Bleeding procedure is as follows: Take the rubber cap off the bleed valve (1). Attach a clear plastic hose to the bleed valve and place the other end of the hose in a vessel (make sure the hose end stays dipped in the fluid throughout the procedure).

  • Page 331: Fuel Injection System

    FUEL INJECTION SYSTEM Section Ed. 07-2010...
  • Page 332 FUEL INJECTION SYSTEM INJECTION FUEL FEEDING SYSTEM (TE-TXCi) ........S.3 INJECTION FUEL FEEDING SYSTEM (TC) ..........S.4 Operation Manual for "HUSQVARNA SERVICE TOOL" for injection fuel feeding system (TE-TXCi) ........... S.5 Operation Manual for "HUSQVARNA SERVICE TOOL" for injection fuel feeding system (TC) .............. S.7 Fuel pump test (TC)..................

  • Page 333: Injection Fuel Feeding System (Te-Txci)

    Lambda sensor heater; Lean or rich mixture (LAMBDA sensor). The "HUSQVARNA SERVICE TOOL" provides a tool to check these parameters in the event the fuel injection malfunctions. The electric fuel pump (2) is installed on the bottom of the tank (1) and is com- posed of rotor, magnet, impeller, brushes, pressure regulator.

  • Page 334: Injection Fuel Feeding System (Tc)

    Atmospheric pressure in the intake manifold (in current location and at cur- rent altitude); Throttle opening; Gear shift position; Fuel injection pulse width; � The "HUSQVARNA SERVICE TOOL" provides a tool to check these parameters in the event the fuel injection malfunctions. � � � �...

  • Page 335: Operation Manual For "Husqvarna Service Tool" For Injection Fuel Feeding System (Te-Txci)

    (TE-TXCi) The injection fuel feeding system does not require scheduled maintenance. The "HUSQVARNA SERVICE TOOL" part no. 8000 H3898 lets you test system components in the event of a malfunction. TE = A malfunction is indicated by the word "FAIL" appearing in the right-hand portion of the dashboard display when the ignition key is set to ON and the right switch is set to RUN.
  • Page 336 FUEL INJECTION SYSTEM In addition to identifying any current malfunction, the software stores past malfunctions that have been resolved: store malfunc- tions can be deleted following the instructions provided in the Operation Manual. The ECU stores the number of service hours of the engine (toler- ance range: + / - 1 hour).

  • Page 337: Operation Manual For "Husqvarna Service Tool" For Injection Fuel Feeding System (Tc)

    Operation Manual for "HUSQVARNA SERVICE TOOL" for injection fuel feeding system (TC) The injection fuel feeding system does not require scheduled maintenance. The "HUSQVARNA SERVICE TOOL" part no. 8000 H3898 lets you test system components in the event of a malfunction. The "HUSQVARNA SERVICE TOOL" is composed of: 1) "Diagnostic Tool"...
  • Page 338 FUEL INJECTION SYSTEM Fuel pump test (TE - TXCi) Remove the pump as described in Section "E". pump operation Connect the RED (+) and BLACK (-) wires on the pump connector to a power supply unit with constant 12V output and make sure that the pump runs. Never keep the pump connected to the power supply unit for more than 3 seconds in a row.

  • Page 339: Fuel Pump Test (Tc)

    FUEL INJECTION SYSTEM Fuel pump test (TC) Remove the pump as described in Section "E". A: fuel reserve sensor Make sure there is no fuel left in the sensor and then set the meter to the "Impedance" scale and measure across the BLUE and WHITE wires. Cor- rect value is as follows: 1.3 KOhm (+/- 10%) at 20 °C.

  • Page 341: Special Tools

    SPECIAL TOOLS Section Ed. 07-2010...
  • Page 342 SPECIAL TOOLS SPECIAL TOOLS 1 (8000 A7015) Crankcase puller 2 (8000 A1580) T.D.C. timing tool 3 (8000 H2146) Flywheel puller 5 (8000 A7345) Jig (TC) (8000 H7345) Jig (TE-TXCi) 7 (8000 A7317) Valve installation / removal tool 8 (8000 A1625) Dial gauge mount 11 (8000 79015) Clutch hub tool 13 (1519 84701) Spring hook 16 (8000 95749) Spark plug tool...

  • Page 343: Tightening Torque Figures

    TIGHTENING TORQUE FIGURES 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. Listed in the table are the tightening torque figures for the most important nuts and screws, which have determined in accordance with thread diameter, pitch and specific application. These figures are obtained after cleaning the threads with solvent. Ed. 07-2010...
  • Page 344 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) ENGINE (8000 A7028) Cylinder head Screw TFEI M6x1-L30 10 Nm 1.02 Kgm Screw TFEI M6x1-L35 10 Nm 1.02 Kgm Screw TFEI M5-L30 5.5 Nm 0.56 Kgm Screw TFEI M5-L25 5.5 Nm 0.56 Kgm Screw TTEI M5x0.8 L.8 Blow-by labyrinth plate (+LOCTITE 243) 6 Nm 0.6 Kgm Special flanged screw L.23.4 Head cover and fuel 8 Nm 0.8 Kgm Special flanged screw L.31.3 Head cover 8 Nm 0.8 Kgm Water temperature sensor M10x1.25 5 Nm 0.5 Kgm Hole plug (water sensor) M10x1.25 8 Nm 0.8 Kgm...
  • Page 345 TIGHTENING TORQUE FIGURES Screw TCEI M5x0.8 L20 Oil pump body 6 Nm 0.6 Kgm Oil drain plug M14x1.5 25 Nm 2.55 Kgm Drilled screw TEF M8x1.25 (alumi- Pipe 8 Nm 0.8 Kgm nium) Oil filler plug Finger-tight Electrical System Screw TEF M6x1-CH8-L20 Coil to chassis 8 Nm 0.8 Kgm Screw TCEI M5-L12 Stator (use LOCTITE 272) 6 Nm 0.6 Kgm Screw TCEI M5-L20 Pick-up sensor (use LOCTITE 272) 6 Nm 0.6 Kgm Flanged nut M12x1 Flywheel 75 Nm 7.65 Kgm Screw TEF M6x1-CH8-L20 Regulator to chassis 8 Nm 0.8 Kgm Spark plug...
  • Page 346 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) CHASSIS (99669) 1 Nm = 0.73756 ft/lb NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows M5x0.8 5.6-6.2 Nm 0.57-0.63 Kgm 4.1-4.5 ft/lb M6x1 7.6-8.4 Nm 0.80-0.85 Kgm 5.8-6.1 ft/lb M8x1.25 24-26 Nm 2.4-2.6 Kgm 17.3-18.8 ft/lb Ed. 07-2010...
  • Page 347 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) HANDLEBAR AND CONTROLS (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) FRONT SUSPENSION (99669) 1 Nm = 0.73756 ft/lb Ed. 07-2010...
  • Page 348 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) REAR SUSPENSION (99669) 1 Nm = 0.73756 ft/lb Ed. 07-2010...
  • Page 349 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) FAIRINGS AND MUDGUARDS (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) ELECTRICAL SYSTEM (99669) 1 Nm = 0.73756 ft/lb Ed. 07-2010...
  • Page 350 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) FUEL SYSTEM (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) WHEELS AND BRAKES (99669) 1 Nm = 0.73756 ft/lb Ed. 07-2010...
  • Page 351 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) EXHAUST (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) INSTRUMENTS (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) COOLING SYSTEM (99669) 1 Nm = 0.73756 ft/lb Ed.
  • Page 352 TIGHTENING TORQUE FIGURES NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows (+/- 5%) Steel screws on plastic, with metal spacers M4 2 Nm 0.2 Kgm 1.45 ft/lb Steel screws on brass, copper, aluminium M4 2 Nm 0.2 Kgm 1.45 ft/lb Steel screws on iron, steel M4 3 Nm 0.3 Kgm 2.2 ft/lb Steel screws on plastic, with metal spacers 4 Nm 0.4 Kgm 3 ft/lb Steel screws on brass, copper, aluminium M5 4 Nm 0.4 Kgm...

  • Page 353: Chassis And Wheels

    CHASSIS AND WHEELS Section Ed. 07-2010...
  • Page 354 CHASSIS AND WHEELS Chassis ......................Y.3 Lubrication points (lubricant) ................ Y.4 Front wheel ....................Y.5 Front wheel removal ..................Y.6 Front wheel installation ................. Y.7 Rear wheel ....................Y.8 Rear wheel removal..................Y.9 Tightening torque figures ................Y.9 Wheel servicing ..................Y.10 Wheel axle warpage ...................

  • Page 355: Chassis

    CHASSIS AND WHEELS Chassis The single frame branches off at the exhaust and is made of steel tubes with circular, rectangular and ellipsoidal section; the rear chassis is made from light alloy. A badly damaged chassis must be replaced. Ed. 07-2010...

  • Page 356: Lubrication Points (Lubricant)

    CHASSIS AND WHEELS Lubrication points (lubricant) 1 Steering bearings (grease) H02333 H02332 Check the assemblies shown in the figure for cracks or damage. If any are found, replace the part. A ENGINE MOUNTING BOLTS B REAR CHASSIS MOUNTING BOLTS C CHAIN GUIDE ROLLER/BEARING D FOOTPEGS/PINS/SPRINGS Ed.
  • Page 357 CHASSIS AND WHEELS Front wheel Light alloy wheel hub and rim with high-strength steel spokes. Type and size of wheel rims ........light alloy: 1.6x21” (TC) Size of tyre.............80/100 x 21” (TE - TXCi) Size of tyre.............90/90 x 21” (TE USA) 90/90 x 21 Cold tyre pressure (TC) ...............0.9-1.0 Kg/sq cm...
  • Page 358 CHASSIS AND WHEELS Removing the front wheel Set a stand or a block under the engine and see that the front wheel is lifted from the ground. Loosen the bolts (1) holding the wheel axle (2) to the front fork mounts. Hold the head of the wheel axle in place, and unscrew the bolt (3) on the opposite side;...
  • Page 359 CHASSIS AND WHEELS Reassembling the front wheel Fit the L.H. spacer on the wheel hub. Fit the wheel between the fork legs so as to set the brake disc into the calliper. Fit the wheel axle (2) from the R.H. side, after greasing it and push it fully home against the L.H.

  • Page 360: Rear Wheel

    CHASSIS AND WHEELS Rear wheel Light alloy wheel hub and rim with high-strength steel spokes. (TC) Type and size of wheel rims ......light alloy: 1.85x19”; (TE - TXCi) Type and size of wheel rims ......light alloy: 2.15x18”; (TE USA) Size of tyre............

  • Page 361: Tightening Torque Figures

    CHASSIS AND WHEELS Removing the rear wheel Set a stand or a block under the engine and see that the rear wheel is lifted from the ground. Unscrew the nut (1) of the wheel axle (3) and extract it. It is not necessary to loosen the chain tensioners (2);...

  • Page 362: Wheel Servicing

    CHASSIS AND WHEELS Wheel servicing Check the wheel hub bearings for wear. If you find too much (radial or axial) clearance, replace the bearings as follows: place the hub on a flat surface with an appropriate hole (for when you knock out the bearing);...

  • Page 363: Wheel Spokes

    CHASSIS AND WHEELS Wheel spokes Make sure all nipples are firmly tightened (4.4 Nm, 0.45 Kgm, 3.2 ft/lb). Re- tighten if needed. Improper tightening will affect motorcycle stability; for a quick check, simply tap the spokes with the tip of a metal tool (such as a screwdriver): a clear, crisp sound indicates proper tightening, a dull sound means that the spokes need to be tightened.

  • Page 364: Rear Chain Sprocket, Secondary Drive Sprocket And Chain

    CHASSIS AND WHEELS 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 2 Exceeding wear If the sprocket is exceedingly worn, replace it after loosening the six screws that retain it to the hub.

  • Page 365: Checking Chain And Sprockets For Wear

    CHASSIS AND WHEELS Checking chain and sprockets for wear Check chain wear as follows: turn the adjuster screws to stretch the chain taut; mark 20 chain links; measure distance “A” (centre distance between 1st and 21st link). Check the transmission sprocket for damage or wear. When worn down like the sprocket shown in the figure, it must be replaced.

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