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Related Manuals for Husqvarna TC 85 19/16 2020
Summary of Contents for Husqvarna TC 85 19/16 2020
- Page 1 OWNER'S MANUAL 2020 TC 85 Art. no. 3402330en...
- Page 3 DEAR HUSQVARNA MOTORCYCLES CUSTOMER Congratulations on your decision to purchase a Husqvarna motorcycle. You are now the owner of a state-of- DEAR HUSQVARNA MOTORCYCLES CUSTOMER the-art, sporty motorcycle that will continue to give you and your child pleasure for a long time if you maintain it properly.
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Page 4: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS PREPARING FOR USE........21 MEANS OF REPRESENTATION......5 Advice on preparing for first use..21 Symbols used ........5 Running in the engine ......23 Formats used ........5 Preparing the vehicle for difficult SAFETY ADVICE .......... - Page 5 TABLE OF CONTENTS 10.10 Adjusting the spring preload of the 11.32 Removing the fuel tank ....63 shock absorber ....... 39 11.33 Installing the fuel tank ..... 64 10.11 Adjusting the riding sag ....40 11.34 Checking for chain dirt 10.12 Checking the basic setting of the accumulation ........
- Page 6 TABLE OF CONTENTS COOLING SYSTEM......... 94 20.5 Chassis ..........121 20.6 Tires ..........122 14.1 Cooling system ........94 20.7 Fork........... 122 14.2 Radiator cover ........94 20.8 Shock absorber ........ 122 14.3 Installing the radiator cover ....94 20.9 Chassis tightening torques ....
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Page 7: Means Of Representation 1
MEANS OF REPRESENTATION 1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understand- ing. -
Page 8: Safety Advice
2 SAFETY ADVICE Use definition – intended use This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations. Info Only operate this vehicle in closed-off areas remote from public road traffic. -
Page 9: Tampering Warning
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. Have malfunctions that impair safety promptly eliminated by an authorized Husqvarna Motorcycles workshop. Adhere to the information and warning labels on the vehicle. -
Page 10: Protective Clothing
– When you ride a motorcycle, set an example for your child and wear suitable protective clothing. In the interest of your child’s safety, Husqvarna Motorcycles recommends that only operating the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the number in parentheses. - Page 11 SAFETY ADVICE 2 The Owner's Manual is also available for download from your authorized Husqvarna Motorcycles dealer and on the Husqvarna Motorcycles website. International Husqvarna Motorcycles website: www.husqvarna-motorcycles.com...
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Page 12: Important Notes
3 IMPORTANT NOTES Manufacturer and implied warranty The work prescribed in the service schedule must only be carried out in an authorized Husqvarna Motorcy- cles workshop and confirmed in the Husqvarna Motorcycles Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty. -
Page 13: Customer Service
IMPORTANT NOTES 3 Customer service Your authorized Husqvarna Motorcycles dealer will be happy to answer any questions you may have regarding your vehicle and Husqvarna Motorcycles. A list of authorized Husqvarna Motorcycles dealers can be found on the Husqvarna Motorcycles website. -
Page 14: View Of Vehicle
4 VIEW OF VEHICLE View of vehicle, front left (example) S03422-10 Hand brake lever ( p. 16) Clutch lever ( p. 16) Fuel tank filler cap Air filter box cover Shift lever ( p. 18) Choke ( p. 18) Fuel tap ( p. -
Page 15: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE 4 View of vehicle, rear right (example) S03423-10 Kill switch ( p. 16) Throttle grip ( p. 16) Fork article number Foot brake lever ( p. 19) Kick starter lever ( p. 19) Level viewer for brake fluid, rear... -
Page 16: Serial Numbers
5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label Type label is located on the front frame tube. 402154-10 Engine number The engine number is located on the left side of the engine under the engine sprocket. -
Page 17: Shock Absorber Article Number
SERIAL NUMBERS 5 Shock absorber article number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. H02222-10... -
Page 18: Controls
6 CONTROLS Clutch lever Clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. K00953-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar. The front brake is engaged using the hand brake lever. -
Page 19: Opening The Fuel Tank Filler Cap
CONTROLS 6 Opening the fuel tank filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –... -
Page 20: Fuel Tap
6 CONTROLS Fuel tap The fuel tap is on the left side of the fuel tank. Using the tap handle on the fuel tap, you can open or close the fuel supply to the carburetor. Possible states Fuel supply closed OFF – Fuel cannot flow from the fuel •... -
Page 21: Kick Starter Lever
CONTROLS 6 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.10 Kick starter lever Kick starter lever is fitted on the right side of the engine. The kick starter lever can be swiveled. -
Page 22: Service Hour Counter
6 CONTROLS 6.13 Service hour counter The service hour counter is attached below the seat. It shows the total number of service hours of the engine. The service hour counter begins counting when the engine is started and stops when the engine is switched off. Info The value indicated by the service hour counter cannot be cleared or adjusted. -
Page 23: Preparing For Use 7
PREPARING FOR USE 7 Advice on preparing for first use Warning Danger of accidents A lack of physical and mental readiness on the part of the child poses a major risk. Children often underestimate or fail to recognize dangerous situations. – Your child must already be able to ride a bicycle. - Page 24 When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized Husqvarna Motorcy- cles workshop. You will receive a delivery certificate when the vehicle is handed over.
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Page 25: Running In The Engine
PREPARING FOR USE 7 Running in the engine – During the running-in phase, do not exceed the specified engine performance. Guideline Maximum engine performance During the first 3 operating hours < 70 % During the first 5 operating hours < 100 % –... - Page 26 – Change the radiator cap. – Mount the air filter dust cover. Air filter dust cover (47206920000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01104-01 – Mount the air filter sand cover. Air filter sand cover (79006922000)
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Page 27: Preparing The Vehicle For Riding On Wet Sand
– Change the radiator cap. – Adjust the carburetor jetting and setting. Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop. – Clean the chain. Chain cleaner ( p. 127) – Grease the chain. -
Page 28: Preparing Vehicle For Rides On Wet And Muddy Circuits
Make sure that no radiator covers ( p. 94) are installed. – Adjust the carburetor jetting and setting. Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop. – Clean the motorcycle. ( p. 111) – Straighten bent radiator fins carefully. -
Page 29: Preparing Vehicle For Low Temperatures Or Snow
PREPARING FOR USE 7 Preparing vehicle for low temperatures or snow – Adjust the carburetor jetting and setting. Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop. M01107-01... -
Page 30: Riding Instructions
8 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –... -
Page 31: Starting Off
Make it clear to your child that he or she must not change into a low gear at high engine speed. Info If unusual noises occur while riding, stop immediately, switch off the engine, and contact an authorized Husqvarna Motorcycles workshop. First gear is used for starting off and for steep inclines. –... -
Page 32: Applying The Brakes
– Check the brake system and do not allow your child to continue riding until the problem is elimi- nated. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system. -
Page 33: Transporting
RIDING INSTRUCTIONS 8 – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. Note Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over. - Page 34 8 RIDING INSTRUCTIONS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –...
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Page 35: Service Schedule 9
Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up- to-date service schedule can always be found on Husqvarna Motorcycles Dealer.net. Your authorized Husq- varna Motorcycles dealer will be glad to advise you. -
Page 36: Recommended Work
● ● Final check: Check the vehicle for operating safety and take a test ride. ○ ● ● ● Make a service entry in the Husqvarna Motorcycles Dealer.net. ○ One-time interval ● Periodic interval Recommended work after every race Every 40 operating hours... -
Page 37: Tuning The Chassis 10
TUNING THE CHASSIS 10 10.1 Checking the basic chassis setting with rider's weight Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork. – For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, link fork and frame, the basic settings of the suspension components must match the rider's weight. -
Page 38: Compression Damping Of The Shock Absorber
The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber. -
Page 39: Adjusting The High-Speed Compression Damping Of The Shock Absorber
The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber. -
Page 40: Measuring The Dimension Of The Rear Wheel Unloaded
10 TUNING THE CHASSIS Guideline Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase the damping; turn counter- clockwise to reduce the damping. 10.7 Measuring the dimension of the rear wheel unloaded Preparatory work –... -
Page 41: Checking The Riding Sag Of The Shock Absorber
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incor- rectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Preparatory work –... -
Page 42: Adjusting The Riding Sag
10 TUNING THE CHASSIS Main work – Measure the full spring length while it is under tension and note down the value. – Loosen screw – Turn adjusting ring until the spring is no longer under ten- sion. Hook wrench (90129051000) –... -
Page 43: Checking The Basic Setting Of The Fork
TUNING THE CHASSIS 10 Info The spring rate is shown on the outside of the spring. Smaller weight differences can be compensated by changing the spring preload. Finishing work – Install the shock absorber. p. 57) – Remove the motorcycle from the lift stand. ( p. - Page 44 10 TUNING THE CHASSIS Main work – Remove protection cap – Push together fork airpump fully. Fork airpump (79412966100) Info The fork airpump is included as part of the motorcy- cle's accessory pack. S03413-10 – Connect the fork airpump to the left fork leg. The fork pump airpump switches on automatically.
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Page 45: Adjusting The Compression Damping Of The Fork
TUNING THE CHASSIS 10 10.14 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Remove protection cap – Turn adjusting screw clockwise all the way. Info The adjusting screw is located at the lower end of the right fork leg. -
Page 46: Handlebar Position
10 TUNING THE CHASSIS Info Turn clockwise to increase the damping; turn counter- clockwise to reduce the damping. 10.16 Handlebar position On the upper triple clamp, there are 2 holes at a distance of to each other. Hole distance A 15 mm (0.59 in) The holes on the handlebar supports are placed at a distance from the center. - Page 47 TUNING THE CHASSIS 10 Guideline Screw, handlebar 20 Nm (14.8 lbf ft) clamp Info Make sure the gap widths are even.
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Page 48: 11 Service Work On The Chassis
11 SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (80329955100) Neither wheel is in contact with the ground. -
Page 49: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS 11 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 46) – Remove the fork protector. ( p. 49) Main work – Push dust boots of both fork legs downward. -
Page 50: Installing The Fork Legs
11 SERVICE WORK ON THE CHASSIS – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. S03427-10 11.6 Installing the fork legs – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front. -
Page 51: Removing The Fork Protector
SERVICE WORK ON THE CHASSIS 11 – Clean and grease the wheel spindle. Long-life grease ( p. 127) – Position front wheel. – Insert the wheel spindle. – Mount and tighten screw Guideline Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft) spindle A00152-12 –... -
Page 52: Installing The Fork Protector
11 SERVICE WORK ON THE CHASSIS 11.8 Installing the fork protector – Position the fork protector on the right fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the fork protector on the left fork leg. Mount and tighten screws Guideline A00141-10... -
Page 53: Installing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS 11 11.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 127) – Insert the lower triple clamp with the steering stem. Mount upper steering head bearing –... - Page 54 11 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, bottom triple 15 Nm (11.1 lbf ft) clamp S03431-10 – Tighten nut Guideline Nut, steering stem M20x1.5 10 Nm (7.4 lbf ft) S03426-10 – Tighten screw Guideline Steering stem clamp 20 Nm (14.8 lbf ft) screw –...
- Page 55 SERVICE WORK ON THE CHASSIS 11 – Clean and grease the wheel spindle. Long-life grease ( p. 127) – Position front wheel. – Insert the wheel spindle. – Mount and tighten screw Guideline Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft) spindle E00247-13 –...
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Page 56: Checking The Steering Head Bearing Play
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time. -
Page 57: Greasing The Steering Head Bearing
SERVICE WORK ON THE CHASSIS 11 Guideline Steering stem clamp 20 Nm (14.8 lbf ft) screw – Tighten screws Guideline Screw, top triple 17 Nm (12.5 lbf ft) clamp – Position the fuel tank breather in the steering stem. Finishing work –... -
Page 58: Removing Front Fender
11 SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Start number plate 4 Nm (3 lbf ft) screw A00150-10 11.16 Removing front fender Preparatory work – Remove the start number plate. ( p. 55) Main work – Remove screws –... -
Page 59: Installing Front Fender
SERVICE WORK ON THE CHASSIS 11 11.17 Installing front fender Main work – Position front fender. – Mount and tighten screws Guideline Screw, front fender 6 Nm (4.4 lbf ft) – Mount and tighten screws Guideline Screw, front fender 6 Nm (4.4 lbf ft) A00138-10 Finishing work –... -
Page 60: Removing The Seat
11 SERVICE WORK ON THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 46) 11.20 Removing the seat – Remove screw – Raise the rear of the seat, pull the seat back, and lift it off. K00964-10 11.21 Mounting the seat... -
Page 61: Installing The Air Filter Box Cover
SERVICE WORK ON THE CHASSIS 11 11.23 Installing the air filter box cover – Attach the air filter box cover in areas and snap it into place in areas S03458-11 11.24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. -
Page 62: Installing The Air Filter
11 SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 127) Info Only press the air filter to dry it, never wring it out. –... -
Page 63: Removing The Main Silencer
SERVICE WORK ON THE CHASSIS 11 11.27 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. Preparatory work –... -
Page 64: Removing The Right Side Cover
11 SERVICE WORK ON THE CHASSIS Main work – Remove screws – Take off outer tube – Remove glass fiber yarn filling from inner tube – Clean the parts that need to be reinstalled and check for damage. – Mount the new glass fiber yarn filling on the inner tube. Info Mount the glass fiber yarn filling so that the thermal protection foil is positioned on the right in the direction... -
Page 65: Installing The Right Side Cover
SERVICE WORK ON THE CHASSIS 11 11.31 Installing the right side cover – Position side cover with holding lug on cut-out – Position the side cover on collar bushings , and push toward the rear. – Engage the side cover in areas V01291-10 11.32 Removing the fuel tank... -
Page 66: Installing The Fuel Tank
11 SERVICE WORK ON THE CHASSIS Main work – Pull off the fuel hose. Info Remaining fuel may flow out of the fuel hose. – Remove screws K00968-10 – Remove screw with the rubber bushing. – Remove the hose from the fuel tank breather. K00969-10 –... -
Page 67: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS 11 Main work – Check the throttle cable routing. ( p. 71) – Position the fuel tank and fit the two spoilers to the sides of the radiator bracket. – Make sure that no cables or throttle cables are trapped or damaged. -
Page 68: Cleaning The Chain
11 SERVICE WORK ON THE CHASSIS 11.35 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. – Remove lubricants from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –... -
Page 69: Adjusting The Chain Tension
SERVICE WORK ON THE CHASSIS 11 Main work – Pull the chain at the end of the chain sliding guard upward to measure chain tension Info Lower chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. -
Page 70: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide
11 SERVICE WORK ON THE CHASSIS Guideline Nut, rear wheel spin- M20x1.5 80 Nm (59 lbf ft) Info The wide adjustment range of the chain adjusters (32 mm (1.26 in)) enables different secondary ratios with the same chain length. Chain adjusters can be turned by 180°. - Page 71 SERVICE WORK ON THE CHASSIS 11 Info When a new chain is mounted, the rear sprocket and engine sprocket should also be changed. New chains wear out faster on an old, worn rear sprocket or engine sprocket. – Check the chain sliding guard for wear. »...
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Page 72: Checking The Frame
– Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by Husqvarna V00858-01 Motorcycles. 11.40 Checking the link fork – Check the link fork for damage, cracking, and deformation. -
Page 73: Checking The Throttle Cable Routing
SERVICE WORK ON THE CHASSIS 11 11.41 Checking the throttle cable routing Warning Danger of accidents The throttle cable may slip out of the guide if routed incorrectly. The throttle slide will then no longer be closed and the speed can no longer be controlled. –... -
Page 74: Checking The Rubber Grip
11 SERVICE WORK ON THE CHASSIS 11.42 Checking the rubber grip – Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated. » If a rubber grip is damaged, worn or loose: –... -
Page 75: Correcting The Fluid Level Of The Hydraulic Clutch
SERVICE WORK ON THE CHASSIS 11 11.45 Correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. –... -
Page 76: Changing The Hydraulic Clutch Fluid
11 SERVICE WORK ON THE CHASSIS 11.46 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. –... - Page 77 SERVICE WORK ON THE CHASSIS 11 – Inject the liquid into the system until it escapes from open- of the master cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. – Remove the bleeding syringe. Mount and tighten screws bleeder screw.
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Page 78: 12 Brake System
Do not make any adjustments while riding. 12.3 Checking the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) -
Page 79: Checking The Front Brake Fluid Level
– Check the brake system and ensure that nobody drives the vehicle before the problem is elimi- nated. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. -
Page 80: Adding The Front Brake Fluid
Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage. -
Page 81: Checking The Front Brake Linings
Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥... - Page 82 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
- Page 83 BRAKE SYSTEM 12 – Remove pin – Take off retainer spring and remove the brake linings. – Clean the brake caliper. – Position new brake linings. Info Always change the brake linings in pairs. – Position retaining spring E00239-10 – Mount pin but do not tighten yet.
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Page 84: Checking The Free Travel Of Foot Brake Lever
12 BRAKE SYSTEM 12.8 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake. -
Page 85: Checking The Rear Brake Fluid Level
Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Stand the vehicle upright. - Page 86 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.
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Page 87: Checking The Rear Brake Linings
Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥... - Page 88 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
- Page 89 BRAKE SYSTEM 12 – Position retaining spring – Mount and tighten pin Guideline Pin, rear brake 4 Nm (3 lbf ft) Info To make it easier to mount the pin, push the retainer spring down. K00999-10 Make sure the retaining spring is seated correctly. –...
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Page 90: 13 Wheels, Tires
13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 46) Main work – Loosen screw by several rotations. – Loosen screws – Press on screw to push the wheel spindle out of the axle clamp. -
Page 91: Removing The Rear Wheel
WHEELS, TIRES 13 – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change front wheel bearing. – Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p. -
Page 92: Installing The Rear Wheel
13 WHEELS, TIRES Main work – Remove nut – Take off chain adjuster . Pull out wheel spindle enough to allow the rear wheel to be pushed forward. – Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket. -
Page 93: Checking The Tire Condition
Checking the tire condition Info Only mount tires approved and/or recommended by Husqvarna Motorcycles. Other tires could have a negative effect on handling characteristics. The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle. -
Page 94: Checking Tire Pressure
DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. Husqvarna Motorcycles recommends that the tires be H01144-01 changed after 5 years at the latest, regardless of the actual wear. -
Page 95: Checking Spoke Tension
Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diameter. -
Page 96: 14 Cooling System
14 COOLING SYSTEM 14.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions. - Page 97 COOLING SYSTEM 14 – Remove screws – Remove right radiator shield – Remove screws – Remove left radiator shield H02536-10 – Position the corresponding radiator cover ( p. 94). The holding lugs point toward the frame. H02356-01 – Position left radiator shield –...
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Page 98: Removing The Radiator Cover
14 COOLING SYSTEM 14.4 Removing the radiator cover Info Only remove left radiator shield if both radiator covers are mounted. – Remove screws – Remove right radiator shield – Remove screws – Remove left radiator shield – Remove corresponding radiator cover. –... -
Page 99: Checking The Coolant Level
COOLING SYSTEM 14 – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –... -
Page 100: Draining The Coolant
14 COOLING SYSTEM 14.7 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature. - Page 101 COOLING SYSTEM 14 Main work – Make sure that screw is tightened. – Position the motorcycle upright. – Take off radiator cap – Completely fill the radiator with coolant. Coolant ( p. 125) V01304-11 – Loosen screw until coolant escapes without bubbles. –...
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Page 102: 15 Tuning The Engine
15 TUNING THE ENGINE 15.1 Checking throttle cable play – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Throttle cable play 2 …... -
Page 103: Carburetor Tuning
TUNING THE ENGINE 15 – Turn barrel adjuster so that there is play in the throttle cable at the throttle grip. Guideline Throttle cable play 2 … 3 mm (0.08 … 0.12 in) – Tighten nut – Slide on sleeve 400192-11 Finishing work –... - Page 104 15 TUNING THE ENGINE Cylindrical part of the needle CYL The cylindrical part of the needle has the greatest influence when the throttle slide is almost closed. Idling jet IJ The idling jet has the greatest influence in the low to mid throttle slide range. If the engine stutters when idling or accelerating with a partially open throttle slide, a smaller idling jet must be used.
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Page 105: Carburetor - Idle
TUNING THE ENGINE 15 402797-01 Column 2 corresponds to a needle in the standard position. Column 1 corresponds to a needle which is half a clip leaner. Column 3 specifies the diameter of the first cylindrical part of the needle. The smaller the diameter of the first cylindrical part of the needle, the richer the mixture. -
Page 106: Carburetor - Adjusting The Idle Speed
15 TUNING THE ENGINE Carburetor – adjusting the idle speed 15.5 – Screw in idle air adjusting screw all the way and turn it to the specified basic setting. Guideline Idle air adjusting screw open 2 turns – Run the engine until warm. Guideline ≥... -
Page 107: Emptying The Carburetor Float Chamber
TUNING THE ENGINE 15 15.6 Emptying the carburetor float chamber Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –... -
Page 108: Plug-In Connector Of Ignition Timing Map Adjustment
15 TUNING THE ENGINE 15.7 Plug-in connector of ignition timing map adjustment Plug-in connector of the ignition timing map adjustment is located on the frame under the fuel tank. Possible states Soft – The plug-in connector of the ignition timing map •... - Page 109 TUNING THE ENGINE 15 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.
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Page 110: 16 Service Work On The Engine
16 SERVICE WORK ON THE ENGINE 16.1 Checking the gear oil level Condition The engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Remove screw with the seal ring. – Check the gear oil level. Gear oil must not run out of the hole. -
Page 111: Adding The Gear Oil
SERVICE WORK ON THE ENGINE 16 Guideline Oil drain plug with 20 Nm (14.8 lbf ft) magnet – Remove filler plug with the O-ring, and fill up with gear oil. Gear oil 0.50 l Engine oil (15W/50) (0.53 qt.) p. 125) –... - Page 112 16 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.
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Page 113: Cleaning, Care 17
CLEANING, CARE 17 17.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –... - Page 114 17 CLEANING, CARE Info The heat produced causes water at inaccessible loca- tions in the engine and on the brake system to evapo- rate. – Push back the protection caps on the handlebar controls to allow water to evaporate. – After the motorcycle has cooled off, lubricate all moving parts and bearings.
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Page 115: Storage 18
Empty the carburetor float chamber. p. 105) – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info Husqvarna Motorcycles recommends raising the motorcycle. – Raise the motorcycle with a lift stand. ( p. 46) –... -
Page 116: Preparing For Use After Storage
18 STORAGE 18.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 46) – Perform checks and maintenance measures when preparing for use. ( p. 28) – Take a test ride. 401059-01... -
Page 117: Troubleshooting 19
TROUBLESHOOTING 19 Faults Possible cause Action – Engine turns but does not start Operating error Carry out the start procedure. p. 28) – Motorcycle was out of use for Empty the carburetor float cham- a long time and there is old ber. - Page 118 19 TROUBLESHOOTING Faults Possible cause Action – Engine has too little power Membrane or reed valve hous- Check the membrane and reed valve ing is damaged housing. – Engine stalls or is popping into Lack of fuel Turn handle of the fuel tap to the the carburetor ONposition.
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Page 119: Technical Data 20
TECHNICAL DATA 20 20.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 84.93 cm³ (5.1828 cu in) Stroke 48.95 mm (1.9272 in) Bore 47 mm (1.85 in) Idle speed 1,400 … 1,500 rpm Crankshaft bearing 1 grooved ball bearing / 1 roller bearing Conrod bearing Needle bearing... - Page 120 20 TECHNICAL DATA Screw, locking lever 6 Nm (4.4 lbf ft) ® Loctite 243™ Screw, power valve stop plate M5x12 6 Nm (4.4 lbf ft) ® Loctite 243™ Screw, water pump wheel 6 Nm (4.4 lbf ft) ® Loctite 243™ Coolant drain plug 8 Nm (5.9 lbf ft) Coolant drain plug...
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Page 121: Carburetor
TECHNICAL DATA 20 20.3 Carburetor Carburetor type KEIHIN PWK 28 Needle position 3rd position from top Idle air adjusting screw open 2 turns Main jet 142 (140, 145, 148) Jet needle NRKC (NRJC) Idling jet 48 (45, 50) Throttle slide Cold start jet 20.3.1 Basic carburetor setting for sandy surfaces... -
Page 122: Carburetor Tuning
20 TECHNICAL DATA 20.3.2 Carburetor tuning 402814-01 M/FT ASL Above sea level TEMP Temperature Open (rotations) idle air adjusting screw Idling jet Jet needle Needle position from top Main jet... -
Page 123: Capacities
TECHNICAL DATA 20 20.4 Capacities 20.4.1 Gear oil Gear oil 0.50 l (0.53 qt.) Engine oil (15W/50) ( p. 125) 20.4.2 Coolant Coolant ( p. 125) 0.8 l (0.8 qt.) 20.4.3 Fuel Fuel tank capacity, approx. 5.2 l (1.37 US gal) Super unleaded (98 octane) mixed with 2-stroke engine oil (1:40) p. -
Page 124: Tires
90/100 - 16 M/C 52M TT Maxxis MAXX CROSS SI Maxxis MAXX CROSS SI The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com 20.7 Fork Fork article number 43.18.8T.04... -
Page 125: Chassis Tightening Torques
TECHNICAL DATA 20 Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload 11 mm (0.43 in) Spring rate Weight of rider: < 45 kg (< 99 lb.) 35 N/mm (200 lb/in) Weight of rider: 45 … 55 kg (99 … 121 lb.) 40 N/mm (228 lb/in) Weight of rider: >... - Page 126 20 TECHNICAL DATA Screw, rear sprocket 35 Nm (25.8 lbf ft) ® Loctite 2701™ Screw, subframe 35 Nm (25.8 lbf ft) ® Loctite 2701™ Screw, top triple clamp 17 Nm (12.5 lbf ft) Steering stem clamp screw 20 Nm (14.8 lbf ft) Engine carrying screw 45 Nm (33.2 lbf ft) Nut, foot brake lever...
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Page 127: Substances 21
SUBSTANCES 21 Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 ®... - Page 128 21 SUBSTANCES Recommended supplier ® MOTOREX – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 129) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.
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Page 129: Auxiliary Substances 22
AUXILIARY SUBSTANCES 22 Air filter cleaner Recommended supplier ® MOTOREX – Racing Bio Dirt Remover Chain cleaner Recommended supplier ® MOTOREX – Chain Clean Fuel additive Recommended supplier ® MOTOREX – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier... - Page 130 22 AUXILIARY SUBSTANCES Rubber grip adhesive (00062030051) Recommended supplier KTM AG – GRIP GLUE Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier ® MOTOREX – Quick Cleaner Special grease (00062010053) Recommended supplier ® Klüber Lubrication –...
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Page 131: Standards 23
STANDARDS 23 JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds. -
Page 132: 24 List Of Abbreviations
24 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly... -
Page 133: Index
INDEX INDEX Chain tension adjusting ......67 Accessories ......10 checking . - Page 134 INDEX Fork legs basic setting, checking ....41 Kick starter lever ..... . 19 bleeding .
- Page 135 INDEX Right side cover Throttle cable play installing ......63 adjusting ......100 removing .
- Page 136 *3402330en* 3402330en 03/2019 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer/KISKA, www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...