TC - Motorcycle HUSQVARNA - Free user manual and instructions

USER MANUAL TC HUSQVARNA

1) The TC models are guaranteed

COMPETITION motorcycles exempt from functional defects, the suggested maintenance table for competition use is shown on page 282. SUPERMOTARD

2) TE and SMR are STREET LEGAL motorcycles

(with LIMITED POWER ENGINE); they are guaranteed exempt from functional defects and covered with legal guarantee, if the STANDARD CONFIGURATION is maintained and the suggested maintenance table, shown on page 288, is observed

WARNING Park the vehicle where it is unlikely to be bumped into or damaged. Even slight or involuntary bumps can cause the vehicle to topple over, with subsequent risk of serious harm to people or children. To prevent the vehicle from tipping over, never park it on soft or uneven ground, nor on asphalt strongly heated by the sun. Engine and exhaust pipes become very hot during riding. Always park your motorcycle where people or children can not easily reach these parts, in order to avoid serious burns.

3. Rear brake control pedal

7. Rear shock absorber spring

8. Rear shock absorber

compression damper adjustment (low and high damping speeds)

9. Rear shock absorber

extension damper adjustment

adjustment (front fork leg bottom side)

16. Extension damper

adjustment (front fork leg top side)

DIMENSION, WEIGHT, CAPACITY

1 - Unscrew the filler cap (1) on the

fuel tank then place the fuel cock (2) on OFF position;

2 - remove the fuel hose (3) from the

carburetor and insert the hose in a vessel; ATTENZIONE*: Fare attenzione a non toccare il motore caldo mentre si opera sul rubinetto carburante. Il rubinetto incorpora un filtro; l’accumulo di sporcizia provoca una diminuizione del passaggio di carburante verso il carburatore. E’ pertanto necessario effettuare la pulizia nel modo seguente:

3 - place the fuel cock (2) on ON position in order to eliminate the fuel

4 - Remove the fuel valve by removing the screws. Wash the fuel screen

filter in cleaning solvent.

5 - Reassemble the fuel valve in the

reverse order of removal. Turn the fuel valve "ON" and check for leaks.

8:44 Pagina 56 - The instrument functions are the following, as shown below.

10- SPEED / RPM (Indication

premuto per 3 secondi il pulsante SCROLL (A). Per conferma dell’avvenuta conversione si attiveranno, per 3 secondi, “SET” ed i segmenti Miles e mph oppure km e kmh; successivamente si tornerà alla funzionalità standard della figura 1. To replace kilometers with miles or miles with kilometers proceed as follows:

1) set to figure 1, stop the engine

and push the knob SCROLL (A).

2) start the engine while pushing

for 3 seconds the knob SCROLL (A). After the kilometers-miles or miles-kilometers setting operation, for 3 seconds, “SET” and miles/mph or km/kmh will be on. Pour passer de km au miles ou de miles à km procéder de la manière suivante:

(figure 3) - SPEED: motorcycle speedmaximum value: 299 kmh or 299 mph; - CLOCK: clock- Reading from 0:00 to 23:59:59 (the data will be lost after battery detachment). To reset the clock, push the knob SCROLL (A) for more than 3 seconds in order to increase the hours; release the knob and then, after 3 seconds, it is possible to increase the minutes; - RPM: engine r.p.m. shown on the vertical LED indicator.

999.9 km / miles (the data will be

numerical value) (figure 10) - SPEED: motorcycle speedmaximum value: 299 kmh or 299 mph; - RPM: engine r.p.m.; both vertical LED indicator and numerical value are on.

10- SPEED /RPM (Indication

The brake control lever (2) is located on the right hand side of the handlebar. The position of the throttle control can be adjusted by loosening the two fastenig screws (*).

13:38 Pagina 70 STEERING LOCK (TE-SMR) The motorcycle is equipped with a steering lock (1) on the R.H. side of the steering head tube. To lock it, procede as follows: turn the handlebar leftwards, place the key in lock and turn counterclockwise. Push the key inwards (if necessary, turn to and from). Turn the key clockwise and remove it from the lock. To unlock the steering lock, reverse the above procedure.

(TE-SMR) The right commutator has the following controls:

Selection control Low beam

Left turn signals (automatic return) Right turn signals (automatic return) To deactivate the turn signals, press the control lever after its returning to center. Warning horn

Lighting control of Low beams and High beam Lighting control of Position light

(TC) On the left side of the handlebar, near the clutch control, is located the engine stop button.

13:38 Pagina 76 REAR BRAKE CONTROL The rear brake control (1) is placed on the right-hand side of the motorcycle. On models TE and SMR as stop switch, during the braking action, causes the rear light to come on.

The lever (1) is placed on the lefthand side of the engine. The operator must release the lever after each gear change to allow it to return to its central position before another gear change can be made. Neutral position (N) is between first (low) and second gears. First gear is engaged by pushing the lever downwards; all the other gears are engaged, by pushing the lever upwards. The position of the gear shift lever on the shaft can be varied by: - loosening screw; - pulling lever out; - placing lever in new position on the shaft when the operation is over tighten the screw and then tightening the screw.

A. Engine-transmission oil level B. fuel level C. coolant level Make sure all caps are properly adjusted. WARNING*: Don’t remove radiator cap when hot!

2. Check all controls

A. Throttle handgrip B. Clutch lever Make sure cables are not damaged and turn smoothly.

Look for brake fluid leaks and worn hoses. Check for proper functioning.

Check spokes and look for worn bearings. Check rims and tyres. Check tyre pressure.

6. Check chain rollers and sprockets

Check wear on chain rollers and sprockets Ensure chain is correctly adjusted and lubricated.

7. Check air filter and intake system

Check that air filter is clean Check all rubber connections and clamps.

8. Check exhaust system

Check hook up, look for cracks Check muffler.

11. Check the electric system (TESMR). Start the engine and check that

the front and rear lamps, the stop light, the turn signals the cluster warning lights and the horn are working correctly.

5) tirare la leva (4) della

frizione. ENGINE START (TE-SMR, SMR 400 excluded) With cold engine, as after a prolonged inactivity of the motorcycle or in presence of a low external temperature, proceed as follows:

1) set fuel cock in ON position;

2) shift gear pedal (1) in neutral

4) turn twice completely the

frizione; In case of difficult starting with warm engine, or after an upset, proceed as follows:

5) mantenendo leggermente aperta la

manopola del comando gas; 15:16 Pagina 88 ENGINE START ( SMR 400 ) With cold engine, as after a prolonged inactivity of the motorcycle or in presence of a low external temperature, proceed as follows:

1) set fuel cock (1) on ON position;

2) shift the transmission lever (A)

into neutral position;

3) pull the black starter knob (2);

4) turn twice completely the throttle

5) while mainteining slowly open

the throttle control grip;

WITH WARM ENGINE, DO

NOT CARRY-OUT ITEMS no. 3 AND 4.

1) set fuel cock on ON position;

4) lower the starter pedal (4)

until a certain resistance is noticed (piston at T.D.C.);

5) pull the lever (5) and lower

further, by a limited stroke, the pedal until the abovementioned resistance is overcome (surpassing of T.D.C.);

6) at this point, release the lever

(5) and the pedal (4);

7) in the case of COLD

STARTING, completely rotate the throttle (6) twice (in the case of warm starting DO NOT carry out this operation);

8) COMPLETELY lower the

pedal (4) until the engine starts.

- SPOKE TENSION OF WHEELS

CHECKING THE OIL LEVEL

By keeping the motorcycle on a flat surface, in vertical position, remove the control screw (1) and check the oil should just barely escape from the hole on the R.H. cover. To fill up, remove the filler cap (2).

ENGINE OIL REPLACEMENT

AND BAG FILTERS-FILTER

CARTRIDGE CLEANING OR

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 10 mm above cells and besides, on TE and SMR models, it doesn't exceed the middle of the expansion tank (2) located in front of the rear shock absorber. The radiator cap is provided of two unlocking positions, the first being for the previous pressure discharge in the cooling system.

THROTTLE CABLE ADJUSTMENT

To check the correct adjustment of the throttle operate as follows: - remove the upper rubber cap (1); - by moving cable (2) back and forth check for 2 mm. clearance; - should the clearance be incorrect, unblock the counter ring-nut (3) and turn the adjusting screw (4) (by unscrewing it, the clearance is reduced, while by screwing screw (4) it is increased); - tighten the counter ring-nut again (3).

(SMR 400 excluded) Adjust the carburetor with warm engine and with the throttle control in closed position. Proceed as follows: - Turn slow running adjusting screw (1) on the left side of the bike, near the fuel cock (turn the screw clockwise to increase the rpm, and anticlockwise to descrease the rpm).

SMR 400 Adjust the carburetor with warm engine and with the throttle control in closed position. Proceed as follows: - Turn slow running adjusting screw (1) on the left side of the bike, near the fuel cock (turn the screw clockwise to increase the rpm, and anticlockwise to descrease the rpm).

13:41 Pagina 110 WARNING*: Exhaust gas contains poisonous carbon monoxide gas. Never run the engine in a closed area or in a confined area.

Use NGK CR8EB spark plug; the gap is 0.027 in. A wider gap may cause difficulties in starting engine and in overloading coil. A gap that is too narrow may cause difficulties when accelerating, when idling the engine or when performing at low speeds. Clean the dirt away from the base of the spark plug before removing it from the cylinder. It is very useful to examine the state of the spark plug just after it has been removed from the engine since the deposits on the plug and the colour of the insulator provide useful indications. Correct heat rating: The tip of the insulator should be dry and the colour should be light brown or grey. High heat rating: In this case, the insulator tip is dry and covered with dark deposits. Low heat rating: In this case, the spark plug is overheated and insulator tip is vitreous, white or grey in colour. ATTENTION * : Puisque les gaz d’échappement contien-nent monoxyde de carbone, il est avis de ne jamais tourner à vide le moteur dans des milieux fermés.

Turn rear pin (1) counterclockwise, remove the saddle from the front afstening screw. Turn forward the housing box complete with the battery (1) (it is not necessary to remove the battery from its housing box). To gain access to the air filter, lift a little the electronic power unit (2). Remove screw (3) and the filter (4). Separate filter (5) from frame (6).

AIR FILTER AND CLEANING

Wash the filter with a specific detergent (AGIP” Filter clean foam air detergent fluid” or similar) then dry it fully (wash filter with gasoline only in case of necessity). Plunge the filter in special oil for filters (AGIP "Foam air filter protection oil" or similar), then wring it to drain superfluous oil. CAUTION*: Do not use gasoline or a low flash-point solvent to clean the element. A fire or explosion could result. CAUTION*: Clean the element in a well ventilated area, and do not allow sparks or flames anywhere near the working area. ASSEMBLY To ensure tight fit, slightly (C) grease filter edge on side facing filter housing. While re-inserting the filter into its housing, make surs that piece A is turned upwards and edge B is on the left lower side of the filter case. Reassemble the parts previously removed (battery: connect the positive cable first). CAUTION*: If the element assembly is not installed correctly, dirt and dust may enter and the engine resulting in rapid wear of the piston rings and cylinder.

ADJUSTMENT To ensure maximum safety, the steering wheel should always be regulated so that the handlebars steering the motorcycle rotate freely without play. To check steering wheel adjustment, place kick stand or other support under the engine so that the front wheel is raised from ground. Place slight pressure on the tips of the handlebars to rotate steering wheel; the handlebars should also rotate without effort. Stand in front of the motorcycle and grasp the lower end of the fork rods sliders moving them in the direction of their axis.

LEVEL On the SMR model the lever position can be adjusted (4 adjustments) for any driver hand size. To decrease the lever distance from the handle grip, turn the adjuster (B) CLOCKWISE. To increase the lever distance from the handle grip, turn the adjuster (B) COUNTERCLOCKWISE. On the TE and TC models the adjuster (2), located on the control lever, allows adjusting of the free play (a). Free play (a) must be at least 3 mm (0.1 in.). The level of the fluid in pump reservoir must never be below the minimum value (1), which can be checked from the window on the rear side of the pump body (TE, TC). For SMR model, check the level on the fluid reservoir. A decrease of the fuel level will let air into the sustem, hence an extension of the level stroke. ATTENZIONE*: Se la leva del freno risulta troppo “morbida”, si è in presenza di aria nella tubazione o di un difetto dell’impianto. Essendo pericoloso guidare il motociclo in queste condizioni, fare immediatamente controllare l’impianto frenante presso il Concessionario Husqvarna. WARNING*: If the brake lever feels mushy when it is applied, there may be air in the brake lines or the brake may be defective. Since it is dangerous to operate the motorcycle under such conditions, have the brake checked immediately by an authorized HUSQVARNA dealer.

POSITION ADJUSTMENT The position of the rear foot brake pedal as to the footrest may be adjusted according to the individual needs. For the adjusting proceed as follows: - loosen the screw (1); - turn the cam (2) in order to adjust the brake pedal idle stroke (A);- the operation done, tighten the screw (1). The adjusting operation carried out, adjust the idle stroke of the pedal as indicated in page 128.

ADJUSTMENT The rear brake foot pedal should have a (B) 5 mm (0.2 in.) idle stroke before starting the true braking action. Should this not happen as follows: - loosen nut (3); - operate the pump rod (4) to increase or decrease the idle stroke; - tighten nut (3) at the end of the operation.

The level (A) must be set between the pump tank notches of MIN and MAX.

LEVEL Free play (A) must be at least 3 mm (0.1 in.). The lever position can be adjusted for any driver hand size. To decrease the lever distance from the handle grip, rotate the adjuster (B) CLOCKWISE. To increase the lever distance from the handle grip, rotate the adjuster (B) COUNTERCLOCKWISE. To check the fluid level, proceed as follows: - remove screws (1), cover (2) and rubber pump diaphragm on the handlebar clutch control; - by keeping the master cylinder (3) in horizontal position, check the fluid level is NOT BELOW 4 mm (0.16 in.) from the upper surface (D) of the pump body; - if necessary, add fluid until the correct level is reached (see TABLE FOR LUBRICATIONSUPPLIES for the fluid type page 44) CAUTION *: NEVER use brake fluid. Reassembly the removed parts using the reverse procedure. Periodically check the connecting hose (see “Periodical maintenance card”): if the hose (C) show is bent or cracked, its replacement is advised,

CONDITIONS The following information is a useful guide for setting up the suspensions according to the road conditions. Always start from the standard calibration before making any change on the suspensions. Afterwards, increase or decrease the adjusting clicks one at a time.

15:26 Pagina 138 ADJUSTING THE COMPRESSION FORK a) COMPRESSION (LOWER REGISTER) Standard calibration: -20 clicks (TC); Standard calibration: -12 clicks (TE-SMR). Remove plug (B) and turn register (A) clockwise until the position of fully closed is reached then, turn back by the mentioned clicks.To obtain a smoother braking action, turn the register anticlockwise. Reverse the operation in order to obtain a harder action. b) EXTENSION (UPPER REGISTER) Standard calibration: - 10 clicks (TE 250); Standard calibration: - 12 clicks (TE-SMR 450, 510; TC). To reset standard calibration turn register (C) clockwise to reach the position of fully closed; then, turn back by the mentioned clicks. To obtain a smoother braking action, turn the register anticlockwise. Reverse the operation in order to obtain a harder action. c) AIR VENT (to carry out after each competition, or monthly). Set the motorcycle on a central stand and release the fork fully and loosen the air vent valve (D). Once this operation is over, tighten the valve.

WARNING: Never force the adjusting screws beyond the maximum opening and closure positions.

For the regular fork operation, both legs must be provided with the necessary oil quantity. Remove the forkrods form the fork to check the oil level inside the forkrods. Work as follows: - remove the power rod caps; - remove springs from the stems letting the oil drop into the latter; - bring forks to stroke end; - check that the level is at distance “A” below the upper limit of rods.

HEIGHT CHANGE The handlebar position (a) and height (b) can be changed for better suiting Your driving requirements. To effect these operations, remove the upper screw (3), upper clamp (1), lower screw (4) then lower clamp (2). a) Handlebar position change Turn the lower clamp (2) 180° to move forward or backward (10mm- 0.04in.) the handlebar position with respect to the original setup. b) Handlebar height change Remove the lower spacer (A) then replace the screw (4) with a new one of L=65 mm (2.56 in.) height. Once these operations are completed, tighten the screws (3) to 2,75-3,05 kgm (27-30 Nm; 19.9-22 Lb/fts) and the screws (4) to 2,0-2,2 kgm (19,621,6 Nm; 14.5-15.9 Lb/fts).

ABSORBER The rear shock absorber must be adjusted according to the rider weight and track conditions. Proceed as follows:

1. With motorcycle on the stand,

measure distance (A).

2. Take the normal riding position

on the motorcycle with all your riding apparel.

3. With somebody’s help, take

the new distance (A).

4. The difference between these

two measurements constitutes the “SAG” of the motorcycle’s rear end. Suggested SAG: 4 in. with cold shock absorber. 3.7 in. with warmed up shock absorber.

5. To get the right SAG according

to your weight, adjust the shock absorber spring preload (page 146). REGLAGE DE L’AMORTISSEUR Régler l’amortisseur arrière selon le poids du conducteur et suivant les condition du sol. Agir comme suit:

1. First turn counterclockwise

fastening rear pin (1) then remove saddle, screws (2) and R.H. side panel (3).

2. Clean ringnut (1) and adjusting

nut (2) of the spring (3).

3. Either with a hook wrench or

an aluminium punch, loosen the ringnut .

4. Turn the adjusting nut as

5. When the adjusting operation

is over (according to your weight and riding style), tighten the ringnut. (Torque for both ringnuts: 5 Kgm; 49 Nm; 36.2 ft/lb).

6. Reassemble R.H. side panel

ADJUSTMENT (BEFORE the following operation, please see the IMPORTANT NOTICE 2) on page 12 Adjustment of the compression stroke is independent from the rebound stroke. A) COMPRESSION - Standard calibration:

1) Low damping speed:

TE-TC: -15 clicks (± 2 clicks) SMR: -5 clicks (± 2 clicks ) (register 4)

2) High damping speed:

15:46 Pagina 150 CHAIN ADJUSTMENT Chain should be checked, adjusted and lubricated as per the Maintenance Chart to ensure security and prevent excessive wear. If the chains becomes badly worn or is poorly adjusted (i.e., if it is too loose or too taught), it could escape from sprocket or break. To adjust the rear chain it is necessary to lower the rear part of motorcycle so to line up the drive sprocket axle, the rear swing arm axle and the rear wheel axle as shown on drawing. Than let turn three times the rear wheel. Now the chain should not be tight. (Fig. A). Fast adjustment (Fig. B.). Push the chain towards the final part of runner and check that between the two elements a distance "A" from 0 to 2 mm (0.08 in.) is present. If this is not the case, go on as follows: - unloose the fastening nut (1) of the wheel axle on the R.H. side; - Unloose the lock nuts (2) on both chain adjusters and turn the screws (3) to obtain the correct tension value; - Tighten the lock nuts. After adjustment check that the wheel is lined up and tighten its axle.

CHECKING THE WEAR OF CHAIN, PINION

AND SPROCKET Proceed as follows: - Fully stretch the chain with the adjusting screws. - Mark 20 chain links. - measure the distance “A” between 1st pin center and 21 st pin center.

2 - Check that the chain is neither worn out nor

damaged. If the rollers or the links are damaged, replace the chain by following the instructions given in the Periodical Maintenance Table. 3 -Check that neither the sprocket nor the crown are damaged. 4 -Wash and clean the chain as described hereunder. Washing the chain without OR Wash using either oil or diesel oil. When using gasoline or tricloroetilene, clean and lubricate the chain to prevent oxidation. Washing the chain with OR Wash using oil, diesel oil, or paraffin oil. Never use gasoline, tricloroetilene, or solvents, as the OR may suffer damages. Use instead special sprays for chains with OR. Lubricating the chain without OR First dry, then plunge the chain in a bisulphide molybdenum lubricant, or in high viscosity engine oil. Warm up the oil before use. Lubricating the chain with OR Lubricate all metallic and rubber (OR) elements using a brush, and use engine oil with SAE 80-90 viscosity for the internal and external parts.

5 - If the chain has been cut, reassemble

using a joint. 6 -Assemble the joint spring by turning the closed side to the chain direction of rotation as shown in figure (page 155).

WARNING: The chain oil has

2- Chain driving roller

0.12 in. (TC,TE); 0.08 in.(SMR)

AVANT 3 mm (TC,TE); 2 mm (SMR) POSTERIORE 3 mm (TC,TE); 2 mm (SMR) REAR

0.12 in. (TC,TE); 0.08 in.(SMR)

2. Front brake pump with oil reservoir (TE,

2. Front brake pump (SMR)

2A. Oil reservoir (SMR)

4. Front brake caliper

6. Rear brake oil tank

11. Rear brake control pedal

Measure the thickness of each disc at the point where it has worn the most. Replace the disc if it has worn past the service limit.

15:47 Pagina 176 DISC CLEANING Poor braking can also be caused by oil on the disc. Oil or grease on the disc must be cleaned off with a high flash-point oil free solvent, such as acetone or lacquer thinner.

• Use only brake fluid from a sealed container (DOT 4). Never use old brake fluid.
• Never allow contaminants (dirt, water, etc.) to enter the brake fluid reservoir.
• Don't leave the reservoir cap off any length of time to avoid moisture contamination of the fluid.
• Handle brake fluid with care because it can damage paint.
• Don't mix two types of fluid for use in the brake.This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake part to deteriorate. ATTENTION!
• Utiliser seulement du fluide pris d’un récipient sigillé (DOT 4). Ne jamais utiliser du fluide usé.

15:47 Pagina 184 WARNING! Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.

• Brake fluid may cause irritation. Avoid contact with skin or eyes. In case of contact, flush thoroughly and call a doctor if your eyes were exposed. Periodically check the connecting hoses (see “Periodical maintenance card”): if the hoses (A) and (B) are worned or cracked, their replacement is advised. ATTENTION! Puisque le fluide des freins ronge rapidement les surfaces vernissées, nettoyer soigneusement les parties intéressées.
• Ce fluide peut causer des irritations. Eviter donc tout contact avec la peau et les yeux. En cas de contact, nettoyer soigneusement la partie intéressée, et s’il s’agit des yeux, appeler le docteur. Vérifier souvent les manchons d’assemblage (voir " Fiche d’entretien périodique "): si sur les tuyanteries (A) et (B) il y a des signes d'usure ou ruptures, il sera nécessaire les remplacer. ACHTUNG! Die Bremsfluessigkeit greift lackierte Oberflaechen schnell an; evetuelle Spuren sofort beseitigen.

BLEEDING (TE, TC) The braking system must be bled after the fluid replacement or when, due to air in the circuit, the lever stroke is long and spongy. Proceed as follows:

BLEEDING (SMR) The braking system must be bled after the fluid replacement or when, due to air in the circuit, the lever stroke is long and spongy. Regarding the front braking system, first proceed to bleed the upper braking system control (bleeding valve 1), then the brake caliper (bleeding valve 1A). In both cases, proceed as follows:

Pagina 194 WARNING! During the bleed operation the fluid level inside the reservoir must never be lower than the minimum level. Tightening torque for bleed valve is 1,2 ÷ 1,6 kgm (12 ÷ 16 Nm; 8.8 ÷ 11.8 ft-lb). As the braking fluid is a very corrosive substance, in the case it comes in contact with your eyes wash them abundantly with water. During the bleeding of the braking circuit keep the handlebar turned leftwards. This is the way to lift the pump tank and to make easier the bleeding of the braking system. If the lever stroke gets stretchy and the braking action results as poor in the case of falls during competitions, or after repair work in shops, repeat the bleeding operation described above. As the bleeding operation does not fully eliminate the air inside the circuit, the small quantity of air remaining inside will be eliminated after a short time of use of the brake. In this case however, the action of the lever will be harder and the stroke shorter. ATTENTION! Pendant l’opération de curage le niveau du fluide, à l’intérieur du réservoir, ne doit jamais se trouver au dessous de la coche du minimum. Couple de serrage pour la soupape de curage: 1,2 ÷ 1,6 kgm (12 ÷ 16 Nm; 8.8 ÷

BLEEDING The braking system must be bled after the fluid replacement or when, due to air in the circuit, the pedal stroke is long and spongy. To bleed the system: - Remove the reservoir cover rubber boot and top up with (DOT

- Attach a clear plastic hose to the bleed valve (1) on the caliper and turn the other end of the hose into a container. - Depress the pedal (2) and keep it full down. - Loosen the bleed union letting out fluid (at first, only air will come out), then, closing the union slightly. - Release the pedal and wait for a few seconds before repeating the operation until only fluid come out of the tube. - Close the bleed union to the prescribed torque and check the fluid level (A) inside the reservoir before replacing the cap. If the bleeding operation has be done correctly, the pedal will have no mushy feel. If not, repeat the operation.

deadening material after every competition and replace it if necessary.

DEADENING MATERIAL First turn counterclockwise fastening rear pin (1) then remove saddle, screws (2) and R.H. side panel (3). Unhook springs (4) fastening the muffler (5) to the exhaust pipes. Remove the two screws fastening the muffler to the rear frame. Remove the six rear rivets (6), clamp and the exhaust terminal (7). Remove innner pipe and replace the deadening material. Reassemble R.H. side panel and saddle.

GROOVE CLEARANCE Use a feeler gauge to check the axial play (H) of the rings in the groove. The “TOP” marking should always be uppermost.

CLEARANCE IInsert the piston ring into the cylinder top (hold the piston ring with the piston), position it well in "square" and measure the distance (A) between the two piston ring end gap.

When assembling, the coupling play must be 0.012÷0.027 mm. The maximum wear limit allowed is 0.055 mm.

13:50 Pagina 224 WHEEL SPOKES Check to make sure that all the nipples are tight; tighten them if necessary. Remember that an insufficient stretch jeopardizes the motorcycle stability. For an instant check, use a metal point (for instance, a screwdriver) to beat the spokes with. A live sound accounts for an accurate tightening, while a dull sound means that a new tightening is necessary.

Blu/ Blue/ Bleu/ Blau/ Azul

Blu/ Blue/ Bleu/ Blau/ Azul

Blu/ Blue/ Bleu/ Blau/ Azul

REPLACEMENT (TE- SMR) Remove the two fastening screws (1) in the inner side of the rear fender and the lens (2). Pull the lamp (3) inside, turn it counterclockwise then remove it from the lamp holder. After replacement, reverse operations for reassembly. NOTES: make sure not to tighten the screws excessively. REMPLACEMENT DES

Chiave candela (TE-TC-SMR) TOOLS SUPPLIED The motorcycle comes with the following tools:

Box wrench 15x27mm (TE-TC-SMR)

Front wheel axle wrench (TC)

Front wheel axle screw Allen wrench (TC)

6- Rear shock absorber oil

5- Front fork oil (1000 cm3 container)

8- Rear shock absorber spring

Rear shock absorber spring (K=5,0 Kg/mm)

Rear shock absorber spring § (K=5,2 Kg/mm)

Muelle amortiguador K=5,0 Kg/mm)

9- Rear shock absorber spring

5- Front fork oil (1000 cm3 container)

6- Rear shock absorber oil

8- Rear shock absorber spring

13:57 Pagina 268 APPENDIX

AFTER-RACE CHECK POINTS

After racing, first clean the motorcycle and then inspect the entire motorcycle, with special attention to the items listed in «MAINTENANCE» table (page 296, 292), such as the air cleaner, carburetor, brakes, etc. Carry out general lubrication, and make adjustment as necessary. STORAGE When the motorcycle is to be stored for any length of time, is should be prepared for storage as follows: - Clean the entire motorcycle thoroughly. - FIRST carry out the operation mentioned hereunder, then fill the tank with fuel mixed with a stabilizer: place the hose (1) in a basin, loosen the drain screw (2) set on the lower side of the basin, then drain the fuel and tighten the screw again. WARNING Never litter the environment with fuel, and let the engine running in open air, never in closed rooms. APPENDICE

CONTROLES APRES CHAQUE

1) Preparation for washing

Before washing, precautions must be taken to keep water out of the following places: Rear opening of the muffler : - Cover with a plastic bag secured with rubber bands. Clutch and brake levers, hand grips, engine stop button: - Cover with plastic bags. Air cleaner intake: - Close up the opening with tape, or stuff in rags.

2) Where to be careful

Avoid spraying water with any great force near the following places: Air cleaner Under the fuel tank: If water gets into the ignition coil or into the spark plug cap, the spark will jump through the water and be grounded out. When this happens,the motorcycle will not start and the affected parts must be wiped dry. Fork head, wheel bearings. Rear suspension links.

12a-senza tabelle-2004-OK 23-06-2005 13:57 Pagina 276 Noise emission warranty MV Agusta Motorcycles S.p.A. warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers. Warranty claims should be addressed to Cagiva U.S.A. 2300 MARYLAND ROAD.

WILLOW GROVE, PA 19090-4193

215-830-3300 Tampering warning Tampering with Noise Control System Prohibited. Federal law prohibits the following acts or causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, and (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below.

1) Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust

2) Removal or puncturing of any part of the intake system.

3) Lack of proper maintenance.

4) Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. Warning statement This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances. SPARK ARRESTER The TE/SMR models are equipped with a U.S. Forest Service approved spark arrester for maximum efficienty and performance.

Proceed as follows: A: First turn counterclockwise fastening rear pin (1) then remove saddle, screws (2) and R.H. side panel (3). Unhook springs (4) fastening the muffler (5) to the exhaust pipes. B: Remove the two screws fastening the muffler to the rear frame. Note*: If silencer or exhaust are difficult to remove, help to slide them apart by tapping gently with a rubber or plastic hammer. C: remove the six rivets (6) and the endcap (7) from silencer’s body; D: examinate SPARK ARRESTER conditions and remove, if necessary, carbon particles from the SPARK ARRESTER screen; E: if necessary, inflate air on the SPARK ARRESTER screen, in the opposite direction in respect of the exhausted gas flow; F: assemble the front endcap on the silencer’s body, mounting the screws in the correct position, providing a tight connection between endcap and silencer’s body, using, if necessary, a silicone paste; G: re-assemble the silencer on motorbike, then R. H. side panel and saddle. Due to the SPARK ARRESTER position on the silencer, if you need only to check the SPARK ARRESTER conditions you can: A: disassemble the silencer from motorbike; B: check SPARK ARRESTER conditions simply looking into the silencer from front endcap opening; C: if the check is positive, you can proceed in re-assembling the silencer on the motorbike; D: if the check is negative, proceed with the maintenance and cleanout procedure.

SMR Tampering Warning: Tampering with Noise Control System Prohibited. Federal law prohibits the following acts or causing therefor: 1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, and

2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below.

1) Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases.

2) Removal or puncturing of any part of the intake system.

3) Lack of proper maintenace.

4) Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalities under state and local ordinances.

Description Operation Engine oil Two-stroke mix oil level Coolant Cooling system Electric fans Spark plugs Throttle body / Carburettor Brakes / Clutch fluid Brakes / Clutch Brakes / Clutch Throttle control Throttle control Choke control Flexible controls and transm. Drive chain Check level Check level Check / Restore level Check for leakage Check operation Check / Replace Check and adjust Check level Check operation Check lines for leakage Check operation Check / Adjust play Check operation Check / Adjust Check / Adjust : presenti solo sui motocicli con motore a 2 tempi : presente solo su alcuni modelli Pre-delivery

Description Tyres Side stand Side stand switch Electrical equipment Instrument panel Lights / Visual signals Horn Headlight Ignition switch Locks Screws and nuts Hose clamps General lubrication General test Operation Check pressure Check operation Check operation Check operation Check operation Check operation Check operation Check operation Check operation Check operation Check / Tighten Check / Tighten Pre-delivery

: only for motorcycles with 2 stroke engine : only for some models

- STANDARD MOTORCYCLE, STREET LEGAL (with LIMITED POWER ENGINE):

- STANDARD MOTORCYCLE, STREET LEGAL (with LIMITED POWER ENGINE):

- STANDARD MOTORCYCLE, STREET LEGAL (with LIMITED POWER ENGINE):