SMR 510 - Motorcycle HUSQVARNA - Free user manual and instructions

USER MANUAL SMR 510 HUSQVARNA

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Capl GB 19-07-2007 10:35 Pagina 2 PRESENTATION Welcome to the Husqvarna motorcycling Family! Your new Husqvarna motorcydle is designed and manufac- tured to be the finest in it field. The instructions in this book have been prepared to provide a simple and understandable guide for your motorcycle's opera tion and care. Follow the instructions carefully to obtain maximum perfor- mance and your personal motorcydling pleosure. Your ouner's manual contains instructions for owner care and maintenance. Information covering repair of major units such as engine, transmission, el. is provided in the Husqvarna Service Manual. The information concerning details or main work of repair or maintenance are described in the Husqvarna Service Manual. This manual is available upon request by stating the code number set on pages 95, 96, 7, 98. Work of this kind requires the attention of a skilled mechanic and the use of special tools and equipment. Your Husqvama dealer has the facilities, experience and original paris necessary to properly render this valuoble service. This “Owner’s Manual” and the “Purchase Registration Booklet”’ are parts and parcels of the motorcyde, hence, they have to re- main with the motorcyde even when sold to another user.This “Owner’s Manual” and the ‘Purchase Registration Booklet” are parts and parcels of the motorcyde, hence, they have to remain with the motorcycle even when sold to another user. This motorcyde uses components designed thanks to systems and state of he art technologies which are thereafter iested in competition. In compefition motorcydes, every detail is verifie after euch race in order to always guarantee better performance. For correct func- tioning of the vehicle, it is necessary to follow the maintenance and control table found on Appendix À. 21: IMPORTANT NOTICES

1) The FC and TXC models are guar-

anteed COMPETITION motors ex- empt from fundtional defects, the sug- gested maintenance table for compe- fition use is shown on Appendix À. 2] TE and SMR are STREET LEGAL motors (with LIMITED POWER EN. GINE}; they are guaranteed exempt from fundional defects and covered with legal guarantee, if the STAN- DARD CONFIGURATION is maintained and the suggested maintenance able, shoum on Appendx À (page A8) is ob- served. AÉTE and SMR are transformed in COMPETITION MOTORCYCLES {with FULL POWER ENGINE), he suggested maintenance table for competition use is shown on Appendix À.

Capl_GB 19-07-2007 10:35 Pagina 3 IMPORTANT The reference fr recognition of he guarantee vil be the MO- TORCYCLE CONFIGURATION, as shown below: A) STANDARD MOTORCYCLE, STREET LEGAL: with LIMITED POWER ENGINE B) COMPETITION MOTORCYCLE, RACING USE: with FULL POW- ER ENGINE This motorcydes was not designed for long trips with the engine always at maximum rpm as can occur whilst travelling on roads or highways. Long trips at full throttle can «use severe damage to the engine. This motorcydes is setup for competition use and therefore guarantees maximum performance with the rider alone. It is thereby not recommended to use the vehi- de on drcuits or off-road with a passenger. ALWAYS Keep in mind that these motoreydes have been de- signed stricly for competition use, that is, for conditions of usage very different from those presented an he rond. ALWAYS keep in that these motorcy- des have been designed stridtly for compe- tition use, that is, for conditions of usage very different from those presented on the road. In order to maintain the vehicles “Guarantee of Fundionality", the dient must follow the maintenance program dicated in the user's manual by carrying out maintenance checks at authorized HUSQVARNA dealers. The cost for substitut- ing parts and for the labour necessary in order to resped the maintenance plan, is charged to the dient. NOTE: the guarantee is EXTINGUISHED in the «ase where the motorcyde is rented. Important Notice Read this manual carefully and pay special attention to state- ments preceeded by the following words: Warning*: Indicates a pos: personal injury or loss of lifi are not followed. Caution*: Indicates a possibility of person- al y or equipment damage if instruc- tions are not followed. Note*: Gives helpful information. Parts Replacement When parts replacement is required, use only Husqvarna ORIGINAL parts. Warning*: After an upset, inspect the mo- torcyde carefully. Make sure that the throttle, brake, dutch and all other sys- tems are undamaged. Riding with a dam- ages motorcycle can lead to a serious «ash. Warning*: Never attempt to start or op- erate your motorcydle unless you are wearing appropriate protective dothing. Always wear a motorcyde helmet, motor- de boots, gloves, goggles and other ap- propriate protective dothing. Warning*: This motorcyde is a state of the art competition bike. Do not attempt to start or ride this motorcyde until you have received expert instruction and are in excellent physical condition.

PRECAUTIONS FOR CHILDREN WARNING

Pak le voie where niet be bumped into or damage. Even sg or mount bumps con cute de vehicle otople over, wi subequent ik of ris am peu or chdren. (@ To prevent he vehide from Hipjing over, never park am Bot or uneven ground, nor on asp tongly heu te y esun. Engine and exhaust pipes become very ht during ding. Aways park your motorcyce where people or cl. den can not euslÿ reach these paris, in order to avoid serious bus.

CONTROLS 1 RIDING. SERV . IGNITION SYSTEM/ELETTRICAL SYSTEM. SPECIAL TOOLS . TIGHTENING TORQUES KITS... OPTIONAL PARTS LIST . APPENDIX.… PRE-DELIVERY NOTE FOR USA/CDN- AUS MODELS. ALPHABETICAL INDEX . PERIODIC MAINTENANCE ADJUSTMENT. Note © References to the “left” or “right” of the motorcyde are in the sense of a person facing forwards. ee. number of teeth © Austria AUS: Australin : Belgium BR Brazil CON: Canada CH: Svitzerland D: Germany E Spain FE France FIN: Finland GB Great Britain E Haly k Japan USA: United States of America @ Mere not specified, all the data and the instructions are referred to any and ll Countries,

Capl_GB 19-07-2007 10:35 Pagina 5 . | IDENTIFICATION DATA The engine number s printed on the upper side of the engine case, whereas he frame number is printed on 1he steering tbe. Always state the number stamped on the frame {und write it on this booket), when plaing orders for spare parts, or when asling or information on your motocycle. VEHICLE IDENTIFICATION NUMBER (V.L.N.) The Hull 17 digit serial, or Vehicle Identification Number, is stamped on te seering hend tube (RL. side). 1 Frame serial number

Model year (2008)(@)

3. Rear brake control pedal T1.Cutch control lever

Displacement (510) 30.56 cu. in Compression ratic 12,9: Starting (TC). ck start (with automatic decompressor) Starting (SMI lecric (with automatic decompressor) Starting (TE-TXC) lectric and kick start [with automatic decompressor) TIMING SYSTEM Type. double overhead camshaft; 4 valve Valve dearance [with engine cold)

PAR Cap1_cB FINAL RATI 1st gear [TE-TXC 250) . st gear [TE-TXC 450-510) 1st gear [TC 250] 1st gear (TC 450] st gear [TC 510] 1st gear [SMR 4: 2nd gear And gear And gear And gear And gear And gear 3rd gear 3rd gear 3rd gear [TC 3rd gear 3rd gear 3rd gear Ah gear Aïh gear Aïh gear Aïh gear Aïh gear Aïh gear Sth gear Sth gear Sth gear [TC Sth gear Sth gear Sih gear 6ïh gear 6ïh gear 6ïh gear 19-07-2007 10:35 Pagina 11 10S TC 510 SR 450-510). (ETC 250) SMR 450-510) . FRAME Type. …Steel single tube cradle fout recangin: ellipsoidal tubes); light alloy rear frame FRONT SUSPENSION Type …"Upside-Doun” telescopic hydraulic front fork with advanced axe (adjustable in compression and rebound stroke]; stanchions

DIMENSION, WEIGHT, CAPACITY

Wheelbase (TCTETXC) Wheelbase (SMR] Overall length (TC). Overall length (TE).. Overall length (SMR} Overall length (TXC). A2in. Overall width 32.28 in Overall height (TC-TE:TXC) 50.59 in. Oral eight (SUR). Saddle height (TC). Sadele height (TE-TKC Saddle height (SMR) Minimum ground clearance (TCTKCTE) . Minimum ground clearance (SMR) Dry weight (TC 250) Dry weight (TC 450) Dry weight (TC 510) Dry weight (TKC 250) . Dry weight (TKC 450) . Dry weight (TKC 510) Dry weight, “ready to race” (TE 250 LE. Dry weight, “ready to race” (TE 450-510 1] Dry weight, “ready to race” [SMR 450-510 1. Coolant capacity. JS. Quarts .16+1.37 Transmission oil Oil and oil filter replacement …Imp. Quarts 1.5U.S. Quarts 1.8 Oil replacement . Imp. Quarts 1.3U.S. Quarts 1.6

TABLE FOR LUBRICATION, SUPPLIES

Final drive chain lubrication

Fillers for radiator

Cap2_cB 9-07-2007 16:20 Pagina 13 CONTROLS FUEL COCK (TC-TXC) The leftside tap (2) is a crew tap: crew the ring nut {A} to dose the tap, loosen the ring nut to open the tap. WARNING*: Be careful not to touch the hot engine while operating the fuel valve. A fuel filter is incorporated in the fuel valves. Accumulation of dirt in the filter will restrict the low of the fuel to the carbure- or. Therefore, the fuel filter should be serviced periodically.

Loosen the input plug (1) on he fuel tank and lose He top; Remove the fuel hose (3) from the crburetor and insert he ose in avessel: Open the tp and drain he fuel out af the tank, Remove 1h fuel vale by removing the sreus. Wah he fuel streen fier in ceaning salvent Reassembe the fuel vale in 1he reverse order of removal. Open the tp and check for lens. FUEL INJECTION ENGINE (TE-SMR) On vehides which are Hited with a fuel injection engine, the fuel pump is uit nt he fuel tank and there is no tap mount ed on he fuel supply system. The quantity of remaining fuel is E | indicated on the digital dash-board by the special warning light [see on page 16).

Cap2 GB 9-07-2007 16:20 Pagina 14 SIDESTAND A sidestand (1) is supplied with every motorcyce. WARNING*: The stand is designed to sup- port the weight of the MOTORCYCLE ONLY. Do not sit on the motorcyde using the stand for support as this could cause structural failure to the stand and could cause serious bodily injury. Peridicll check he side stand {see “Perodicl maintenance card}; check that the springs are not damaged and that the side stand freely moves, the side stand is nos, lubricate the fastening pivot (A). FUEL Recommended fuel: premium grade unleaded fuel. (R.O.N. Note*: Do not continue operation if the en- gine pings or knocks. The engine will be da- maged and could seize. WARNING*: If "knocking" or "pinging" oc- eurs, try a different brand of gasoline or hi- gher octane grade. WARNING*: Gasoline is extremely flamma- ble and can be explosive under certain con- ditions. Always stop the engine and do not smoke or allow flames or sparks in the area where the motorcyde is refueled or gasoline is stored. WARNING*: Do not overfill the tank. After refueling, make sure the tank cap (1) is do- sed securely. [TC-TXC/ CLLLCCRERLELLCECEEEEE CELL CLEECEECECCEEEE EEE EE EEE EEE EEE EEE EEE EEE TE EEENE EEE EEEN NN EN NN NIRNNTRNNNN NN NRRNIRRL

Cap2_cB 9-07-2007 16:20 Pagina 15 CARBURETOR CHOKE (TC-TXC) The starter knob, located on he left side of he earburetor, is used to enrich the mixture during the engine start. Pull out the Knob to open he starter, and pull he lever up- ardé o dose. The carburetor is equipped with fo knobs: 1 BLACK KNOB: COLD start (°)

COLD START (TE-SMR) For a cold start, the models with a fuel injection engine are fit ted with a black Hnob (3) located on the left of the hroïtle body. Pal the knob outwards to open the starter and push inwards to dose.

(TE-SMR) The motoryce is equipped with a digital instrument: on the instrument are located 5 warning High too: igh beam, lights {with display ghting], blnkers, neural and fuel reserve. T-BLUE warning High “HIGH BEAM"

2. GREEN vaming light "LIGHTS"

3 GREEN vaming ightBLINKERS" 4 GREEN warning ght NEUTRAL" 5 ORANGE warming light Fuel reserve” (1,812 1.58 mp. gt 1.9 LS. NOTES = Mer the engine starting, for the first 2 seconds, fe instru- ment shous ie version of the checking SW: after the check, the instrument shows the lost planned function. = When he motorccle engine is OFF, the instrument doesn't also show ts fundlons. = To select the instrument functions and to set to zero the func- fins, use the SCROLL knob [A = The instrument functions ar te fllowing, as shown belou. 1-SPEED / 0DO (figure 1 page 17) 2 SPEED / H (figure 2, page 17) 3-SPEED / CLOCK (figure 3, page 17)

4- SPEED / TRIP 1 [figure 4, page 18)

S-SPEED / STP 1 (figure 5, page 18] 6-SPEED / AVS 1 (figure 6, page 18) T-SPEED / SPEED MAX figure 7, page 19) 8-SPEED / TRIP 2 (figure 8, page 19) 9-SPEED / TRP 2 / CLOCK (figure 9, page 19 10: SPEED / RPM engine rp.m.numercl value figure 10, page 19} NOTE The RPM function, shown on the vertical LED indicator, is AL- WAYS on. *IMPORTANT: Fundions of the GREEN waming light (4) PNEUTRAL" in case of FUEL INJECTION SYSTEM malfundion {contact your local HUSQVARNA Dealer) a] With the GEARBOX NOT in NEUTRAL position: he warning light FLASHES INTERMITTENTLY. b) With he GEARBOX in NEUTRAL position: fhe warning light is inifily constaily ON then it FLASHES TWICE IN RAPID SUCCESSION then returns to being constantly ON. This cyde repeats sel. After eliminafing the malfuncton, the warning light (4) returs o its normal operation.

ure 1) = SPEED: motoreydle speed: maximum value: 299 kmh or 299 mph: = ODO: odometer- maximum value: 99999 km; = RPHE engine r.p.m. shown on he vertical LED indicator. To replace Klometers with miles or miles with Kilometers pro- cœed 0 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 kélometers miles or miles-klometers setting opero- ion, for 3 seconds, “SET” and miles/mph or km/kmh will be on. NOTE After the previously described operation, the ODO setting will be convert and all the others data will be reseted (the H Counter is unchanged).

2- SPEED / H / RPM (figure 2)

= SPEED: motorcyce speedmaximum value: 299 kmh or 299 mph: = H:shous he running hours of the engine [data are saved in permanent memory every 10 minutes): Maximum value: 9999.59: = RPM: engine rpm. shown on the vertical LED indicator.

3- SPEED / CLOCK / RPM (figure 3)

= SPEED: motorcycle speedmoximum value: 299 kmh or 299 mph; = CLOCK: dock Reading rom 0:00 to 23:59:59 [ie data will be lost after battery detachment}: To reset he clock, push the lnob SCROLL (A) for more than 3 seconds in order to icrense he hours; eleuse he knob and then, fer 3 seconds, ti possible o increase 1he minutes: = RPM engine r.p.m. shown on the vertical LED indicator.

PAR Cap3 GB 9-07-2007 16:22 Pagina 18 SPEED / TRIP 1 / RPM (figure 4) - De motorcycle speedmaximum value: 299 kmh or 299 mph; = TRIP 1: distance. maximum value: 999.9 km (the data will be Lost after battery detachment). Hthe STP 1 will be set to zero, the functions TRIP 1 and AVS 1 will be set to zero too. The function TRIP 1 is ON unitedly with the function STP 1 (*). = RPM engine rp.m. shown on the vertical LED indicator. {'} see figure 5

5- SPEED / STP 1 / RPM (figure 5)

= SPEED: motorcyde speedmaximum value: 299 kmh or 299 mph; = SIP: miles/kilometers covered time- Reading from 0:00 to 23:59:59 [the data will be lost after battery detachment). To adivate the function STP 1, push the knob SCROLL {A) for more Hhan 3 seconds. = Iststep: function ON; = And step: stop t the counters; = Sd step: STP 1 zerosetig; TRIP 1 and ANS 1 dota zero seting; = Aih step: fundion ON; = Sih step: stop t the counters; and so filowing NOTE STP 1 data*TRIP 1 data=AVS 1 (*). = RPHE engine .p.m. shown on he vertical LED indicator. {'} see fqure 6

6- SPEED / AVS 1 / RPM (figure 6)

= SPEED: motoreyde speedmaximum value: 299 kmh or 299 mph; = ANS: shows the covered average speed of the motocyde, according with a distance (TRI 1} and a miles/klometers covered time {STP 1} the data wil be lost after battery de- tachmeni. NOTE the STP 1 will be set to zero, the TRIP 1 and AVS 1 functions will be set to zero too. = RPHE engine .p.m. shown on the vertical LED indictor.

- sr motoreyde speedmaximum value: 299 kmh or 299 2 VAE house motor AAIHUI speed (rech MAX speed), kmh or mph. Maximum value: 299 kmh or 299 mph. To set to zero V MAX, push the knob SCROLL {A} for more han 3 seconds: = RPM: engine r:p.m. Shoum on the vertical LED indicator.

- sr motoreyde speedmaximum value: 299 kmh or 299 mph; = TRIP 2: distance. maximum value: 999, 9 km / miles (the data ill be lost after battery detachment; To set to zero TRIP 2, push the knob SCROLL (A) for more than 3 seconds; = RPM engine r.p.m. shoumn on he vertical LED indictor. 9-TRP 2 / CLOCK / RPM (figure 9) = TRIP distance: Max value: 999.9 km miles [he data will belos after baïery detachment}. To set to zero TRIP 9, push the knob SCROLL {A} for more han 3 seconds = CLOCK: dk Reuding from 0:00 to 23:59:59 {the dt will be lot after battery detachment), To reset he dock, push the knob SCROLL (A) for more than 3 seconds in order oin- érense the hours, releose the knab then, after 3 seconds, is possible to increose te minutes; = RPM engine cp.m. shoumn on the vertical LED indicatr. "4889 À

value) (figure 10) = SPEED: motorcyce speedmaximum value: 299 kmh or 299 mph: 2 RPM engine rpm both vert LED indictor and numerical value are on. © 1200 =! ” 183806 2 CLK RPM RPM

Cap4 GB 9-07-2007 16:23 Pagina 20 THROTTLE CONTROL The hrohle Knob {1}, is located an the right hand sde of the handlebar. The postion of the hrohle control can be adjusted by losening he wo Fstenig screus . CAUTION Do not forget to tighten the screws (A) after the adjustment.

The brake control lever (2) is located on he right and side of the handlebar. The posion of the throle control can be ad. justed by losening he wo fstenig screus CAUTION Do not forget to tighten the screws (B) after the adjustment. STEERING LOCK (TE-SMR) The motrcyde is equipped with a steering lock {1} on the RH. side of he string head tube. To lock, procede as follows: turn the handlebar lfiwards, place 1he key in lock and turn counterdockwise. Push the key inwards [if necessary, turn 10 and from. Turn the Key dlodkwise and remove it from the lock. To unlock he steeing lok, reverse the above procedure.

Cap4_ GB 11-07-2007 16:50 Pagina 21 . R.H. HANDLEBAR COMMUTATOR (TE-TXC-SMR) LH. HANDLEBAR COMMUTATOR (TE-SMR) ENGINE STOP BUTTON (TC-TXC) The right utator has the following controls: On the left side of the handlebar, near the clutch control, is lo- à gi tt Bon CONTROLS: cated the engine stop button.

3) Engine start - stop switch (TE-SMR) 1) High beam flash (self cancelling) CLUTCH CONTROL E |

The hydraulic dutch control lever is located on the left-hand side of the handlebar and is protected against dit with a rub- Selection control High beam ber guard. The clutch control position on the handlebar can be ndjusted by loosening the lower fastening screw (A).

3) = Left turn signals (automatic retumn) | L

Right turn Signal [automafe retum Do not forget to tighten the screwr after the adjustment. TE-SMR ©) To deactivate the turn signals, press the control lever after is TCTXC returning to center.

The reur brake control (1) is placed on ie righéhand side of the motor. On models TE and SMR as top switch, during the brakng action, causes the rer light to come on.

The lever (1) is placed on he ef hand side of the engine. The operator must releuse he lever after each gear change to al low to return t ts central position before another gear change can be made. Neutal position (N] is between fist ou] and setond gear. Fist gear is engaged by pushing he lever dounwards; al the her gars are engaged, by pushing the leve upwards. Te ps fe ur a he nb id

= loosening screw; = puling lever ouf; = placng lever in new position on te shaft en the operation is over fighten the screw and then fightening the screv. CAUTION*: Do not shift gears without disen- gegins the dutch and dosing the throttle. le engine could be damaged by overspeed and shock. WARNING*: Do not downshift when travel- ing at a speed that would force the engine to overrev in the next lower gear, or cause the rear wheel to lose traction. Ne Neutral NE: Neutral TE-SMR-TXC

WARNING! Before each ride, to prevent accident or falures during ride, make sure to go through fllowing ist.

A. Engine-ransmission oil level

€ coolant level Make sure all caps are properly adiusted. WARNING*: Don't remove radiator cap when hot! Check all controls À. Throtile handgrip

Make sure cables are not damaged and turn smoothly. Check brakes Look for brake fluid leaks and worn hoses. Check for prop- er fundioning. Check suspensions Compress fork and rear suspensions. Look for oil leaks and ensure proper fundtioning. Check wheels Check spokes and look for worn bearings. Check rims and tyres. Check tyre pressure. Check chain rollers and sprockets Check wear on chain rollers and sprockets Ensure chain is correcily adjusted and lubricated. Check air filter and intake system Check that ai Fler is clean Check all rubber connections and damps.

Check hook up, look for cracks Check muffler.

À. Spark plug B. Cylinderhead nuts €. General check of torque 10.Check steering action Check bearing play. 11.Check the electric system (TE- SMR). Start the engine and check that the front and rear lamps, the stop light, the turn signals_ the cluster warning lighis and the horn are working correcily. WARNING*: Failure to perform these checks every day before you ride may result in serous damage or a severe acident. Before using the motoreyde for sporting activities run in the engine for vo hours at lens to increse the ie and 1he per. formance of he engine. During the first halhour of driving we advise kecping a low speed and avoïding sudden accelerations, Never open the throtle Fly. Change 1he ol and carry out al the necessary maintenance op- erations, Alter the first Hal hour af drving, gb incrense the rev number, but never run the engine at fu throle. Never Keep low speeds when he High geurs are insert. Slowiy drive the motoreyle for #o hours before using t for sporting ucivifies.

Cap5_cB 9-07-2007 16:25 Pagina 24 ENGINE START (TE-SMR) th cod engine, a after a pralonged inacivity of the motor- eye or in presence of a low extemal temperature, proceed as follows:

1) st igniton key {1} in IGNITION position {he buzz that you

hear when you tum the key t IGNITION is caused by the fuel pump which put he feeding system under pressure;

Put the start lever (2) in it initial position as soon as the en- gi is idling. When starting with an alreudy warmed up en- gine DO NOT USE the starter. When a cold engine hos just been started, do not increase revs, to ensure an adequate ol warmup and circulation. NOTE A safety switch is set on the luth lever support. This switch al. lows you OMLY to start 1he engine with dle gearbox, or with the geurengaged and he due lever pulled. IMPORTANT NEVER START WITH DISCONNECTED BATTERV.

Make sure he ful tps in he OPEN postion, en hf gear Though he engine is prvided il an automañ decampressr, pedal in neural poson. can be ecssay, n some cases [arbre long ar string Pull 1e starter Knob (BLACK knob (2) fr cod starting, RED fais do alary one ano ke an E | Knob {3} for warm string), pul the luth conrl lever, al sert dpt Li of hard. then press the engine start button [1]. these cases, pull the lever (5) whilst simul aneously pressing Rage the dut rar he starter button, rlese he lever (5) Keeping the buton FAURE EURE OI RE prssed and dtevars eee he lite sv. Â order to adjust he lever decompresor re play [approximtehy 3 mm-012 in. te lever holder is provided with te ajuster 6}: he adusment ea be ls effet with he fightener (7 on the RH. side ofhe engine [use this fighter its not possible ob- fun he correct re play with he ajuster on he hanleba “after a prolonged inactiviy of the moorcyl or in presence fa low external temperature. | vÉ FRE mn À \-

ENGINE START (TC-TXC) 3) pull the starter knob (BLACK lnob 2 for cald starting, 4) lower the starter pedol (4) until a certain resistance is no- RED knob 3 for warm starting) ficed [piston at T.D.C.}: Proceed follows:

1) make sure the fuel top (A) ii the Open potion;

2] D on pal 1 al on *: after a prolonged inacvity of the motoreyl or in presence da low exteral temperature.

5) pul the lever {5} and lover further, by a limited sroke, he 6) at this point, release te ever [5] and he pedal[4; 7} in he case of OLD STARTING, completely rotae he throte pedal until the abovementioned resistance is overcome (6) tvice (in he case of warm starting DO MOT cary out {surpassing of LDC}: his operation): 27 NB

8) COMPLETELY lower the pedal (4) until he engine stats.

TO DEACTIVATE THE STARTING DEVICE. In case the engine does not star, repeat this procedure. IMPORTANT NOTE IN CASE OF COLD STARTS AT LOW TEMPERATURES Ii recommended to brifly warmup he engine at dle until, after having disengaged the starter, there is a normal re- sponse from he engine when opening fe rot. ln this way the ail eu rench ll the surfaces needing übrco- fin and the colant wi reach he necessary temperature for correct engine function. Avoid overheating the engine. IMPORTANT Never acelerate the engine after a cld start. WARNING*: Exhaust contains poisonous car- bon monoxide gas. Never run the engine in a dosed garage or in a confined area. In the case of using a kick-starter, keep in mind the undermentioned note. Kid start pedal WARNING*: This high performance motorcy- de can some times «kick back» strongly when you are starting it. Do not attempt to start this motorcyde un- less you are wearing high top heavy sided riding boots. You could seriously hurt you leg if the kickstarter kicked back and your foot slipped.

BEFORE MOVING OFF, DEACTIVATE THE RED

Hit is a problem to start he engine when hot, or following a fall, proceed as follows:

1) the transmission {1} should be placed in neutral; bus B (2) OF THE STARTER ON THE CARBURET-

2) pull the RED knob of the starter (2); .

Cap5 GB 9-07-2007 16:25 Pagina 30 . STOPPING THE MOTORCYCLE AND THE ENGINE = Press the engine stop RED button (3). WARNING*: In the event of stuck throtile or - TC dose the fuel cock (4). other malfunction which causes the engine = Close the throtile (1) completely so that the engine will help - TESMR: turn towards left the ignition key. to run uncontrollably, immediately depress slow down the motorcyde. the engine stop button and hold it down. = For normal braking, gradually apply both front and rear Control the motorcyde by normal use of the brakes while down shifting [for maximum deceleration, ap- WARNING*: Independent use of the front or brakes and steering while holding the en- ply the front and rear brakes firmly). rear brake may be advantageous under gine stop button down. = When stopped, pull the dutch lever and shift gear lever (2} certain conditions. Use caution when using in neutral position. the front brake, espedally on slippery sur- faces. Improper use of the brakes can lead to a serious crash.

CHECKING THE OIL LEVEL

Keeping he motrbile level and in a vertical posion, check the oil level through the inspection [1] window on the right erankease. Make sure the level is in between he MIN and MAX ENGINE OIL REPLACEMENT AND BAG FILTERS-FIL. - remove the three fiters (4), (5) and (6) on the LH. side of TER CARTRIDGE CLEANING OR REPLACEMENT the engine, check O-Rings for wear then dean filters with fu- ef renssemble using he reverse procedure; WARNING“: Be careful not to touch hot en in order to replace he fltr cartridge (3, unscew the three notches, gine oil. fostening screws then the filter cartridge cover; ds. : Drain he ci with WAR ENGINE: proced flous: 2 af filer replacement, ressemble the drain cap (2), he Teil up, remove the ill cap (2. 2 remove oi ler cap 1}: engine guard {A} fn pour the recommended oil quant. = remove he engine guard {A} = place an oil drain pan under the engine block = remove he oi drain cap (2) - drain the used oil completely then clean the magneto on the ap; Note*: Have this operation made with warmed-up engine. WARNING*: Be careful not to touch hot en- gine oil.

Check level (1) in right-hand radiator when engine is cold {ploce he motocycle so that is perpendiular to he ground. The coclant should be approximately 10 mm above call and besides, on TETIC and SUR models, it doesn't exced the mid. dle of the expansion tank (2) located in front of te rer shock absorber. The raditor cp is provided of io unlocking postions, the First being for the previous pressure discharge in 1he cooling system. WARNING Avoid removing radiator cap when engine is hot, as coolant may spout out and cause scalding. WARNING TE-SMR: Because the cooling fan (A) can be adtivated even when the start switch is in OFF position, always keep at a safe distance from the fan vanes. NOTE Difficulties may arise in eliminating coolant from varnished surfaces. If this oceurs, wash off with water.

REPLACEMENT OF COOLING FLUID

Place a vessel on the RH. side of the cylinder, under the coalant drain screw (1). FIRST remove he screw (1) hen SLOWLY open the RH. radia- tor cap: slope the motorcycle on he right side to drain the coalant esiyin the vessel. Renssemble the crew [1]. Pour the necessary quantity of coolant in the raditor then pape ge order ii an use di bu

Capé_cB 9-07-2007 16:09 Pagina 33 Peridically check 1he connecting hoses (see “Periodial main- tenance card”): ts will avoid coolantleakages and conse- quent engine sezure: 1 hoses {A} show crack, swelling or Rardenings due to sheos descafion, their replacement shal be advisble. Check the corect fighting of he lamps (BJ.

THROTTLE CABLE ADJUSTMENT

Le eh core adm he ol pr + ous: = remove he upper rubber cap {1}: = by moving cable (2) back and fort check for 2 mm. earance; = should he dearance be incoreci, unblodk he counter ring- au (3) and turn the adjusting screw (4) [by unscrewing it, the dlearane is reduced, while by screving serew (4 it is increased}: - tighten the counter ring-nut again (3). WARNING*: Operation with damaged throt- tle cable could result in an unsafe riding condition. WARNING*: Exhaust gas contains poisonous carbon monoxide gas. Never run the engine in a dosed area or in a confined area. NOTE In case of hrole control cables {1} and (2 replacement it is necessary Lo respect, during reussembly, the meusure À {0mm/04 in.) as shown in the picture, Then ressemble E | guard cover [B) using srew {3} and adjust hrohile control cables on handlebar us described at side. To replace throile control cables, frst remove ha fuel tank as shown on pages 35, 36.

Cap6_ GB 9-07-2007 16:09 Pagina 34 ADJUSTING THE CARBURETTOR (TC-TXC) Ajust the carburetor with warm engine and with the throtle in closed position. Wok as flows: = Turn low running adjusting screw (1) on he let sde of he bike, , unil he engine is tuning over a fair high rpm {turn he crew dockwise t increase the rpm, and anfclock- vise o descrens te rpm). = Turn adjusting screw (2 dockwise until he fly closed pot fin is reuched then turn back 1,5 turns (250) 2,0 turns (450510) = progressvey losen adjusting crew {1} to obtain he slow running required. ADJUSTING THE IDLE (TC-TXC) Ajust the crburetor with warm engine and with he throtle contrl in dosed position, Proceed as follows: = Turn low running adusting screw (1) on he let sde of he bike, near the fuel cod (turn the crew lockwise to increuse the rpm, and anfclockwise to descrense the rpm).

ADJUSTING THE IDLE (TE-SMR) Ajust the earburetor with warm engine and with he throtle contrl in dosed position, Proceed as follows: = turn the ide speed adjustment screw (3) on the throtle body, Iocted on the right side of the vehide, until he idle speed of 1600 RPM is reached {tum clockwise to increase the speed and anticlockuise t reduce ie speed).

Use NGK CRBEB spark plug: he gup is 0.027 in. À wider gap may cause difficulties in starting engine and in oveloading cuil. A gap hat is oo narrow may eause dficufies when aceleat- ing, when iding he engine or when performing at low speeds. Clean the dirt away from he base of the spark plug before re- moving it from the cylinder after removing the cap [1]. Ai very sell examine te st of he spak plug ut alter it has been removed from the engine since the de plug and he colour of the insulator provide useful indications. Correct heat rating: The tip of the or should be dry and the colour should be Hight broun ar 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 vitre- ect a spark gleg sith a older or y and cautiously. À t00 hot a heat range may ion and possible engine dam- plug with 100 «old a heat range may, foul as he result of 00 much carbon Before refitting the plug, thoroughly dean the Slecrodes and'fhe insulter using a brass-mot Ange il hi h k ply a little graphite grease to the sparl g thread; fit and screw the spark plug by Eur then tighten to the torque of 10+12 Nm- 7.4+8.9 H/1b. Loosen the spark plug then tighten it og to the torque of 10+12 Nm- 7.4+8.9 ft, Spark plugs which have œacked insulators or «orroded electrodes should be replaced.

VOLTAGE REGULATOR (TXC-TE-SMR) The voltage regultor {3} is fited to he right side of te chas- sis, on the front.

Cap6_ GB 9-07-2007 16:09 Pagina 36 .

ADJUSTING THE VALVE PLAY HOW TO REMOVE THE TANK (TC-TXC) Remove the locking screw (A) and pull out the tank with its conveyors. To check he vale cearance,proceed as follows, WITH COLD Close the fuel tup (2) and loosen the strap {3} on the connect: ENGINE: ing pipe o the arburetor,pul te pipe out of he carbure. Remove the screws (4) and the side panel. First tu counterdodkwise fostening reur pin (1) then remove the suddle. 1 2 a: 7 en. |

Cap6 GB 9-07-2007 16:09 Pagina 37 . HOW TO REMOVE THE TANK (TE-SMR) Le tank, hen disconnet te connecor of the fuel pump Pul au he tank with comveÿrs. Rene je sus (1 nd ele ones eme de om man bin, Remove 1h serews (1) and he sde panels. Remove he lock Disconnect the feeding pump (8) from the outlet coupling (C) ing srew (A) of he tank. an he fuel pump in he lower back sein af the tank. E |

Remove he spark plug (5), he four cylnder head cover fus Check, hy means on feeler gauge, that he valve denrance is Otherise, Hit he retaiing dip [7] using a ook ete rock fening screws (6] and the cylinder head cover. 0,10-0,15 mm (0.004-0.006 in.) for INTAKE and 0,15+0,20 er arm slide to one side, extract the pad with a pair of pliers Engage second gear and, moving the vehicle forwards and mm (0.006+0.008 in.] for EXHAUST: and check the thickness; backwards, bring the piston to Top Den Center {in His condi- Depending on the res, ft a new pad {us spare parts, pads fon , the mark on the cyinder head is aligned with the two are supplied ranging from 1.60 mm to 2.60 mm in steps of marks on the idle gear of the camshalis, os ilusrated in he 0.05 mm) and return the lip and rocker arm; figure). Check he valve dlearance again and, core, reassembly the removed parts using the reverse procedure. LLLLCORGR LÉLELCLELEELEEELECECECEECECEECELE EEE ELLE EE EEE CEE EEE EEE EEE EEE NUE EURE NN NN NNRRE TR RNNIRNNIRR

Turn rear pin (1) counterclockwise, remove the suddle 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 Fr, lift a lle the electronic power uni (2). Remove screw (3} and the filter (4). Separate ter (5) from frame (6).

AIR FILTER AND CLEANING

Wash the fer with a specific detergent (AGIP” Filter clean foum air detergent Hluid” or similar) then dry it fully (uosh filter with gasaline onl in case of necessiy]. Plunge the fier in special ol for Flers (AGIP Foum air fier protection ol" ar similar}, then wring it to drain superfluous oi. CAUTION*: Do not use gasoline or a low flash-point solvent to dean the element. A fire or explosion could result. CAUTION*: Clean the element in a well ven- tilated area, and do not allow sparks or flames anywhere near the working area. ASSEMBLY To ensure fight fi, highly C] grense filter edge on side faing filter housing. Wie reinseting the ler into is housing, make sus that piece À is turned upwards and edge 8 is on the left lower side of te filter case. Reassemble the ports previously removed {baïtery: connect the positive cable first). CAUTION*: If the element assembly is not installed corredly, dirt and dust may enter and the engine resulting in rapid wear of the piston rings and cylinder.

To ensure maximum safety, the steering wheel should always be regulated so that the handlebars steering the motorcycle rotate ha 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 steer- ing wheel; the handlebars should also rotate without effort. Stand in front ofthe motorcycle and grasp the lower end of the fork rods sliders moving them in the direction of their axis.

play is nficed, proceed with adjustment as follous: loose stering sleevenut (1). ILoosen four sreus hat Fi teeing heu to ok rod (3). Turn the stering ring nut (2) dockwise of he stering leeve proper tool, adust play propel. Tighten steering sleeve nut (1) to a torque setting of 579+65,1 Lb/f: (78,4*88,3 Nm). Tighten four serews on the steering head (3) to a torque of 22,5#26,5 Nm (16.6+19.5 Lb/f]. CAUTION*: Do not ride a motorcycle with damaged steering stem bearings. An un- safe handling condition can result.

CHECK OF THE FRONT BRAKE FLUID LEVEL On the SMR model the Lever position can be adjusted [4 adjusiment) for any driver inf size, To decrese he lever distance from the handle grip, turn the udjuster (B) CLOCKMISE, To increase the lever distance from 1he handle gi um er (5) OUTERCLDCNSE On ie TE, DC und TC models he adjuster [2], located on the conti lever, allows adjusting of the free play a). Fre play a must be at lens 3 mm (0. in. The eve fe fi in pump reseoir mu never be below the minimum value (1), which an be checked from he window on the re side of the pump body (TE, TC). For SMR model, check he level on he fluid reservoir A decrense of the fuel level will let air into the sustem, hence an extension of the level sroke. WARNING*: If the brake lever feels mushy when it is applied, there may be air in the brake lines or the brake may be defedive. Since it is dangerous to operate the motor- «de under such conditions, have the brake checked immediately by an authorized HUSQVARNA dealer. CAUTION*: Do not spill brake fluid on to any painted surface or lenses. CAUTION*:Do not mix two brands of flui Change the brake fluid in the brake I you wish to switch to another fluid brand. CAUTION*: Brake fluid may cause irritation. Avoid contact with skin or eyes. In case of contact, flush thoroughly with water and call a doctor if your eyes were exposed. A: to encrease clearance B: to decrease clearance TE-TC-TXC EAN (CO EE

The position of the rear ot brake pedal as to te fotrst may be dust according to the individual needs. For the dust ing proceed as follows: = loosen the scew {1}: = turn the cam (2) in order to adjust the brake pedal ile Stoke (A; the operation done ighten he screu (1.

The adjusting operation carried ou, adjust the ide sroke of he pedal as indicated in page 43. The re brake foot pedl should have a (8] 5 mm (0.2 in ide stroke before stating the true braking action. Should this not happen os follows: 2 loosen nut (3}; - operate the pump rod (4) to increase or decrease the idle stroke; = tighten nt (3) at he end of he operation. WARNING When the idle stroke figures are not met, ke pads will be subjected to a fast t may bring to the TOTAL BRAKE IN-

Cap7 GB 9-07-2007 16:27 Pagina 43 . | CHECKING THE FLUID LEVEL - by Keeping the master cylinder (3) in horizontal position, CAUTION*: NEVER use brake fluid. ehedk the fluid level is NOT BELOW 4 mm (0.16 in.] from he upper surface (D) of the pump body: Reussembly he removed paris using fe reverse procedure. = iFmecessary, ad fluid unfil the correct level is reached see TABLE FOR LUBRICATIONSUPPLIES For the Hu type page 12. Periodially check he connecing hose [see “Perodical main- tenanee card}: 1he hose (C) show is bent or cradked, ts re- placement is adhised. The level (A] must be set between he pump tank nothes.

ADJUSTMENT OF THE CONTROL LEVER AND

CHECK OF THE HYDRAULIC CLUTCH FLUID LEVEL Free play (A) must be a eus 3 mm (0. in). The lever position can be adjusted for any river hand sie. To decreas fe lever distance from the handle grp,rotat the ajuster (B) CLOCKWISE. To increase le lever distance from he handle grip, ot the TC-TXC ajuster (B) COUNTERCLOCKWISE. To check he fluid level proceed os folous: = remove screws {1}, cver (2) and rubber pump diaphrogm on the handlebar duth control 143 ERBE

Proceed as follows: = remove serews (1), cap (2) and rubber pump diaphragm; = remove the bleeding niple (3): = mount a spinge in the bleeding npple hole, then ref with fresh fluid see LUBRICATION TABLE on page 12. CAUTION *: NEVER use brake fluid. = ref until fluid is discharged from the lower hole (B) on the pump body WITHOUT BUBBLES.

The fluid level. MUST NEVER BE below 4 mm from he top (A) of the dutch pump body (see picture]. Reassemble the re- moved pars. 4 mm (0.16 in.)

The following information is a useful guide for seing up the suspensions according to 1he rond conditions. Always stat from the standard calibration before making any change on the suspensions. Aferwards,inrense or decrense the adjsting lis one at a time. HARD GROUND Fork softr compression adjustment. Shodk absorber: softer compression adjusiment. The sofer adjustment for the two suspensions is also used both in compression and in extension when driving ot top speed, in order to have better grip f he fire. SANDY GROUND Fork have à harder compression adjustment, or replace the standard spring with a harder one, and make à sofer com- pression adjustment and a harder extension adjustment at the same time. Shock absorber: have a harder compression, and expeiall a harder extension adjusiment. Work on the spring preload 10 lower the moorcyde rar sie. MUDDY GROUND Fork: have a harder compression adjustment, or replace the standard spring with a harder one. Shock absorber: have a harder compression and extension ad- justments, or replace the standard spring with a harder one. Work on he spring preload 1 if he motoreyl eur side. We achise replcing the springs of both suspensions to com- pense the weight ncrese due to the ping of the mu. RARE RIRE RENTREE) NOTE: When he fork result as efther too soft or too hard for amy nd much ol inside the fork will involve a more frequent air justment conditions, check 1e ol level inside the Forkrod. drainage. When the suspensions do not reuc to 1he changes The level can either be too low or too high. Remember that too of calibration, check that he adjusting units are not blocked.

PAR Cap7_ GB 9-07-2007 16:27 Pagina 46 The standard calbrtions and the adjusiment procedures are sion on he no ges. he sing tb uon re lg he pl ace, eh on pags, 6

ADJUSTING THE COMPRESSION FORK

a) Compression (Louer register) Sd clbraïor 5 dc CD) Standard calibration: -12 clicks (TE-SMRJ. enot l (B) nd um rie A) dus ni he ps ion of full closed is reached then, turn back by the men- fioned diks.T obtain a smoother braking action, turn he reg- ister anticlockwise. Reverse the operation in order to obtain a harder action. bj EXTENSION {upper register) Slandard calbraion: 15 die (TCTNG; Standard calbraion: 12 dde (TESMR). To reset standard calibration turn register [C] clockwise to reach the position o fully dosed: then, tum back by the men- fioned cils. To obaïn a smoother brakäng action, turn the register anticlockwise. Reverse the operation in order to obtain a harder action. €] AIR VENT [to carry ou after ench competition, or month. TESMR: set the motorele on n central stand and release the fotk fully and loose the air vent valve {D}. Once this apero- tion is over, tighten the valve. TIGTC: Place Ie vehicle on a central stand, pull the fork all out, then remove the ep {E) and press the valve mit afp. Ft the cp back in. WARNING! NEVER loosen the screw (F)

WARNING: Never force idjusting screws beyond

the maximum opening and dosure positions.

For the regular fok operation, both legs must be provided ih he necessary ol quant. Remove the forkrods form the fork to check te ol level inside the Forkrods. Wok a follows: = remove he pover rod caps: = remove springs from the stems leting he oi drop into he ler, = bring for to stroke end: = check that he level is af distance “A° below ie upper limit of rods.

OIL QUANTITY IN EACH FORK LEG

-1C 310 cm { au. a] -TE: 775 cm° (47.3 cu. in. = SMR: 740 cm° (45.1 cu. in.) A=100mm (3.94 in) - SMR A=120mm (4.72 in.)-TE NOTE Besides the serial spring with fexibility index: K-4,5 N/mm (TE) K-4,8 N/mm (TCINC 250) K-5 N/mm (TCTXC 450,510 - SUR) and relevant preload spacer harder or sofer springs, together with spacers are abailable upon request. NOTE Always replace both he spring and the spacers to Keep the preload value unchanged. RAR RIRE RE NRNN RER NNANRINNRNNNNNNNNN NN) NNNN NN LNN LEE LLE IL LL LL) LLLLLLLLELLEL EL I

Cap7_ GB 9-07-2007 16:27 Pagina 48 . HANDLEBAR POSITION AND HEIGHT CHANGE c) Hondlebar poston change b) Handlebar high change . . Turn the lower dmp (2 180° to move forward or badkward Remove te lower space (A) en replace the crew (4) wi a The handlebar postion [0] and heght (b) can be changed for {mme Q.Oéin.} he handlebar position with respect to the neurone of L-65 mm (2.56 in.) height. fete siting Your driving DE To ph) PU original sep. Once these operations are completed,fighten the screus (3) to mn e pp se , upper clamp (1), lower 2.153,05 kgm (27-30 Nm; 19.9-22 Lh/fs] and the screws (4) screw (4) then Lower amp (2). 10 2,02,2 kgm (19,6-21,6 Nm; 14.5:15.9 Lh/hs).

Cap8 GB 9-07-2007 16:28 Pagina 49 À ADJUSTING THE SHOCK ABSORBER 4. The difference between these ho mensurements constiutes ADJUSTING THE SHOCK ABSORBER SPRING the “SAG" of the motoreycle’s rear end. PRELOAD The reur shock absorber must be adusted according o the rd. ee on Suggested SKG: 4 in. with cld shock absorber 3.7 in. with Proced os flous: Proceed os follous: varmed up shock absorber. 1. First turn counterdockwise fstening rear pin (1) then re- E

5. To get the right SAG according to your weight, adjust the

1. With motrcydle on he stand, meusure distance (A). A cer nine pl db

2. Take he normal riding position on the motorcydle with al

3. With somebody s help, take he new distance [A].

move suddle, screws {2} and RH. side panel (3). WARNING*: Never disassemble shock ab- sorber, which contains highly compressed nitrogen. Contact your Dealer for such ma- jor service. Do not indnerate. Bas of he panel srew Cas of eur wheel pin PAR

Cap8_cB 11-07-2007 17:23 Pagina 50 Clean ringnut {1} and adjusting nut (2) of he spring (3). Ether il a hook wrench or an aluminium punch, loosen the ringnut . um the adusting nut as required. When the udusfing operation is over [according to your weight and riding style), tighten the ringnut.(Torque for both ringnuts: 5 Km; 49 Nm; 36.2 f/1). Reussemble RH. side panel and saddle. WARNING*:Be careful not to touch hot ex- haust pipe while adjusting the shock abosr- ber.

Adjustment of the compression stoke is independent from the rebound Stoke. A] COMPRESSION Standard calibration:

1) Low damping speed:

= 15 did (à 2 dics) {register 4)

2) High domping speed:

215 dis (2 2 dicks) {register 6) To reset the standard calibration, turn upper registers (4) and {6} dodkwise until reaching fully losed position. Return then back for the mentioned dicks. In order to obtain a smooth braking action, turn the registers anticlockwise. Reverse the operation in order to obtain a harder braking action.

8) EXTENSION - Standard calibration:

= 18 is (à 2 dids) To reset le standard calibration, tu lower register (5) lock wise ul reaching fully led position. Return then back for the mentioned dde, In order to obtain a smooth braking action, turn the register anticlockwise. Reverse the operation im order o bain a harder braking action.

Cap9_cB 19-07-2007 10:50 Pagina 51 CHAIN ADJUSTMENT Chain should be chedked, adjusted and lubricated as per the Maintenance Chart to ensure security and prevent excessive wear, IF the chain becomes badly worn or is poor adjusted fie, it is too oose or too taughi}, it could escape from sprocket or break. To adjust the rear chain ti necessary to lower the rear part of motoreyde so 1 line up he drive sprocket anle, te rer suing arm le and the rear wheel ae os shovn on drawing. Than let turn three times he reur wheel. Now the chain should not be ight. (Fig. A).

Fast adjustment (Fig. B). In the point shown in the figure, fit a bush {a}, 35 mm diame- ter (or altemnatively a shim in the same size) and make sure the lower branch (C) of the chain is slightly taut. Hit is not, proceed us follows: on the right side, with a 27 mm Allen screwdriver, loosen the Locking nut (1) of the wheel pin; with a 12 mm screwdriver, loosen the check nuts (2) on both chain stretchers and work on the screws (3) to achieve the right tension; - when the adjustment is over, tighten the check nuts (2) and the wheel pin nut (1). When the adjustment is over check the wheel for alignment. A= 0+2 mm (00.08 in.] [Fig.A ]

PAR cap9_GB 19-07-2007 10:50 Pagina 52 CHECKING THE WEAR OF CHAIN, PINION AND SPROCKET Proceed as folous: fully stretch the chain with the adjsting srews. = mark 20 chain links. = meosure the distance “A" between 1st pin center and 21 st pin center. WEAR STANDARD LIMIT 317,5 mm 323 mm Check he pinion damages or wear and replace it should the wear degree be as the one shoum in igur. Remove the wheel and check 1he wear of he rear sproket teelh. The below figure shows he outline of teth in normal and excessive wear. Should the sprocket be badly wo out, re- place it by loosenng he six fstening srews o the hub. WARNING*: Misalignment of the wheel will result in abnormal wear and may resul an unsafe riding condition. Note*: In muddy and wet conditions, mud sticks to the chain and sprockets resulti an overtight chain. The pinion, the chain, and the rear sprocket wheel wear increases when running on muddy ground. Normal consumption NRA

Excessive consumption

LUBRICATING THE CHAIN

Lubricate the chain following these instructions. WARNING * : Never use grease to lubricate the chain. Grease helps to acumulate dust and mud, which ac as abrasive and hepl to rapidly wear out the chain, the sprocket, and the crown. Disassembling and deaning When particularly dirty, remove and clean the chain before lu- brication. Work as follows: 1-Set a stand or a block under the engine and see that the rear wheel is lified from the ground. Remove: screws [1], transmission sprocket guard (2), dip (3), master link (4) and transmission chain (5); To reussemble, reverse the above procedure. CEYIL

rollers or the links are damaged, replace he chan by fol Lowing the instructions given in the Periodical Maintenance Table. 3 Check hat neïther he sprocket nor he croum are damaged. 4-Wash and deun he chain as described hereunder. Washing the chain without OR Wash using either oil or diesel oil. When using gasoline or tri- doroetilene, dean and lubricate the chain io prevent oxidation. Washing the chain with OR Wash using oi, diesel oil, or paraffin oil. Never use gosoline, tridoroetilene, or solvents, as the OR may suffer damages. Use insteud special sprays for chains with OR. Lubricating the chain without OR First dry, then plunge the chain in a bisulphide molybdenum Aubricant, or in high viscosity engine oil. Warm up the oi be- ore use. Lul ing 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. 51e chain has been cu, ressemble using a joint. 6-Assemble the joint spring (u) by tuning the closed side to the chain direction of rotation as shown in figure below. NOTE*: Even ll he joints are reusable when in good con- diions, for safety purposes we advise using new joints when reussembling the chain. T-Aecuraelyadjust ie chain as described on page 51.

WARNING: The chain oil has NEVER to get in

contact with the tires or the rear brake disk. Chain tension rollers, chain driving roller, E chain guide, chain runner Check the wear of the above mentioned elements and replace them when necessary. WARNING*: Check the chain guide aligne- ment, and remember that a bent element «an cause a rapid wear of the chain. In this case, a chain fleeting from the sprocket may ensue.

. Do not operate the front brake lever when the wheel has been Set a stand or a blok under he engine and se al he ont Fomayad: is causes he clip piston o move ouvrier he td ue ground. Lcsen he bol (1) lg mal, y dom he wheel with brake dis on top. ork stanchions. SMR: remove the io screws (A) and the brake caliper. Hold the head of the wheel axle (2) in place, unscrew the bolt (3) on the opposit side; draw the wheel axe out.

Fit the LH. spacer on he wheel hub. TETCIIC: Fit he wheel between the front for legs so that he brake disc is ited into he cliper. SMR: Fit the wheel between the front ok legs. Fit he wheel axe {2} from ie RH. ide, fr greusing it and push it to he stop on the LH. leg; during this operation, the wheel should be tured. Tighten the screw (3) on the fork LH. side but DO NOT lock it. Nov, pump for a while, pushing the handlebar dounwardsunfil you are sure that he for legs are perfecly aligned.

Lock: he screus [1] on the RH. leg (104 Nm/ 1,05 Kgm/ 7.7 fl), the screw (3) on the LH. ide (51,45 Nm/ 5,25 Kgm/ 3 fa the sreus (1) on the LH. leg (10,4 Nm/ 1,05 Kgm/ 71 flb SMR: ft he brake caliper on he disc semble ie caliper on is holding plate and tighten he serews {A} at 25,5 Nm/ 2,6 Kqm/ 18.8 Hb. Check hat he brake disc sides beleen he caliper pad with- out any friction. NOTE After reossembly, pump the brake control lever until he pads are aguint te brake dis,

Do not operat the rearbrake pedal when the wheel has been removed: his causes he caliper piston to move outards. Alter removal, y down the wheel with brake dis on top. Aer reossemby, pump the brake control pedal until the pads are aguinst te brake dis, Unscrew the nt (1 of he wheel pin {3} and xtrct it. is not necessary o unloose the chain adusers (2: in his way, the chain tension wil remain unchanged after the reussembly. Proc the complete rer wheel, by taking care of he spacers located at the hub sdes. To renssemble, reverse 1he above procedure remembering to insert te disc into he cliper.

6. Rear brake oil tank

Care should be taken to keep he fires propery nflated. See The mayor components are brake master cylinder with lever fire data for correct ire inflation pressure (page 11). Replace (front) or pedal (rear), brakeline, caliper assembly and disc. Trarbaek the fre if ts wear exceeds what is shown on the table below. 8 eu ble als E LESEND Re brake caliper

1. Front brake control lever 3, eur ra disc

cap9_ GB 19-07-2007 10:51 Pagina 58 . BRAKE PADS REMOVAL PADS WEAR (TETCTIC) PADS WEAR [SHR) Inspec pas fr wear. a In front: his “A must never be lover than he ane 2 Remove spring (1). Service limit A is: 3,8 mm (0.1 in. pointed out by he wear control noches. = Remove pins (2). Hservic limit is exceeded, alays replace the pad in poirs. b) À the bad: thicmess “A” must never be lower han 3,8 = Remove pads. mm I service limit is exceeded, aluoys replace he pds in pairs. CAUTION! Don't operate the brake lever or pedal while removing the pads. TE-TC-TXC FRONT SMR

Cap9_ GB 19-07-2007 10:51 Pagina 59 . | PADS CLEANING WARNING! Be care ht no die brake ui or an oil ges on rate De no! atfempt Lo Lepossns vesil Et MneE iA or il hat inaderenty gets fully effective. Pump the brake lever or h _. 5 pedal until the pads are against the discs. Rep the pads with new ones iFthey cannot be deaned sofis- The brake will not fundion on the first ap- orny. plication of the lever or pedal. PADS INSTALLATION = Intel new brake pads, = Renssemble he fo pins [2] and he springs (1) TE-TC-TXC TE-TC-TXC FRONT

DISC WARPAGE Meusure the thickness of each disc at 1he point where it has Ron Fe varpage. Service mit fr both dis is IS mm worn the most. Replace the disc if it has worn post the service nt es Replce the dis if warpage is more than service lit. Disc Thickness

Poor braking can also be œaused by oil on the disc. Oil or The broke fluid should be checked and changed in accordance grease on the dise must be leaned of with a high sh point with he Peiodic Maintenance Chart or whenever it is contami- ail fee solvent, such as acetone or lcquer thinner. nated with dit or water, Don change the Huid in he rain or E when a strong wind is blowing, CAUTION!

• Use only brake fluid from a sealed con- tainer (DOT 4). Never use old brake fluid.

• Never allow contaminants (dirt, water, etc.) to enter the brake fluid reservoir.

• Don't leave the reser cap off any length of time to avoid moisture contami- nation 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 boili point and could cause the brake to be in- [al effective. It may also cause the rubber brake part to deteriorate.

Cap9_GB 19-07-2007 10:51 Pagina 62 . To replace the fluid, proceed as follows: = Remove he rubber cap on the bleeding valve (1) or A]. 2 Mtoh a eur plastic hose o the leeding valve on he brake ealiper and tu the ther end of the hose into a container. 2 Remove fluid reservoir cap {2Jor (24: 21 mm wrench} and the rubber. = Loosen bleeding valve on the brake aliper. Se] un. (2)

cap9_GB 19-07-2007 10:51 Pagina 63 . | = Pump with brake lever (3) or brake pedal (34) in order to Restore the brake fluid level [A] or (8) then renssemble the push brake Huïd ut fine. rubber and he fluid reservoir cap (page 62]. = Cose the bleeding valve and fill the reservoir with fresh broke Huid. After the brake fluid replacement, it is necessary o operate = Open the Bleeding vale, apply he brake using the brake the brokng system bleeding {see pages 64 and 65). lever or pedal, dose the Bleeding vave with he brake lever ar pedal applied and then quickly release te lever or pedal. = Repeat this operation until he brake line is fl and clear fluid strts coming out of the plastic hose: now dose the bleeding vahre.

PAR Cap9_GB 19-07-2007 10:51 Pagina 64 WARNING! Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately. rake fluid may cause ation. Avoid contact with skin or eyes. In case of contad, flush thoroughly and «all a doctor if your eyes were exposed. lly check the connedting hoses (see if the racked, their replacement is advised. FRONT BRAKING SYSTEM BLEEDING (TE, TC, TXC) The brakäng system must be bled ter he fluid replacement or when, due to air in the circuit, the Lever stoke is long and spongy. Proced os follows: 2 Remove the rubber cap on he bleeding valve [1]. = Aftch a dear plastic hose to the leeding valve on ie brake ealper and turn 1he other end of he hose into a container {make sure that he end of the hose is submerged in brake fluid during the entre Hleeding operation).

PAR cap9_GB 19-07-2007 10:51 Pagina 65 = Remove id reservoir cap (2), the rubber and fil he rser- voir with fresh brake fluid. = Open the leeding valve and pump th brake lever (3) sev- eral times until the fluid, clear and without bubbles, comes out of the hose: now dose the bleeding valve. = Restore the brake fluid level [A] then reassemble the rubber and he fluid reservoir cap (2). 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 ftb). As the braking fluid is a very corro- sive substance, in the case it comes in contact with your eyes wash them abundantly with water. During the bleeding of the braking Le drcuit keep the handlebar turned leftwards. Thi is the way to lift the pump tank and to make eusier 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. does not ide the dr- inated 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.

Cap9_cB 19-07-2007 10:51 Pagina 66 FRONT BRAKING SYSTEM BLEEDING (SMR) The braking system must be bled after the fluid replacement or when, due 1 arin he cire, he lever stoke is ong and spongy. Regarding the front braking system, frtproceed 10 bed the upper braking system control (bleeding valve 1], then the brake calier (bleeding valve 1A). In both cases, proceed as follous: = Remove the rubber ap on the leeding valve {1 or [IA].

= Mtoh a lear plastic ose o the bleeding valve on the brake caliper and tu the other end of the hose into a container {make sure that he end of he hose is submerged in brake fluid during he entre Hleeding operation. = Remove fuid reservoir cap (2), the rubber and Hi the reser. voir with fresh brake fluid. = Open the bleeding valve and pump with brake lever several fimes until the Huid, clear and without bubbles, comes out of the hose: nou dose he bleeding valve.

PAR Cap9_GB 19-07-2007 10:51 Pagina 67 = Restre the brake fluid level [A] then renssemble he rubber and the fluid reservoir cap. 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-b). As the braking fluid is a very corro- sive substance, in the case it comes in contact with your eyes wash them abundantly with water. the bleeding of the braking Le drcuit keep the handlebar turned leftwards. This is the way to lift the pump tank and to make eusier 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 dr- «uit, the small quantity of air re- maining 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.

REAR BRAKING SYSTEM BLEEDING

The braking system must be bled alter the fluid replacement or when, due t ar in 1he crc, he pedl stoke is long and spongy. To bled he system: = Remove he reservoir cover {A} (21 mm wrench} rubber boot and op up th (DOT 4] bre Fluid.

- Depress the ped (2) and keep t ul doun. = Loosen the bleed union leting out fluid [a first, any ir will come out, then, closing he union sig. = Relense he pedl and vit for a feu seconds before repeut ing he operation until only fluid come ut of he tube. - lose he bleed union to the prescibed torque and check the fluid level () inside the reservoir belre reussemblle the cap

1Fthe beeding operation has be done correct, he pedal will have no mushyfel. of, epeat the operation. NOTE Should the motorcyde, due to a fall during a competition or Shop repars, show some elstcty of the brake lever stroke, with a subsequentbraking effiency decreas, you’ to repeat the circuit bleeding as above described. 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; 11.8 fHb).

Cap9_cB 19-07-2007 10:51 Pagina 69 EXHAUST MUFFLER The mulfler reduces the noise of he exhaustgases, but ti an inegral part of the exhaust as wel. As such, its conditions af fect he motoreyle performance. When the noise on 1he exhaust is oo high, it means that the deudening material set on the hled tube inside the mulfler is deerorated.

WARNING: Check the deadening material af-

ter every competition and replace it if neces- sary.

Fist tu counterdodkwise fostening rear pin (1) then remove suddle, srews (2} and LH. side panel (3). Using an 8 mm T- shaped spanner on the outside and a 10 mm Tshaped spanner on he inside, remove the Iocking crew [4] of ne muffe. Remove he spring (5) and with an 8 mm Tshaped spanner re- move the scrw {8}; then pu out he mufler. Remove he six rer ivet 6], camp and te exhaust terminal {7). Remove innner pipe and replace 1he deadening material. Reassemble LH. side panel and sodd. NOTE: When diffuculties are found in remov- ing the muffler, lightly beat with a rubber or plastic hammer.

PAR Cap9_GB 19-07-2007 10:52 Pagina 70 SERVICE LIMIT NOTE This chapter shows the main che t be urred out when the engine and some pars of he byke must be overhnuled. More detailed information, together with the disassembly/re- assembly procedures are carried in the Husguama s Workshop Manuel. CYLINDER-PISTON FITTING The cylinder and piston are supplied matched, if by chance cylinders and pistons become mismatched then measure heir diameter s follows: a) Gyinder bore (De) Use an internal micrometer and take the reading “A” at 20 mm-08 in. (250) or 10 mm-0.4 in. (450-510) distance from the top. AIT Def 450-510

CLEARANCE WEAR LIMIT

PISTON RING CUT SETTING #2: “d" CUT POSITION PISTON RING CUT SETTING *:"d" CUT POSITION CHALET

PAR Capl0_GB 9-07-2007 16:35 Pagina 75 ns | CLUTCH UNIT Check he distrtion of each plate (both lined and unlined by resting on a flat surface; use a feeler gauge. The luth plates should not be but or scored. Wear mit: 0,2 mm (0.00078 in). Check the hidkness of the dutch lining plate. CLUTCH HOUSING:FRICTION DISC CLEARANCE E |

PAR Capl0 GB 9-07-2007 16:35 Pagina 76 CLUTCH SPRING Meosure the free length “L" of each spring using a gouge. “L' new spring = 41 mm/ él in. Service limit: 39 mm/ 1.53 in. VALVE GUIDE Acurately chedk the valve guide. À dial comparator se in a way to determine the play in both *X" and “Y” directions, which are perpendicular to one another, is used to detect the wear on he coupling beiveen the guide and the vae. New intke valve standard play: 0,008-9,035 mm/ 0.00031- 000138 in. Sent limit 0,05 mm/ 0.002 in. New exhaust vahe standard play: 0,018-0,045 mm/ 0.0007- 0.00177 in. Service limit: 0,08 mm/ 0.003 in. VALVE Check that the valve shank and the contact surface with the valve seat are in perfect conditions. Piings, eracks, or any oth- er deformation or wear must not appear on these elements. Carry out the following checks: - deformation of the valve shank by seting the shank on a stker, and measuring the extent of he deformation by a comparator. Working limit: 0.05 mm (0.00197 in). = check he concert of the valve head by resting an angle amparar against the head and then rofate the valve in a Vee lock. Wear limit:0.0012 in.

PAR Capl0 GB 9-07-2007 16:35 Pagina 77 VALVE SPRING The weakening of he springs causes a decrense of he engine power and it aflen is responsible of the noise and he vibro- fins coming from the valves. Im hs case, check the free length “L”. When he workäng lim- it indicated has been overcomed, replace the springs. “L" new spring = 35 mm/ 1.38 in. (250): 43,4 mm/ 1.71 in. (450510) ie limit: 33 mm/ 1.3 in. (250); 41 mm/ 1.6 in. (450 510) NOTE: Replace all he spring valves when even one of these ho over. comed the he working limit. Check the spring valve sguareness. Error limit not above 1.5 mm {0.059 in.) on each side. CAMSHAFT Check that cam surfaces are scored,stepped, grooved etc. Insert the camshaft between two references and then check de- viation using to comparators. Wear limit: 0.0039 in. Check that the cams are in good conditions, without wear or deformation. Cam height “4” INTAKE (new) = 36,57 mm/ 144 in. EXHAUST {new = 35,94 mm/ AI in. INTAKE

DOUCEMENT EEE EEENEENENNEUNENENEENENNENNNNNNNINNENNNNNENNNNNNNNNNNNNT

Caplla GB 9-07-2007 16:33 Pagina 78 À OVERHAULING THE WHEELS DEFORMATION RIM WHEEL SPOKES The tables hereunder show the type of control he rim and ; chi Wed als aeto be submited te, suowo | mur | onde sure that all he nipples are fight, ighten them Note*: if the rim is badly, it should be re- Îess than 0,5 mm ot an insuffident steich jeopardizes the motor placed. Side skid {0.02in) ; For a instant check, use a metal point (fr instance, a screv- sont mn | (0 Win) driver) to beat the spokes with A live sound accounts for un ac- Erenticty (03 in) ci in, he à dul sound means hat a new fight

IGNITION SYSTEM (TC-TE-SMR-TXC) ELECTRIC SYSTEM (TE-SMR) The ignition system includes the following elements: = Generator (1) on the inner sde of LH. crankease cover; = Electronic oil {2} under he fuel tank; = Electric power unit CD. [3] under he fuel tank; = Voltage regultor [4] under the fuel tank (TETXCSMR) = Spark plug (5) on the RH. side of clnder head: = Starting motor 12V-450W [6] behind the ylinder (TE-TKC- SR}: = let start remote control suite {8} under he sadle (TE- TCSMR) = Potentiometer (10) on he throtle body (TESMR}; The electric system includes the following elements: : Headlamp with tvo flaments bulb of 124-35/35W and parking ghtbul of 24-34: = Rear lights with stop bulbs of 12-21W and parking light bulb of 125: 2 Pilot ghts bulb of 121,24: = Turn Signal bulb of 12-10 = Instrument bulb of 122: = To fuses (9), a 15A fuse and a 20A fue (13), under the Two 20A fuses on the electric starter contactor (8); = Buñery 126 (7) under he saddle. = Relay (14) for he electric fan, on he R.H. side of he frame; = Coolant temperature sensor {15}: = Electric fn (16). = Hoshingindiator device (17) = LAMBDA probe (18) = Drop sensor (11) [SMR}: right sde panel:

34. Pressure sensor [40] {°}: it stops he engine

35. Fuel pump in use of a fol

Caplla GB 11-07-2007 17:51 Pagina 86 BATTERY The sealed battery does not require any maintenance work. When elecrlyt laks, or other Fïlures to 1he electrical system are detected, apply to the HUSQVARNA Dealer. I the vehicle remains unused for long periods, it is recom- mended to remove battery From electrical system and store it in a dry place. = Mer an intensive use of he battery, is advisable a stan- dard low charge {12V-6Ah battery: 0.64 For 8 hours]. = Rapid recharging is advised only in situations of extreme ne- cessty sine the life of lead elements is drashclly reduced 6h for 0.5 hours with 12V-6Ah batteries). BATTERY CHARGER To gui acess to he battery (2: = first tu counterclockwise fastening rear pin {1} hen re- move the sad; = first remove the BLACK or BLUE negative cable, then the RED positive cable [when reassemblng, Frt connect the RED pos- itve cable, then the BLACK or BLUE negative cable}; = remove he battery (3) rom its housing. Check, using a volimeter, hat battery voltage is not es than M of, the battery needs to be charged. Using a battery charter with a constant voltage, first connect the RED positive cable to the batterys positive terminal then te su or BLUE negative cable to he batery's negative ter- minal. Apply to the constant voltage of 14,4 V a current of x" Ampere as results in the belowe diagram (depending on the amount of carging required). The voltage renches a constant value only after a few hours, therefore it is suggested NOT to mensure it immediately after having charged or discharged he battery. Always check he charge level biforerenstaling ton he ve de. The battery should be kept dean and the terminals coated with grense. WARNING*: The battery contains sulfuric id. Avoid contact with skin, eyes or doth- ing. Antidote: EXTERNAL - Flush with water. INTERNAI - Drink large quantities of water

diately. Eyes: Flush with water for no less than 15 minutes and get prompt medical at- tention.

Caplla GB 9-07-2007 16:33 Pagina 88 . HEADLAMP BULBS REPLACEMENT (TE-SMR) REAR TAIL LIGHT BULB REPLACEMENT (TE. SMR) To gain access t he healamp bulbs, proceede as folous: = remove the two fastening elastis {1} and the heudlamp Remove the vo fastening screws (1) in he iner sde of the holder; rear fender and the lens (2). = remove the vo flamentsbulb connector;_ (2) and the boot (3) = releose the bu holding spring [4] and then the bulb sel. To replace the parking ght bulb (5) extrait from the inside cer. Alter replacement, reverse operations fr renssembly.

Caplla GB 9-07-2007 16:33 Pagina 89 Pull he lamp (3) inside, tum it counterdlockuise then remove from he lamp holder. After replacement, reverse operations fr renssembiy. NOTES: make sure not to tighten the screws excessively.

(TE. SMR) Pull out the number plate lompholder {4} from the back of the vehe. Pul out the lompholder and the bulb. Rotate he bulb (5) to remove from the lumphalder. Once the bulb has been replaced, reverse 1he above procedure. 189 NuNE

Caplla GB 9-07-2007 16:33 Pagina 90 . ADJUSTMENT OF HEADLIGHT (TE- SMR) Adiust the preadlamp aiming by turing screw {1} o louer or the high beum. Wen checking the proper arieting of heudlight, inflot fies a right pressure, st a person on the saddle and place the mo- force perpendicular with ts longitudinal mis 10 meter (33 #1) from a wall or screen, Then race an horizontal line equal to the heght of hendlight center and a vertical one in line with ts longitudinal avis. 1Fpossible, execute his operation in a shadowy place. Wen the low beum is on, the upper boundary limit between dark and lt zone should be 9/10 1h of hendlight center from groud. LLLCLCISURE CELL ECE EEE ELCLECEELCECECLCEE CEE ELEC EEE EE EEE ENT ENEEENEENNENU EN E UNE N NE EN RENRRE NN R NN TRNNTRR

6- Rear shock absorber oil

8- Rear shock absorber spring

AFTER-RACE CHECK POINTS

fer racing, Frst deun the motoryce and then nspeci he en- tire motorcyce, with special attention to the items listed in MAINTENANCE» table (Appendix A}, such as the air deuner, earburetor, brakes, et. Cary out general lubricaton, and make adjusiment as netes- say. STORAGE (TCTONC] Wen the motorcycle is t be sored for any length of time, is Should be prepared for storage os follows: = en the entre motoryce thoroughp. = first carry out the operation mentioned hereunder, then fl the tank with fuel mixed with a tablier: place the hose [1 in a basi,loosen the drain srew (2) se on he lower ide of he bain, then drain the fuel and tighten he screw again. WARNING Never litter the environment with fuel, and let the engine running in open air, never il dosed rooms. -Lubrcate the drive chain and all the cables. = Spraÿ ol on al unpainted metal surfaces to prevent usting. vod geting il on rubber parts r in the brakes. = Set the motoreyle on a box or stand so that both wheels are raised of the ground. (IF hs cannot be done, ut boards un- der he front and rear wheel t keep dampness away from the fire rubber). - Tie a plostic bag over the exhaust pipe to prevent moisture from entering, =Put a over over He motoryce to Keep dust and dir from col. lecting on it. To put he motorcycle bak int he use ufr storage. - Make sure the spark plug is fight. -lthe fuel tank. = Run he engine to warm the ol then drain he oil. -Putin fresh ransmission oil (page 31). - Check all the points listed under the inspection and Adjusiment Section [Appendix A). - Lubricate the points [listed in the Lubrication Section {appendix A].

CLEANING IMPORTANT RECOMMENDATION Premised that, before the motorcycle washing, it is necessary to protect opportunely from the water the following parts: a) Rear opening of the muffler, b) Clutch and brake levers, hand grips, handlebar commuia- tors; d Air deaner intake; d) Fork head, wheel bearings; e) Rear suspension links, it is necessary ABSOLUTELY TO AVOID THAT HIGH PRESSURE JETS OF WATER OR AIR come to contact with THE ELECTRICAL PARTS AND FUEL INJECTION PARTS, especially the elec- tronic control unit (1) and the sensors group MAQ.S. (2).

1) Preparation for washing

Before washing, precautions must be taken to keep water out the following places:

• Reur opening of the mufler : 2 Cover with a plastic bag secured with rubber bands. «Cut and brake levers, hand grip, engine stop button: = Cover il plstc bags.

• Gr deaner intake: = Close up he opening with tape, or stuff in rags.

2) Where t be careul

vod spraying water with any great force near the following places: + C Air deaner « CUnder he fuel tank: A water get into the. igniton ai ar into the spark plug cop, the spark will jump through the water and be grounded ou. Wen this happens he motocycle il not start and the affect ed parts must be wiped dry Cork head, wheel beaings. « CRear suspension links.

= Remove the plastic bags, and clean the air leuner intake. = Luce he points ste he Maintenance Table {Appendx A). =Brely warm the engine Test he brakes before riding he motorcyce. WARNING*: Never wax or lubricate the brake disc Loss of braking and an accident could result. Clean the dise with an oilless solvent such ans acetone. Observe the sol- vent warnings. Wen remove grensers (1) to lubrcate reur suspension link needle begrings, is necessary t lubricate shock absorber lou er needl bearing [2 oo: remove nut (3) and bushing.

Description Operation Pre-delivery Description Operation Pre-delivery Engine oil Check level a Tyres Check pressure a To-stroke mix oi level Check level El Side stand Check operation a Coolant Check / Restore level a Side stand switch Check operation a Cooling system Check for leakage a Electrical equipment Check operation a Electric fans Check operation a Instrument panel Check operation El Spark plugs Check / Replace a Lights / Visual signals Check operation a Throttle body / Carburettor Check and adjust a Horn Check operation a Brakes / Clutch fluid Check level a Headlight Check operation a Brakes / Clutch Check operation a lgnition switch Check operation El Brakes / Clutch Check lines for leakage a Locks Check operation a Throttle control Check operation a Screws and nuts Check / Tighten a Throttie control Check / Adjust pla a Hose clamps Check /Tighten a Choke control Check operation 3 General lubrication = Flexible controls and transm.… Check / Adjust a General test a Drive chain Check / Adjust e & _:only for motorcycles with 2 stroke engine + : only for some models

IN ACCEPTING DELIVERY OF THIS MOTORCYCLE THE BUYER OR TRANSFEREE ACKNOWLEDGES THAT HE HAS THOROUGHLY INSPECTED THE MOTORCYCLE, AND FURTHER AGRÈES TO ACCEPT THE MOTORCYCLE AS 1S WITH ALL DEFECTS OR FAULTS, CONCEALED OR OBVIOUS. HE FURTHER AGREES THAT NO WARRANTIES ATTACH, EXPRESS OR IMPLIED, INCLUDING ANY WAR- RANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. THE BUYER OR TRANSFEREE INDEMNIFIES AND HOLDS HARMLESS CAGIVA USA, MV Agusta Motor S.p.A., THEIR AGENTS AND EMPLOYEES. FOR ANY FAILURE OF PERFORMANCE, COST OF SERVICE, OR REPAIR. THE BUYER FURTHER ACKNOWLEDGES THAT THIS MOTORCYCLE 1S NOT IN- TENDED FOR USE ON PUBLIC STREETS, ROADS, HIGHWAYS, OR TRAILS UNDER PUBLIC JURISDICTION AND THAT USE ON SUCH MAY VIOLATE STATE AND FEDERAL LAW. Noise emission warranty MY Agusta Motor 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 sys- tem for purposes other than resale, and to all subsequent buyers. Warranty claims should be addressed to Cagiva U.S.A. 2300 MARYLAND ROAD.

215-830-3300 PAR a CLLCLALAL EL

PAR Capl2 GB 19-07-2007 11:06 Pagina 103 Tampering war Tampering with Noise Con System Prohibited. Federal low prohibits the following acts or causing thereof: A1} 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 ulfimate purchaser or while it is in use, and 12} the use of the vehicle after such device or element of de- sign has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the ac listed below.

1) Removal of, or puncturing the muffler, baffles, header pipes

or any ofher component which conducts exhaust gases. 2} Removal or punduring of any part of the intake system.

3) Lack of proper maintenance.

4) Replacing any moving part of the vehide, or paris of the

@xhaust or intake system, with parts other than those speci- fied by the manufacturer. Le product should be checked for repair ar replacement if the motoreyle noise has increased significantly through us. Otherwise, the owner may betome subject to penalies under State and tal ordinancs,

Cap12_cB 19-07-2007 11:06 Pagina 104 SPARK ARRESTER The TE/TXC/SMR models are equipped with a LLS. Forest Service approved spark arrester for maximum efficenty and performante.

! SPARK ARRESTER" MAINTENANCE AND

CLEANOUT INSTRUCTIONS Proceed os follous: A: Fist tu counterdodkwise fastening rer pin {1} then re- move sud, screws (2) and LH. side panel (3). Using un 8 mm Tshaped spanner on the outside and a 10 mm Tshaped spanner on he inside, remove the lcking screw (4 of he mulfler.

B: Remove the spring [5] and with an 8 mm Tshaped spanner remove he crew (8; then pull out he mulfler. Note*: If silencer or exhaust are difficult to remove, help to slide them apart by tapping gently with a rubber or plastic hammer. €: remove he six rives (6) and he endep {7} from slencers oûy; D: examinate SPARK ARRESTER conditions and remove, fnec- essary, carbon parties from ie SPARK ARRESTER screen; E: necessary, info air on the SPARK ARRESTER screen, in the opposte direction in respect of the exhausted gas flow FE À F: assemble the front endeup on he slence‘s body, mounting he screws in the correct position, providing a fight connec- fion between endeup and silencer's body, using, neces- sary, a silicone poste; 6: rassemble he slencer on motrbike, fhen LH. side panel and saddl. Due to the SPARK ARRESTER position on the silence, if you meed only to check ne SPARK ARRESTER conditions you can: A: disassemble the silence from motorbike; : check SPARK ARRESTER conditions simply looking into he i- lence from front endeap opening; iF the check is poste, you can proceed in re-assembling de lencer on emo the check is negañive,proceed with the maintenance and dleanout procedure. 8° æ _Æ TN e

Tampering Warning: E Tampering with Noise Control System Prohibited. Federal law prohibits the following acts or causing therefor: 1lTre 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 deery to the ultimate purchaser ar While it is in use, an

2) The use of the vehicle her 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, bulles, 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 penal- ities under state and local ordinances. PAR a

Batter Brake Brake disc deanin Brake disc warpag Brake disc wear . Brake pad assembly Brake pad weur . Brake pad dsossembil Chain lubrication Checks after every competitior Checks during running Check of air filter Check of chain, pion, croun wear Check of dlutch fluid level Check of cooling lui Check of front brake Check of engine ol Check of rear brake fluid level Cleaning the air filter Guth Clutch control. “49 Engine où replacement 42 Engine EL TG). Engine start Engine stop. Gearbox outletpinio General deaning Handlebar commutators Handlebarposton change Hegdlomp bubs replacement Hydraulie dut bling [ee Agnition

Lamp light plote replacement Long inactivity Rear tilig Removal tank . Removing the front wheel. Removing the rear wheel . Running in

Steering lock Side stand Spark arresier Spark plug Spark plug check Special took: Starting decompressor

Wheel pin bendin Wheel spokes Wheels.

Model year (2008)(@)

10- SPEED /RPM (Indid

DUUEUEEIE EE EEEMENEEENTENEENEENEEENEENENEEEEEENEENEUENENNNNNNNNNENNNNNNNNNENNENNNNNNNNNNNENNNN 117 BEBE

15 did (4 2 its) {uiuste 4)

DOUDOU CLELLE LL] ASIRERE

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