TC 250 - Motorcycle HUSQVARNA - Free user manual and instructions

Product Type	Off-road competition motorcycle
Brand	HUSQVARNA
Model	TC 250
Engine	Single-cylinder 4-stroke, liquid cooling, 249.5 cm³, bore 76 mm, stroke 55 mm, compression ratio 12.9:1
Fuel System	Unleaded gasoline 98 octane, tank 9.2 L (reserve 1.8 L), carburetor Keihin FCR-MX 37 mm
Ignition	Capacitive discharge electronic, digital variable advance, spark plug NGK CR8EB (gap 0.7 mm)
Primary Drive	Pinion 20 teeth, crown 67 teeth, ratio 3.350
Transmission	6-speed constant mesh, ratios: 1st 1.866, 2nd 1.529, 3rd 1.263, 4th 1.086, 5th 0.954
Clutch	Multi-disc oil bath, hydraulic actuation
Secondary Drive	Chain, pinion 12 teeth, crown 50 teeth, ratio 4.166
Front Suspension	Inverted telescopic hydraulic fork, stem Ø 45 mm, travel 300 mm, adjustable compression and rebound
Rear Suspension	Progressive with hydraulic mono-shock, travel 325 mm, adjustable preload, compression and rebound
Brakes	Front: fixed disc Ø 260 mm, hydraulic floating caliper; Rear: floating disc Ø 240 mm, hydraulic floating caliper
Tires	Front: 80/100 x21" Pirelli MT 32; Rear: 100/90 x19" Pirelli MT 32; cold pressure front 0.9-1.0 kg/cm², rear 0.8-0.9 kg/cm²
Dimensions (L x W x H)	2200 mm x 820 mm x 1270 mm
Seat Height	970 mm
Instrumentation	Digital display with speed, odometer, trips, clock, RPM, max speed, average speed, ride time
Starting	Kick-start with automatic and manual decompressor
Coolant	Capacity 1.1-1.3 L
Engine/Transmission Oil	Oil change with filter: 1.7 L; simple drain: 1.5 L. See lubrication table page 44
Safety	Hydraulic brakes, steering lock, emergency engine stop, manual decompressor
Periodic Maintenance	Oil change, level checks, air filter cleaning, chain adjustment, general lubrication, brake and suspension inspection

Frequently Asked Questions - TC 250 HUSQVARNA

How to start the engine when cold?

Turn the fuel valve to ON, put in neutral, pull the black choke, twist the throttle twice, pull the clutch and press the start button (or use the kick starter). Release the clutch after starting.

What engine oil to use and how to check the level?

Use a quality 4-stroke engine oil, recommended viscosity (see table page 44). With the engine warm and motorcycle upright, remove the check screw (1); oil should seep slightly. Top up through the filler cap (2).

How to adjust the chain tension?

Lower the rear wheel to align sprockets. Push the chain forward; slack should be 0-2 mm. Loosen axle nut and locknuts, turn adjuster screws, then retighten.

What checks to perform before each ride?

Check oil, fuel and coolant levels, operation of throttle, clutch, brakes, suspension, tire pressure, chain condition, air filters, exhaust, tightness and lights (road models).

How to clean the air filter?

Remove the seat and battery tray, take out the filter. Wash it with a specific detergent (Agip Filter Clean or equivalent), rinse, dry, soak with special oil (Agip Foam Air Filter Protection), squeeze out excess. Grease the edge before reassembly.

What type of fuel to use?

Unleaded gasoline 98 octane. If the engine pings, change brand or use a higher octane fuel. Do not exceed the lower level of the filler neck.

How to adjust the suspension according to terrain?

For hard terrain: softer compression. Sandy: firmer compression and rebound, preload to lower rear. Muddy: stiffer springs. Proceed in increments of one click at a time. Check fork oil level if adjustments are insufficient.

How to bleed the brake system?

After fluid change or if lever is spongy, attach a hose to the bleed screw, open it, operate lever/pedal until fluid appears without bubbles. Maintain pressure, close screw, top up reservoir. Use DOT 4.

What to do after a fall?

Carefully inspect the throttle, brakes, clutch and all controls. Check for damage. If necessary, bleed brakes if lever travel changes. Consult a Husqvarna dealer if in doubt.

What is the engine break-in procedure?

Perform about 2 hours of moderate riding. The first half hour at very low speed without abrupt acceleration. Gradually increase revs. After 2 hours, you can use the motorcycle for competition. Perform an oil change after break-in.

USER MANUAL TC 250 HUSQVARNA

Side view of a white and black Husqvarna TE250 motorcycle with visible tracks and wheels (no text or symbols on the bike body)

Side view of a Mascat 250 motorcycle with visible tracks and wheels (no text or symbols on the vehicle itself)

R: A RICHIESTA (VEDERE PAGINE 262 e 266)
R: UPON REQUEST (SEE PAGES 262 and 266)
R: SUR DEMANDE (VOIR PAGES 262 et 266)
R: AUF ANFRAGE (SEHEN SEITEN 262 und 266)
R: BAJO PEDIDO (VER PÁGINAS 263 y 267)

Side view of a white and gray semi-motor motorcycle with visible engine and wheels (no text or symbols on the bike body)

R: SMR

Stylized black-and-white graphic of a stylized character resembling a bell or hat with a crown-like shape (no text or symbols)

TE 250-450-510, TC 250-450-510, SMR 400-450-510/2006

CARATTERISTICHE - USO - MANUTENZIONE SPECIFICATIONS - OPERATION - MAINTENANCE CARACTERISTIQUES - UTILISATION - ENTRETIEN MERKMALE - GEBRAUCH - WARTUNG CARACTERISTICAS - USO - MANTENIMIENTO

Unless specified, data and prescription are referred to all t he models.

Welcome to the Husqvarna motorcycling Family!

Your new Husqvarna motorcycle is designed and manufactured to be the finest in its field. The instructions in this book have been prepared to provide a simple and understandable guide for your motorcycle's operation and care.

Follow the instructions carefully to obtain maximum performance and your personal motorcycling pleasure. Your owner's manual contains instructions for owner care and maintenance. Information covering repair of major units such as engine, transmission, etc. 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 262, 264, 266. Work of this kind requires the attention of a skilled mechanic and the use of special tools and equipment.

Your Husqvarna dealer has the facilities, experience and original parts necessary to properly render this valuable service.

This “Owner’s Manual” and the “Purchase Registration Booklet” are parts and parcels of the motorcycle, hence, they have to remain with the motorcycle even when sold to another user. This motorcycle uses components designed thanks to systems and state of the art technologies which are thereafter tested in competition.

In competition motorcycles, every detail is verified after each race in order to always guarantee better performance. For correct functioning of the vehicle, it is necessary to follow the maintenance and control table found on page 282-288.

PRESENTATION

Side view of a Mascat 250 motorcycle with visible tracks and wheels (no text or symbols on the bike body)

MOTOCROSS

Black-and-white photo of a motorcyclist mid-jump, wearing gear and helmet (no visible text or symbols)

AVIS IMPORTANT

1) The TC models are guaranteed COMPETITION motorcycles exempt from functional defects, the suggested maintenance table for competition use is shown on page 282.

Side view of a white and gray semi-traw bike with visible dynamics and wheels (no text or symbols on the bike body)

SUPERMOTARD

Black-and-white photo of a motorcyclist in action on a paved field (no visible text or symbols)

Side profile of a white and black Mascat with visible wheels and engine components (no text or symbols on the bike body)

ENDURO

Person riding a dirt bike outdoors with mountainous background (no visible text or symbols)

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

Side view of a Mascat 250 motorcycle with visible tracks and wheels (no text or symbols on the bike body)

Black-and-white photo of a motorcyclist mid-air during a jump, wearing gear and racing suit (no visible text or symbols)

Side profile of a white and gray semi-traw bike with visible dynamics and wheels (no text or symbols on the bike body)

SUPERMOTARD

Motorcyclist in action on a paved field, wearing helmet and racing gear (no visible text or symbols)

Side view of a Husqvarna TE250 motorcycle with visible tracks and wheels (no text or symbols on the bike body)

ENDURO

Black-and-white photo of a rider on a dirt bike in a grassy outdoor field with mountains in the background (no visible text or symbols)

If TE and SMR are transformed in COMPETITION MOTORCYCLES (with FULL POWER ENGINE), the suggested maintenance table for competition use is shown on pages 282 and 288.

IMPORTANT

The reference for recognition of the guarantee will be the MOTORCYCLE CONFIGURATION, as shown below:

A) - STANDARD MOTORCYCLE, STREET LEGAL: with LIMITED POWER ENGINE B) - COMPETITION MOTORCYCLE, RACING USE: with FULL POWER ENGINE

This motorcycles 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 cause severe damage to the engine.

This motorcycles was not designed for urban use and is not equipped with a cooling fan and thermostat. Long stops at the traffic lights can cause overheating and the boiling of radiator water.

This motorcycles is setup for competition use and therefore guarantees maximum performance with the rider alone. It is thereby not recommended to use the vehicle on circuits or off-road with a passenger.

ALWAYS keep in mind that these motorcycles have been designed strictly for competition use, that is, for conditions of usage very different from those presented on the road.

In order to maintain the vehicle's “Guarantee of Functionality”, the client must follow the maintenance program indicated in the user's manual by carrying out maintenance checks at authorized HUSQVARNA dealers. The cost for substituting parts and for the labour necessary in order to respect the maintenance plan, is charged to the client. NOTE: the guarantee is EXTINGUISHED in the case where the motorcycle is rented.

Note

- References to the “left” or “right” of the motorcycle are in the sense of a person facing forwards.

● Z: number of teeth
● A: Austria

AUS: Australia

B: Belgium

BR: Brazil

CDN: Canada

CH: Switzerland

D: Germany

E: Spain

F: France

FIN: Finland

GB: Great Britain

I: Italy

J: Japan

USA: United States of America

- Where not specified, all the data and the instructions are referred to any and all Countries.

Read this manual carefully and pay special attention to statements preceded by the following words:

WARNING*: Indicates a possibility of severe personal injury or loss of life if instructions are not followed.

CAUTION*: Indicates a possibility of personal injury or equipment damage if instructions are not followed.

Note*: Gives helpful information.

Parts Replacement

When parts replacement is required, use only Husqvarna ORIGINAL parts.

Préliminaires

WARNING*: After an upset, inspect the motorcycle carefully. Make sure that the throttle, brake, clutch and all other systems are undamaged. Riding with a damaged motorcycle can lead to a serious crash.

WARNING*: Never attempt to start or operate your motorcycle unless you are wearing appropriate protective clothing. Always wear a motorcycle helmet, motorcycle boots, gloves, goggles and other appropriate protective clothing.

WARNING*: This motorcycle is a state of the art competition bike. Do not attempt to start or ride this motorcycle until you have received expert instruction and are in excellent physical condition.

PRECAUTIONS FOR CHILDREN 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.

LUBRICATION TABLE, SUPPLIES......44

CONTROLS 46

RIDING....80

SERVICE LIMITS....198

OPTIONAL PARTS LIST......262,264,266

APPENDIX 268

NOTE FOR USA/CDN- AUS MODELS .. 275-278

PRE-DELIVERY INSPECTION 279

PERIODIC MAINTENANCE - ADJUSTMENT....282-288

ALPHABETICAL INDEX 298

IDENTIFICATION DATA

The engine number is printed on the upper side of the engine case, whereas the frame number is printed on the steering tube (see on page 20).

Always state the number stamped on the frame (and write it on this booklet), when placing orders for spare parts, or when asking for information on your motorcycle.

FRAME NUMBER

RESUME Page

PRESENTATION......4

AVIS IMPORTANT 6

ELEMENTS D'IDENTIFICATION......18

DONNEES TECHNIQUES ......26

TABLEAU DE GRAISSAGE, RAVITAILLEMENTS ....44

COMMANDES....46

MODE D'EMPLOI DE LA MOTO....80

LIMITE D'USURE ....198

SYSTEME D'ALLUMAGE/SYSTEME ELECTRIQUE....226-232

OUTILS SPECIAUX....250

COUPLES DE SERRAGE....252 KIT....260

ELEMENTS EN OPTION ......262,264,266

APPENDICE....268

NOTE POUR LES MODELES USA/CDN- AUS ....275-278

OPERATIONS DE PRÉ LIVRAISON .....280 ENTRETIEN PERIODIQUE -

REGLAGES....282-288

INDEX ALPHABETIQUE ....298

ELEMENTS D'IDENTIFICATION

The full 17 digit serial, or Vehicle Identification Number, is stamped on the steering head tube (R.H. side).

NUMERO D'IDENTIFICATION DU MOTOCYCLE (V.I.N.)

(●): Year of the model

(●): An du modèle

Close-up of mechanical components with a numbered label (1) pointing to a specific part, no readable text or symbols present.

Close-up of an internal mechanical assembly with hoses and components (no visible text or symbols)

1. Matricola telaio
2. Matricola motore
3. Matricule cadre
4. Matricule moteur
5. Frame serial number
6. Engine serial number
7. Rahmen Nr.
8. Motor Nr.
9. Matrícula bastidor
10. Matrícula motor

NUMERO DI IDENTIFICAZIONE DEL MOTOCICLO (V.I.N.)

The full 17 digit serial, or Vehicle Identification Number, is stamped on the steering head tube (R.H. side).

NUMERO D'IDENTIFICATION DU MOTOCYCLE (V.I.N.)

* Varies-Can be 0 thru 9 or X (check digit for factory use)

graph TD
    A["TE 450"] --> B["USA"]
    B --> C["Model designation"]
    C --> D["ZCG ECENB"]
    D --> E["* 6 v 100000"]
    E --> F["Sequential number (+)"]
    F --> G["Model year (2006)(●)"]

* Varies-Can be 0 thru 9 or X (check digit for factory use)

graph TD
    A["TE 510 USA"] --> B["ZCG"]
    A --> C["ECEHB"]
    A --> D["Model designation"]
    D --> E["* 6 v"]
    D --> F["Sequential number (+)"]
    D --> G["100000"]
    D --> H["Model year (2006) (●)"]

* Varies-Can be 0 thru 9 or X (check digit for factory use)

* Varies-Can be 0 thru 9 or X (check digit for factory use)

TC 450 USA Model designation ZCG TC 450 * 6 V 000001 Sequential number (+) T Model year (2006) (●)

* Varies-Can be 0 thru 9 or X (check digit for factory use)

⑤

graph TD
    A["TC 510 USA"] --> B["Model designation"]
    B --> C["ZCG TC 510"]
    C --> D["* 6 v 000001"]
    D --> E["Sequential number (+)"]
    E --> F["Model year (2006) (●)"]

* Varies-Can be 0 thru 9 or X (check digit for factory use)

⑦

graph TD
    A["SMR 450"] --> B["USA"]
    B --> C["Model designation"]
    C --> D["ZCG"]
    C --> E["AFENB"]
    C --> F["* 6 v"]
    C --> G["100000"]
    F --> H["Sequential number (+)"]
    G --> I["Model year (2006) (●)"]

* Varies-Can be 0 thru 9 or X (check digit for factory use)

⑧

graph TD
    A["SMR 510"] --> B["USA"]
    B --> C["ZCG"]
    B --> D["AFEHB"]
    C --> E["Model designation"]
    D --> E
    E --> F["Sequential number (+)"]
    F --> G["* 6 v 100000"]
    G --> H["Model year (2006) (●)"]

* Varies-Can be 0 thru 9 or X (check digit for factory use)

Close-up mechanical component with numbered annotation (1) and arrow pointing to a detail area (no readable text or symbols)

Close-up of an automotive engine bay with visible hoses and components (no text or symbols)

1. Matricola telaio

2. Matricola motore

3. Frame serial number

4. Engine serial number

5. Matricule cadre

6. Matricule moteur

7. Rahmen Nr.

8. Motor Nr.

9. Matrìcule bastidor

10. Matrìcule motor

UBICAZIONE COMANDI

1. Front brake lever
2. Throttle grip
3. Rear brake control pedal
4. Choke (L.H. side)
5. Fuel tank filler cap
6. R.H. commutator (engine electric start)
7. Rear shock absorber spring preload adjustment
8. Rear shock absorber compression damper adjustment (low and high damping speeds)
9. Rear shock absorber extension damper adjustment

POSITION DES COMMANDES

Technical diagram of a motorcycle with numbered parts and exploded views, likely for assembly or maintenance instructions.

AVVIAMENTO A PEDALE A RICHIESTA (VEDERE PAGINE 262 e 266)

KICK START UPON REQUEST (SEE PAGES 262 and 266)

Type......single cylinder, 4 stroke

Cooling ....liquid

Bore (250)....2.99 in.

Bore (400)....3.6 in.

Bore (450-510)....3.81 in.

Stroke (250) 2.17 in.

Stroke (400-450)......2.39 in.

Stroke (510)......2.67 in.

Displacement (250)....15.22 cu. in.

Displacement (400)......24.37 cu. in.

Displacement (450)......27.39 cu. in.

Displacement (510)....30.56 cu. in.

Compression ratio 12,9:1

Starting (TC) kick start (with automatic decompressor)

Starting (SMR).....electric (with automatic decompressor)

Starting (TE) .....electric and kick start (with automatic decompressor)

TIMING SYSTEM

Type ......double overhead camshaft; 4 valve

Valve clearance (with engine cold)

Intake....0.004 ÷ 0,006 in.

Exhaust 0.006 ÷ 0,008 in.

DONNEES TECHNIQUES

MOTEUR

Type....Dry sump with two oil pump rotor and cartridge filter

IGNITION

Type ....C.D.I. electronic, with variable advance (digital control) Spark plug type ....NGK CR8EB Spark plug gap ....0.027 in.

LUBRIFICATION

Spillo conico (TC)......OBDVR

Spillo conico (TE/SMR)......OBDVT

(Throttle Position Sensor)

Diametro diffusore ......mm 38

Getto massimo 165

Getto minimo....25

Valvola gas....1.0

Spillo conico....52

Tacca fiss. spillo 4a

Type (250....."Keihin" FCR-MX 37 with acceleration pump and throttle position sensor

Tipo (450-510) Keihin" FCR-MX 41 with acceleration pump and throttle position sensor

Venturi diameter (250)......1.46 in.

Venturi diameter (450-510) 1.61 in.

High speed jet (250 175

High speed jet (450-510) 180

Low speed jet (250, TE-SMR 450/510) ....50

Low speed jet (TC 450-510)....55

Starting jet (250)....72

Starting jet (450-510) 85

Starting air jet....0.16 in.

Main air jet 200

Low air jet 100

Floater ......g 11.2

Throttle piston....15

Metering pin (TC)......OBDVR

Metering pin (TE_SMR)......OBDVT

Metering pin slot (TE_SMR)....3rd

Metering pin slot (TC 250)....4th

Metering pin slot (TC 450-510)....5th

Idle mixture adjusting screw (turns)....1+1/2

CARBURETOR (SMR 400)

Type ...... "Mikuni" TMR 38 with acceleration pump and T.P.S. (Throttle Position Sensor)

Venturi diameter 1.50 in.

High speed jet 165

Low speed jet 25

Throttle piston....1.0

Metering pin....52

Metering pin groove....4th

Main nozzle....P4

Idle mixture adjusting screw 2

Acceleration pump jet....30

PRIMARY DRIVE

Drive pinion gear- Clutch ring gear (TC 250) ......Z 20- Z 67

Drive pinion gear- Clutch ring gear (TE 250) ......Z 24- Z 88

Drive pinion gear- Clutch ring gear (450-510)......Z 23- Z 63

Transmission ratio (TC 250) 3,350

Transmission ratio (TE 250)....3,666

Transmission ratio(400-450-510)....2,739

CARBURATEUR (250-450-510)

Gicleur principal (250)....175

Gicleur principal (450-510) 180

Gicleur ralenti (250, TE-SMR 450/510) ....50

Gicleur ralenti (TC 450-510) ....55

Gicleur de starter (250)....72

Gicleur de starter (450-510)....85

Gliceur air starter ....mm 4

Type ......oil bath multiple disc clutch, hydraulic control

TRANSMISSION

Type......constant mesh gear type

Transmission ratio (TE-SMR)

1st gear....2,000 (z 28/14)

2nd gear....1,611 (z 29/18)

3rd gear 1,333 (24/18)

Transmission ratio (TC)

1st gear....1,866 (z 28/15)

2nd gear (250) 1,529 (z 26/17)

2nd gear (450-510)....1,444 (z 26/17)

Transmission ratio (TE 250-450)....3,846

Transmission ratio (TC 450-510). 3,571

Transmission ratio (TC 250)....4,166

Transmission ratio (TC 510).... 3,357

Transmission ratio (SMR 400-450-510) 3,000

EMBRAYAGE

1st gear (TE 250) ......28,205

1st gear (TE 450) ......21,070

1st gear (TE 510)....19,565

1st gear (TC 250) ......26,055

1st gear (TC 450) 18,261

1st gear (TC 510)....17,159

1st gear (SMR 400-450-510) ...... 16,435

2nd gear (TE 250) ......22,721

2nd gear (TE 450) 16,973

2nd gear (TE 510) 15,761

2nd gear (TC 250) ......21,348

2nd gear (TC 450) 14,130

2nd gear (TC 510) ......13,283

2nd gear (SMR 400-450-510) ...... 13,239

3rd gear (TE 250) 18,803

3rd gear (TE 450) 14,047

3rd gear (TE 510) ......13,043

3rd gear (TC 250) ......17,631

3rd gear (TC 450) ......12,357

3rd gear (TC 510) ......11,616

3rd gear (SMR 400-450-510)....10,956

RAPPORTS TOTAUX DE TRANSMISSION

4th gear (TE 250) ......15,329
4th gear (TE 450) ......11,451
4th gear (TE 510)....10,633
4th gear (TC 250)....15,172
4th gear (TC 450) ......10,633
4th gear (TC 510) 9,995
4th gear (SMR 400-450-510)....8,932
5th gear (TE 250) ......12,974
5th gear (TE 450) 9,692
5th gear (TE 510) 9,000
5th gear (TC 250) ......13,324
5th gear (TC 450) 9,338
5th gear (TC 510) 8,778
5th gear (SMR 400-450-510) .....7,560
6th gear (TE 250) ......11,491
6th gear (TE 450) 8,584
6th gear (TE 510) ......7,971
6th gear (SMR 400-450-510) ......6,696

Anteriore (SMR)......SANREMO in lega leggera: 3,50x17"

Posteriore (TE) ......TAKASAGO “Excel” in lega leggera: 2,15x18"

Posteriore (TC) ......TAKASAGO “Excel” in lega leggera: 1,85x19"(250); 2,15x19"(450-510)

Posteriore (SMR) .....SANREMO in lega leggera: 4,25x17"

FRAME

Type ....Single-beam with circular steel tubes; light alloy rear frame

FRONT SUSPENSION

Type .... "Upside-Down" telescopic hydraulic front fork with advanced axle (adjustable in compression and rebound stroke); stanchions tubes ø 1.77 in. (250) and ø 1.97 in. (400-450-510) Legs axis stroke(TE, TC) 11.8 in.; (SMR) 9.84 in.

REAR SUSPENSION

Type....progressive with hydraulic single shock absorber

Wheel stroke (TE) 12.6 in.

Wheel stroke (TC)....12.8 in.

Wheel stroke (SMR)....1 1 .4 in.

FRONT BRAKE

Type....fixed disc 10.24 in. dia (TE, TC). floating disc 12.6 in. dia (SMR)

with hydraulic control; floating caliper (TE, TC) or fixed caliper (SMR)

REAR BRAKE

Type.... floating disc, ∅ 9.45 in. with hydraulic control and floating caliper

RIMS

Front (TE, TC) TAKASAGO "Excel" in light alloy: 1.6x21"

Front (SMR)..SANREMO in light alloy: 3,50x17"

Rear (TE)......TAKASAGO “Excel” in light alloy: 2,15x18”

Rear (TC) ..... TAKASAGO "Excel" in light alloy: 1,85x19"(250); 2,15x19"(450-510)

Rear (SMR) ..SANREMO in light alloy: 4,25x17"

CADRE

Radhub (SMR)....290 mm

VORDERRADBREMSE

Delantera (SMR)...SANREMO in liga ligera: 3,50x17"

Trasera (TE) ...TAKASAGO “Excel” in liga ligera: 2,15x18”

a freddo (anteriore TC)....0,9÷1,0 Kg/cm2

a freddo (anteriore TE)....0,9..1,0 Kg/cm2

(●) a freddo (posteriore TE)....1,0 Kg/cm2

Cold tire pressure (front TC)....0,9,0 Kg/cm2; 12.84.2 psi

Cold tire pressure (rear TC).....0,8,9 Kg/cm2; 11.42.8 psi

Cold tire pressure (front TE)....0,9,0 Kg/cm2; 12.84.2 psi

Cold tire pressure (rear TE).....0,8,9 Kg/cm2; 11.42.8 psi

(●) Cold tire pressure (front TE)......1,1 Kg/cm2; 15.6 psi

(●) Cold tire pressure (rear TE)......1,0 Kg/cm2; 14.2 psi

(*)Cold tire pressure 1,4 kg/cm ^2 (front SMR).... 20 psi

(●)Cold tire pressure 1,8 kg/cm ^2 rider only (front SMR).... 25,6 psi

(●)Cold tire pressure 2,0 kg/cm ^2 rider and (front SMR)....28,4 psi passenger

(*)Cold tire pressure 1,6kg/cm ^2 (rear SMR) 22.7 psi

(●)Cold tire pressure (rear SMR).... 2,0 kg/cm ^2 rider only 28.4 psi

(●)Cold tire (rear SMR).... 2,2 kg/cm ^2 rider and passenger 31,3 psi

(●) Road use

(*) in case of racing use

PNEUS

Avant

(TE) ......Michelin ENDURO COMP. 3 ou

Pirelli MT 83 Scorpion;ou Dunlop 54R-D907;90/90x21"

(TC) Pirelli 51R-MT 32A;

80/100 x 21"

(SMR)....Pirelli MTR 21 DRAGON-EVO; 120/70-17"

Arrière

(TE)......Michelin ENDURO COMP. 3 ou Pirelli MT 83

Scorpion ou Dunlop 70R-D907; 120/90x18" (250); 140/80x18" (450 - 510)

(TC)......Pirelli NHS (62) MT 32; 100/90x19" (250); 110/90x19" (450 - 510)

(SMR) ......Pirelli MTR 22 DRAGON-EVO; 150/60x17"

froid (avant TE) ......0,9.-1,0 Kg/cm2

(trasero TE). 1,0 Kg/cm2e.

DIMENSION, WEIGHT, CAPACITY

Wheelbase (TC 250)....58.46 in.

Wheelbase (TC 450-510)....57.95

Wheelbase (TE 250)....57.87 in.

Wheelbase (TE 450-510)....57.95 in.

Wheelbase (SMR 400-450-510).....58.86 in.

Overall length (TC 250)......86.61 in.

Overall length (TC 450-510) ......85.51 in.

Overall length (TE 250)......88.19 in.

Overall length (TE 450-510)......87.1 in.

Overall length (SMR 400-450-510)......86.22 in.

Overall width (TC)....32.28 in.

Overall width (TE-SMR)....33.07 in.

Overall height (TC 250)....50 in.

Overall height (TC 450-510) .....50.39 in.

Overall height (TE 250)....50.39 in.

Overall height (TE 450-510)....50.79 in.

Overall height (SMR 400-450-510)......49.21 in.

Saddle height (TC 250)....38 in.

Saddle height (TC 450-510) ......38.58 in.

Saddle height (TE 250)....38 in.

Saddle height (TE 450-510)......38.58 in.

Saddle height (SMR 400-450-510)......36.02 in.

Minimum ground clearance (TC 250) ..13.19 in.

Minimum ground clearance (TC 450-510) 13.38 in.

Minimum ground clearance (TE 250) 13.19 in.

Minimum ground clearance (TE 450-510) 13.38 in.

Minimum ground clearance

((SMR 400-450-510)....10.63 in

DIMENSIONS, POIDS, CAPACITE

Empattement (TC 250) ......mm 1485

Empattement (TC 450-510)......mm 1472

Empattement (TE 250) ......mm 1470

Empattement (TE 450-510) ......mm 1472

Empattement (SMR 400-450-510) .....mm 1495

Kerb weight, without fuel
(TC 250)....lb 230.8
Kerb weight, without fuel
(TC 450) ... lb 242.5
Kerb weight, without fuel
(TC 510) lb 244.7
Kerb weight, without fuel
(TE 250)....lb 244.7
Kerb weight, without fuel
(TE 450).... lb 256.4
Kerbweight, without fuel
(TE 510) .... Ib 257.5
Kerb weight, without fuel ....
(SMR 400) lb 268.3
Kerbweight, without fuel ....
(SMR 450) .... Ib 269.4
Kerb weight, without fuel ....
(SMR 510) .... Ib 270.5

Fuel tank capacity, (1.58 Imp. Quarts, 1.9 US qt. reserve included) ....Imp. Gall. 2

US Gall. 2.4

Coolant capacity......Imp. Quarts 2.0÷2.4

Transmission oil

Oil and oil filter replacement ....

Imp. Quarts 1.5

U.S. Quarts 1.8

Oil replacement ....Imp. Quarts 1.3

U.S. Quarts 1.6

Poids en orde de marche, sans carburant
(TC 250) ......kg 104,7
Poids en orde de marche, sans carburant
(TC 450) ......kg 110
Poids en orde de marche, sans carburant
(TC 510) ......kg 111
Poids en orde de marche, sans carburant
(TE 250) ......kg 111
Poids en orde de marche, sans carburant
(TE 450) ......kg 116,3
Poids en orde de marche, sans carburant
(TE 510) ....kg kg 116,8
Poids en orde de marche, sans carburant
(SMR 400) ......kg 121,7
Poids en orde de marche, sans carburant
(SMR 450) ....kg 122,2
Poids en orde de marche, sans carburant
(SMR 510) ... kg 122,7

The cock, placed on the left side, has three positions:

OFF - Closed; the fuel does not come out;

ON - Open; the fuel flows from the main flux;

RES - Reserve; the fuel flows from the reserve flux.

When difficulties in flowing arise while running, set the right cock lever on RES position.

After filling up, take the cock on ON position again.

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 flow of the fuel to the carburetor. Therefore, the fuel filter should be serviced periodically. To service:

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;

COMMANDES

ROBINETS CARBURANT

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

SIDESTAND A sidestand (1) is supplied with every motorcycle.

WARNING\*: The stand is designed to support the weight of the MOTORCYCLE ONLY. Do not sit on the motorcycle using the stand for support as this could cause structural failure to the stand and could cause serious bodily injury.

Periodically check the side stand (see “Periodical maintenance card”); check that the springs are not damaged and that the side stand freely moves. If the side stand is noisy, lubricate the fastening pivot (A).

Mechanical assembly diagram showing a chain link and gear mechanism (no text or symbols)

CARBURANTE

Recommended fuel: premium grade unleaded fuel. (R.O.N. 98).

Note*: Do not continue operation if the engine pings or knocks. The engine will be damaged and could seize.

WARNING*: If "knocking" or "pinging" occurs, try a different brand of gasoline or higher octane grade.

WARNING*: Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke or allow flames or sparks in the area where the motorcycle is refueled or gasoline is stored.

WARNING*: Do not overfill the tank. After refueling, make sure the tank cap (1) is closed securely.

CARBURANT

1 Huaqatma

CARBURETOR CHOKE The starter knob, located on the left side of the carburetor, is used to enrich the mixture during the engine start. Pull out the knob to open the starter, and pull the lever upwards to close it.

The carburetor is equipped with two knobs:

1) BLACK KNOB: COLD start (°)

2) RED KNOB: WARM start (°)

Technical diagram of engine components with numbered labels pointing to specific parts

(°) Ver pagina. 85

STRUMENTO DIGITALE, SPIE (TE-SMR)

DIGITAL INSTRUMENT, WARNING LIGHTS (TE-SMR)

The motorcycle is equipped with a digital instrument; on the instrument are located 4 warning lights too: high beam, lights (with display lighting), blinkers and neutral.

1- BLUE warning light "HIGH BEAM"
2- GREEN warning light "LIGHTS"
3- GREEN warning light "BLINKERS"
4- GREEN warning light "NEUTRAL"

NOTES

• After the engine starting, for the first 2 seconds, the instrument shows the version of the checking SW; after the check, the instrument shows the last planned function.
• When the motorcycle engine is OFF, the instrument doesn't also show its functions.
• To select the instrument functions and to set to zero the functions, use the SCROLL knob (A).

INSTRUMENT DIGITAL, VOYANTS (TE-SMR)

- The instrument functions are the following, as shown below.

1- SPEED / ODO (figure 1)

2- SPEED / H (figure 2)

3- SPEED / CLOCK (figure 3)

4- SPEED / TRIP 1 (figure 4)

5- SPEED / STP 1 (figure 5)

6- SPEED / AVS 1 (figure 6)

7- SPEED / SPEED MAX (figure 7)

8- SPEED / TRIP 2 (figure 8)

9- SPEED / TRP 2 / CLOCK (figure 9)

10- SPÉED / RPM (engine r.p.m. numerical value) (figure 10)

1- SPEED / ODO (figure 1)

NOTE

The RPM function, shown on the vertical LED indicator, is ALWAYS on.

Close-up of a motorcycle front panel with display and control buttons (no readable text or symbols)

1- SPEED (kmh o mph) / ODO / RPM (figura 1)

• SPEED: motorcycle speed-maximum value: 299 kmh or 299 mph;
• ODO: odometer- maximum value: 99999 km;
• RPM: engine r.p.m. shown on the vertical LED indicator.

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.

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).

1- SPEED (kmh ou mph) / ODO / RPM (figure 1)

• SPEED: motorcycle speedmaximum
  value: 299 kmh or 299 mph;
• H: shows the running hours of the engine (data are saved in permanent memory every 10 minutes)- Maximum value: 9999:59;
• RPM: engine r.p.m. shown on the vertical LED indicator.

3- SPEED / CLOCK / RPM (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.

2- SPEED / H / RPM (figure 2)

• SPEED: motorcycle speedmaximum value: 299 kmh or 299 mph;
• TRIP 1: distance- maximum value: 999.9 km (the data will be lost after battery detachment). If the STP 1 will be set to zero, the functions TRIP 1 and AVS 1 will be set to zero too.
• RPM: engine r.p.m. shown on the vertical LED indicator.

The function TRIP 1 is ON unitedly with the function STP 1 (\*).

(*): see figure 5

4- SPEED / TRIP 1 / RPM (figure 4)

- SPEED: motorcycle speedmaximum value: 299 kmh or 299 mph;

- STP 1: miles/kilometers covered time- Reading from 0:00 to 23:59:59 (the data will be lost after battery detachment).

To activate the function STP 1, push the knob SCROLL (A) for more than 3 seconds.

- 1st step: function ON;

- 2nd step: stop to the counters;

- 3rd step: STP 1 zero-setting; TRIP 1 and AVS 1 data zero-setting;

- 4th step: function ON;

- 5th step: stop to the counters; and so following

NOTE

STP 1 data+TRIP 1 data=AVS 1 (*).

- RPM: engine r.p.m. shown on the vertical LED indicator.

(*): see figure 6

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

• SPEED: motorcycle speedmaximum value: 299 kmh or 299 mph;
• AVS 1: shows the covered average speed of the motorcycle, according with a distance (TRIP 1) and a miles/kilometers covered time (STP 1) (the data will be lost after battery detachment).

NOTE

If the STP 1 will be set to zero, the TRIP 1 and AVS 1 functions will be set to zero too.

- RPM: engine r.p.m. shown on the vertical LED indicator.

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

- SPEED: motorcycle speedmaximum value: 299 kmh or 299 mph; - V MAX: shows the motorcycle MAXIMUM speed (reached 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 than 3 seconds; - RPM: engine r.p.m. shown on the vertical LED indicator.

8- SPEED / TRIP 2 / RPM (figure 8)

- SPEED: motorcycle speedmaximum value: 299 kmh or 299 mph; - TRIP 2: distance- maximum value: 999, 9 km / miles (the data will 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. shown on the vertical LED indicator.

7- SPEED / V MAX / RPM (figure 7)

A E N E +5

7

km/h 86 108 MAX RPM

8

km/h 48 TRP 48.89 2 RPM

9- TRP 2 / CLOCK / RPM (figura 9)

• TRIP 2: distance- Max value: 999.9 km / miles (the data will be lost after battery detachment).
  To set to zero TRIP 2, push the knob SCROLL (A) for more than 3 seconds;
• 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 then, after 3 seconds, it is possible to increase the minutes;
• RPM: engine r.p.m. shown on the vertical LED indicator.

10- SPEED /RPM (engine r.p.m. 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.

9- TRP 2 / CLOCK / RPM (figure 9)

The throttle knob (1), 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 (*).

POIGNEE DES GAZ

Do not forget to tighten the screws (A) after the adjustment.

ATTENTION

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 (*).

COMMANDE FREIN AVANT

Do not forget to tighten the screws (B) after the adjustment.

ATTENTION

The motorcycle is equipped with a steering lock (1) on the R.H. side of the steering head tube. To lock it, proceed 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.

BLOC DE DIRECTION

(TE-SMR)

Close-up of mechanical components with a numbered label (1) pointing to a specific part, no readable text or symbols present.

COMMUTATORE DESTRO SUL MANU-BRIO

(TE-SMR)

The right commutator has the following controls:

1) Engine start button
3) Engine start - stop switch

L.H. HANDLEBAR COMMUTATOR (TE-SMR)

CONTROLS:

1) D High beam flash (self cancel-ling)

2) D Selection control High beam

Selection control Low beam

3) Left turn signals (automatic return)

→ Right turn signals (automatic return)

To deactivate the turn signals, press the control lever after its returning to center.

4) Warning horn

5) Lighting control of Low beams and High beam

Lighting control of Position light

• Off

COMMUTATEUR DROIT SUR LE GUIDON

(TE-SMR)

Labeled diagram of a bicycle steering wheel showing key parts: handle, grip, and lever with numbered annotations.

TE - SMR/J

Labeled diagram of a bicycle brake lever mechanism showing five numbered parts with Chinese annotations

PULSANTE ARRESTO MOTORE (TC)

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

BOUTON D'ARRET MOTEUR (TC)

The hydraulic clutch control lever is located on the left-hand side of the handlebar and is protected against dirt with a rubber guard. The clutch control position on the handlebar can be adjusted by loosening the lower fastening screw (A).

COMMANDE DE L'EMBRAYAGE

Do not forget to tighten the screw after the adjustment.

ATTENTION

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.

Mechanical assembly diagram showing motor components and wiring (no text or symbols visible)

COMANDO CAMBIO

The lever (1) is placed on the left-hand 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.

COMMANDE DU CHANGEMENT DE VITESSES

CAUTION*: Do not shift gears without disengaging the clutch and closing the throttle. The engine could be damaged by overspeed and shock.

WARNING*: Do not downshift when traveling at a speed that would force the engine to over-rev in the next lower gear, or cause the rear wheel to lose traction.

Before each ride, to prevent accidents or failures during ride, make sure to go through following list.

1. Check all fluids

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.

3. Check brakes

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

4. Check suspensions

Compress fork and rear suspensions. Look for oil leaks and ensure proper functioning.

MODE D'EMPLOI DE LA MOTO

CONTROLES PRELIMINAIRES

ATTENTION!

Check spokes and look for worn bearings.

Check rims and tyres.

Check tyre pressure.

1. Check chain rollers and sprockets

Check wear on chain rollers and sprockets

Ensure chain is correctly adjusted and lubricated.

1. Check air filter and intake system

Check that air filter is clean

Check all rubber connections and clamps.

1. Check exhaust system

Check hook up, look for cracks

Check muffler.

1. Check torque

A. Spark plug

B. Cylinder-head nuts

C. General check of torque

1. Check steering action

Check bearing play.

1. 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 lights and the horn are working correctly.

WARNING*: Failure to perform these checks every day before you ride may result in serous damage or a severe accident.

1. Contrôle des roues

(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 position;
3) pull the BLACK starter knob (2);
4) turn twice completely the throttle control grip (3).
5) pull the clutch control lever (4).

6) press the engine start-stop switch (6) then the start button (7). Release the clutch control lever (4).

Close-up of a mechanical engine component with hoses and valve (no visible text or symbols)

3

TE-SMR ①

Mechanical component with lever and handle assembly, labeled TE_SMR (no readable text or symbols beyond label)

Close-up of a mechanical component with no visible text or symbols

⑥ ⑦ TE-SMR

Mechanical component with lever and wrench, labeled (4), no readable text or symbols beyond label

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

1) shift gear pedal (1) in neutral position;
2) pull the RED starter knob (2);
3) pull the clutch control lever (3);

Mechanical assembly diagram showing a valve mechanism with no visible text or symbols

TE-SMR

Close-up of a mechanical lever handle and lever with a labeled component (no readable text or symbols)

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 control grip (3);
5) while maintaining slowly open the throttle control grip;

6) pull the clutch control lever;

7) press the engine start-stop switch (B) then the start button (1). Release the clutch lever.

IN CASO DI AVVIAMENTO A CALDO, NON EFFETTUARE LE OPERAZIONI 3 E 4.

WITH WARM ENGINE, DO NOT CARRY-OUT ITEMS no. 3 AND 4.

DÉMARRAGE DU MOTEUR (SMR 400)

Close-up of a mechanical component with no visible text or symbols

Technical diagram of a mechanical assembly with labeled parts and annotation A

Close-up mechanical assembly showing a pipe joint and valve (no visible text or symbols)

③

Close-up of a mechanical lever mechanism with a tool and directional arrow (no text or symbols visible)

B 4 TE-SMR

Close-up of a mechanical lever mechanism with no visible text or symbols

Starting decompressor

Though the engine is provided with an automatic decompressor, can be necessary, in some cases (carburetor flooding or starting difficulties due to a battery inadequate charge), to use the manual starting decompressor on the L.H. side of the handlebar. In these cases, pull the lever (5) whilst simultaneously pressing the starter button, release the lever (5) keeping the button pressed and afterwards release the latter as well.

In order to adjust the lever decompressor free play (approximately 3 mm-0.12 in.), the lever holder is provided with the adjuster (6); the adjustment can be also effected with the tightener (7) on the R.H. side of the engine (use this tightener if it is not possible to obtain the correct free play with the adjuster on the handlebar).

Close-up mechanical assembly showing hoses and components in a vehicle (no visible text or symbols)

5 6

AVVIAMENTO DEL MOTORE (TC)

1) set fuel cock on ON position;
2) shift gear pedal (1) in neutral position;
3) pull the starter knob (BLACK knob 2 for cold starting *, RED knob 3 for warm starting);
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.);

DÉMARRAGE DU MOTEUR (TC)

*: after a prolonged inactivity of the motorcycle or in presence of a low external temperature.

Close-up of a car engine bay with hoses and a valve, no visible text or symbols

1 TC

Close-up of a mechanical assembly with hoses and components, no visible text or symbols

Close-up of a mechanical engine component with hoses and springs (no visible text or symbols)

Close-up mechanical assembly showing internal components and a numbered label (4), no readable text or symbols present.

Close-up of a motorcycle's front wheel and hand lever assembly (no visible text or symbols)

Mechanical assembly diagram showing engine components and a numbered annotation (4), no readable text or symbols present.

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.
WARM STARTING: BEFORE MOTORCYCLE STARTING, PRESS RED CHOKE KNOB (3) ON CARBURETOR TOWARD THE INSIDE IN ORDER TO DEACTIVATE THE STARTING DEVICE.

In case the engine does not start, repeat this procedure.

Close-up of a motorcycle's handle and lever mechanism, labeled with number 5 (no text or symbols on the device itself)

Mechanical assembly diagram showing engine components and a numbered label (4), no readable text or symbols present.

6

Mechanical assembly diagram showing engine components with no visible text or symbols

Technical diagram of an engine component with numbered annotation pointing to a specific part

NOTA IMPORTANTE IN CASO DI AVVIAMENTO A FREDDO A BASSE TEMPERATURE

It is recommended to briefly warm-up the engine at idle until, after having disengaged the starter, there is a normal response from the engine when opening the throttle.

In this way the oil can reach all the surfaces needing lubrication and the coolant will reach the necessary temperature for correct engine function.

Avoid overheating the engine.

IMPORTANT

Never accelerate the engine after a cold start.

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

In the case of using a kick-starter, keep in mind the undermentioned note.

Kick start pedal

WARNING*: This high performance motorcycle can some times «kick back» strongly when you are starting it.

Do not attempt to start this motorcycle unless you are wearing high top heavy sided riding boots. You could seriously hurt you leg if the kickstarter kicked back and your foot slipped.

NOTE IMPORTANT DANS LE CAS DE LA MISE EN ROUTE A' FROID ET TEMPERATURES BAS

Close-up of a motorcycle's internal engine and drivetrain components (no visible text or symbols)

ARRESTO DEL MOTOCICLO E DEL MOTORE

STOPPING THE MOTORCYCLE AND THE ENGINE

• Close the throttle (1) completely so that the engine will help slow down the motorcycle.
• For normal braking, gradually apply both front and rear brakes while down shifting (for maximum deceleration, apply the front and rear brakes firmly).
• When stopped, pull the clutch lever and shift gear lever (2) in neutral position.
• Press the engine stop RED button (3).
• Close the fuel cock (4).

ARRET DU MOTOCYCLE ET DU MOTEUR

WARNING*: Independent use of the front or rear brake maybe advantageous under certain conditions. Use caution when using the front brake, especially on slippery surfaces. Improper use of the brakes can lead to a serious crash.

Close-up of a bicycle brake lever mechanism with a hand and two curved levers, no visible text or symbols

Close-up of a mechanical assembly with labeled parts (no readable text or symbols)

③ TE-SMR

4

Close-up of a mechanical lever handle and grip with labeled component (no text or symbols beyond label)

WARNING*: In the event of stuck throttle or other malfunction which causes the engine to run uncontrollably, IMMEDIATELY depress the engine stop button and hold it down. Control the motorcycle by normal use of the brakes and steering while holding the engine stop button down.

Before using the motorcycle for sporting activities run in the engine for two hours at least to increase the life and the performance of the engine.

During the first half-hour of driving we advise keeping a low speed and avoiding sudden accelerations. Never open the throttle fully.

Change the oil and carry out all the necessary maintenance operations. After the first half-hour of driving, lightly increase the rev number, but never run the engine at full throttle. Never keep low speeds when the high gears are inserted. Slowly drive the motorcycle for two hours before using it for sporting activities.

RODAGE

CHECKS WHILE RUNNING IN

• SPOKE TENSION OF WHEELS (see page 224);
• TIGHTENING OF WHEELS (see page 254-258);
• FORK PIN TIGHTENING (see page 254);
• CHAIN ADJUSTMENT (see page 150);
• STEERING BEARING PLAY (see page 120);
• HANDLEBAR TIGHTENING (see page 254);
• ENGINE GRIP TO FRAME (see page 254);
• SUCTION FITTING GRIP (see page 252);
• HEAD AND CYLINDER NUTS GRIP (see page 252)
• OFTEN CHECK THE BATTERY CHARGE CONDITION (see page 236.)

CONTROLES PENDANT LE RODAGE

• CONTROLE DE LA TENSION DES RAYONS DES ROUES (224);
• CONTROLE DU SERRAGE ROUES (se reporter à la page 254-258);
• CONTROLE DU SERRAGE GOUPILLE FOURCHE (se reporter à la page 254);
• CONTROLE DU REGLAGE CHAINE (se reporter à la page 150);
• CONTROLE DU JEU DES ROULEMENTS DE LA DIRECTION (se reporter à la page 120);
• CONTROLE DU SERRAGE DU GUIDON (se reporter à la page 254);
• CONTROLE DU SERRAGE DU MOTEUR SUR LE CADRE (se reporter à la page 254);
• CONTROLE DU SERRAGE DU RACCORD D'ASPIRATION (se reporter à la page 252);
• CONTROLE DU SERRAGE ECROUS, TETE ET CYLINDRE (se reporter à la page 252);

- CONTRÔLER FRÉQUENTEMENT L'ÉTAT DE CHARGE DE LA BATTERIE (VOIR PAGE 236)

KONTROLLEN WÄHREND DES EINFAHRENS

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).

CONTROLE DU NIVEAU DE L'HUILE

Note*: Have this operation made with warmed-up engine.

WARNING*: Be careful not to touch hot engine oil.

Technical diagram of a motorcycle engine showing labeled components with arrows and numbered annotations

SOSTITUZIONE OLIO MOTORE E PULIZIA- SOSTITUZIONE FILTRI METALLICI ED A CARTUCCIA

ENGINE OIL REPLACEMENT AND BAG FILTERS-FILTER CARTRIDGE CLEANING OR REPLACEMENT

WARNING\*: Be careful not to touch hot engine oil.

Drain the oil with WARM ENGINE; proceed as follows:

• remove oil filler cap (1);
• remove the engine guard (A);
  ● place an oil drain pan under the engine block;
• remove the oil drain cap (2), drain the used oil completely then clean the magneto on the cap;

VIDANGE D'HUILE MOTEUR ET NETTOYAGE- REEMPLACEMENT DES FILTRES A TAMIS ET DE LA CARTOUCHE FILTRANTE

Technical diagram of a vehicle's internal components with numbered labels pointing to parts A, 2, and 3.

Technical diagram of a vehicle's internal components with numbered parts labeled 4, 5, and 6

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.

WARNING

Avoid removing radiator cap when engine is hot, as coolant may spout out and cause scalding.

NOTE

Difficulties may arise in eliminating coolant from varnished surfaces. If this occurs, wash off with water.

REPLACEMENT OF COOLING FLUID

Place a vessel on the R.H. side of the cylinder, under the coolant drain screw (1).

FIRST remove the screw (1) then SLOWLY open the R.H. radiator cap; slope the motorcycle on the right side to drain the coolant easily in the vessel. Reassemble the screw (1). Pour the necessary quantity of coolant in the radiator then warm up the engine in order to eliminate any possible air bubble.

CONTROLE DU NIVEAU REFRIGERANT

Close-up of mechanical components with a numbered label (2) and an arrow pointing to a detail, no readable text or symbols present.

Close-up of an automotive engine component with hoses and a numbered annotation (1), no readable text or symbols present.

Close-up of a car engine bay with visible components and a numbered annotation (2), no readable text or symbols present.

Technical diagram of a mechanical assembly with labeled component '2'

Periodically check the connecting hoses (see “Periodical maintenance card”): this will avoid coolant leakages and consequent engine seizure: If hoses (A) show cracks, swelling or hardenings due to sheats desiccation, their replacement shall be advisable. Check the correct tightening of the clamps (B).

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).

WARNING*: Operation with damaged throttle cable could result in an unsafe riding condition.

Labeled diagram of a mechanical or electrical component with numbered parts 1, 2, 3, and 4 pointing to different cable types.

NOTE (SMR 400 excluded)

In case of throttle control cables (1) and (2) replacement it is necessary to respect, during reassembly, the measure A (10mm/0.4 in.), as shown in the picture. Then reassemble guard cover (B) using screw (3) and adjust throttle control cables on handlebar as shown on page 106.

To replace throttle control cables, first remove tha fuel tank as shown on page 114.

NOTE (exclu SMR 400)

ADJUSTING THE CARBURETTOR (SMR 400 excluded)

Adjust the carburettor with warm engine and with the throttle in closed position.

Work as follows:

• Turn slow running adjusting screw (1) on the left side of the bike, , until the engine is turning over at fairly high rpm (turn the screw clockwise to increase the rpm, and anticlockwise to decrease the rpm).
• Turn adjusting screw (2) clockwise until the fully closed position is reached then turn back 1,5 turns (250-450) or 2 turns (510).
• progressively loosen adjusting screw (1) to obtain the slow running required.

ADJUSTING THE IDLE (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 decrease the rpm).

REGLAGE DU CARBURATEUR (exclu SMR 400)

Technical diagram of an engine component with numbered parts labeled 1 and 2

REGISTRAZIONE CARBURATORE (SMR 400)

Adjust the carburettor with warm engine and with the throttle in closed position. Work as follows:

• Turn slow running adjusting screw (1) on the left side of the bike, , until the engine is turning over at fairly high rpm (turn the screw clockwise to increase the rpm, and anticlockwise to decrease the rpm).
• Turn adjusting screw (2) clockwise until the fully closed position is reached then turn back 2 turns.
• progressively loosen adjusting screw (1) to obtain the slow running required.

REGLAGE DU CARBURATEUR (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 decrease the rpm).

REGLAGE DU RALENTI SMR 400

Close-up of a mechanical assembly showing internal components and tubing (no visible text or symbols)

Close-up mechanical assembly showing a motor and suspension components (no visible text or symbols)

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

SPARK PLUG CHECK

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.

Close-up of an automotive engine bay with visible hoses and components, no text or symbols present

CAUTION*: Select a spark plug with a colder or hotter heat range carefully and cautiously. A spark plug with too hot a heat range may lead to preignition and possible engine damage. A spark plug with too cold a heat range may foul as the result of too much carbon buildup.

Before refitting the plug, thoroughly clean the electrodes and the insulator using a brass-metal brush. Apply a little graphite grease to the spark plug thread; fit and screw the spark plug by hand then tighten to the torque of 10÷12 Nm-7.4÷8.9 ft/lb. Loosen the spark plug then tighten it again to the torque of 10÷12 Nm-7.4÷8.9 ft/lb. Spark plugs which have cracked insulators or corroded electrodes should be replaced.

VOLTAGE REGULATOR (TE-SMR)

The voltage regulator (1) is fastened on the right side of the frame at the back of the steering sleeve.

Apply a little graphite grease to the spark plug thread; fit and screw the spark plug by hand then tighten to the torque of 10÷12 Nm-7.4÷8.9 ft/lb. Loosen the spark plug then tighten it again to the torque of 10÷12 Nm-7.4÷8.9 ft/lb.

Close-up of a mechanical component with a numbered annotation (1) pointing to a feature, no readable text or symbols present.

To check the valve clearance, proceed as follows, WITH COLD ENGINE:

First turn counterclockwise fastening rear pin (1) then remove the saddle; Set the fuel cock (2) on OFF position then loosen clamp (3) on the carburettor fuel hose; remove the hose from the fuel cock.

Remove the fuel tank fastening screw (A) then the fuel tank assembly with conveyors.

REGLAGE DU JEU DES SOUPAPES

Close-up of a mechanical component with a labeled arrow pointing to a circular feature, marked with letter A (no text or symbols beyond label)

Remove the spark plug (5), the four cylinder head cover fastening screws (6) and the cylinder head cover; Engage second gear and, moving the vehicle forwards and backwards, bring the piston to Top Dead Center (in this condition, the mark on the cylinder head is aligned with the two marks on the idle gear of the camshafts, as illustrated in the figure); Check, by means of a feeler gauge, that the valve clearance is 0,10÷0,15 mm (0.004÷0.006 in.) for INTAKE and 0,15÷0,20 mm (0.006÷0.008 in.) for EXHAUST; Otherwise, lift the retaining clip (7) using a hook, let the rocker arm slide to one side, extract the pad with a pair of pliers and check the thickness; Depending on the result, fit a new pad (as spare parts, pads are supplied ranging from 1.60 mm to 2.60 mm in steps of 0.05 mm) and return the clip and rocker arm; Check the valve clearance again and, if it's correct, reassembly the removed parts using the reverse procedure.

Close-up of a mechanical engine assembly with numbered components (no visible text or symbols)

Close-up of a mechanical gear assembly with no visible text or symbols

Close-up of mechanical gears and linkages in a vehicle (no visible text or symbols)

Close-up of mechanical gear assembly with numbered component (7), no visible text or symbols

CONTROLLO FILTRO ARIA

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.

CONTROLE FILTRE A AIR

Illustration of a mechanical component with a circular feature and curved motion lines, no text or symbols present.

Technical diagram showing labeled components of a mechanical or electrical assembly with numbered annotations

A 4 3

Technical diagram of a mechanical component with numbered parts labeled 5, 6, and B

Illustration of hands operating a mechanical component with a circular housing and a labeled section (no text or symbols)

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.

REGLAGE DU JEU DES PALIERS DU GUIDON

Side view of a white and black MiR100 motorcycle with visible dynamics and suspension components (no text or symbols)

If play is noticed, proceed with adjustment as follows:
- loosen steering sleeve nut (1);
- loosen four screws that fix steering head to fork rods (3);
- Turn the steering ring nut (2) clockwise of the steering sleeve proper tool, to adjust play properly;
- tighten steering sleeve nut (1) to a torque setting of 57,9÷65,1 Lb/ft; (78,4÷88,3 Nm)
- tighten four screws on the steering head (3) to a torque of 22,5÷26,5 Nm (16.6÷19.5 Lb/ft).

CAUTION*: Do not ride a motorcycle with damaged steering stem bearings. An unsafe handling condition can result.

Technical diagram of a mechanical assembly with numbered components labeled 1, 2, and 3.

ADJUSTMENT OF THE CONTROL LEVER AND CHECK OF THE FRONT BRAKE FLUID 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 system, hence an extension of the level stroke.

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.

Technical diagram of a mechanical assembly with numbered components and an inset view labeled B

TE-TC SPAKE 2.00

2.00

1 UP

SMR ①

TE-TC a 2

TE-TC + A 2 B -

A: to encrease clearance
B: to decrease clearance

CAUTION*: Do not spill brake fluid on to any painted surface or lenses.

CAUTION*: Do not mix two brands of fluid. Change the brake fluid in the brake line if 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.

REAR BRAKE PEDAL 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.

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.

WARNING

When the idle stroke figures are not met, the brake pads will be subjected to a fast wear that may bring to the TOTAL BRAKE INEFFECTIVENESS.

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

Technical diagram of a vehicle's internal components with labeled parts and directional arrow B

Close-up of a mechanical assembly with hoses and components, no visible text or symbols

ADJUSTMENT OF THE CONTROL LEVER AND CHECK OF THE HYDRAULIC CLUTCH FLUID 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 LUBRICATION-SUPPLIES 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,

REGLAGE DU LEVIER DE COMMANDE ET CONTRÔLE DU NIVEAU FLUIDE DE L'EMBRAYAGE HYDRAULIQUE

TC 1 2 B A 3 C D 4 mm (0.16 in.)

HYDRAULIC CLUTCH BLEEDING

Proceed as follows:

• remove screws (1), cap (2) and rubber pump diaphragm;
• remove the bleeding nipple (3);
• mount a syringe in the bleeding nipple hole, then refill with fresh fluid (see LUBRICATION TABLE on page 44).

CAUTION *: NEVER use brake fluid.

Refill 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 the top (A) of the clutch pump body (see picture). Reassemble the removed parts.

PURGE DE L'EMBRAYAGE HYDRAULIQUE

Agir comme suit:

Close-up mechanical assembly showing engine components and a numbered label (3), no readable text or symbols present.

① ② B A 4 mm (0.16 in.)

ADJUSTING THE SUSPENSIONS ACCORDING TO PARTICULAR TRACK 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.

HARD GROUND

Fork: softer compression adjustment.

Shock absorber: softer compression adjustment.

The softer adjustment for the two suspensions is also used both in compression and in extension when driving at top speed, in order to have better grip of the tires.

SANDY GROUND

Fork: have a harder compression adjustment, or replace the standard spring with a harder one, and make a softer compression adjustment and a harder extension adjustment at the same time.

Shock absorber: have a harder compression, and especially a harder extension adjustment. Work on the spring preload to lower the motorcycle rear side.

REGLAGE DES SUSPENSION PAR RAPPORT AUX CONDITIONS DE LA PISTE

Fork: have a harder compression adjustment, or replace the standard spring with a harder one.

Shock absorber: have a harder compression and extension adjustments, or replace the standard spring with a harder one. Work on the spring preload to lift the motorcycle rear side. We advise replacing the springs of both suspensions to compensate the weight increase due to the piling of the mud.

TERREIN BOUEUX

When the fork results as either too soft or too hard for any adjustment conditions, check the oil level inside the forkrod.

The level can either be too low or too high. Remember that too much oil inside the fork will involve a more frequent air drainage. When the suspensions do not react to the changes of calibration, check that the adjusting units are not blocked.

The standard calibrations and the adjustment procedures are shown on the next pages. The springs available upon request, together with the preload spacers, are shown on pages

NOTE:

Black-and-white action photo of a motorcyclist mid-jump, wearing helmet and number 52, with no visible text or symbols on the bike or background.

Black-and-white photo of a motorcyclist in action on a dirt track, kicking up dust (no visible text or symbols)

Black-and-white action photo of a dirter mid-jump, kicking up dust (no visible text or symbols)

Black-and-white photo of a motorcyclist performing a trick on a track, wearing racing gear and number 100 (no visible text or symbols)

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.

REGLAGE FOURCHE A COMPRESSION

a) COMPRESSION (REGISTRE INFÉRIEUR)

Close-up of a mechanical component with a rotary knob and cross symbol (no readable text or symbols)

Technical diagram showing a mechanical assembly with labeled component D and directional arrow

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.

NOTE

Besides the serial spring (21) with flexibility index K=4.8 N/mm (TE-TC) and K=5 (SMR) and relevant preload (25) spacer harder or softer springs, together with spacers are aballable upon request.

NOTE

Always replace both the spring and the spacers to keep the preload value unchanged.

NIVEAU D'HUILE DE LA FOURCHE

Diagram illustrating a hand pouring liquid into a container with an inset showing a bottle and water displacement measurement.

A=90mm (3.54 in.)- TE 250, TC 450-510

A=100mm (3.94 in.)- TC 250

A=110mm (4.33 in.)- SMR

A=120mm (4.72 in.)- TE 450-510

Technical diagram of mechanical assembly with numbered parts, including a zoomed-in view of a component.

MODIFICA POSIZIONE ED ALTEZZA MANUBRIO

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 (19,6-21,6 Nm; 14.5-15.9 Lb/fts).

MODIFICATION DE LA POSITION ET DE L'HAUTEUR DU GUIDON

Labeled mechanical component diagram showing parts numbered 1 to 4 with arrows indicating assembly or movement.

A 4 R X

Close-up of a mechanical coupling with bolts and a curved arrow indicating rotational motion (no text or symbols)

4 "L"

REGISTRAZIONE AMMORTIZZATORE

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.

1. To get the right SAG according to your weight, adjust the shock absorber spring preload (page 146).

WARNING*: Never disassemble shock absorber, which contains highly compressed nitrogen. Contact your Dealer for such major service. Do not incinerate.

ADJUSTING THE SHOCK ABSORBER SPRING PRELOAD Proceed as follows:

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 required.
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 and saddle.

WARNING*:Be careful not to touch hot exhaust pipe while adjusting the shock abosrber.

Diagram of a car handle with a circular component and curved motion lines, no text or symbols present

③ ② HOTOM SPORTS

TE-SMR ① ② ③

TC ① ② ③

REGISTRAZIONE FRENO IDRAULICO AMMORTIZZATORE

(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:

● TC 250-450-510: -15 clicks (± 2 clicks)

● TE 250-450-510: -12 clicks (± 2 clicks)

● SMR 400-450-510: -15 clicks (±2 clicks)

(register 6)

To reset the standard calibration, turn upper registers (4) and (6) clockwise until reaching fully closed position. Return then back for the mentioned clicks. In order to obtain a smooth braking action, turn the registers anticlockwise. Reverse the operation in order to obtain a harder braking action. B) EXTENSION - Standard calibration:

● TC 250-450-510: -25 clicks (±2 clicks)

● TE 250-450-510: -16 clicks (± 2 clicks)

● SMR 400-450-510: -16 clicks (±2 clicks)

To reset the standard calibration, turn lower register (5) clockwise until reaching fully closed position. Return then back for the mentioned clicks. In order to obtain a smooth braking action, turn the register anticlockwise. Reverse the operation in order to obtain a harder braking action.

● TE-TC: -15 clicks (± 2 clicks)

● SMR: -5 clicks (± 2 clicks) (registre 4)

● TC 250-450-510: -15 clicks (± 2 clicks)

● TE 250-450-510: -12 clicks (± 2 clicks)

● SMR 400-450-510: -15 clicks (±2 clicks)

(registre 6)

● TE 250-450-510: -16 clicks (± 2 clicks)

● TE-TC: -15 Klicks (± 2 Klicks)

● SMR: -5 clicks (± 2 clicks) (Eintellschraube 4)

● TC 250-450-510: -15 Klicks (± 2 Klicks)

● TE 250-450-510: -12 Klicks (± 2 Klicks)

● SMR 400-450-510: -15 clicks (±2 clicks) (Eintellschraube 6)

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.

A = 0÷2 mm (0÷0.08 in.)

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.

STANDARD	WEAR LIMIT
317,5 mm(12.5 in.)	323 mm(12.7 in.)

Check the pinion damages or wear and replace it should the wear degree be as the one shown in figure.

Remove the wheel and check the wear of the rear sproket teeth. The figure shows the outline of teeth in normal and excessive wear. Should the sprocket be badly worn out, replace it by loosening the six fastening screws to the hub.

WARNING*: Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition.

Note*: In muddy and wet conditions, mud sticks to the chain and sprockets resulting in an overtight chain. The pinion, the chain, and the rear sprocket wheel wear increases when running on muddy ground.

CONTROLE USURE CHAINE, PIGNON ET COURONNE

Agir comme suit:

Black and white geometric gear-like shape with radial teeth and central hole (no text or symbols)

graph TD
    A["Consumo normal"] --> B["Normal consumption"]
    B --> C["Consommation normale"]
    C --> D["Normaler verbrauch"]
    D --> E["Consumo normal"]
    F["Consumo excessive"] --> G["Excessive consumption"]
    G --> H["Consommation excessive"]
    H --> I["Oververbrauch"]
    I --> J["Consumo excessive"]

LUBRICATING THE CHAIN

Lubricate the chain following these instructions:

WARNING * : Never use grease to lubricate the chain. Grease helps to accumulate dust and mud, which act as abrasive and hepl to rapidly wear out the chain, the sprocket, and the crown.

LUBRIFICATION CHAINE

Disassembling and cleaning

When particularly dirty, remove and clean the chain before lubrication.

Work as follows:

Set a stand or a block under the engine and see that the rear wheel is lifted from the ground.

Remove: screws (1), transmission sprocket guard (2), clip (3), master link (4) and transmission chain (5); To reassemble, reverse the above procedure.

Labeled diagram of a motorcycle's wheel assembly with numbered parts for identification

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).

NOTE *: Even if all the joints are reusable when in good conditions, for safety purposes we advise using new joints when reassembling the chain. 6 -Accurately adjust the chain as described on page 150. WARNING: The chain oil has NEVER to get in contact with the tires or the rear brake disk.

Chain tension rollers, chain driving roller, chain guide, chain runner

Check the wear of the above mentioned elements and replace them when necessary.

WARNING * : Check the chain guide alignment, and remember that a bent element can cause a rapid wear of the chain. In this case, a chain fleeting from the sprocket may ensue.

Labeled diagram of a motorcycle's front wheel and drivetrain components with numbered parts

1- Rullo tendicatena
2- Rullo guidacatena
3- Guidacatena
4- Pattino catena

1- Chain tension roller
2- Chain driving roller
3- Chain guide
4- Chain slider

Removing the front wheel

Set a stand or a block under the engine and see that the front wheel is lifted from the ground. Loosen the bolts (1) holding the wheel axle (2) to the front fork stanchions.

SMR: remove the two screws (A) and the brake caliper. Hold the head of the wheel axle (2) in place, unscrew the bolt (3) on the opposite side; draw the wheel axle out.

Do not operate the front brake lever when the wheel has been removed; this causes the caliper piston to move outwards. After removal, lay down the wheel with brake disc on top.

AVIS

Side view of a white and silver MiR500 motorcycle on a stand, showing front wheel, rear wheel, and suspension components (no text or symbols visible)

SMR A

TE-TC 1 2

TE-TC 1 3

2 1 SMR

Close-up of a mechanical brake assembly with labeled parts (1, 3), no readable text or symbols beyond labels

NOTAS

Reassembling the front wheel

Fit the L.H. spacer on the wheel hub.

TE-TC: Fit the wheel between the front fork legs so that the brake disc is fitted into the caliper.

SMR: Fit the wheel between the front fork legs.

Fit the wheel axle (2) from the R.H. side, after greasing it and push it to the stop on the L.H. leg; during this operation, the wheel should be turned. Tighten the screw (3) on the fork L.H. side but DO NOT lock it. Now, pump for a while, pushing the handlebar downwards until you are sure that the fork legs are perfectly aligned.

Lock: the screws (1) on the R.H. leg (10,4 Nm/ 1,05 Kgm/ 7.7 ft-lb), the screw (3) on the L.H. side (51,45 Nm/ 5,25 Kgm/ 38 ft-lb), the screws (1) on the L.H. leg (10,4 Nm/ 1,05 Kgm/ 7.7 ft-lb).

SMR: fit the brake caliper on the disc; assemble the caliper on its holding plate and tighten the screws (A) at 25,5 Nm/ 2,6 Kgm/ 18.8 ft-lb.

Check that the brake disc slides between the caliper pads without any friction.

NOTE

After reassembly, pump the brake control lever until the pads are against the brake disc.

Mechanical assembly diagram showing a brake disc and wheel assembly with labeled parts (no readable text or symbols)

Close-up of a mechanical assembly with no visible text or symbols

Removing the rear wheel

Unscrew the nut (1) of the wheel pin (3) and extract it. It is not necessary to unloose the chain adjusters (2); in this way, the chain tension will remain unchanged after the reassembly. Extract the complete rear wheel, by taking care of the spacers located at the hub sides.

To reassemble, reverse the above procedure remembering to insert the disc into the caliper.

Do not operate the rear brake pedal when the wheel has been removed; this causes the caliper piston to move outwards.

After removal, lay down the wheel with brake disc on top. After reassembly, pump the brake control pedal until the pads are against the brake disc.

AVIS

Mechanical assembly diagram showing two labeled components (1 and 2) of a brake system with mechanical components and wiring.

Mechanical assembly diagram showing a gear and component with numbered parts labeled 2 and 3

PNEUMATICI

Care should be taken to keep the tires properly inflated. See tire data for correct tire inflation pressure (38). Replace the tire if its wear exceeds what is shown on the table below.

PNEUS

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

AVANT	3 mm (TC,TE); 2 mm (SMR)
ARRIERE	3 mm (TC,TE); 2 mm (SMR)

REIFEN

Close-up of a bicycle wheel with visible tire, disc, and hub assembly (no text or symbols)

Close-up of a motorcycle wheel and brake disc assembly (no text or symbols visible)

FRENI

The mayor components are brake master cylinder with its lever (front) or pedal (rear), brakeline, caliper assembly and disc.

FREIN

1. Front brake control lever
2. Front brake pump with oil reservoir (TE, TC)
3. Front brake pump (SMR)
   2A. Oil reservoir (SMR)
4. Front brake hose
5. Front brake caliper
6. Front brake disc
7. Rear brake oil tank
8. Rear brake hose
9. Rear brake caliper
10. Rear brake disc
11. Rear brake pump
12. Rear brake control pedal

LEGENDE

Don't operate the brake lever or pedal while removing the pads.

ATTENTION!

USURA PASTIGLIE (TE)

Inspect pads for wear. Service limit "A" is: 3,8 mm (0.15 in.). If service limit is exceeded, always replace the pads in pairs.

USURE DES PASTILLES (TE)

USURA PASTIGLIE (SMR)

a) In front: thickness "A" must never be lower than the one pointed out by the wear control notches. b) At the back: thickness "A" must never be lower than 3,8 mm. If service limit is exceeded, always replace the pads in pairs.

USURE DES PASTILLES (SMR)

Mechanical assembly diagram showing two labeled components (1 and 2) with no visible text or symbols

TE-TC FRONT REAR

SMR FRONT REAR

PULIZIA PASTIGLIE

Be careful that no disc brake fluid or any oil gets on brake pads or discs. Clean off any fluid or oil that inadvertently gets on the pads or disc with alcohol. Replace the pads with new ones if they cannot be cleaned satisfactorily.

NETTOYAGE DES PASTILLES

• Install new brake pads.
• Reassemble the two pins (2) and the springs (1).

MONTAGE DES PASTILLES

Do not attempt to ride the motorcycle until the brake lever or pedal are fully effective. Pump the brake lever or pedal until the pads are against the discs. The brake will not function on the first application of the lever or pedal.

ATTENTION!

Mechanical assembly diagram showing two labeled components (1 and 2) with no visible text or symbols

USURA DISCO FRENO

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.

Disc Thickness

Measure disc warpage. Service limit for both discs is 0,15 mm (0.006 in.) Replace the disc if warpage is more than service limit.

DISQUE PAPILLOTANT

Technical line drawing of a bicycle wheel assembly with visible gears and levers (no text or symbols)

Close-up of a bicycle's front wheel and brake system (no visible text or symbols)

Technical line drawing of a mechanical gauge or dial assembly (no text or symbols)

Technical line drawing of a mechanical assembly with a dial indicator (no text or symbols)

PULIZIA DISCO

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.

NETTOYAGE DU DISQUE

Technical line drawing of a bicycle wheel assembly with visible gears and levers (no text or symbols)

Close-up of a bicycle's wheel and suspension system components (no visible text or symbols)

Close-up of a hand using a wrench to connect a car tire with a cable, no visible text or symbols

SOSTITUZIONE FLUIDO

The brake fluid should be checked and changed in accordance with the Periodic Maintenance Chart or whenever it is contaminated with dirt or water. Don't change the fluid in the rain or when a strong wind is blowing.

CAUTION!

* 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.

REPLACEMENT DU FLUIDE

To replace the fluid, proceed as follows:

• Remove the rubber cap on the bleeding valve (1) or (1A).
• Attach a clear plastic hose to the bleeding valve on the brake caliper and turn the other end of the hose into a container.
• Remove fluid reservoir cap (2) or (2A) and the rubber.
• Loosen bleeding valve on the brake caliper.

Mechanical assembly diagram showing a motor and linkage mechanism (no text or labels)

Mechanical assembly diagram showing a brake system with labeled component (1A), no readable text or symbols present.

Close-up of a bicycle wheel with visible tire, disc, and bucket (no text or symbols)

Mechanical assembly diagram showing a wheel with gear and a cylinder inserted (no text or symbols)

Close-up of a mechanical lever handle and grip assembly (no visible text or symbols)

Close-up of a motorcycle's front bumper with labeled component (2), no visible text or symbols on the body itself.

Close-up of a mechanical assembly with hoses and components, no visible text or symbols

• Pump with brake lever (3) or brake pedal (3A) in order to push brake fluid out of line.
• Close the bleeding valve and fill the reservoir with fresh brake fluid.
• Open the bleeding valve, apply the brake using the brake lever or pedal, close the bleeding valve with the brake lever or pedal applied and then quickly release the lever or pedal.
• Repeat this operation until the brake line is filled and clear fluid starts coming out of the plastic hose: now close the bleeding valve.- Restore the brake fluid level (A) or (B) then reassemble the rubber and the fluid reservoir cap (pag. 179).

After the brake fluid replacement, it is necessary to operate the braking system bleeding (see pages 184 and 192).

Close-up of a mechanical lever handle and grip with a numbered annotation (3) pointing to the lever (no text or symbols on the object itself)

Mechanical assembly diagram showing motor components and wiring (no text or symbols visible)

Close-up of a mechanical pipe fitting with a labeled component (A), no visible text or symbols beyond the label.

Close-up of a motorcycle engine component with labeled parts (A), no visible text or symbols beyond the label.

Close-up of a mechanical assembly with hoses and components, no visible text or symbols

ATTENZIONE!

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 worried or cracked, their replacement is advised.

ATTENTION!

Close-up of a motorcycle's front wheel and steering wheel assembly, showing tire alignment and mounting bracket (no text or symbols)

Close-up of a motorcycle's front wheel and suspension components, labeled with number B (no text or symbols on the main subject)

SPURGO IMPIANTO FRENANTE ANTERIORE (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:

• Remove the rubber cap on the bleeding valve (1).
• Attach a clear plastic hose to the bleeding valve on the brake caliper and turn the other end of the hose into a container (make sure that the end of the hose is submerged in brake fluid during the entire bleeding operation).
• Remove fluid reservoir cap (2), the rubber and fill the reservoir with fresh brake fluid.
• Open the bleeding valve and pump with brake lever (3) several times until the fluid, clear and without bubbles, comes out of the hose: now close the bleeding valve.

CURAGE INSTALLATION DE FREINAGE AVANT (TE, TC)

Mechanical assembly diagram showing a brake caliper and suspension components (no text or labels)

Close-up of a bicycle wheel with visible tire, disc, and mechanical components (no text or symbols)

Diagram of a mechanical device with numbered parts labeled ②, ③, and ②

- Restore the brake fluid level (A) then reassemble the rubber and the 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 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 ring 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 bedding 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 short time of use of the brake. In this however, the action of the lever will be and the stroke shorter.

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:

• Remove the rubber cap on the bleeding valve (1) or (1A).
• Attach a clear plastic hose to the bleeding valve on the brake caliper and turn the other end of the hose into a container (make sure that the end of the hose is submerged in brake fluid during the entire bleeding operation).
• Remove fluid reservoir cap (2), the rubber and fill the reservoir with fresh brake fluid.

CURAGE INSTALLATION DE FREINAGE AVANT (SMR)

Close-up of mechanical components with wires and connectors (no visible text or symbols)

1A SMR

Close-up of a hand using a wrench to connect a cable to a car wheel (no visible text or symbols)

- Open the bleeding valve and pump with brake lever several times until the fluid, clear and without bubbles, comes out of the hose: now close the bleeding valve. - Restore the brake fluid level (A) then reassemble the rubber and the fluid reservoir cap.

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).

ATTENTION!

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 ring 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 feeding 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 short time of use of the brake. In this however, the action of the lever will be and the stroke shorter.

ATTENTION!

Close-up of a mechanical component with labeled section A (no text or symbols on the object itself)

SPURGO IMPIANTO FRENANTE POSTERIORE

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 4) brake fluid.
• 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.

CURAGE DU SYSTEME DE FREINAGE ARRIERE

Close-up of a bicycle's wheel assembly with visible components and a numbered label (1), no readable text or symbols present.

Close-up of a motorcycle's front wheel and suspension mechanism (no text or symbols visible)

Close-up of a motorcycle wheel and suspension mechanism (no text or symbols visible)

Close-up mechanical assembly of a vehicle engine and motor (no visible text or symbols)

Close-up of a mechanical assembly with hoses and a labeled component (A), no readable text or symbols present.

NOTA

Should the motorcycle, due to a fall during a competition or shop repairs, show some elasticity of the brake lever stroke, with a subsequent braking efficiency decrease, you'll to repeat the circuit bleeding as above described.

AVIS

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).

ATTENTION!

The muffler reduces the noise of the exhaust gases, but it is an integral part of the exhaust as well. As such, its conditions affect the motorcycle performance. When the noise on the exhaust is too high, it means that the deadening material set on the holed tube inside the muffler is deteriorated.

WARNING: Check the deadening material after every competition and replace it if necessary.

REPLACING THE MUFFLER 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 inner pipe and replace the deadening material. Reassemble R.H. side panel and saddle.

NOTE: When difficulties are found in removing the muffler, lightly beat with a rubber or plastic hammer.

SILENCIEUX D'ECHAPPEMENT

Diagram of a mechanical component with a numbered callout (1), showing a curved line and a circular feature on top (no text or symbols present)

Diagram of a car hood with numbered annotations pointing to different components

SMR ④ ⑤ ⑦ ⑥

LIMITI DI USURA

NOTA

This chapter shows the main checks to be carried out when the engine and some parts of the byke must be overhauled. More detailed information, together with the disassembly/reassembly procedures are carried in the Husqvarna's Workshop Manual.

CYLINDER-PISTON FITTING

The cylinder and piston are supplied matched; if by chance cylinders and pistons become mismatched then measure their diameters as follows: a) Cylinder bore (Dc) Use an internal micrometer and take the reading “A” at 20 mm-0.8 in. (250 cm ^3 ) or 10 mm-0.4 in. (400-450-510 cm ^3 ) distance from the top.

LIMITE D'USURE

AVIS

b) Piston diameter (Dp) Take the piston diameter at "B" distance of 6 mm/0.24 in. (TE-TC 250), 8 mm/0.31 in. (SMR 400), 9 mm/0.35 in. (TC 450-510), 10 mm/0.39 in. (TE-SMR 450) o 11 mm/0.43 in. (TE-SMR 510) dalla base.

PISTON RING/PISTON RINGS 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.

SEGMENTS-RAINURE SUR LE PISTON

Close-up of hands assembling a mechanical component (no visible text or symbols)

PISTON RING/CYLINDER CLEARANCE

Inser 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.

COUPLAGE SEGMENTS-CYLINDRE

When assembling, the coupling play must be 0.012÷0.027 mm.

The maximum wear limit allowed is 0.055 mm.

ACCOUPLEMENT GOUJON-PIED DE BIELLE

Technical line drawing of a mechanical assembly (no text or symbols visible)

Technical line drawing of a mechanical device with three gauges and central actuator (no text or symbols)

DISCHI FRIZIONE

The clutch plates should not be burnt or scored. Check the thickness of the clutch lining plate.

Thickness of new plate: 3 mm (0.118 in.).

Wear limit 2,9 mm (0.114 in.)

GROUPE D'EMBRAYAGE

Illustration of two hands adjusting a mechanical component with a caliper (no text or symbols present)

Check the distortion of each plate (both lined and unlined) by resting on a flat surface; use a feeler gauge. Wear limit: 0,2 mm (0.00078 in.).

Illustration of hands operating a mechanical component with a tool, no text or symbols present

Technical diagram of a mechanical gear or cam mechanism with concentric circular components and hatched areas indicating material sections (no text or labels)

MOLLA FRIZIONE

Measure the free length “L” of each spring using a gauge. “L” new spring = 41 mm/ 1.61 in. Service limit: 39 mm/ 1.53 in.

RESSORT D'EMBRAYAGE

Accurately check the valve guide. A dial comparator set 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 the coupling between the guide and the valve. New intake valve standard play: 0,008-0,035 mm/ 0.00031-0.00138 in. Service limit: 0,05 mm/ 0.002 in.

New exhaust valve standard play: 0,018-0,045 mm/ 0.0007-0.00177 in. Service limit: 0,08 mm/ 0.003 in.

GUIDE-SOUPAPE

Check that the valve shank and the contact surface with the valve seat are in perfect conditions. Pittings, cracks, or any other deformation or wear must not appear on these elements.

Carry out the following checks: - deformation of the valve shank by setting the shank on a "V" striker, and measuring the extent of the deformation by a comparator.

Working limit: 0.05 mm (0.00197 in.).

SOUPAPE

Line drawing of a mechanical device with a dial and base mount (no text or symbols)

Technical line drawing of a mechanical testing setup with a dial gauge and pressure gauge mounted on a base (no text or symbols)

MOLLA VALVOLA

The weakening of the springs causes a decrease of the engine power and it often is responsible of the noise and the vibrations coming from the valves. In this case, check the free length “L”. When the working limit indicated has been overcomed, replace the springs. “L” new spring = 35 mm/ 1.38 in. (250); 43,4 mm/ 1.71 in. (400-450-510) Service limit: 33 mm/ 1.3 in. (250); 41 mm/ 1.6 in. (400-450-510)

NOTE:

Replace all the spring valves when even one of these has overcomed the the working limit. Check the spring valve squareness. Error limit not above 1.5 mm (0.059 in.) on each side.

RESSORT DE SOUPAPE

Technical line drawing of a mechanical component with threaded sections and a L-shaped outline (no text or symbols)

ALBERO A CAMME

Check that cam surfaces are scored, stepped, grooved etc. Insert the camshaft between two references and then check deviation using two comparators. Wear limit: 0.0039 in. Check that the cams are in good conditions, without wear or deformation.

Cam height "H"

INTAKE (new) = 36,57 mm/ 1.44 in.

EXHAUST (new) = 35,94 mm/1.41 in.

ARBRE A CAMES

Technical drawing of a mechanical assembly with shafts and housing (no text or labels)

EXHAUST

H

Technical mechanical drawing of a shaft assembly (no text or labels)

REVISIONE RUOTE

OVERHAULING THE WHEELS

The tables hereunder show the type of control the rim and wheel axle are to be submitted to.

REVISION DES ROUES

Note*: if the rim is badly, it should be replaced.

Technical line drawing of a mechanical device with dual scales and adjustment knobs (no text or symbols)

Technical line drawing of a pressure gauge mounted on a mechanical component (no text or symbols)

PIEGATURA PERNO RUOTA

If the bending figure is over the allowable max. limit, straighten or replace the axle. If the wheel axle cannot be straightened within the max. limits (0,2 mm - 0.008 in.) stated, replace it.

COURBURE PIVOT ROUE

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.

RAYONS DE ROUE

Illustration of a hand using a tool to measure a mechanical device with a dial and test tube (no text or symbols)

Technical line drawing of mechanical linkage components (no text or symbols)

IMPIANTO ACCENSIONE (TC-TE-SMR) IMPIANTO ELETTRICO (TE-SMR)

The ignition system includes the following elements:

• Generator (1) on the inner side of L.H. crankcase cover;
• Electronic coil (2) under the fuel tank;
• Electronic power unit (3) under the saddle;
• Voltage regulator (4) on the right side of the frame at the back of the steering sleeve (TE-SMR);
• Spark plug (5) on the R.H. side of cylinder head;
• Starting motor 12V-450W (6) behind the cylinder (TE-SMR);
• Electric start remote control switch (8) under the saddle (TE-SMR);
• Condenser (10) under the saddle. The electric system includes the following elements:
• Headlamp with two filaments bulb of 12V-35/35W and parking light bulb of 12V-3W;
• Rear lights with stop bulbs of 12V-21W and parking light bulb of 12V-5W;
• Pilot lights bulb of 12V-1,2W;
• Turn signals bulb of 12V-10W;
• Instrument bulb of 12V-2W;
• Three15 A fuses (9) (one of them is a spare fuse), under the saddle;
• Battery 12V-6Ah (7) under the saddle.

SYSTEME D'ALLUMAGE (TC-TE-SMR) SYSTEME ÉLECTRIQUE (TE-SMR)

Technical diagram of a mechanical assembly with numbered annotations pointing to components

Labeled diagram of an electronic device interior with numbered components and wiring connections

Hurveirna ④ ⑤

Technical diagram of a car engine showing labeled parts with numbered annotations

Pos. Pos.	Colore Colour
B	Blu/ Blue/ Bleu/ Blau/ Azul
Br	Marrone/ Brown/ Maron/ Braun/ Castano
Bk	Nero/ Black/ Noir/ Schwarz/ Negro
G	Verde/ Green/ Vert/ Grün/ Verd
Gr	Grigio/ Grey/ Gris/ Grau/ Gris
Y	Giallo/ Yellow/ Jaune/ Gelb/ Amarillo
O	Arancio/ Orange/ Orange/ Orange/ Arancio
P	Rosa/ Pink/ Rosa/ Rose/ Rosa
R	Rosso/ Red/ Rouge/ Rot/ Rojo
Sb	Azzurro/ Sky blue/ Azur/ Hellblau/ Celeste
V	Viola/ Violet/ Violet / Violett / Viola
W	Bianco/ White/ Blanc/ Weiss/ Blanco

SCHEMA ELETTRICO TE-SMR TE-SMR WIRING DIAGRAM SCHÉMA ÉLECTRIQUE TE-SMR SCHALTPLAN TE-SMR ESQUEMA ÉLECTRICO TE-SMR

LEGENDA SCHEMA ELETTRICO (TE -SMR)

1. Electronic power unit

2. Alternator

3. Voltage regulator

4. Rear stop switch

5. Front stop switch

6. Condenser

7. Instrument

8. R.H. front turn indicator

9. Front headlamp

10. Parking lights

11. L.H. front turn indicator

12. Horn

13. L.H. commutator

14. Turn indicators flasher

15. Tail light

16. Battery

17. Electric start remote control switch

18. Starting motor

19. Spark plug

20. R.H. rear turn indicator

21. L.H. rear turn indicator

22. Gear shift position sen- sor

23. Electronic coil

24. Carburetor throttle position sensor

25. Engine stop

26. Engine start

27. Clutch microswitch

28. Speed

29. Scroll

LÉGENDE DU SCHÉMA ÉLECTRIQUE (TE -SMR)

1. Electronic power unit
2. Alternator
3. Voltage regulator
4. Condenser
5. Battery
6. Electric start remote control switch
7. Starting motor
8. Spark plug
9. Gear shift position sensor
10. Electronic coil
11. Carburetor throttle position sensor
12. Engine stop
13. Engine start
14. Clutch microswitch

LÉGENDE DU SCHÉMA ÉLECTRIQUE (TC 250)

1. Electronic power unit
2. Alternator
3. Voltage regulator
4. Condenser
5. Battery
6. Electric start remote control switch
7. Starting motor
8. Spark plug
9. Gear shift position sensor
10. Electronic coil
11. Carburetor throttle position sensor
12. Engine stop
13. Engine start
14. Clutch microswitch

LÉGENDE DU SCHÉMA

ÉLECTRIQUE (TC 450-510)

The sealed battery does not require any maintenance work. When electrolyte leaks, or other failures to the electrical system are detected, apply to the HUSQVARNA Dealer.

If the vehicle remains unused for long periods, it is recommended to remove battery from electrical system and store it in a dry place.

• After an intensive use of the battery, it's advisable a standard low charge (12V-6Ah battery: 0.6A for 8 hours).
• Rapid recharging is advised only in situations of extreme necessity since the life of lead elements is drastically reduced (6A for 0.5 hours with 12V-6Ah batteries).

BATTERY CHARGER

To gain access to the battery (3):

• first turn counterclockwise fastening rear pin (1) then remove the saddle;
  ● release elastic (2);
• first remove the BLACK negative cable, then the RED positive cable (when reassembling, first connect the RED positive cable, then the BLACK negative cable);
• remove the battery (3) from its housing.

BATTERIE

Labeled mechanical assembly diagram showing components numbered 2 and 3 in a vehicle interior

Check, using a voltmeter, that battery voltage is not less than 12,5 V. If not, the battery needs to be charged.

Using a battery charter with a constant voltage, first connect the RED positive cable to the battery's positive terminal then the BLACK negative cable to the battery's negative terminal. Apply to the constant voltage of 14,4 V a current of "x" Ampere as results in the below diagram (depending on the amount of charging required).

The voltage reaches a constant value only after a few hours, therefore it is suggested NOT to measure it immediately after having charged or discharged the battery.

Always check the charge level before reinstalling it on the vehicle.

The battery should be kept clean and the terminals coated with grease.

WARNING*: The battery contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL - Flush with water. INTERNAL - Drink large quantities of water or milk. After milk take magnesia, beaten eggs or vegetable oil. Call physician immediately. Eyes: Flush with water for no less than 15 minutes and get prompt medical attention.

WARNING*: Batteries produce explosive gas, ventilate when charging or using in enclosed space. When using a battery charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases.

Interior view of a vehicle showing battery pack, charging module, and engine compartment (no visible text or symbols)

SOSTITUZIONE LAMPADINE PROIETTORE (TE-SMR)

REPLACEMENT (TE-SMR)

To gain access to the healamp bulbs, proceed as follows:

• remove the two fastening elastics (1) and the headlamp holder;
• remove the two filaments bulb connector; (2) and the boot (3)
• release the bulb holding spring (4) and then the bulb itself.

REMLACEMENT DES

AMPOULES DU PHARE AVANT (TE-SMR)

To replace the parking light bulb, (5) extract it from the inside cover. After replacement, reverse operations for reassembly.

Close-up of a motorcycle's front suspension system with labeled component (no readable text or symbols)

Labeled diagram of a vehicle interior showing numbered components and structural elements

SOSTITUZIONE LAMPADA FANALE POSTERIORE (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 AMPOULES DU PHARE ARRIÈRE (TE- SMR)

Close-up of a metal bracket with a numbered annotation (1) pointing to a specific feature, no readable text or symbols present.

② CJ VA

Close-up of a motorcycle's front bumper with a circular component and directional arrows indicating motion (no text or symbols)

③

REGISTRAZIONE FANALE ANTERIORE (TE, SMR)

ADJUSTMENT OF HEADLIGHT (TE, SMR)

When checking the proper orienting of headlight, inflate tires at right pressure, sat a person on the saddle and place the motorcycle perpendicular with its longitudinal axis 10 meters (33 ft) from a wall or screen. Then trace an horizontal line equal to the height of headlight center and a vertical one in line with its longitudinal axis. If possible, execute this operation in a shadowy place. When the low beam is on, the upper boundary limit between dark and lit zone should be 9/10 th of headlight center from ground.

REGLAGE DU PHARE (TE, SMR)

Adjust the preadlamp aiming by turning screw (1) to lower or lift the high beam.

The motorcycle comes with the following tools:

1-8000 66802

Box wrench 15x27mm (TE-TC-SMR)

2-8000 96997

Front wheel axle wrench (TC)

3-8000 56920

Front wheel axle screw Allen wrench (TC)

4-8000 A4349

Spark plug wrench

(TE-TC-SMR)

DOTATION D'OUTILS

Ringschlüssel15x27mm

(TE-TC-SMR)

2-8000 96997

Close-up of a car's head panel showing a transparent dome and a small object, with no visible text or symbols.

Technical diagram showing four labeled parts of a wrench tool, including handle, shaft, and end cap.

		ATTREZZI SPECIALI	SPECIAL TOOLS	OUTILS SPECIAUX	SONDERWERKZEUGE	HERRAMIENTAS ESPECIALES
1	1517 94702	Estrattore basamento	Crankcase puller	Extracteur carter	Kurbelgehäuse-Auszieher	Extractor cárter
2	8000 A1580	Protezione alb. motore	Crankshaft guard	Protection vilebrequin	Schutz für Kurbewelle	Protección por cigueñal
3	8000 A1559	Estrattore volano	Flywheel extractor	Extracteur pour volant	Auszieher für Schwungrad	Extractor volante
4	8000 A1512	Attrezzo contr. accensione	Ignition checking tool	Outil contrôle allumage	Kontrollwerkzeug für Zundung	Herramienta control encendido
5	8A00 90622	Supporto per montaggio	Support for assy	Support pour montage	Halterung für Montage	Soporte por el montaje
6	8000 A1576	Attrezzo mont. semiconi	Half cone assembling tool	Outil montage demi-cône	Werkzeug für montage	Herramienta porta comparador
7	8000 A1625	Attrezzo portacomparatore	Dial gauge holding tool	Outil support comparateur	Werkzeug Komparatorhalter	Herramienta porta comparador
8	8000 A1579	Attrezzo smont. semiconi	Half cone disassembling tool	Outil demontage demi-cône	Werkzeug für Ausbau der Half-Kebel	Herramienta desmontaje semi-conos
9	8000 79015	Chiave di fermo mozzo frizione	Clutch hub retaining wrench	Cléf d'arret moyeau embrayage	Halterungsschlussel der	Llave bloquear cubo
10	1519 84701	Gancio per molle	Spring hook	Crochet pour ressort	Federhaken	Gancho para resorte

COPPIE DI SERRAGGIO / TIGHTENING TORQUES / COUPLES DE SERRAGE

MOTORE	ENGINE	MOTEUR
Applicazione	Application	Application
Vite fiss. cappello albero a camme	Camshaft cap fastening screw	Vis de fixation capuchon arbre distribution
Tappo perno bilanciere	Rocker arm axle plug	Bouchon axle culbuteur
Vite fiss. coperchio testa	Cylinder head cover fastening screw	Vis de fixation couvercle culasse cylindre
Dado fiss. testa	Cylinder head fastening nut	Ecrou de fixation culasse cylindre
Dado fiss. testa e cilindro	Cylinder head and cylinder fastening nut	Ecrou de fixation culasse et cylindre
Vite fiss. tubo olio sulla testa cilindro	Oil hose to cylinder head fastening screw	Vis de fixation tuyau huile sur la culasse cylindre
Tappo foro olio su perno di biella	Oil hole plug on conrod pin	Bouchon pour trou huile sur pivot de bielle
Dado fiss. ingr. conduttore trasm. primaria	Primary drive driving gear fastening nut	Ecrou de fixation engrenage conducteur transm. primaire
Vite fiss. disco centrifugo su albero a camme ASPIRAZIONE	Centrifugal disc on INTAKE CAMSHAFT fastening screw	Vis de fixation disque sur arbre distribution (ADMISSION)
Vite fiss. pattino catena distribuzione	Timing chain slider fastening screw	Vis de fixation glissière chaine distribution
Vite fiss. piastrine ritegno cuscinetti basamento	Crankcase bearings plates fastening screw	Vis de fixation plaquettes roulements carters
Tappo scarico olio motore	Engine oil drain plug	Bouchon de vidange huile moteur
Tappo filtro olio motore	Engine oil filter plug	Bouchon filtre huile moteur
Vite fiss. coperchio filtro olio	Engine oil filter cartridge cover fastening screw	Vis de fixation couvercle filtre huile
Vite fiss. cornetto carburatore	Carburetor union fastening screw	Vis de fixation manchon carburateur
Dado fiss. alternatore	Alternator fastening nut	Ecrou de fixation alternateur
Vite fiss. statore	Stator plate fastening screw	Vis de fixation stator
Candela accensione	Spark plug	Bougie d'allumage
Vite fiss. pick-up	Pick-up fastening screw	Vis de fixation pick-up
Dado fiss. mozzo e campana frizione	Clutch hub and disc housing fastening nut	Ecrou de fixation moyeau et cage embrayage
Vite fiss. piastra ritegno ingranaggi avviamento	Starting gears stop plate fastening screw	Vis de fixation plaque engrenage démarrage
Vite fiss. tamburo selettore	Gearbox forks driving shaft fastening screw	Vis de fixation tambour selecteur
Vite fiss. saltarello e piastra comando cambio	Gear control click and plate fastening screw	Vis de fixation cliquet et plaque commande de vitesse
Vite fiss. segnalatore marce	Gear shift position sensor fastening screw	Vis de fixation signaleur de vitesse
Dado fiss. girante pompa acqua	Water pump rotor fastening nut	Ecrou de fixation couronne pompe eau
Vite fiss. corpo pompa acqua	Water pump body fastening screw	Vis de fixation corps pompe eau
Vite fiss. piastrina anello di tenuta per pignone uscita cambio	Drive sprocket seal ring plate fastening screw	Vis de fixation plaquette bague de retenue pignon sortie boîte de vitesse

VERSCHRAUBUNGSMOMENTE / PATAS DE TORSION

MOTOR		Filettatura Threading Filetate Gewinde Filetado	± 5%
Anwendung	Aplicación
Befestigungsschraube Nockenwelle Kappe	Tuerca fijación caballete eje distribución	M6x1	12 Nm	1,2 Kgm	8.7 ft/lb
Kipphebelachse Verschluss	Tapón perno balancin	M14x1,5 (+LOCTITE 243)	25 Nm	2,55 Kgm	18.4 ft/lb
Befestigungsschraube Zylinderdeckel	Tornillo fijación tapa culata	M6x1	8 Nm	0,8 Kgm	5.8 ft/lb
Befestigungsmutter Zylinderkopf	Tuerca fijación culata	M8x1,25	15 Nm	1,5 Kgm	10.8 ft/lb
Befestigungsmutter Kopf und Zylinder	Tuerca fijación culata y cilindro	M10x1,5 (+MOLIKOTE HSC)	37 Nm+90°	3.8 Nm+90°	27.5 ft/lb+90°
Befestigungsschraube Ölrohr-Zylinderkopf	Tornillo fijación tubo aceite en la culata	M10x1	15 Nm	1,5 Kgm	10.8 ft/lb
Ölstopfen auf der Kurbelzapfen	Tapón oroficio aceite su perno de biela	M14x1 (+LOCTITE 243)	20 Nm	2 Kgm	14.5 ft/lb
Befestigungsmutter Antriebsrad	Tuerca fijación engranaje conductor transm. primaria	M18x1,25 (+LOCTITE 243)	180 Nm	18 Kgm	130 ft/lb
Befestigungsschraube Scheibe für Nockenwelle (ANSAUGSEITE)	Tornillo fijación disco en el eje distribución (ASPIRACION)	M6x1 (+LOCTITE 243)	8 Nm	0,8 Kgm	5.8 ft/lb
Befestigungsschraube Ventilsteuerungkette Gleitbahn	Tornillo fijación plado cadena distribución	M8x1,25	12 Nm	1,23 Kgm	8.9 ft/lb
Befestigungsschraube Gehauselager Platte	Tornillo fijación placa cojinete de carter	M6x1 (+LOCTITE 272)	11 Nm	1,1 Kgm	7.9 ft/lb
Motorölablaßstopfen	Tapón vaciado aceite motor	M16x1,5	25 Nm	2,55 Kgm	18.4 ft/lb
Motorölfilter Verschluss	Tapón filtro aceite motor	M14x1,5	25 Nm	2,55 Kgm	18.4 ft/lb
Befestigungsschraube Wechselfilterdeckel	Tornillo fijación tapa filtro aceite	M5x0,8 (+LOCTITE 243)	6 Nm	0,6 Kgm	4.3 ft/lb
Befestigungsschraube Vergasermuffe	Tornillo fijación tubo toma aire carburador	M4x0,7 (+LOCTITE 272)	3 Nm	0,3 Kgm	2.2 ft/lb
Befestigungsmutter Alternator	Tuerca fijación alternador	M12x1	75 Nm	7,65 Kgm	55.3 ft/lb
Befestigungsschraube Stator	Tornillo fijación estator	M6x1 (+LOCTITE 272)	8 Nm	0,8 Kgm	5.8 ft/lb
Zündkerze	Bujia de encendido	M10x1	10÷12 Nm	0,98÷1,23 Kgm	7.4÷8.9 ft/lb.
Befestigungsschraube Pick-up	Tornillo fijación pick-up	M5x0,8 (+LOCTITE 272)	6 Nm	0,6 Kgm	4.3 ft/lb
Befestigungsmutter Kupplungscheibenhalternabe und Kupplungkorb	Tuerca fijación cubo y campana embrague	M18x1	75 Nm	7,6 Kgm	55 ft/lb
Befestigungsschraube Anlasserantriebsrad Platte	Tornillo fijación placa engrenaje de arranque	M6x1 (+LOCTITE 243)	8 Nm	0,8 Kgm	5.8 ft/lb
Befestigungsschraube Trommel	Tornillo fijación. tambor selector	M8x1,25 (+LOCTITE 243)	20 Nm	2 Kgm	14.5 ft/lb
Befestigungsschraube Strumhaken und Gangschaltung Platte	Tornillo fijación saltarelo y placa mando cambio	M6x1 (+LOCTITE 243)	8 Nm	0,8 Kgm	5.8 ft/lb
Befestigungsschraube Gangkontrol	Tornillo fijación señalador velocidad	M5x0,8 (+LOCTITE 243)	6 Nm	0,6 Kgm	4.3 ft/lb
Befestigungsmutter Wasserpumprotor	Tuerca fijación rotor bomba agua	M5x0,8 (+LOCTITE 243)	3,9 Nm	0,4 Kgm	2.9 ft/lb
Befestigungsschraube Wasserpumpkörper	Tornillo fijación corpo bomba agua	M6x1(+LOCTITE 542)	8 Nm	0,8 Kgm	5.8 ft/lb
Befestigungsschraube für Dichtringsplatte von Abtriebritzel	Tornillo fijación placa anillo de retención piñón salida cambio	M5x0,8 (+LOCTITE 243)	6 Nm	0,6 Kgm	4.3 ft/lb

COPPIE DI SERRAGGIO / TIGHTENING TORQUES / COUPLES DE SERRAGE

MOTOTELAIO	CHASSIS	CHASSIS
Applicazione	Application	Application
Vite fiss. inferiore telaio posteriore	Rear frame lower fastening screw	Vis de fixation inferieur cadre arrière
Vite fiss. protezione motore	Engine guard fastening screw	Vis de fixation protection moteur
Vite fiss. rullo catena	Rear chain roller fastening screw	Vis de fixation rouleau chaine
Vite fiss. cavalletto laterale	Side stand fastening screw	Vis de fixation bequille lateral
Vite fiss. superiore telaio posteriore	Rear frame upper fastening screw	Vis de fixation superieur cadre arrière
Vite fiss.telaio-piastra motore	Frame to engine plate fastening screw	Vis de fixation cadre - plaque moteur
Vite fiss. inferiore motore	Engine lower fastening screw	Vis de fixation inferieur moteur
Vite fiss. cavallotti frizione e freno anteriore	Clutch and front brake controls clamp fastening screw	Vis de fixation cavaliers embrague et frein avant
Vite fiss. supporti comando gas	Throttle control holders fastening screw	Vis de fixation supports commande gaz
Vite fiss. superiore tubazione freno anteriore (TE, SMR)	Front brake hose upper fastening screw (TE, SMR)	Vis de fixation superieur tuyau frein avant (TE, SMR)
Vite fiss. superiore tubazione freno anteriore (TC)	Front brake hose upper fastening screw (TC)	Vis de fixation superieur tuyau frein avant (TC)
Vite fiss. pedale freno posteriore	Rear brake control pedal fastening screw	Vis de fixation pédale frein arrière
Vite fiss. pompa freno posteriore	Rear brake pump fastening screw	Vis de fixation pompe frein arrière
Vite fiss. piastrina pompa freno anteriore (SMR)	Front brake pump plate fastening screw (SMR)	Vis de fixation plaque pompe frein avant (SMR)
Vite fiss. serbatoio liquido freno posteriore	Rear brake fluid tank fastening screw	Vis de fixation réservoir liquide frein arrière
Interruttore stop posteriore (TE, SMR)	Rear stop control switch (TE, SMR)	Interrupteur stop arrière (TE, SMR)
Vite fiss. connettore interruttore stop anteriore (SMR)	Front control switch connector fastening screw (SMR)	Vis de fixation connecteur Interrupteur stop avant (SMR)
Vite fiss. camma pedale freno posteriore	Rear brake pedal adjusting cam fastening screw	Vis de fixation came pédale frein arrière
Vite fiss. piastrina guidatubazione freno anteriore	Front brake hose guide plate fastening screw	Vis de fixation plaque guide tuyau frein avant
Vite fiss. tappo serbatoio freno anteriore (SMR)	Front brake tank cap fastening screw (SMR)	Vis de fixation bouchon réservoir frein avant (SMR)
Vite fiss. gambe forcella	Front fork legs fastening screw	Vis de fixation tige fourche avant
Vite fiss. perno ruota anteriore	Front wheel axle fastening screw	Vis de fixation piovot roue avant
Ghiera registro cuscinetti di sterzo	Steering bearings adjusting ring nut	Collier de réglage roulement guidon
Dado perno di sterzo	Steering pivot fastening nut	Ecrou de fixation pivot guidon
Vite fiss. morsetto superiore manubrio	Handlebar upper clamp	Vis de fixation etau superieur guidon
Vite fiss. supporto manubrio	Handlebar holder fastening screw	Vis de fixation support guidon
Vite fiss. protezioni steli forcella	Front fork legs guard fastening screw	Vis de fixation protection tige fourche avant
Vite fiss. anelli protezioni steli forcella	Front fork legs ring guard fastening screw	Vis de fixation bague protection tige fourche avant
Dado fiss. perno forcellone	Rear swing arm axle fastening nut	Ecrou de fixation pivot fourche
Dado fiss. bilanciere-forcellone	Rear swing arm to rocker arm fastening nut	Ecrou de fixation balancier- fourche arrière
Dado fiss. tirante-bilanciere	Tie rod to rocker arm fastening nut	Ecrou de fixation tirant- balancier

VERSCHRAUBUNGSMOMENTE / PATAS DE TORSION

CHASSIS
Chassis Aplicación	CHASSIS Aplicación	Filettatura Threading Filetate Gewinde Filetado	±5%
Befestigungsschraube Hinterrahmen (untere)	Tornillo fijación inferior bastidor trasero	M8x1,25	25,5 Nm	2,6 Kgm	18.8 ft/lb
Befestigungsschraube Motorschutz	Tornillo fijación protección motor	M6x1	14,7 Nm	1,5 Kgm	10.8 ft/lb
Befestigungsschraube Kettenrolle	Tornillo fijación rodeta cadena	M8x1,25	26,95 Nm	2,75 Kgm	19.9 ft/lb
Befestigungsschraube Seitenständer	Tornillo fijación caballete lateral	M8x1,25 (+LOCTITE 243)	11,75 Nm	1,2 Kgm	8.7 ft/lb
Befestigungsschraube Hinterrahmen (obere)	Tornillo fijación superior bastidor trasero	M8x1,25	25,5 Nm	2,6 Kgm	18.8 ft/lb
Befestigungsschraube Rahmen-Motorplatte	Tornillo fijación bastidor -placa motor	M8x1,25 (+LOCTITE 270	35,3 Nm	3,6 Kgm	26 ft/lb
Befestigungsschraube Motor (untere)	Tornillo fijación inferior motor	M8x1,25	35,3 Nm	3,6 Kgm	26 ft/lb
Befestigungsschraube Kupplunghalter und Vorderbremse	Tornillo fijación conexiones embrage y freno delantero	M6x1	4,9 Nm	0,5 Kgm	3.6 ft/lb
Befestigungsschraube Gasgriffhalter	Tornillo fijación suportes mando gas	M6x1	4,9 Nm	0,5 Kgm	3.6 ft/lb
Obere Befestigungsschraube Vorderbremserohr (TE, SMR)	Tornillo fijación superior tuberia freno delantero (TE, SMR)	M10x1	19 Nm	1,95 Kgm	14 ft/lb
Obere Befestigungsschraube Vorderbremserohr (TC)	Tornillo fijación superior tuberia freno delantero (TC)	M10x1	24,7 Nm	2,5 Kgm	18.2 ft/lb
Befestigungsschraube Hinterbremsenpedal	Tornillo fijación pedal freno trasero	M10x1,25 (+LOCTITE 243)	41,65 Nm	4,25 Kgm	30.7 ft/lb
Befestigungsschraube Hinterbremsenpumpe	Tornillo fijación bomba freno trasero	M6x1	10,4 Nm	1,05 Kgm	7.7 ft/lb
Befestigungsschraube Vorderbremsenpumpeplatte (SMR)	Tornillo fijación placa bomba freno delantero (SMR)	M6x1	10,4 Nm	1,05 Kgm	7.7 ft/lb
Befestigungsschraube Hinterbremseöltank	Tornillo fijación deposito líquido freno trasero	M6x1	2,45 Nm	0,25 Kgm	1.8 ft/lb
Schalter Hinterradbremslicht (TE, SMR)	Interruptor stop trasero (TE, SMR)	M10x1	19 Nm	1,95 Kgm	14 ft/lb
Befestigungsschraube Verbinder für Schalter Vorderradbremslicht (SMR)	Tornillo fijación conector interruptor stop delantero (SMR)	M2x0,4	0,8 Nm	0,1 Kgm	0,6 ft/lb
Befestigungsschraube Hinterbremse Pedalnocken	Tornillo fijación excéntrico pedal freno trasero	M6x1	14,7 Nm	1,4 Kgm	10.8 ft/lb
Befestigungsschraube Rohrplatte Vorderbremse	Tornillo fijación placa guía-tuberia freno delantero	M6x1	6 Nm	0,6 Kgm	4.4 ft/lb
Befestigungsschraube Vorderbremse Öltankstöpsel (SMR)	Tornillo fijación tapón deposito freno delantero (SMR)	M6x1	4,9 Nm	0,5 Kgm	3.6 ft/lb
Befestigungsschraube Vordergabelschafte	Tornillo fijación varillas horquilla delantera	M8x1,25	25 Nm	2,5 Kgm	18.4 ft/lb
Befestigungsschraube Vorderradzapfen	Tornillo fijación perno rueda delantera	M6x1	10,4 Nm	1,05 Kgm	7.7 ft/lb
Einstellzwinge Lenkungslager	Virola aiuste cojinetes de la guía	M25x1	3,45 Nm	0,35 Kgm	2.5 ft/lb
Befestigungsmutter Lenkbolzen	Tuerca eje de la guía	M24x1	83,3 Nm	8,5 Kgm	61.4 ft/lb
Befestigungsschraube Obere Lenkerklemme	Tornillo fijación abrazadera superior del manillar	M8x1,25	28,4 Nm	2,9 Kgm	20.9 ft/lb
Befestigungsschraube Lenkerhalterung	Tornillo fijación suporte del manillar	M10x1,5	21,1 Nm	2,15 Kgm	15.6 ft/lb
Befestigungsschraube Vordergabelstangen	Tornillo fijación protección varillas horquilla delantera	M5x0,8	7,85 Nm	0,8 Kgm	5.8 ft/lb
Befestigungsschraube Schutzring für Vordergabelstangen	Tornillo fijación anillo protecciones varillas horquilla delantera	M5x0,8	2,45 Nm	0,25 Kgm	1.8 ft/lb
Befestigungsmutter Hintergabelzapfen	Tuerca fijación perno horquilla trasera	M16x1,5 (+LOCTITE 243)	122,5 Nm	12,5 Kgm	90.3 ft/lb
Befestigungsmutter Kipphebel-Hintergabel	Tuerca fijación balancín- horquilla trasera	M12x1,25	80 Nm	8,2 Kgm	59 ft/lb
Befestigungsmutter Spannstange- Kipphebel	Tuerca fijación tirante- balancín	M12x1,25	80 Nm	8,2 Kgm	59 ft/lb

COPPIE DI SERRAGGIO / TIGHTENING TORQUES / COUPLES DE SERRAGE

MOTOTELAIO	CHASSIS	CHASSIS
Applicazione	Application	Application
Dado fiss. telaio-tirante	Frame to tie rod fastening nut	Ecrou de fixation cadre- tirant
Ingrassatore	Rocker arm to tie rod lubricator	Graisseur
Vite fiss. ammortizzatore-telaio	Rear shock absorber to frame fastening pivot	Vis de fixation amortisseur-cadre
Vite fiss. bilanciere- telaio	Rocker arm to frame fastening pivot	Vis de fixation balancier - cadre
Vite fiss. guidacatena-forcellone (TE-SMR)	Chain guide to rear swing arm fastening screw (TE-SMR)	Vis de fixation guide-chaine/fourche arrière (TE-SMR)
Vite fiss. anteriore guidacatena-forcellone (TC)	Chain guide to rear swing arm front fastening screw (TC)	Vis de fixation avant guide-chaine/fourche arrière (TC)
Vite fiss. posteriore guidacatena-forcellone (TC)	Chain guide to rear swing arm rear fastening screw (TC)	Vis de fixation arrière guide-chaine/fourche arrière (TC)
Vite fiss. staffa-guidacatena (TE-SMR)	Bracket to chain guide fastening screw (TE-SMR)	Vis de fixation etrier/guide-chaine (TE-SMR)
Vite fiss. inf. pattino catena e passatubazione freno posteriore	Chain slider and rear brake hose clamp lower fastening screw	Vis de fixation inf. glissière chaine et passe-tuyau frein arrière
Vite fiss. post. pattino catena e passatubazione freno posteriore (TC)	Chain slider and rear brake hose clamp rear fastening screw	Vis de fixation arrière glissière chaine et passe-tuyau frein arrière (TC)
Vite fiss. copricatena (TE-SMR)	Chain guard fastening screw (TE-SMR)	Vis de fixation carter de chaine (TE-SMR)
Dado fiss. tendicatena	Chain adjuster fastening nut	Ecrou de fixation tendeur de chaine
Vite fiss. spoiler a serbatoio	Spoiler to fuel tank fastening screw	Vis de fixation spoiler-réservoir
Vite fiss. superiore portanumero anteriore (TC)	Front number holder upper fastening screw (TC)	Vis de fixation superieur porte-numero avant (TC)
Vite fiss. inferiore portanumero anteriore (TC)	Front number holder lower fastening screw (TC)	Vis de fixation inferieur porte-numero avant (TC)
Vite fiss. protezione ammortizzatore	Rear shock absorber guard fastening screw	Vis de fixation protection amortisseur arrière
Vite fiss. anteriore parafango posteriore	Rear fender front fastening screw	Vis de fixation avant garde-bouie arrière
Vite fiss. posteriore parafango posteriore	Rear fender rear fastening screw	Vis de fixation arrière garde-bouie arrière
Vite fiss. parafango anteriore	Front fender fastening screw	Vis de fixation garde-bouie avant
Vite fiss. protezione radiatore	Radiator guard fastening screw	Vis de fixation protection radiateur
Vite fiss. pannello laterale	Side panel fastening screw	Vis de fixation panneau lateral
Vite fiss. portatarga	License plate fastening screw	Vis de fixation porte-balai
Dado fiss. catadiottro posteriore	Rear reflector fastening nut	Ecrou de fixation catadioptrique arrière
Vite fiss. anello passatubazione freno al cupolino	Brake hose ring to front fairing fastening screw	Vis de fixation bague passe-tuyau frein au carenage avant
Vite fiss. indicatori direzione	Turn signals fastening screw	Vis de fixation clignotant
Vite fiss. gruppo ottico anteriore	Front headlamp fastening screw	Vis de fixation gruppo phare avant
Vite fiss. cavi teleruttore	Electric start remote control switch cables fastening screw	Vis de fixation cable telerupteur
Vite fiss. tampone anteriore serbatoio carburante	Fuel tank front rubber pad fastening screw	Vis de fixation tampon avant réservoir essence
Vite fiss. rubinetto serbatoio carburante	Fuel cock fastening screw	Vis de fixation robinet réservoir essence
Vite fiss. posteriore serbatoio carburante	Fuel tank rear fastening screw	Vis de fixation arrière réservoir essence
Vite fiss. anteriore scatola filtro	Air filter box front fastening screw	Vis de fixation avant scatola filtro

VERSCHRAUBUNGSMOMENTE / PATAS DE TORSION

CHASSIS
Aplicación	CHASSIS Aplicación	Filettatura Threading Filetate Gewinde Filetado	±5%
Befestigungsmutter Rahmen- Kipphebel	Tuerca fijación bastidor -tirante	M12x1,25	80 Nm	8,2 Kgm	59 ft/lb
Fettbüchse	Lubricador suspension trasera	M6x1	2,95 Nm	0,3 Kgm	2,2 ft/lb
Befestigungsschraube Stossdämpfer-Rahmen	Tornillo fijación amortiguador- bastidor	M10x1,25	52,4 Nm	5,35 Kgm	38,6 ft/lb
Befestigungsschraube Kipphebel - Rahmen	Tornillo fijación balancín - bastidor	M10x1,25	52,4 Nm	5,35 Kgm	38,6 ft/lb
Befestigungsschraube Kettenführung- Hintergabel (TE-SMR)	Tornillo fijación guia-cadena- horquilla trasera (TE-SMR)	M8x1,25	25 Nm	2,5 Kgm	18.4 ft/lb
Befestigungsschraube Vordere Kettenführung - Hintergabel (TC)	Tornillo fijación delantera guia-cadena/horquilla trasera (TC)	M8x1,25 (+LOCTITE 243)	10,4 Nm	1,05 Kgm	7.7 ft/lb
Befestigungsschraube Hintere Kettenführung - Hintergabel (TC)	Tornillo fijación trasero guia-cadena/horquilla trasera (TC)	M6x1 (+LOCTITE 243)	10,4 Nm	1,05 Kgm	7.7 ft/lb
Befestigungsschraube Buegel-Kettenführung (TE-SMR)	Tornillo fijación brida/guia-cadena (TE-SMR)	M6x1 (+LOCTITE 243)	2 Nm	0,2 Kgm	1.5 ft/lb
Befestigungsschraube Untere Gleitbahn und Rohrführung für Hinterbremse	Tornillo fijación inferior plato cadena y guía-tuberia freno trasero	M5x0,8	4,4 Nm	0,45 Kgm	3.2 ft/lb
Befestigungsschraube Hintere Gleitbahn und Rohrführung für Hinterbremse (TC)	Tornillo fijación trasero plato cadena y guía-tuberia freno trasero (TC)	M5x0,8	4,4 Nm	0,45 Kgm	3.2 ft/lb
Befestigungsschraube Kettenkasten (TE-SMR)	Tornillo fijación cubre-cadena (TE-SMR)	M5x0,8	4,4 Nm	0,45 Kgm	3.2 ft/lb
Befestigungsmutter Kettenspanner	Tuerca fijación tensor de cadena	M8x1,25	4,4 Nm	0,45 Kgm	3.2 ft/lb
Befestigungsschraube Spoiler-Kraftstoffbehälter	Tornillo fijación spoiler-deposito gasolina	M6x1	6 Nm	0,6 Kgm	4.4 ft/lb
Befestigungsschraube Obere Vordernummerträge (TC)	Tornillo fijación superior portanumero delantero (TC)	M6x1	6 Nm	0,6 Kgm	4.4 ft/lb
Befestigungsschraube Untere Vordernummerträger (TC)	Tornillo fijación inferior portanumero delantero (TC)	M6x1	10,4 Nm	1,05 Kgm	7.7 ft/lb
Befestigungsschraube Stossdämpferschutz	Tornillo fijación protección amortiguador	M6x1	6 Nm	0,6 Kgm	4.4 ft/lb
Befestigungsschraube Vordere Hinterkotflügel	Tornillo fijación delantero guarda-barros delantero	M6x1	10,4 Nm	1,05 Kgm	7.7 ft/lb
Befestigungsschraube Hintere Hinterkotflügel	Tornillo fijación trasero guarda-barros delantero	M6x1	6 Nm	0,6 Kgm	4.4 ft/lb
Befestigungsschraube Vorderkotflügel	Tornillo fijación guarda-barros delantero	M6x1	10,4 Nm	1,05 Kgm	7.7 ft/lb
Befestigungsschraube Kühlerschutz	Tornillo fijación protección radiator	M6x1	6 Nm	0,6 Kgm	4.4 ft/lb
Befestigungsschraube Streifen	Tornillo fijación panel latera	M6x1	6 Nm	0,6 Kgm	4.4 ft/lb
Befestigungsschraube Schildtraeger	Tornillo fijación porta-matrícula	M6x1	6 Nm	0,6 Kgm	4.4 ft/lb
Befestigungsmutter Rückstrahler	Tuerca fijación catafaros trasero	M4x0,7	1,9 Nm	0,2 Kgm	1.4 ft/lb
Befestigungsschraube Bremsenrohrführung für Verkleidung	Tornillo fijación anillo guía-tuberia freno-cúpula delantera	ø 3,5	1,9 Nm	0,2 Kgm	1.4 ft/lb
Befestigungsschraube Blinker	Tornillo fijación intermitentes	M6x1	6 Nm	0,6 Kgm	4.4 ft/lb
Befestigungsschraube Vordere optische Gruppe	Tornillo fijación grupo óptico delantero	ø 3,9	1,45 Nm	0,15 Kgm	1 ft/lb
Befestigungsschraube Kabel für Fernschalter Anlasser	Tornillo fijación cable teleruptor	M6x1	10,4 Nm	1,05 Kgm	7.7 ft/lb
Befestigungsschraube für Kraftstoffbehälter Vordere Stopfen	Tornillo fijación tampón delantero deposito gasolina	M6x1	10,4 Nm	1,05 Kgm	7.7 ft/lb
Befestigungsschraube Treibstoffhahn	Tornillo fijación grifo deposito gasolina	ø5,5	2,45 Nm	0,25 Kgm	1.8 ft/lb
Hinterbefestigungsschraube Kraftstoffbehälter	Tornillo fijación trasero deposito gasolina	M6x1	10,4 Nm	1,05 Kgm	7.7 ft/lb
Befestigungsschraube Vorderfiltergehäuse	Tornillo fijación delantera caja filtro aire	M6x1	10,4 Nm	1,05 Kgm	7.7 ft/lb

COPPIE DI SERRAGGIO / TIGHTENING TORQUES / COUPLES DE SERRAGE

MOTOTELAIO	CHASSIS	CHASSIS
Applicazione	Application	Application
Dado fiss. flangia scatola filtro	Air filter box flange fastening nut	Ecrou de fixation flangia bôte filtre à air
Vite fiss. pinza freno	Front brake caliper fastening screw	Vis de fixation etrier frein
Vite fiss. inferiore tubazioni freni	Brake hoses lower fastening screw	Vis de fixation inferieur tuyau freins
Vite fiss. perno ruota anteriore (SMR)	Front wheel axle fastening screw (SMR)	Vis de fixation pivot roue
Vite fiss. pinza freno	Front brake caliper to caliper holding plate fastening screw (SMR)	Vis de fixation etrier frein
Vite fiss. piastra pinza freno alla forcella (SMR)	Brake caliper holding plate to front fork (SMR)	Vis de fixation plaque etrier frein –fourche avant (SMR)
Vite fiss. perno ruota (TE-TC)	Front wheel axle fastening screw (TE-TC)	Vis de fixation pivot roue
Vite fiss. disco freno anteriore (TE-TC)	Front brake disc fastening screw (TE-TC)	Vis de fixation disque frein
Vite fiss. disco freno anteriore (SMR)	Front brake disc fastening screw (SMR)	Vis de fixation disque frein
Vite fiss. disco freno posteriore (TE-TC)	Rear brake disc fastening screw (TE-TC)	Vis de fixation disque frein
Nipplo per raggio ruota anteriore	Front wheel nipple	Nipplo per raggio roue
Nipplo per raggio ruota posteriore	Rear wheel nipple	Nipplo per raggio roue
Dado fiss. corona	Rear wheel sprocket fastening nut	Ecrou de fixation couronne arrière
Dado perno ruota posteriore	Rear wheel axle fastening nut	Ecrou de fixation pivot roue
Perno ruota anteriore	Front wheel axle	Pivot roue avant
Vite fiss. coperchio pignone cambio al carter sinistro	Drive sprocket cover fastening screw	Vis de fixation couvercle pignon-carter gauche
Vite fiss. silenziatore di scarico	Exhaust silencer fastening screw	Vis de fixation silencieux d'echappement
Vite fiss. tubi di scarico alla testa cilindro	Exhaust pipes to cylinder head fastening screw	Vis de fixation tuyau d'echappement au culasse cylindre
Vite fiss. strumento	Instrument fastening screw	Vis de fixation instrument
Vite fiss. radiatore	Radiator fastening screw	Vis de fixation radiateur

VERSCHRAUBUNGSMOMENTE / PATAS DE TORSION

CHASSIS
Aplicación	CHASSIS	Filettatura Threading Filetate Gewinde Filetado	± 5%
	Aplicación
Befestigungsmutter Flansch Filtergehäuse	Tuerca fijación brida caja filtro aire	M5x0,8	3,45 Nm	0,35 Kgm	2.5 ft/lb
Befestigungsschraube Vorderradsattel	Tornillo fijación zapata freno delantero	M8x1,25	25,5 Nm	2,6 Kgm	18.8 ft/lb
Untere Befestigungsschraube für Bremsrohr	Tornillo fijación inferior tuberias frenos	M10x1	19 Nm	1,95 Kgm	14 ft/lb
Befestigungsschraube Vorderradzapfen (SMR)	Tornillo fijación perno rueda delantera (SMR)	M10x1,5	51,45 Nm	5,25 Kgm	38 ft/lb
Befestigungsschraube Vorderradbremssattel-Platte (SMR)	Tornillo fijación zapata freno delantero-placa (SMR)	M10x1,5	25,5 Nm	2,6 Kgm	18.8 ft/lb
Befestigungsschraube Vorderradbremssattelplatte-Vordergabel (SMR)	Tornillo fijación placa zapata freno- horquilla (SMR)	M10x1,5	25,5 Nm	2,6 Kgm	18.8 ft/lb
Befestigungsschraube Vorderradzapfen (TE-TC)	Tornillo fijación perno rueda delantera (TE-TC)	M20x1,5	51,45 Nm	5,25 Kgm	38 ft/lb
Befestigungsschraube Vorderradbremsscheibe (TE-TC)	Tornillo fijación disco freno delantero (TE-TC)	M6x1 (LOCTITE 243)	14,7 Nm	1,5 Kgm	10.8 ft/lb
Befestigungsschraube Vorderradbremsscheibe (SMR)	Tornillo fijación disco freno delantero (SMR)	M8x1,25	34,7 Nm	3,54 Kgm	25.6 ft/lb
Befestigungsschraube Hinterradbremsscheibe (TE-TC)	Tornillo fijación disco freno trasero (TE-TC)	M6x1 (LOCTITE 243)	14,7 Nm	1,5 Kgm	10.8 ft/lb
Befestigungsnippel Vorderrad	Nipple por radio rueda delantera	M4,07x0,75	4,4 Nm	0,45 Kgm	3.2 ft/lb
Befestigungsnippel Hinterrad	Nipple per radio rueda trasera	M4,5x0,75	4,4 Nm	0,45 Kgm	3.2 ft/lb
Befestigungsmutter Hinterkranz	Tuerca fijación corona trasera	M8x1,25 (+LOCTITE 243)	34,3 Nm	3,5 Kgm	25.3 ft/lb
Befestigungsmutter Hinterradzapfen	Tuerca fijación perno rueda trasera	M20x1,5	142,1 Nm	14,5 Kgm	104.8 ft/lb
Vorderradzapfen	Perno rueda delantera	M20x1,5	142,1 Nm	14,5 Kgm	104.8 ft/lb
Befestigungsschraube Deckel Ritzel-L. Gehause	Tornillo fijación tapa piñón cambio-carter izquierdo	M6x1	10,4 Nm	1 Kgm	7.7 ft/lb
Befestigungsschraube Abgasschalldämpfer	Tornillo fijación silenciador de escape	M6x1	10,4 Nm	1 Kgm	7.7 ft/lb
Befestigungsschraube Ausapuffrohr-Zylinderkopf	Tornillo fijación tubos de escape alla culata cilindro	M6x1	10,4 Nm	1 Kgm	7.7 ft/lb
Befestigungsschraube Instrumente	Tornillo fijación instrumento	ø4,8	3,45 Nm	0,35 Kgm	2.5 ft/lb
Befestigungsschraube Kühler	Tornillo fijación radiator	M6x1	7 Nm	0,72 Kgm	5.2 ft/lb

KIT

	Code No.Nr. CodeCode NrN. Cod.	DENOMINAZIONE	NAME	DESIGNATION	BESHREIBUNG	DENOMINACION
1	8000 A1320	Kit protezione carter destro (TE-TC)	R.H. crankcase guard kit (TE-TC)	Kit protection couvercle carter D. (TE-TC)	R. Gehausedeckel Schutz Kit (TE-TC)	Kit protección tapa bancada derecha
2	8000 A4295	Kit carburatore KEIHIN 37 (TC 250) RACING	Carburetor KEIHIN 37 Kit (TC 250) RACING	Kit carburateur KEIHIN 37 (TC 250) RACING	Vergaser Kit KEIHIN 37 (TC 250) RACING	Kit carburador KEIHIN 37 (TC 250) RACING
2	8000 A6115	Kit carburatore KEIHIN 37 (TE 250) RACING	Carburetor KEIHIN 37 Kit (TE 250) RACING	Kit carburateur KEIHIN 37 (TE 250) RACING	Vergaser Kit KEIHIN 37 (TE 250) RACING	Kit carburador KEIHIN37 (TE 250) RACING
2	8000 A5918	Kit carburatore KEIHIN 41 (TE-SMR 450/510)- RACING	Carburetor KEIHIN 41 Kit (TE-SMR 450/510)- RACING	Kit carburateur KEIHIN 41 (TE-SMR 450/510)- RACING	Vergaser Kit KEIHIN 41 (TE-SMR 450/510)- RACING	Kit carburador KEIHIN 41 (TE-SMR 450/510)- RACING
2	8000 A4296	Kit carburatore KEIHIN 41 (TC 450/510)-RACING	Carburetor KEIHIN 41 Kit (TC 450/510)-RACING	Kit carburateur KEIHIN 41 (TC 450/510)-RACING	Vergaser Kit KEIHIN 41 (TC 450/510)-RACING	Kit carburador KEIHIN 41 (TC 450/510)-RACING
2	8000 A3091	Kit carburat. MIKUNI 38 (SMR 400)-RACING	Carburetor MIKUNI 38 Kit (SMR 400)-RACING	Kit carburateur MIKUNI 38 (SMR 400)-RACING	Vergaser Kit MIKUNI 38 (SMR 400)-RACING	Kit carburador MIKUNI 38 (SMR 400)-RACING
3	8000 A0865	Paramotore (TE-TC)	Engine guard (TE-TC)	Garde moteur (TE-TC)	Motorschutz (TE-TC)	Para motor (TE-TC)
4	8000 A0677 (*)	Kit compl. poggiapiedi (TE-SMR)	Compl. footrest Kit (TE-SMR)	Appui-pied complet (TE-SMR)	kompl. Fussraster-Kit (TE-SMR)	Kit compl. apoyapiés (TE-SMR)
5	8B00 A0226 (*)	Kit indicatori di direzione (TE-SMR)	Blinkers Kit (TE-SMR)	Kit clignotants (TE-SMR)	Blinkers Kit (TE-SMR)	Kit intermitentes (TE-SMR)
6	8000 A3191	Kit gancio per la fase di partenza della gara (TC)	Hook Kit for race starting phase (TC)	Kit crochet pour phase de départ de la compétition (TC)	Kit Haken für die Phase von Abreise des Wettkampfes (TC)	Kit gancho por fase de salida de la competición (TC)

*:Non per USA/CDN - Not for USA/CDN - Ne pas pour USA/CDN-Keine für USA/CDN - No por U.S.

KIT

5 2 5 * 4 1 3 TE

Labeled diagram of a 200 motorcycle showing key components including wheel, suspension, and suspension parts

SMR 5 2 5 * 4

*: KIT AVVIAMENTO A PEDALE
*: KICK STARTER KIT
*: KIT DÉMARRAGE À PÉDALE
*: KIT KICKSTARTER
+: KIT ARRANQUE A PEDAL

PARTI OPTIONAL (TE)

1- Gruppo anelli di tenuta motore	8000 99923
2- Corona posteriore
	8A00 96837 (Z=47)
	8B00 96837 (Z=48)
	8C00 96837 (Z=49)
	8D00 96837 (Z=50)★
3- Pignone uscita cambio
	8000 63827 (Z=12)
	8000 63828 (Z=13) §
	8000 63829 (Z=14) &
	8000 63830 (Z=15)

§: STANDARD on 250-450 model

&: STANDARD on 510 model

ELEMENTS EN OPTION (TE)

① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ ⑩ ⑪ ⑫ ⑬

PARTI OPTIONAL (TC)

OPTIONAL PARTS LIST (TC)

1. Engine seals kit	8000 99923
2. Workshop manual	8000 A5911
3. Rear sprocket
	8A00 96837 (Z=47) && 8B00 96837 (Z=48)
	8C00 96837 (Z=49)
	8D00 96837 (Z=50) §, &
4. Drive sprocket
	8000 63827 (Z=12) §
	8000 63828 (Z=13)
	8000 63829 (Z=14) &, && 8000 63830 (Z=15)
5. Engine basket kit (250)	8000 A4223
Engine basket kit (450-510)	8000 A4226
6. Front fork oil(1000 cm3 container)	8000 80260
8-Front fork spring+spacer kit(K=4,8 N/mm)	8000 98789 *
9-Rear shock absorber spring(K=5 Kg/mm)	8000 ..... *
10. Spare parts catalogue	8000 A5912
11. Brake fluid (250 cm3 container)	8000 71445
12. Electric starter kit	8000 A6487
*: STANDARD
§: STANDARD on 250 model&: STANDARD on 450 model&&: STANDARD on 510

ELEMENTS EN OPTION (TC)

AFTER-RACE CHECK POINTS After racing, first clean the motorcycle and then inspect the entire motorcycle, with special attention to the items listed in «MAIN-TENANCE» 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 COMPETITION

Technical diagram of a mechanical assembly with numbered annotations pointing to components

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.

3) After washing

• Remove the plastic bags, and clean the air cleaner intake.
• Lubricate the points listed in the Maintenance Table (P. 286-292).
• Briefly warm-up the engine
• Test the brakes before riding the motorcycle.

WARNING*: Never wax or lubricate the brake disc. Loss of braking and an accident could result. Clean the disc with an oilless solvent such as acetone. Observe the solvent warnings.

NETTOYAGE

When remove greasers (1) to lubricate rear suspension link needle bearings, it's necessary to lubricate shock absorber lower needle bearing (2) too: remove nut (3) and bushing.

Mechanical assembly diagram with numbered annotations pointing to components

Technical diagram showing exploded view of mechanical components with numbered parts and assembly details

NOTES FOR USA/CDN MODEL

Side profile of a white and black Husqvarna TE250 motorcycle with visible dynamics and wheels (no text or symbols on the bike body)

Side view of a Masch踏板 (Husqvarna TC250) motorcycle with visible tracks and wheels, no text or symbols on the vehicle itself.

Side view of a white and silver semi-motor motorcycle with visible engine and wheels (no text or symbols on the bike body)

DISCLAIMER OF WARRANTY

IN ACCEPTING DELIVERY OF THIS MOTORCYCLE THE BUYER OR TRANSFEREE ACKNOWLEDGES THAT HE HAS THOROUGHLY INSPECTED THE MOTORCYCLE, AND FURTHER AGREES TO ACCEPT THE MOTORCYCLE AS IS WITH ALL DEFECTS OR FAULTS, CONCEALED OR OBVIOUS. HE FURTHER AGREES THAT NO WARRANTIES ATTACH, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. THE BUYER OR TRANSFEREE INDEMNIFIES AND HOLDS HARMLESS CAGIVA U.S.A., MV Agusta Motorcycles S.p.A., THEIR AGENTS AND EMPLOYEES. FOR ANY FAILURE OF PERFORMANCE, COST OF SERVICE, OR REPAIR. THE BUYER FURTHER ACKNOWLEDGES THAT THIS MOTORCYCLE IS NOT INTENDED 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

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 gases.
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 efficiency and performance.

"SPARK ARRESTER" MAINTENANCE AND CLEANOUT INSTRUCTIONS

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.

Diagram of a mechanical component with a circular arrow labeled '1' pointing to a ring (no text or symbols beyond label)

③ ②

Technical diagram of a mechanical assembly with numbered components and labeled parts

NOTES FOR "AUS" MODEL

Side profile of a white and black Husqvarna TE250 motorcycle with visible dynamics and wheels (no text or symbols on the bike body)

Side view of a Mascat 250 motorcycle with visible tracks and wheels (no text or symbols on the bike body)

Side view of a white and black semi-traw bike with visible engine and wheels (no text or symbols on the bike body)

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 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.

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.

Description	Operation	Pre-delivery	Description	Operation	Pre-delivery
Engine oil	Check level	☐	Tyres	Check pressure	☐
Two-stroke mix oil level	Check level	☐ *	Side stand	Check operation	☐
Coolant	Check / Restore level	☐	Side stand switch	Check operation	☐
Cooling system	Check for leakage	☐	Electrical equipment	Check operation	☐
Electric fans	Check operation	☐ * *	Instrument panel	Check operation	☐
Spark plugs	Check / Replace	☐	Lights / Visual signals	Check operation	☐
Throttle body / Carburettor	Check and adjust	☐	Horn	Check operation	☐
Brakes / Clutch fluid	Check level	☐	Headlight	Check operation	☐
Brakes / Clutch	Check operation	☐	Ignition switch	Check operation	☐
Brakes / Clutch	Check lines for leakage	☐	Locks	Check operation	☐
Throttle control	Check operation	☐	Screws and nuts	Check / Tighten	☐
Throttle control	Check / Adjust play	☐	Hose clamps	Check / Tighten	☐
Choke control	Check operation	☐	General lubrication		☐
Flexible controls and transm.	Check / Adjust	☐	General test		☐
Drive chain	Check / Adjust	☐

※ : only for motorcycles with 2 stroke engine

※※: only for some models

Image containing a series of vertical black bars on white background, resembling a barcode or pattern.

SMR 400, 450, 510- 2006 - TE 250, 450, 510 - 2006	WARTUNGSTABELLE (FÜR DIESE KONTROLLEN WENDEN SIE SICH AN IHREN VERTRAGSHÄNDLER HUSQVARNA) ESQUEMA DE MANTENIMIENTO PERIODICO(PARA EFECTUAR ESTAS OPERACIONES DIRÍJASE A SU CONCESIONARIO HUSQVARNA)
TEILE- PARTICULAR	COUPON- CUPÓN	COUPON- CUPÓN	COUPON- CUPÓN
SMR 400, 450, 510- 2006 - TE 250, 450, 510 - 2006- ÜBLICHES MOTORRAD, STRAße GESETZLICH (mit beschränktem MACHT-MOTOR):SMR 400, 450, 510- 2006; TE-TC 250, 450, 510 - 2006- MOTOCICLO DE SERIE, PARA USO VIAL (A POTENCIA LIMITADA):SMR 400, 450, 510- 2006; TE-TC 250, 450, 510 - 2006	NACH DEN ERSTEN 1000Km- DESPUES LOS PRIMEROS 1000Km	ALLE 5000 KM CADA 5000 KM	ALLE 10000Km CADA 10000Km	WECHSELN WENN NÖTIG- SUBSTITUIR SI NECESARIO	SIEHE SEITE VER PAGINA
SMR 400, 450, 510- 2006-MOTOCICLO DA COMPETIZIONE, PER USO AGONISTICO (A PIENA POTENZA)- COMPETITION MOTORCYCLE, RACING USE (with FULL POWER ENGINE)- MOTOCYCLE DE COMPÉTITION, POUR USAGE SPORTIF (AVEC LA PLEINE PUISSANCE)	NACH DEN ERSTEN 3 STUNDEN- DESPUES LAS PRIMERAS 3 HORAS	ALLE 5 STUNDEN CADA 5 HORAS	ALLE 15 STUNDEN CADA 15 HORAS
TREIBSTOFFROHR- TUBERÍAS CARBURANTE			C	X	#
GERÁUSCHDÄMPFENDES MATERIAL FÜR AUSPUFF- MATERIAL FONOABSORBENTE SILENCIADOR				X	196-197, 279
AUSPUFFROHR UND SCHALLDÄMPFER- TUBO DE ESCAPE Y SILENCIADOR		C		X	#
RADSPEICHENSSPANNUNG- TENSION RADIOS RUEDAS	C		C		224-225
RADNABENLAGER- COJÍNETES CUBOS RUEDAS			C	X	#
KRANZ- CORONA TRASERA			S		#
SCHRAUBENANZIEHUNG FÜR HINTERKRANZ- TORSION TORNILLOS CORONA TRASERA	C	C	C		152-153, 158-159
SEKUNDÄRE ÜBERTRAGUNGSKETTE- CADENA TRANSMISIÓN SECUNDARIA	CL	CL	S		152-153
KONTROLLE VERSCHRAUBUNG KALTGESENKBOLZEN- CONTROL GENERAL AJUSTE TUERCAS	C	C			#

LEGENDE- LEYENDA
S: WECHSELN- SUBSTITUCIÓN
C: KONTROLLIEREN- CONTROL
P: REINIGEN- LIMPIEZA
R: REVISION- REVISION
L: SCHMIERUNG-BESCHMEIREN- ENGRESAJE-LUBRICACIÓN

: SIEHE WERKSTATTHANDBUCH- VER MANUAL DE OFICINA

ANMERKUNG- NOTAS
DICHTUNGWECHSE: BEI JEDEM DEMONTAGE- SUBSTITUIR LAS EMPACURAS EN EL CASO DE DESMONTAJE
SCHRAUBEN VERSCHLEISS: WECHSELN- SUBSTITUIR TORNILLOS Y TUERCAS EN EL CASO DE DESGASTE
SCHLAMMIGES UND SANDIGES GELÄNDEN: EIN ALLGEMEINE KONTROLLE DURCHFÜHREN- DESPUÉS DE LA CARRERA SOBRE UN TERRENO FANGOSO O ARENOSO, EFECTUAR UN CONTROL GENERAL

INDICE ALFABETICO

Pagina

A

Accensione 28

Adjusting the carburetor 108

Adjusting the clutch....130

Adjusting the driven transmission 150

Adjusting the fork 138

Adjusting the front brake control lever....124

Adjusting the headlamp 246

Adjusting the idle 108

Adjusting the rear brake idle stroke 128

Adjusting shock absorber hydraulic brake....148

Adjusting shock absorber preload spring....146

Adjusting the rear brake pedal position 126

Adjusting the steering bearing play....120

Adjusting the suspensions according to the track special conditions....134

Adjusting the throttle cable 106

Adjusting the valve play 114

B

Battery 236

Brakes....166

Brake disc cleaning....174

Brake disc warpage 172

Brake disc wear 172

Brake pad assembly 170

Brake pad wear 168

Brake pad disassembly....168

C

Carburettor 30

Carburettor starter 52

Chain lubrication....154

Checks after every competition....268

Checks during running in 96

Check of air filter....118

Check of chain, pinion, crown wear 152

Check of clutch fluid level 130

Check of cooling fluid 104

Check of front brake fluid level 124

Check of engine oil 98

Check of rear brake fluid level....128

Cleaning the air filter 118

Clutch 32

Clutch control 74

INDEX ALPHABETIQUE

Page

A

Control position....22

D Digital instrument ....54

Draining the front brake fluid....172

Draining the rear brake fluid 174

Driven transmission chain....32

E Engine assembling fits ....198

Electric diagram 229, 231, 235

Electric elements ......226

Engine lubrication....42, 44

Engine oil replacement....100,

Engine start 84

Engine stop....90

F Filling the braking system ....182

Fluid change 180

Fork oil level 140

Fuel....50

Fuel cock....46

Front brake control 68

Front braking system bleeding 168

Front fork....36

G Gearbox control ....78

Gearbox outlet pinion 32

General cleaning....272

H Handlebar commutators ....72

Handlebar position change 142

Headlamp bulbs replacement 242

Hydraulic clutch bluding 132

I Ignition 28

Important notice 14

L Long inactivity ....268

E Embrayage ....32

Nettoyage plaquettes ....170

Motorcycle stop....90

Muffler on the exhaust 196

0

Oil filters replacement 100

Overhauling the wheels 222

P

Pad cleaning 170

Parts replacement....14

Pilot lights ....54

Preliminary checks 80

R

Rear brake control 76

Rear crown 32

Rear fork 36

Rear taillight bulb replacement 244

Running in 94

Rear braking system bleeding 192

Removing the front wheel 160

Removing the rear wheel 162

S

Steering lock 70

Side stand....48

Spark-arrester....279

Spark plug....28

Spark plug check 110

Special tools 250

Starting decompressor 86

T

Throttle control 68

Tires 38,164

Tool outfit 248

V

Vehicle identification number 20

Voltage regulator....112

W

Wheel pin bending 224

Wheel spokes 224

Wheels 36

secondaire 150