WR 250 - Off-road motorcycle HUSQVARNA - Free user manual and instructions

USER MANUAL WR 250 HUSQVARNA

WARNING: After an upset, inspect the motorcy-

cle 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 appro- fpriate protective clothing. Always wear à mo- torcycle helmet, motorcycle boots, gloves, gog- gles 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 condi- tion.

1- Front brake lever

8- Gear change pedal. The

gearbox has five gears. Depress the pedal to shift in- to 1st gear. Raise the pedal to shift into 2nd, 3rd, 4th, 5h.

10- Fuel valve. When the fuel

valve is turned to "OFF" fuel cannot flow from the fuel tank to the carburetor. When the fuel valve is tur- ned "ON", fuel will flow the tank to the carburetor.

11- Air release plug

12- Compression damper adju-

stment (bottom side)

stment (low and high dam- ping speeds)

DIMENSION, WEIGHT, CAPACITY

The cock set on left side of tank has three positions: OFF - closed; no fuel outlet; ON - open; fuel outflows from the main flow; RES - reserve; fuel outflows from the reserve flow. When running, should feed problem ensue, set cock lever on RES position. After filling up, take the cock in 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- Drain the fuel from the fuel

tank. Disconnect the fuel line.

2- Remove the fuel valve by re-

moving the screws. Wash the fuel screen filter in cleaning sol- vent.

3- Reassemble the fuel valve in

WARNING: Gasoline is extremely flam-

Pagina 48 - The instrument functions are the following, as shown below.

10- SPEED / RPM (Indication

RPM (figure 1) - SPEED: motorcycle Speedmaximum 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: - start the engine and push for 3 seconds the knob SCROLL (A). After the kilometers-miles or mileskilometers setting operation, for 3 seconds, “SET” an 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).

- 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.

(figure 4) - 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). lfthe STP 1 will be set to zero, the functions TRIP 1 and AVS 1 will be set to zero too. The function TRIP 1 is ON unitedly with the function STP 10). - RPM: engine, rp.m. shown on the vertical LED indicator. (‘): see figure 5

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(figure 5) - 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 (À) for more than 3 seconds. - 1st step: function ON; - 2nd step: stop to the counters; - 8rd step: STP 1 zero-setting; TRIP 1 and AVS 1 data zero- setting; - 4th Step: function ON; - Sth step: stop to the counters; and 50 following NOTE STP 1 data+TRIP 1 data=AVS 1

- RPM: engine r.p.m. shown on the vertical LED indicator. (‘): see figure 6

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(figure 6) - 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 lfthe 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.

DOUTE ENNENENEUENEEEEEEEENNEENEENENEENENNNNUNNENENNNNNENNNNNNNNNNNNNNNNNNNT LLLELL TI

(figure 7) - SPEED: motorcycle Sspeedmaximum 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 zer seconds; - RPM: engine r.p.m. shown on the vertical LED indicator.

(figure 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.

10- SPEED /RPM (Indication

Ne) THROTTLE CONTROL The throttle (1) knob, located on the right-hand side of the handlebar. The position on the handlebar can be adjusted by loosening the two fixing screws. CAUTION Do not forget to tighten the screws (À) after the adjustment. FRONT BRAKE CONTROL The brake control lever (2) is situated on the right-hand side of the handlebar and controls the front wheel brake. The position on the handlebar can be adjusted by loosening the two fixing screws. CAUTION Do not forget to tighten the screws (B) after the adjustment.

Pagina 62 STEERING LOCK (USA/CDN excluded) The motorcycle is equipped with a steering lock (3) on the right- hand side of the steering head tube. To lock it, proceed as follows: - place key in lock and turn anti- clockwise; - push key inwards (if necessary, turn to and from); - turn key clockwise and remove it from lock. To unlock the steering lock, reverse the above procedure.

(USA/CDN excluded) GUIDON (exclu USA/CDN)

% = Activation of left turn indicators (self cancelling) = Activation of right turn indicators (self cancelling) To deactivate the indicator, press the control lever after its returning to center.

4) HORN = (fes ) Warning horn

= Lighting control of low- ind high beam.

DUMONT EEE NET EENNENENNENEENUTENNNEUNENNUNNNNNNNNNNENNNNNNNNNNNNNNNNNNNT LLLLLECLLLI

The lever (1) is placed on the left- hand side of the engine. After every shift, the lever automatically returns to its central position. 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 whem the operation is over tighten the screw and then tightening the screw. 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 tra- veling at a speed that would force the engine to overrev in the next lower gear, or cause the rear wheel to lose traction. KICKSTART PEDAL The kickstart pedal (1) is situated on the right-hand side of the motorcycle. COMMANDE DU

CHECKS WARNING! Before each ride, to prevent accidents or failures during ride, make sure to go through following list. CAUTION": Don't start the engine while voltage regulator is disconneted from main wiring harness (WR; Enduro USA/CDN)

A. 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. Cluich lever device Make sure cables are not damaged and turn smoothly. Check brakes Look for brake fluid leaks and worn cables. Check for proper functioning. Check suspensions Compress fork and rear suspensions. Look for oil leaks and ensure proper functioning.

Check spokes and look for worn bearings. Check rims and tyres. Check tyre pressure. Check chain rollers and sprockets Check wear on chain rollers and sprockets Ensure chain is correctly adjusted and lubricated. . Check air filter and intake system Check that air filter is clean Check all rubber connections and clamps. . Check exhaust system Check hook up, look for cracks Check muffler. Check torque A. Spark plug B. Cylinder-head nuts C. General check of torque

10. Check steering action

11. Check the electric system

(USA/CDN Enduro) Start the engine and check that the phares, the stop light, the turn indicators (USA excluded), the instrument panel pilot lights (USA/CDN excluded), and the horn, are working correctly.

Le) WARNING": Failure to perform these checks every day before you ride may result in serous damage or a severe. ENGINE STARTING

Ît 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. This will enable the lubricant to reach the correct working temperature thereby guaranteeing a correct functioning of all engine parts. WARNING*: Exhaust contains poiso- nous carbon monoxide gas. Never run the engine in a closed garage or in a confined area.

WARNING: This high performance mo-

Pagina 84 RUNNING IN To obtain the best settling of the engine moving elements, for driving your motorcycle to the best of your capability, run in the engine for several hours, following these procedures:

1. FROM STOP POSITION. Start the engine

and run at idle, but open the throttle periodically and briefly until the engine is thoroughly warmed up. Within 3-4 minutes the coolant temperature will have reached approximately 60° C/140° F. (Do not ride the motorcycle).

2. Stop the engine, and let it cool down

naturally until its temperature is equal to the ambient air temperature. This will allow the piston to align itself to any imperfections which might exist at the cylinder wall.

3. Repeat steps 1 and 2. (Do not ride the

4. Bring the engine up to normal running

temperature. Ride the motorcycle approximately 10 minutes at moderate speeds. Then repeat cool down procedure. AVOID HARD ACCELERATIONS.

5. Bring engine up to normal temperature.

Ride motorcycle approximately 15 minutes at moderate to high speeds. Again avoid hard accelerations. 6.Repeat cool down procedure.

7. Full throttle operation must be avoided

(see page 244). Note*: After break in, install a new spark plug and change the transmission oil.

CHECKING By keeping the motorcycle on a flat surface and in vertical position, remove the control screw (C), and check the level through the hole in the screw. Note*: Have this operation made with warmed-up engine. A Draining plug B Filing cap C Levelling screw

To completely replace the oil, unscrew the plug (A) under the oil sump and let oil come out, then screw the plug again with its gasket and pour fresh oil from the hole of the loading plug. Use only the prescribed quantity and type of oil (see on page 34,56). Note*: Have this operation made with warmed-up engine. A Draining plug

Check level (A) 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. 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 The filling of cooling fluid is carried out through the radiator cap: about the fluid quantity to be filed, see page 30. For draining, a) remove the pump cover by loosening the two screws (1), or: b) the draining screw (2) set on the pump cover. Let the fluid drain fully, then reassemble the pump cover or the screw previously removed. WARNING": Coolant on tires will make them slippery and can cause an accident or injury. Periodically check the connecting hoses (see “Periodical maintenance card”): this will avoid coolant leakages and consequent engine seizure: If hoses show cracks, swelling or hardenings due to sheats desiccation, their replacement shall be advisable. Check the correct tightening of the clamps.

THROTTLE CABLE ADJUSTMENT The throttle cable can be adjusted using the screw set on the throttle, or using the adjusting screw set on the carburettor cover. To check for proper adjustment of throttle cable, proceed as follows: - remove rubber cap; - move transmission sheath to and fro to ensure a play of approx. 1 mm; - should play be greater than 1 mm, loosen lock nut (1) and register (2); should play less than 1 mm, then tighten lock nut and register: - if register (2) should not provide sufficient movement to allow for correct adjustment, then adjust register placed on carburetor. There should be approx. 1 mm play on latter register; should this not be the case, then loosen lock nut (1), and loosen or tighten screw (2), to respectively increase or decrease the play.

WARNING: Operation with

damaged throttle cable could result in an unsafe riding condition.

If standard spark plug is to be replaced, it is important that new spark plug have the same heat range and thread length. Correct heat grade: The tip of the insulator should be dry and the colour should be light brown or grey. High heat grade: In this case, the insulator tip is dry and covered with dark deposits. Low heat grade: In this case, the spark plug is overheated and insulator tip is vitreous, white or grey in colour. Check distance between electrodes using a thickness gauge, and adjust distance “A” according to the type of spark plug, as shown on page 26. A wider gap may cause difficulties in starting engine and in overloading coil.

ADVANCE The spark advance is factory set and must be checked either when replacing the ignition system, or whenever the engine assembly is inaccurate. For this check, make sure that the reference point stamped on the base be aligned with the one stamped on the stator, (either matched with the upper fastening: fig. À). When replacing the half- casings, reset the accurate spark advance as follows, without reassembling the Stator: a) Remove the spark plug and introduce a comparator into its seat; b) Fit special tool (cod. n° 8 pag. 242) on the crankshaft and take the piston to T.D.C. and zeroset the comparator in this position (fig. B);

EXHAUST VALVES “H.T.S:"

The cylinder features a central valve (A), connected to two side valves (B) on the “Booster” by means of gears. This system is driven by a centrifugal regulator placed on the left of the engine. The regulator opens the valves when the engine turns at approx. 6,200 rpm. In this way all engine output is obtained even when the engine is revved up. When closing, the central valve stroke is adjusted by a plate fastened to the rack, and when opening, the stroke is adjusted by another plate fastened near the “Booster”. To adjust the stroke, remove the cylinder head, the exhaust pipe and the timing covers as described on page 112.

Turn rear pin (1) anticlockwise, remove the saddle from the front fixing crew. Remove screw (3). Remove air 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 Aid” or similar) then dry it fully (wash filter with gasoline only in case of necessity). Plunge the filter in special oil for fiers (AGIP "Foam air flter 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. À fire or explo- sion could resutt. 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, slightiy (C) grease fiter edge on side facing filter housing. While re-inserting the filter into its housing, make surs that piece À is turned upwards and edge B is on the left lower side of the filer case. Reassemble the parts previously removed (battery: connect the positive cable first). CAUTION": If the element assem- bly is not installed correctly, dirt and dust may enter and the engi- ne resulting in rapid wear of the piston rings and cylinder.

Pagina 116 NOTE When running on dusty roads clean the filter every 30 minutes.

STEERING WHEEL BALL PLAY

ADJUSTMENT To ensure maximum safety, the steering wheel should always be regulated so that the handlebars steering the motorcycle rotate freely without play. To check steering wheel adjustment, place kick stand or other support under the engine so that the front wheel is raised from ground. Place slight pressure on the tips of the handlebars to rotate steering wheel; the handlebars Should also rotate without effort. Stand in front of the motorcycle and grasp the lower end of the fork rods sliders moving them in the direction of their axis. NOTE En roulant sur des routes poussiereuses, nettoyer le filtre toutes les 30 minutes.

LEVEL 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 tank must never be below the minimum value (1), which can be seen from the window on the pump body. A decrease of the fuel level will let air into the sustem, 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 li- nes or the brake may be defecti- ve. Since it is dangerous to ope- rate the motorcycle under such conditions, have the brake checked immediately by an authorized HUSQVARNA dealer. CAUTION": Do not spill brake fluid on to any painted surface or lenses. CAUTION*“:Do not mix two brands of fluid. Change the brake fluid in the brake line if you wish to switch to another fluid brand.

10:16 Pagina 122 CAUTION*: Brake fluid may cause irritation. Avoid con- tact with skin or eyes. In case of contact, flush thoroughly with water and call a doctor if your eyes were exposed.

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) for lowering or rising the pedal; - the operation done, tighten the screw (1). The adjusting operation carried out, adjust the idle stroke “A” of the pedal as indicated in page

ADJUSTMENT The rear brake foot pedal should have a (A) 5 mm 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

CHECKING THE FLUID LEVEL

The level (1) must be set between the pump tank notches of MIN and MAX.

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 expecially a harder extension adjustment. Work on the spring preload to lower the motorcycle rear side.

Pagina 130 À ADJUSTING THE FRONT FORK a) COMPRESSION (LOWER REGISTER) Standard calibration: -23 clicks. 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. To reset standard calibration turn register (C) clockwise to reach the position of fully closed: then, turn back by the mentioned clicks. To obtain a smoother braking action, turn the register anticlockwise. Reverse the operation in order to obtain a harder action. c) AIR VENT (to carry out after each competition, or monthly). Set the motorcycle on a central stand and release the fork fully and loosen the air vent valve (D). Once this operation is over, tighten the valve.

WARNING: Never force the adjusting

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=4,2 N/mm preload (25) spacer harder or softer springs, together with spacers are abailable upon request. See the list OPTIONAL PARTS on page 262. NOTE Always replace both the spring and the spacers to keep the preload value unchanged.

HEIGHT CHANGE The handlebar position (a) and height (b) can be changed for better suiting Your driving requirements. To effect these operations, remove the upper screw (3), upper clamp (1), lower screw (4) then lower clamp (2). a) Handiebar 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 (8) 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).

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

1. With motorcycle on the stand,

measure distance (A).

2. Take the normal riding position

on the motorcycle with all your riding apparel.

3. With somebody's help, take

the new distance (A).

4. The difference between these

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

5. To get the right SAG according

1. Clean ringnut (1) and adjusting

nut (2) of the spring (3).

2. Either with a hook wrench or

an aluminium punch, loosen the ringnut .

3. Turn the adjusting nut as

4. When the adjusting operation

is over (according to your weight and riding style), tighten the ringnut. (Torque for both ringnuts: 5 Kgm). WARNING*:Be careful not to touch hot exhaust pipe while adjusting the shock abosrber.

ADJUSTMENT Adjustment of the compression stroke is independent from the rebound stroke. A) COMPRESSION - Standard calibration:

maximum open (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: -15 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. REGLAGE AMORTISSEUR HYDRAULIQUE La course de compression peut être réglée séparément de celle d'extension.

Pagina 142 À CHAIN ADJUSTMENT Chain should be checked, adjusted and lubricated as per the Maintenance Chart to ensure security and prevent excessive wear. [f the chains becomes badly worn or is poorly adjusted (ie. 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. À). 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 is present. If this is not the case, go on as follows: - Unloose the fastening nut of the wheel pin (1) on the right side; - Unloose the lock nuts (2) on both chain adjusters and turn the screws (3) to obtain the correct tension value; - Tighten the lock nuts. After adjustment check that the wheel is lined up and tighten its axle.

CHECKING THE WEAR OF CHAIN, PINION

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

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.

The chain should be checked, adjusted and lubricated as shown on the “Maintenance Chart”. WARNING * : Never use grease to lubricate the chain. Grease helps to accumulate dust and mud, which act as abrasive and hepl to rapidiy wear out the chain, the sprocket, and the crown. 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. 1 -Remove the sprocket guard (3), the spring (1), the joint (2) and the chain.

2- Check that the chain is neither worn out nor

Pagina 148 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- Ifthe chain has been cut,

reassemble using a joint. 6 -Assemble the joint spring by turing the closed side to the chain direction of rotation as shown in figure. 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 142

WARNING: The chain oil has NEVER

11.- Pedale comando freno posteriore 10:39 Pagina 154 À BRAKES Hydraulic disc brakes with floating calipers are used on both wheels for superior braking performance. The mayor components are brake master cylinder with its lever (front) or pedal (rear), brakeline, caliper assembly and disc. LEGENDA 1 Front brake control lever 2-. Front brake pump with oil tank

6- Rear brake oil tank

10 - Rear brake pump

11 - Rear brake control pedal

CRRCRRR RER ER RERR RE NRN INR

-Remove springs (1). -Remove pins (2). -Remove pads. CAUTION! Don't operate the brake lever or pedal while removing the pads. PADS WEAR 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.

Pagina 158 PADS CLEANING Be careful that no disc brake fluid or any oil gets on brake pads or discs. Clean off any fluid or oil that inadverently gets on the pads or disc with alcohol. Replace the pads with new ones if they cannot be cleaned satisfactorily. PADS INSTALLATION - Install new brake pads. - Reassemble the two pins (1) and the springs (2).

DRAIN - Attach a clear plastic hose to the bleed valve on the caliper and turn the other end of the hose into a container. - Loosen bleed valve so fluid begins to drain. - Remove reservoir cap and rubber. - Pump with brake pedal to push brake fluid out of line. WARNING! Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.

• Brake fluid may cause irritation. Avoid contact with skin or eyes. In case of contact, flush thoroughly and call a doctor if your eyes were exposed. Periodically check the connecting hoses (see “Periodical maintenance card”): if the hoses (A) and (B) are worned or cracked, their replacement is advised.

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.

Pagina 168 FLUID CHANGE 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.

BLEEDING The braking system must be bled when, due to air in the circuit, the lever stroke is long and spongy. To bleed the system: - Disconnect the brake caliper and position it so that the pipe fitting (pump to caliper) is perpendicular to the ground. - Remove the pump body cover (1). - Remove the anti-emulsion disc and fil! up the tank with new fluid (DOT 4). - Attach a clear hose to bleed the valve and run into a clear glass container as shown in figure. Make sure that the end of the hose is submerged in brake fluid during the entire bleeding operation. - Open the bleed valve on the caliper and pump the lever. Allow the pads to contact the disc.

BLEEDING The braking system must be bled 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 on the caliper and turn the other end of the hose into a container. - Depress the pedal and keep it full down. - Loosen the bleed union letting out fluid (at first, only air will come out), then, closing the union slightiy. - 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 inside the reservoir before replacing the cap.

GROOVE CLEARANCE Use a feeler gauge to check the axial play of the rings in the groove.

CON. ROD SMALL END -

PISTON - PIN ASSEMBLY

The table hereunder shows the possible coupling which allow to abtain a radial clearance of 0.000078-:0.000393 in. C: rod selection colour. When should a radial clearance greater than the consented limit of 0.000539 in. be noticed and the colour mark under the connecting small end is no more visible, collect the connecting rod small end "A" diameter and assemble the right cage according to it. NOTE When requesting the cage, specify the selection. ACCOUPLEMENT AXE -

PISTON - PIEDS DE BIELLE

10:42 Pagina 194 À CLUTCH UNIT The clutch plates should not be burnt or scored. Check the thickness of the clutch lining plate. Thickness of new plate:

10: 42 Pagina 200 COMPRESSION RATIO CONTROL To check if the compression ratio is correct, proceed as follows; a) remove the cylinder together with the head from the block; b) remove the piston from the connecting rod, properly clean it, insert it in the cylinder till it touches the corresponding profile on the explosion chamber (this chamber too must be free from incrustations); c) screw a comparator in the sparking plug hole and reset it on the piston position as decribed at fig. A; d) remove the piston and reassemble it on the connecting rod: e) remount the cylinder together with the head by placing a 0.0197 in. gasket on the block; f) place the piston at the top dead center and control the reading on the comparator, which must be: 0.055:-0.059 in. (g) in case of different readings, reset the right condition by using a cylinder base gasket having the right thickness.

CARBURETTOR “MIKUNI” (COMPETITION MOTORCYCLE) The manufacturer has determined the carburetor setting after several and extensive tests; therefore, the standard carburetion has not to be changed. Using the bike in particular environmental conditions, may be necessary to change the standard tuning. This operation must be performed by Husqvarna Dealer. The following instructions inform about the carburetor basic knowledge and setting change. The exploded view show the main carburetor parts. The parts which meter air and fuel are precisely machined and vary for the size. These elements belong to the three main circuits for supplying the mixture to the several openings of the gas valves.

Pagina 204 À CARBURETOR ADJUSTMENT The above instructions show how to change the standard carburetor setting. Before change the carburetion, ride the bike and observe the engine response at the various gas throttle opening, the acceleration etc. Beore change the carburetion, it is necessary to start with standard carburetion setting. Standard carburetor setting is the following: Part - main jet 400 - jet needle J8-6DJ8-60 - jet needle rd groove - pilot jet 35 - Starter jet 80 - idle air screw 1 and 1/2 - slide 4.0

TEMPERATURE For reasons of safety, should height and temperature be included between two series of values of the side diagram, select jets of greater dimensions. (The list of jets supplied on request is found on pages 208-212). EXAMPLE: With the temperature at 12°C (54°F), and at 1,100 metres (3,600 ft) height, select the 380 full- power jet and the 30 idling jet.

- Adjust the idle air screw as indicated at page 96. - Judge if the pilot jet is correct. If mixture is rich, use a smaller jet: if is lean, use a larger jet. Example: With standard pilot jet size 40, if mixture is rich, mount a jet size 35. If mixture is lean, mount a jet size 45. Idle jet Size code 30 8A0086919 35 (standard) 800086919 40 8B0086919

MAIN CIRCUIT ADJUSTMENT

With throttle control opened from 3/4 to full, adjust the main circuit after idle circuit adjustment. - fthe jet size is between two values (see diagram at page 207), choose the larger jet not to damage the piston. - Adjust the main circuit before intermediate circuit adjustment. Example: When using the 400 start jet and the mix is too rich, replace these jets with and the 390 jet If the mix is too lean, use 410 jet .

VALVOLA GAS REPLACEMENT

The throttle valve cutaway size is stamped on the top of the valve; ifthe throttle valve has to be changed, make throttle valve increments of 0.5 (a larger cutaway provides a leaner mixture and a smaller cutaway make the mixture richer). Throttle valve Size CodeNumber 2,5 8A0086918 3,5 8B0086918

ADJUSTMENT Adjust the intermediate circuit by changing the jet needle retainer groove. Jet needle Size Code J8.6DJ8-59 8A0086920 J8.6DJ8-60 (standard ) 800086920 J8.6DJ8-61 8B0086920 NOTE: for carburetor overhauling are available the following spare parts: Name CodeNumber THROTTLE CABLE ADJUSTING SET 800072318

Pagina 218 À The lists below show the standard carburetor setting in different environmental and riding conditions; refer to this list when change the carburetor setting.

NORMAL TRACK CONDITIONS AND

25°C (103°F) (Standard setting) Part - main jet 400 jet needle (groove) J8.6DJ8-60 (3rd) - pilot jet 35 - idle air screw (turns) 1-12

NORMAL TRACK CONDITIONS AND

TEMPERATURE BELOW 10°C (76°F) Part - main jet 410 - jet needle (groove) J8.6DJ8-60 (4th) — pilot jet 35 idle air screw (turns) 1-84

NORMAL TRACK CONDITIONS AND

SAND TRACK CONDITIONS AND

25°C (103°F) Part -- main jet 410 - jet needle (groove) J8.6DJ8-60 (Ath) - pilot jet 35 -idle air screw (turns) 1-12

SAND TRACK CONDITIONS AND

TEMPERATURE BELOW 10°C (76°F) Part - main jet 420 - jet needle (groove) J8.6DJ8-60 (5th) - pilot jet 35 -idle air screw (turns) 1-84

SAND TRACK CONDITIONS AND

If the bending figure is over the allowable max. limit, straighten or replace the axe. lfthe wheel axle cannot be straightened within the max. limits (0,2 mm - 0.008 in.) stated, replace it. WHEEL SPOKES Check to make sure that all the nipples are tight; tighten them if necessary. Remember that an insufficient stretch jeopardizes the motorcycle stability. For an instant check, use a metal point (for instance, a screwdriver) to beat the spokes with. À live sound accounts for an accurate tightening, while a dull sound means that a new tightening is necessary.

DIAGRAM (WR, USA/CDN

excluded- "Enduro" USA/CDN) A. Headlamp B. RH front indicator C. LH front indicator D. Left switch E. Horn F Rear stop switch G. Front stop switch H. Regulator 1 Alternator L. Turn signal flash device M. HT. coil N. Spark plug ©. RH rear indicator P LH rear indicator Q.Rear light BR. Instrument lighting S. Parking light. T. Electronic module U. Scroll

HEADLAMP BULBS REPLACEMENT (WR, “Enduro” USA/CDN) To gain access to the healamp bulbs, proceede 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. To replace the parking light bulb, (5) extract it from the inside cover. After replacement, reverse operations for reassembly. REMPLACEMENT DES

REPLACEMENT (WR) 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

ADJUSTMENT OF HEADLIGHT

When checking the proper orienting of headlight, inflate tires at right pressure, sat a person on the saddle and place the motorcycle perpendicular witfr its longitudinal axis 10 meters 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. Adjust the preadlamp aiming by turning screw (1) to lower or lift the lifht beam.

MIS TS. VAS ASPTAZONS

Inlet valve screw Môxi 78:87 |ogt-08 | 58:64 Vis de fixage soupape d'aspiration TES. NSENTO aIDeTO MOÎOTE Engine shaft fxing screw Môxt(e) | 122:186 | 125:130 | 0:10 [Vis de fixation insert arbre moteur Jado MSS. pignone trasm. primaria Primary drive pinion nut migxt | 51-569 | 52:58 | a76:410 Ecrou de fxage pignon transmission primaire Dado ss. leva rnvo dlsirbuzione Timing system lever fixing nut Moos | 51:67 |052:058 | 38:42 Écrou de fixation levier transmission distrbution TE TSS. NYANAQO VaIVOTE QT SCANCO Exhaust valve gear fixing screw Mext 78:88 [Vis de fixation engrenages soupapes d'échappement MS TES. piastnna cuscimelto valvole qT scarico Exhaust valve bearing plate fxing screw MS08(m| 51457 | 052058 | 38:42 [Vis de fixation plaque palier soupapes d'échappement ie ss, forcella comando vaivola di scarico Screw Ining exhaust valve control fork - - - is de fixation fourche de contrôle soupape d'échappement PHgONErO TES. CAO Cylinder stud boit Mioxt,5 | 196:21,6 Po:22 144158 Prisonniers cylindre MIS TS. pero rinviO AVVIEMTENTS Start transmission pin fxing screw Môxi 19:87 |ogt-os | 58:64 [Vis de fixation pivot tranmission starter

DGSE. PIASIAINA CUSCINENO AIDETO PAS

AFTER-RACE CHECK POINTS

After racing, first clean the motorcycle and then inspect the entire motorcycle, with special attention to the items listed in «MAINTENANCE», such as the air clea- ner, 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. - Empty the fuel from the fuel tank, and empty the carburetor float bowl. (If left in for a long time, the fuel will deteriorate). - Lubricate the drive chain and all the ca- bles. - Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on rub- ber parts or in the brakes. - Set the motorcycle on a box or stand so that both wheels are raised off the ground. (If this cannot be done, put boards under the front and rear wheels to keep dam- pness away from the tire rubber). APPENDICE

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. © Aïr 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: © Aïr cleaner © Under the fuel tank: lf 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. © Transmission chain. © Digital instrument. NETTOYAGE

- Remove the plastic bags, and clean the air cleaner intake. - Lubricate the points listed in the Periodic maintenance schedule (page 282). - Start the engine and run it for 5 minutes. - Test the brakes before riding the motorcy- cle. WARNING*: Never wax or lubricate the brake disc. Loss of braking and an acci- dent could result. Clean the disc with an oilless solvent such ans acetone. Observe the solvent warnings.

IMP.13-250-2006 11-07-2005 13:52 Pagina 274 D Noise emission warranty MV Agusta Motorcycles S.p.A. warrants that this exhaust system, at the time of sale, meets all appli- cable 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, re- pair, 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 ino- perative by any person. Among those acts presumed to constitute tampering are the acts listed below.

1) Removal of, or punciuring the muffler, baffles, header pipes or any other component which con-

ducis exhaust gases.

2) Removal or punciuring 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 signi- ficanily through use. Otherwise, the owner may become subject to penalties under state and local ordinances. CLCLLLLLLLELELELLEELELEEEEEECEEEEEEEEEEEEEEEE EE EEE CEE EURNNUNN ENT NN EN N NN NUE RR NN

IMP.13-250-2006 11-07-2005 13:52 Pagina 275 D SPARK ARRESTER The WR model is equipped with a U.S. Forest Service approved spark arrester for maximum efficienty and performance.

“ SPARK ARRESTER” MAINTENANCE AND CLEANOUT INSTRUCTIONS

Proceed as follows: A: Remove the screws (1) and the RH. side panel (2). B: Remove the two screws (3) fastening the muffler to the rear frame. Extract the silencer from the union manifold to the exhau- st pipe. 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 four screws (4) and the endcap (5) 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. 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: ifthe check is negative, proceed with the maintenance and cleanout procedure.

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IMP.13-250-2006 11-07-2005 13:52 Pagina 276 <- Tampering Warning: Tampering with Noise Control System Prohibited. Federal law prohibits the following acts or causing therefor: 1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, and

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

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

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

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

3) Lack of proper maintenace.

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

Description Operation Pre-delivery Description Operation Pre-delivery Engine oil Check level a Side stand switch Check operation a ivo-stroke mix oi level Check level as Electrical equipment Check operation 2 Coolant Check / Restore level a Instrument panel Check operation 2 Cooling system Check for leakage n Lights / Visual signals Check operation a Electric fans Check operation 28% Hom Check operation ni Spark plugs Check / Replace a Headlight Check operation a Throttle body / Carburettor Check and adjust a Ignition switch Check operation a Brakes / Clutch fluid Check level a Locks Check operation a Brakes / Clutch Check operation a Screws and nuts Check / Tighten a Brakes / Clutch Check lines for leakage a Hose clamps Check / Tighten a Throtte control Check operation a General lubrication a Throtte control Check / Adjust pla a General test a Choke control Check operation a Flexible controls and transm.… Check / Adjust a Drive chain Check / Adjust a # only for motorcycles with 2 stroke engine Jyres Check pressure a ##: only for some models Side stand Check operation nl DUDBEDDUDPUPNIEEEPEENEENENMNNENNT

Adjusting the driven transmission . Adjusting the fork… Adjusting the front brake control lever . Adjusting the headlamp Adjusting the idle … Adjusting the rear brake idle stroke Adjusting shock absorber hydraulic brake Adjusting shock absorber preload spring Adjusting the rear brake pedal position . n Adjusting the steering bearing play 116 Adjusting the suspensions according to the track special conditions Adjusting the throttle cable . Assembling brake pads …

Brakes Brake disc cleaning Brake disc warpage Brake disc wear. Brake pad assembly . Brake pad disassembly Brake pad wear

Pagina 304 agina es Chain lubrication Checks after every competitiol Checks during running i Check of air filter . Check of chain, pinion, crown weai Check of compression ratrio Check of cooling fluid … Check of exhaust valve position Check of front brake fluid level. Check of gearbox oil . Check of rear brake fluid level Cleaning the air filter Clutch Clutch control Clutch disc disassembly Cooling fluid replacement Control location

Digital instrument. Draining the brake fluid Draining the front brake fluid Draining the rear brake fluid Driven transmission chain

Filing the braking system Fork oil level

Gearbox controls . Gearbox outlet piniol General cleaning .

Motorcycle identification number. Motorcycle stop … Muffler on the exhaust

Overhauling, adjusting, maintenance of “Mikuni” carburettor Overhauling the wheels.

Rear brake control. Rear braking system bleeding . Rear crown Rear suspension . Removing the front wheel Removing the rear wheel Running in …

Throttle control. Transmission oil change Tool outfit

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IMP.15-250-2006 12-07-2005 10:32 Pagina 315 MEMORANDUM DOUTE ENENENENEEEEENNEEENEENENENNENNENCNNENNNNNNNEENNNNENNNNENNNNNNNS