TE-TC 250 - Off-road motorcycle HUSQVARNA - Free user manual and instructions

USER MANUAL TE-TC 250 HUSQVARNA

1) The TE and TC models are guaranteed

COMPETITION motorcycles exempt from functional defects, the suggested maintenance table for competition use is shown on page 286

This motorcycle is equipped with an electric start and it is manufactured in two different versions. “A” VERSION : motorcycle equipped with engine start button (1) and engine stop button (2) (TC; TE-SMR); “B” VERSION :motorcycle equipped with engine start button (1) and engine start - stop switch (3) (TE-SMR).

ELETTRICO secondo le istruzioni che seguono. VERSION “A”: please follow the instructions herewith: This motorcycle DOES NOT HAVE AN IGNITION SWITC H, therefore when working on the vehicle, there is the danger of engine startup if the starter switch is inadvertently touched. Consequently, FOR ALL THOSE

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.

3. Engine stop button (USA and

4. Rear brake control pedal

adjustment (front fork leg bottom side)

13. Extension damper

adjustment (front fork leg top side)

compression damper adjustment (low and high damping speeds)

16. Rear shock absorber

extension damper adjustment

8.66 in. with hydraulic control and floating

DIMENSION, WEIGHT, CAPACITY

COMANDI CONTROLS RUBINETTO CARBURANTE FUEL COCK Il rubinetto, posto sulla sinistra, consta di tre posizioni: OFF - chiuso; non c'è uscita di carburante; ON - aperto; il carburante esce dal flusso principale; RES - riserva; il carburante esce dal flusso di riserva. Qualora, durante la marcia, si dovessero riscontrare difficoltà di alimentazione porre la levetta del rubinetto in posizione RES. Dopo aver fatto rifornimento, riportare il rubinetto in posizione ON. 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:

WARNING: BEFORE the following

operation, please see the IMPORTANT NOTICE 2) on page 12

1 - Unscrew the filler cap (1) on the

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

2 - remove the fuel hose (3) from the

carburetor and insert the hose in a vessel; ATTENZIONE*: Fare attenzione a non toccare il motore caldo mentre si opera sul rubinetto carburante. Il rubinetto incorpora un filtro; l’accumulo di sporcizia provoca una diminuizione del passaggio di carburante verso il carburatore. E’ pertanto necessario effettuare la pulizia nel modo seguente: ATTENZIONE: PRIMA di effettuare l’operazione, consultare l’AVVERTENZA IMPORTANTE 2) riportata a pag. 12

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

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

filter in cleaning solvent.

5 - Reassemble the fuel valve in the

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

Instrument functions: - KMH/MPH Speed up to 270 km/h-168 mp/h; - TRP Trip distance accurate to 10 m-33 ft (if max values are exceeded, restart from 0); - AVS average speed, automatic start/stop function (after 10 hours or 1000 km-620 mi, you have to RESET) - STP stopwatch, starts at the start of journey (maximum 10 hours; if max values are exceeded, restart from 0); - MAX maximum speed (since last RESET); - DST total distance up to

(to select the functions, push the RIGHT button)

( to reset the functions, push the LEFT button approx. 5 seconds)

1) DST and the first figure of total

distance are flashing (the power supply has been interrupted due to severe jarring) - Remove the batteries (see instructions on the next pages), check contacts and clean, if necessary. - RE-enter DST, WS and CLK (see instructions on the next pages).

- Check the correct instrumentholding plate fastening. - Check distance and position of the magnet (see instructions on the next pages).

4) LCD display is sluggish

357) approx. 2 years or as soon as

SET “WS”- WHEEL CIRCUMFERENCE

PROGRAMMATION “CLK”- HEURE

SET “DST”- TOTAL MILEAGE

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 (*).

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

“A” VERSION R.H. HANDLEBAR COMMUTATOR (TE, SMR, USA excluded) VERSION “A”

(TE, SMR, USA excluded) The right commutator has the following controls:

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

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

(TC, TE-USA) On the right side of the handlebar, near the front brake control, is located the engine start button (1).

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

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

The lever (1) is placed on the left-hand side of the engine. After every shift, the lever automatically returns to neutral 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 when the operation is over tighten the screw and then tightening the screw.

ATTENTION: BEFORE the following operation, please see the IMPORTANT NOTICE 2) on page 12

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 device Make sure cables are not damaged and turn smoothly.

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

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

6. Check chain rollers and sprockets

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

7. Check air filter and intake system

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

8. Check exhaust system

Check hook up, look for cracks Check muffler.

11. Check the electric system (TE,

SMR, Enduro USA). Start the engine and check that the front and rear lamps, the stop light, the turn signals (Enduro USA excluded), the cluster warning lights and the horn (Enduro USA excluded) are working correctly.

MOTORANLASSEN 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

2) shift the transmission into

3) pull the starter knob (2);

4) turn twice completely the

throttle control grip (3);

5) while mainteining slowly

open the throttle control grip, press the start button (4). Au moteur froid, c'est-à-dire après arrêt prolongé du motocycle ou en présence de basse température ambiante, opérer de la manière suivante:

WITH WARM ENGINE, DO

NOT CARRY-OUT ITEMS no. 3 AND 4.

- SPOKE TENSION OF WHEELS

CHECKING THE OIL LEVEL

ATTENTION: BEFORE the following operation, please see the IMPORTANT NOTICE

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

ENGINE OIL REPLACEMENT

AND BAG FILTERS-FILTER

CARTRIDGE CLEANING OR

REPLACEMENT (BEFORE the following operation, please see the IMPORTANT NOTICE 2) on page 12) 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;

ATTENTION: BEFORE the following operation, please see the IMPORTANT NOTICE 2) on page 12 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. The radiator cap is provided of two unlocking positions, the first being for the previous pressure discharge in the cooling system.

THROTTLE CABLE ADJUSTMENT

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

ADJUSTING THE CARBURETTOR 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, near the fuel cock (turn the screw clockwise to increase the rpm, and anticlockwise to descrease the rpm). - Turn the mix strength adjusting screw (2) either clockwise or anticlockwise to have the engine running as regularly as possible; STANDARD adjustment: turn adjusting screw clockwise until the fully closed position is reached then turn back of 2 turns (250-400) or 1+3/4 turns (450). - progressively loosen adjusting screw (1) to obtain the slow running required.

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

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

“A” VERSION MOTOCICYCLE

First turn counterclockwise fastening rear pin (1) then remove the saddle; Remove vent hose (2) from handlebar; Set the fuel cock (3) on OFF position then loosen clamp (4) on the carburettor fuel hose; remove the hose from the fuel cock. Remove the eight screws (5) which fix the conveyors to fuel tank and recover the bushes under the screws; Remove the conveyors, the four screws (6) which fix the spoilers to the radiators and recover the bushes under the screws; Remove the spoilers, the fuel tank fastening screw (A) and the fuel tank.

MOTOCICYCLETTE VERSION “A”

“A” VERSION MOTOCICYCLE

THE ELECTRIC SYSTEM.

MOTOCICYCLETTE VERSION “A”

Turn rear pin (1) counterclockwise, remove the saddle from the front afstening screw. “A” VERSION MOTOCICYCLE (Page 12)

DISCONNECT THE BATTERY FROM

THE ELECTRIC SYSTEM as described on page 12. 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

ASSEMBLY To ensure tight fit, slightly (C) grease filter edge on side facing filter housing. While re-inserting the filter into its housing, make surs that piece A is turned upwards and edge B is on the left lower side of the filter case. Reassemble the parts previously removed (battery: connect the positive cable first). CAUTION*: If the element assembly is not installed correctly, dirt and dust may enter and the engine resulting in rapid wear of the piston rings and cylinder.

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

BRAKE FLUID LEVEL (TE, TC, SMR) BEFORE the following operation, please see the IMPORTANT NOTICE on page 12. The driver will set the adjustment according to his needs. Note: free play must be at least 3 mm (0.1 in.). Turn adjusting nut (2) for the adjustment. The level of the fluid in pump reservoir must never be below the minimum value (1), which can be checked from the window on the rear side of the pump body (TE, TC). For SMR model, check the level on the fluid reservoir. A decrease of the fuel level will let air into the sustem, hence an extension of the level stroke.

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

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

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

CONTROL LEVER AND CHECK

OF THE HYDRAULIC CLUTCH

FLUID LEVEL The driver will set the adjustment according to his needs. Note: free play must be at least 3 mm (0.1 in.). Turn adjusting nut (B) for the adjustment. AVVERTENZA *: Non utilizzare MAI liquido per freni. TABLE FOR LUBRICATIONSUPPLIES for the fluid type page 44) CAUTION *: NEVER use brake fluid.

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 (A) of the pump body; - if necessary, add fluid until the correct level is reached (see STEUERHEBELEINSTELLUNG UND

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.

ADJUSTING THE COMPRESSION 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.

NOTA: Non forzare le viti di registro oltre la posizione di apertura e chiusura massima.

WARNING: Never force the adjusting

screws beyond the maximum opening and closure positions.

(BEFORE the following operation, please see the IMPORTANT NOTICE 2) on page 12). 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.

A = 80 mm (3.15 in.)

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

1. With motorcycle on the stand,

measure distance (A).

2. Take the normal riding position

on the motorcycle with all your riding apparel.

3. With somebody’s help, take

the new distance (A).

4. The difference between these

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

5. To get the right SAG according

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

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; 49 Nm; 36.2 ft/lb).

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

1) Low damping speed:

● TE 450: -12 clicks (± 2 clicks) ● TE 250 - SMR 400, 450 - TC 250 TC 450: -15 clicks (± 2 clicks) (register 4)

2) High damping speed:

CHAIN ADJUSTMENT (BEFORE the following operation, please see the IMPORTANT NOTICE 2) on page 12) Chain should be checked, adjusted and lubricated as per the Maintenance Chart to ensure security and prevent excessive wear. If the chains becomes badly worn or is poorly adjusted (i.e., if it is too loose or too taught), it could escape from sprocket or break. To adjust the rear chain it is necessary to lower the rear part of motorcycle so to line up the drive sprocket axle, the rear swing arm axle and the rear wheel axle as shown on drawing. Than let turn three times the rear wheel. Now the chain should not be tight. (Fig. A). Fast adjustment (Fig. B.). Push the chain towards the final part of runner and check that between the two elements a distance "A" from 0 to 2 mm (0.08 in.) is present. If this is not the case, go on as follows: - unloose the fastening nut (1) of the wheel axle on the R.H. side; - Unloose the lock nuts (2) on both chain adjusters and turn the screws (3) to obtain the correct tension value; - Tighten the lock nuts. After adjustment check that the wheel is lined up and tighten its axle.

CHECKING THE WEAR OF CHAIN, PINION

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.

WARNING: The chain oil has

2- Chain driving roller

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

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

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

2. Front brake pump with oil reservoir (TE,

2. Front brake pump (SMR)

2A. Oil reservoir (SMR)

4. Front brake caliper

6. Rear brake oil tank

11. Rear brake control pedal

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.

• 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. ATTENTION! Puisque le fluide des freins ronge rapidement les surfaces vernissées, nettoyer soigneusement les parties intéressées.

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 CLEANING Poor braking can also be caused by oil on the disc. Oil or grease on the disc must be cleaned off with a high flashpoint oil free solvent, such as acetone or lacquer thinner.

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

LINES - Remove the rubber cap on the bleed valve. - Attach a clear plastic hose to the bleed valve on the caliper and turn the other end of the hose into a container. - Open the bleed valve (counterclockwise to open), and pump brake lever or pedal until all the fluid is drained from the line. - Close the bleed valve and fill the reservoir with fresh brake fluid. - Open the bleed valve, apply the brake using the brake lever or pedal, close the valve with the brake lever or pedal applied, and then quickly release the lever or the pedal. Repeat this operation until the brake line is filled and fluid starts coming out of the plastic hose. REMPLISSAGE DES

BLEEDING (TE, TC) 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 fill 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. - During this operation, you'll notice that air bubbles will come out of the brake pump reservoir. This is normal. Watch the hose. When new, clear fluid, without bubbles, come out, close the bleed valve. - Carefully pry the pads apart, using a soft pry bar, forcing them back into the caliper housing. Repeat the entire sequence until no bubbles are seen at the hose or in reservoir. Reassemble the front disc brake guard in the reverse order as was shown for dismalting.

WARNING: During bleeding the

BLEEDING (SMR) Bleed the braking circuit when the lever stroke gets stretchy due to the presence of air inside the circuit. Work as follows: - Remove the caliper and fit a 4 mm shim in place of the disc, fastening it by an elastic; - Fit the caliper and the pipe fastening unit perpendicular to the ground, and support it conveniently; - Remove pump cap (1) on the handlebar and fill up with the new fluid DOT4; - Fit a transparent plastic pipe on the bleed valve of the caliper and plunge the other end of the pipe into a basin (check to make sure that, during the whole operation, the end of the pipe is fully plunged into the fluid); - Open the bleed valve on the caliper and move the lever several times until the fluid, clear and without bubbles, comes out of the pipe; now close the bleed valve; - Reassemble the pump cap on the handlebar and the brake caliper; - Remove the brake pump from the handlebar and place it in vertical position, in line with the piping; - Reassemble the pump on the handlebar, carry our another bleeding action, fill up with fluid, and tighten the valve on the caliper to the prescribed torque.

deadening material after every competition and replace it if necessary.

DEADENING MATERIAL Remove the screws (1) and the R.H. side panel (2). Unhook springs (3) fastening the muffler (4) to the exhaust pipes. Remove the two screws fastening the muffler to the rear frame. Remove innner pipe (5) and replace the deadening material. Remove the six rear rivets (5), clamp and the exhaust terminal (6). NOTE: When diffuculties are found in removing the muffler, lightly beat with a rubber or plastic hammer.

0.43 in. (450) from the base.

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

CLEARANCE Insert the piston ring into the cylinder bottom (where wearing is the lowest) and position it well in "square" and measure the ditance between the two piston ring end gap.

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

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

Blu/ Blue/ Bleu/ Blau/ Azul

IGNITION SYSTEM-ELECTRIC SYSTEM (TC-TE USA) The ignition system- electric system includes the following elements: - Generator (1) on the inner side of L.H. crankcase cover; - Electronic coil (2) under the saddle; - Electronic power unit (3) under the fuel tank; - Voltage regulator (4) on the right side of the frame at the back of the steering sleeve (TC 450); - Voltage regulator (4) in the lower steering tube zone, behind the front number holder (TC 250); - Spark plug (5) on the R.H. side of cylinder head; - Starting motor 12V-450W (6) behind the cylinder; - Electric start remote control switch (8) under the saddle; - Three15 A fuses (9) (one of them is a spare fuse), under the saddle; - Battery 12v-2,3Ah (7) under the saddle(250); - Battery 12v-6Ah (7) under the saddle (450).

REPLACEMENT (TE- SMR) To gain access to the tail light bulb, proceede as follows: - remove the two fastening screws (1) and the rear lens (2); - extract the bulb holding inner cover, (3) turn the bulb (4) counterclockwise, remove and replace it. REMPLACEMENT DES

Front wheel axle wrench

Front wheel axle screw Allen wrench

9- Rear shock absorber spring

7- Rear shock absorber oil

5- Rear sintered pad couple (for sandy and muddy

Muelle amortiguador § K=5,0 Kg/mm)

5. Rear sintered pad couple

7. Rear shock absorber oil

9. Rear shock absorber spring

(K=4,8 Kg/mm) Rear shock absorber spring § (K=5,0 Kg/mm)

Muelle amortiguador § K=5,0 Kg/mm)

7- Rear shock absorber oil

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

9- Rear shock absorber spring

8000 A2925 8G00 96837 (Z=45) * 8000 96837 (Z=46) 8A00 96837 (Z=47) 8B00 96837 (Z=48) 8C00 96837 (Z=49) 8D00 96837 (Z=50) 8000 63827 (Z=12) 8000 63828 (Z=13) 8000 63829 (Z=14) 8000 63830 (Z=15) * 8000 63831 (Z=16)

5- Rear sintered pad couple

(for sandy and muddy grounds)

Dopo la gara, pulire il motociclo come sottoriportato poi ispezionare il veicolo ponendo particolare attenzione ai punti indicati nel paragrafo “MANUTENZIONE” come filtro aria, carburatore, freni etc. Effettuare una lubrificazione generale ed eventualmente le registrazioni necessarie. APPENDIX

AFTER-RACE CHECK POINTS

After racing, first clean the motorcycle and then inspect the entire motorcycle, with special attention to the items listed in «MAINTENANCE», such as the air cleaner, carburetor, brakes, etc. Carry out general lubrication, and make adjustment as necessary. APPENDICE

CONTROLES APRES CHAQUE

1) Preparation for washing

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

2) Where to be careful

Noise emission warranty MV Agusta Motorcycles S.p.A. warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers. Warranty claims should be addressed to Cagiva U.S.A. 2300 MARYLAND ROAD.

WILLOW GROVE, PA 19090-4193

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

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

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

3) Lack of proper maintenance.

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

Proceed as follows: A: Remove the screws (1) and the R.H. side panel (2). Unhook springs (3) fastening the muffler (4) 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 (5) and the endcap (6) 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: if the check is negative, proceed with the maintenance and cleanout procedure.

NOTES FOR “AUS” MODEL

TE 250 SM 450R Tampering Warning: Tampering with Noise Control System Prohibited. Federal law prohibits the following acts or causing therefor: 1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, and

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

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

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

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

3) Lack of proper maintenace.

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

Description Operation Engine oil Two-stroke mix oil level Coolant Cooling system Electric fans Spark plugs Throttle body / Carburettor Brakes / Clutch fluid Brakes / Clutch Brakes / Clutch Throttle control Throttle control Choke control Flexible controls and transm. Drive chain Tyres Side stand Check level Check level Check / Restore level Check for leakage Check operation Check / Replace Check and adjust Check level Check operation Check lines for leakage Check operation Check / Adjust play Check operation Check / Adjust Check / Adjust Check pressure Check operation Pre-delivery

Description Side stand switch Electrical equipment Instrument panel Lights / Visual signals Horn Headlight Ignition switch Locks Screws and nuts Hose clamps General lubrication General test Operation Check operation Check operation Check operation Check operation Check operation Check operation Check operation Check operation Check / Tighten Check / Tighten ❆ : only for motorcycles with 2 stroke engine ❆❆ : only for some models Pre-delivery