OWNER'S MANUAL 2014 125 TC EU 250 TC EU Art. no.
DEAR HUSQVARNA CUSTOMER 1 Congratulations on your decision to purchase a Husqvarna motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. DEAR HUSQVARNA CUSTOMER We wish you a lot of enjoyment in riding this vehicle. Enter the serial numbers of your vehicle below. Chassis number ( Engine number ( p. 10) Dealer's stamp p.
TABLE OF CONTENTS TABLE OF CONTENTS 1 2 3 4 5 6 7 8 MEANS OF REPRESENTATION ......................................... 4 1.1 Symbols used ........................................................ 4 1.2 Formats used......................................................... 4 SAFETY ADVICE ................................................................ 5 2.1 Use definition - intended use.................................. 5 2.2 Safety advice ......................................................... 5 2.
TABLE OF CONTENTS 11.29 11.30 11.31 11.32 3 Sealing the air filter box ................................... Removing the main silencer ................................. Installing the main silencer.................................... Changing the glass fiber yarn filling of the main silencer ........................................................... 11.33 Removing the right side cover .............................. 11.34 Installing the right side cover ................................ 11.
1 MEANS OF REPRESENTATION 1.1 Symbols used The symbols used are explained below. Indicates an expected reaction (e.g., to a work step or a function). Indicates an unexpected reaction (e.g., to a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized Husqvarna workshop.
2 SAFETY ADVICE 2.1 Use definition - intended use 5 Husqvarna sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations. Info The motorcycle may only be used in closed off areas remote from public road traffic. 2.2 Safety advice A number of safety instructions need to be followed to operate the vehicle safely.
2 SAFETY ADVICE 6 Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these components to cool down before starting work on them. Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons.
3 IMPORTANT INFORMATION 3.1 Manufacturer and implied warranty 7 The work prescribed in the service schedule must be carried out by an authorized Husqvarna workshop only and confirmed in the customer's service & warranty booklet and in the Husqvarna dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.
4 VIEW OF VEHICLE 4.1 View of the vehicle from the left front (example) 8 L01903-10 1 Filler cap 2 Air filter box lid 3 Fuel tap ( 4 Choke ( p. 13) 5 Shift lever ( 6 Plug-in stand ( p. 13) p. 13) p.
4 VIEW OF VEHICLE 4.2 View of vehicle, rear right (example) 9 L01904-10 1 Clutch lever ( 2 Kill switch ( p. 11) p. 11) 3 Fork compression adjustment 4 Throttle grip ( 5 Hand brake lever ( p. 11) p. 11) 6 Shock absorber rebound adjustment 7 Level viewer for brake fluid, rear 8 Shock absorber compression adjustment 9 Foot brake lever ( 10 Kick starter ( 11 Fork rebound adjustment p. 14) p.
5 SERIAL NUMBERS 5.1 Chassis number 10 The chassis number 1 is stamped on the right side of the steering head. 401945-10 5.2 Type label The type label 1 is fixed to the front of the steering head. 401946-10 5.3 Engine number The engine number sprocket. 1 is stamped on the left side of the engine under the engine 401949-10 5.4 Fork part number The fork part number 1 is stamped on the inner side of the fork stub. 401947-10 5.
6 CONTROLS 6.1 Clutch lever 11 (125 TC EU) The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 1 L01907-10 (250 TC EU) The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 1 B01826-10 6.2 Hand brake lever 1 Hand brake lever is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. L01908-10 6.
6 CONTROLS 6.5 Map‑Select switch (250 TC EU) 12 The Map‑Select switch 1 is fitted on the right side of the handlebar. Possible states Performance – This position is used for higher performance. Soft – This position is used for better rideability. L01818-10 6.6 The engine characteristic can be changed on the handlebar using the Map‑Select switch. Opening the filler cap Danger Fire hazard Fuel is highly flammable.
6 CONTROLS 6.8 Fuel tap 13 The fuel tap is on the left side of the fuel tank. With tap handle on the fuel tap, you can open or close the supply of fuel to the carburetor. 1 Possible states • Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor. • Fuel supply open ON – Fuel can flow from the fuel tank to the carburetor. The fuel tank empties fully. L01808-10 6.9 Choke 1 The choke is fitted on the left side of the carburetor.
6 CONTROLS 14 (250 TC EU) The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-13 6.11 Kick starter The kick starter 1 is fitted on the right side of the engine. The top part can be swiveled. L01606-10 6.12 Foot brake lever 1 Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. L01905-11 6.
7 PREPARING FOR USE 7.1 Advice on first use Danger Danger of accidents Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Warning Risk of injury Missing or poor protective clothing presents an increased safety risk. – Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle.
7 – PREPARING FOR USE 16 Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight – 335 kg (739 lb.) Maximum permissible front axle load 145 kg (320 lb.) Maximum permissible rear axle load 190 kg (419 lb.) Check the spoke tension. ( p. 68) Info The spoke tension must be checked after half an hour of operation. – Run in the engine. ( 7.2 – p.
7 PREPARING FOR USE – – 17 Change the radiator cap. Mount the dust cover for the air filter. Dust cover for air filter (77206920100) Info Observe the Husky Power fitting instructions. B00435-01 – Mount the dust cover for the air filter for sand. Sand cover for air filter (59006922000) Info Observe the Husky Power fitting instructions. – Adjust the carburetor jetting and setting. Info B00436-01 The recommended carburetor tuning is available from your authorized Husqvarna workshop.
7 PREPARING FOR USE 18 – Clean the chain. – Mount the steel sprocket. Tip Do not grease the chain. 600868-01 7.6 – Clean the radiator fins. – Carefully align bent radiator fins. – If used in sand regularly, replace the piston every 10 operating hours. Preparations for riding on wet and muddy surfaces – Mount the rain cover for the air filter. Rain cover for air filter (77206921100) Info Observe the Husky Power fitting instructions. – Adjust the carburetor jetting and setting.
7 PREPARING FOR USE 7.8 Preparing for riding at low temperatures or in snow – 19 Mount the rain cover for the air filter. Rain cover for air filter (77206921100) Info Observe the Husky Power fitting instructions. – B00437-01 Adjust the carburetor jetting and setting. Info The recommended carburetor tuning is available from your authorized Husqvarna workshop.
8 RIDING INSTRUCTIONS 8.1 Checks and maintenance work when preparing for use 20 Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the gear oil level. ( – Check the front brake fluid level. ( – Check the rear brake fluid level. ( – Check the front brake linings. ( p. 58) – Check the rear brake linings. ( p. 62) – Check that the brake system is functioning properly.
8 RIDING INSTRUCTIONS 8.3 Starting off 21 Info The plug-in stand must be removed before riding. When you are riding, the side stand must be folded up and secured with the rubber band. – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. 8.4 Shifting, riding Warning Danger of accidents If you change down at high engine speed, the rear wheel can lock up. – Do not change into a low gear at high engine speed.
8 RIDING INSTRUCTIONS 8.6 Stopping, parking 22 Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these components to cool down before starting work on them.
8 RIDING INSTRUCTIONS 8.8 Refueling 23 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard.
9 SERVICE SCHEDULE 9.1 Service schedule 24 Every 30 operating hours - corresponds to about 210 liters of fuel (55.5 US gal) Every 20 operating hours - corresponds to about 140 liters of fuel (37 US gal) Every 10 operating hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race x (125 TC EU) Change the gear oil. x (250 TC EU) ● Check the front brake linings. ( p. 58) ● ● ● Check the rear brake linings. ( p.
9 SERVICE SCHEDULE 9.2 Service work (as additional order) 25 Annually Every 40 operating hours - corresponds to about 280 liters of fuel (74 US gal) Once after 20 operating hours x Change the rear brake fluid. x ● Change the hydraulic clutch fluid. ● Change the front brake fluid. x ( p. 54) Grease the steering head bearing. x ( p. 39) Check/set the carburetor components. x Service the shock absorber. x Change the connecting rod, conrod bearing and crank pin.
10 TUNING THE CHASSIS 10.1 Checking the basic chassis setting with the rider's weight 26 Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork. – For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspension components must match the rider's weight. – As delivered, Husqvarna offroad motorcycles are adjusted for an average rider's weight (with full protective clothing).
10 TUNING THE CHASSIS 27 Guideline Compression damping, low-speed (125 TC EU) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, low-speed (250 TC EU) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.4 Adjusting the high-speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury.
10 TUNING THE CHASSIS 28 – Turn adjusting screw – Turn counterclockwise by the number of clicks corresponding to the shock absorber type. 1 clockwise up to the last perceptible click. Guideline Rebound damping (125 TC EU) L01669-12 Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping (250 TC EU) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.
10 TUNING THE CHASSIS 10.8 Checking the riding sag of the shock absorber 29 – Measure distance – With another person holding the motorcycle, the rider, wearing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times. A of the unloaded rear wheel. ( p. 28) The rear wheel suspension levels out. – Another person now measures the distance between the rear axle and the fixed point. – Note down the value as dimension C.
10 TUNING THE CHASSIS Finishing work – Install the shock absorber. 10.10 Adjusting the riding sag 30 x( p. 41) – Install the main silencer. ( – Install the right side cover. ( – Remove the motorcycle from the lift stand. ( p. 44) p. 45) p. 33) x Preparatory work – Raise the motorcycle with the lift stand. ( p. 33) – Remove the right side cover. ( – Remove the main silencer. ( – Remove the shock absorber. – After removing the shock absorber, clean it thoroughly. p. 45) p. 44) x( p.
10 TUNING THE CHASSIS 10.12 Adjusting the compression damping of the fork 31 Info The hydraulic compression damping determines the fork suspension behavior. – Turn adjusting screws 1 clockwise all the way. Info 1 Adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. – Turn counterclockwise by the number of clicks corresponding to the fork type.
10 TUNING THE CHASSIS 10.14 Handlebar position 32 On the upper triple clamp, there are two holes a distance of Hole distance A A apart. 15 mm (0.59 in) The holes on the handlebar support are placed at a distance of Hole distance B B from the center. 3.5 mm (0.138 in) The handlebar can be mounted in four different positions. In this way, the handlebar can be mounted in the position that is most comfortable for the rider. B00025-11 10.
11 SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with the lift stand – 33 Raise the motorcycle at the frame below the engine. The wheels should no longer touch the ground. – Secure the motorcycle against falling over. Lift stand (54829055000) 401942-01 11.2 Removing the motorcycle from the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Remove the motorcycle from the lift stand.
11 SERVICE WORK ON THE CHASSIS 34 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Clean and oil the dust boots and inner fork tube of both fork legs. – Press the dust boots back into their normal position. – Remove excess oil. Finishing work – Position the fork protection. ( – 11.5 p. 34) Remove the motorcycle from the lift stand. ( p.
11 SERVICE WORK ON THE CHASSIS 11.8 Installing the fork legs 35 x Main work – Position the fork legs. Bleeder screws 1 face forward. Info Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the top edge of the upper triple clamp. L01910-10 – Tighten screws 2. Guideline Screw, top triple clamp – Tighten screws M8 17 Nm (12.5 lbf ft) M8 12 Nm (8.9 lbf ft) 3.
11 SERVICE WORK ON THE CHASSIS 11.10 Installing the fork protector 36 x Main work – Position the fork protection on the left fork leg. Mount and tighten screws 1. Guideline Remaining screws, chassis – M6 10 Nm (7.4 lbf ft) Position the fork protection on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) B00306-10 Finishing work – Install the fork legs. 11.11 x ( p. 35) – Install the front wheel. x ( p.
11 SERVICE WORK ON THE CHASSIS 11.12 Installing the lower triple clamp 37 x Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 102) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. – Check whether the top steering head seal – Slide on protective ring – Position the upper triple clamp with the steering. – Mount screw – Position the fork legs. 1 is correctly positioned. 2 and O-ring 3.
11 SERVICE WORK ON THE CHASSIS – Mount and tighten screw 38 7. Guideline Screw, top steering stem M8 Loctite® 243™ 17 Nm (12.5 lbf ft) L01916-11 – Tighten screws 8. Guideline Screw, top triple clamp M8 17 Nm (12.5 lbf ft) – Secure the wiring harness with cable holder – Position the brake caliper. Mount and tighten screws 9. L01915-11 bk. Guideline Screw, front brake caliper – M8 Loctite® 243™ 25 Nm (18.4 lbf ft) Position the brake line and clamp. Mount and tighten screws bl.
11 SERVICE WORK ON THE CHASSIS – 39 Move the handlebar to and fro over the entire steering range. The handlebar must be able to move easily over the entire steering range. There should be no perceptible detent positions. » If detent positions are noticeable: – Adjust the play of the steering head bearing. – Check the steering head bearing and replace if required. Finishing work – Remove the motorcycle from the lift stand. ( 11.14 Adjusting the play of the steering head bearing p. 39) p.
11 SERVICE WORK ON THE CHASSIS 11.17 Installing the start number plate – 40 Position the start number plate. Mount and tighten screw 1. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) The holding lugs engage. – Position brake line 2 in the brake line guide. B01875-10 11.18 Removing the front fender Preparatory work – Remove the start number plate. ( Main work – Remove screws p. 39) 1 and 2. Remove the front fender. B01876-10 11.
11 SERVICE WORK ON THE CHASSIS 11.20 Removing the shock absorber 41 x Preparatory work – Raise the motorcycle with the lift stand. ( – Remove the right side cover. ( – Remove the main silencer. ( Main work – Remove screw p. 33) p. 45) p. 44) 1. – Remove screw cap – Press angle lever 2. L01669-10 – 3 toward the rear. Press linkage lever 4 downward. – Remove screw – Remove the shock absorber from the top. L01668-10 5. L01664-11 11.
11 SERVICE WORK ON THE CHASSIS 11.22 Removing the seat 42 – Remove screws – Raise the rear of the seat, push the seat back, and lift it off. – Hook in the front of the seat at the collar bushing of the fuel tank, lower at the rear and simultaneously push forward. – Make sure that the seat is correctly locked in. – Mount and tighten the screws for securing the seat. 1 in the recessed grips on the left and right. B01819-10 11.
11 SERVICE WORK ON THE CHASSIS 43 Main work – Push air filter holder toward the air filter at position and detach it at end . Swing the air filter holder to one side and remove the air filter with the air filter support. 1 – A B Remove the air filter from the air filter support. L01632-10 11.27 Cleaning the air filter and air filter box x Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc.
11 SERVICE WORK ON THE CHASSIS 11.29 Sealing the air filter box 44 x – Seal the air filter box in the marked area A. 401559-01 11.30 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Preparatory work – Remove the right side cover. ( Main work – Remove screws – p. 45) 1. Pull the main silencer off of the manifold at the rubber sleeve 2. L01633-10 11.
11 SERVICE WORK ON THE CHASSIS 45 Main work – Remove screws – 1. Pull out inner tube 2. Pull the glass fiber yarn filling 3 from the inner tube. – Clean the parts that are to be reinstalled. – Mount the new glass fiber yarn filling – Slide outer tube – 3 on the inner tube. 4 over the inner tube with the new glass fiber yarn filling. Mount and tighten all screws 1. B00486-10 Finishing work – Install the main silencer. ( – 11.33 p. 44) p. 45) Install the right side cover.
11 SERVICE WORK ON THE CHASSIS 46 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
11 SERVICE WORK ON THE CHASSIS 47 Main work – Position the fuel tank and fit the two spoilers to the sides of the radiator bracket. – Make sure that no cables are trapped or damaged. – Mount the fuel tank vent hose. L01671-10 – Mount and tighten screw 1 with the rubber bushing. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) L01919-11 – Mount and tighten screws 2 with the collar bushings. Guideline Remaining screws, chassis – M6 10 Nm (7.4 lbf ft) Connect the fuel hose.
11 SERVICE WORK ON THE CHASSIS – 48 Clean the chain regularly and then treat with chain spray. 400725-01 11.39 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load.
11 SERVICE WORK ON THE CHASSIS 49 Main work – Loosen nut – – 1. Loosen nuts 2. Adjust the chain tension by turning adjusting screws 3 to the left and right. Guideline Chain tension 55… 58 mm (2.17… 2.28 in) 3 Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks . The rear wheel is then correctly aligned. A – Tighten nuts – Make sure that chain adjusters – Tighten nut 2.
11 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower bolt edge of the chain is in line with or below the chain sliding guard: – – 50 Change the chain sliding guard. x Check the chain sliding guard for tightness. » If the chain sliding guard is loose: – Tighten the chain sliding guard. Guideline Screw, chain sliding guard M6 6 Nm (4.4 lbf ft) Loctite® 243™ L01639-10 – Check the chain sliding piece for wear.
11 SERVICE WORK ON THE CHASSIS 11.42 Checking the frame 51 x – Check the frame for cracking and deformation. » If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. x Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by Husqvarna. 402015-01 11.43 Checking the swingarm x – Check the swingarm for damage, cracking, and deformation.
11 SERVICE WORK ON THE CHASSIS 52 (250 TC EU) – Check the routing of the throttle cable. The throttle cable must be routed along the back of the handlebar, to the right of the frame, below the fuel tank bracket, and to the carburetor. » If the throttle cable is not routed as specified: – Correct the routing of the throttle cable. L01809-10 11.45 Finishing work – Install the fuel tank. x( – Mount the seat. ( p.
11 SERVICE WORK ON THE CHASSIS 53 Info When the adjusting screw is turned counterclockwise, the clutch lever moves away from the handlebar. When the adjusting screw is turned clockwise, the clutch lever moves closer to the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding! (250 TC EU) – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw .
11 SERVICE WORK ON THE CHASSIS 11.49 Changing the hydraulic clutch fluid 54 x Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. (125 TC EU) – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover – Fill bleeding syringe 1. 2 with membrane 3.
11 SERVICE WORK ON THE CHASSIS 55 – Inject the liquid into the system until it escapes from bore hole cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe. Mount and tighten the bleeder screw. – Correct the fluid level of the hydraulic clutch. 6 of the master Guideline Fluid level under top level of container L01223-10 – 4 mm (0.16 in) Position the cover with the membrane. Mount and tighten the screws.
12 BRAKE SYSTEM 12.1 Checking the free travel of the hand brake lever 56 Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating. Adjust the free travel on hand brake lever according to specifications. – Push the hand brake lever forward and check free travel ≥ 3 mm (≥ 0.12 in) Free travel of hand brake lever » A.
12 BRAKE SYSTEM 12.4 Checking the front brake fluid level 57 Warning Danger of accidents Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized Husqvarna workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid.
12 BRAKE SYSTEM 58 Main work – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – – – 1. 2 with membrane 3. Add brake fluid to level A. Remove screws Remove cover Guideline 5 mm (0.2 in) A Dimension (brake fluid level below top edge of container) Brake fluid DOT 4 / DOT 5.1 ( – p. 100) Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilled brake fluid immediately with water. L01804-10 12.
12 BRAKE SYSTEM 59 Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container! – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – 1. Remove cover 2 with membrane 3.
12 BRAKE SYSTEM 60 – Correct the brake fluid to level A. Guideline A Dimension (brake fluid level below top edge of container) Brake fluid DOT 4 / DOT 5.1 ( – – 5 mm (0.2 in) p. 100) 2 with membrane 3. Mount and tighten screws 1. Position cover Info Wash off overflowed or spilled brake fluid immediately with water. L01804-10 12.8 Checking the free travel of foot brake lever Warning Danger of accidents Brake system failure.
12 BRAKE SYSTEM 61 – Disconnect spring – Loosen nut travel. – To adjust the basic position of the foot brake lever individually, loosen nut turn screw accordingly. 1. 4 and, with push rod 5, turn it back until you have maximum free 2 and 3 Info The range of adjustment is limited. – 5 Turn push rod accordingly until you have free travel basic position of the foot brake lever. A. If necessary, adjust the Guideline Free travel at foot brake lever – Hold screw 3… 5 mm (0.12… 0.
12 BRAKE SYSTEM 62 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
12 BRAKE SYSTEM 63 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
12 BRAKE SYSTEM 64 – Insert the brake linings, insert pin 4, and mount cotter pins 3. Info Always change the brake linings in pairs. Info Make sure that decoupling plate brake lining. 7 is mounted on the piston side of the – Operate the foot brake lever several times until the brake linings are lying correctly against the brake disc and there is a pressure point. – Add brake fluid to level B01905-10 A. Brake fluid DOT 4 / DOT 5.1 ( – Mount and tighten screw cap p.
13 WHEELS, TIRES 13.1 Removing the front wheel 65 x Preparatory work – Raise the motorcycle with the lift stand. ( p. 33) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes. L00215-10 – – – – 1 by several rotations. Loosen screws 2. Press on screw 1 to push the wheel spindle ouf of the axle clamp. Remove screw 1.
13 WHEELS, TIRES 66 – Mount and tighten screw 2. Guideline Screw, front wheel spindle L00212-11 M24x1.5 45 Nm (33.2 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly against the brake disc. – Remove the motorcycle from the lift stand. ( – Pull the front wheel brake and push down hard on the fork several times. p. 33) The fork legs become aligned. – Tighten screws 3. Guideline Screw, fork stub 13.3 Removing the rear wheel M8 15 Nm (11.
13 WHEELS, TIRES 13.4 Installing the rear wheel 67 x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the wheel bearing. x – Clean and grease shaft seal rings – Insert the spacers.
13 WHEELS, TIRES 68 – Check the front and rear tires for cuts, run-in objects and other damage. » If the tire exhibits cuts, run-in objects or other damage: – – Change the tire. Check the depth of the tread. Info Note local national regulations concerning the minimum tread depth. Minimum tread depth 400602-10 » If the tread depth is less than the minimum permissible depth: – – ≥ 2 mm (≥ 0.08 in) Change the tire. Check the tire age.
13 WHEELS, TIRES 69 » If the spoke tension varies: – – Correct the spoke tension. x Check the spoke torque. Guideline Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Spoke nipple, rear wheel M4.5 5… 6 Nm (3.7… 4.
14 COOLING SYSTEM 14.1 Cooling system 70 (125 TC EU) Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. 1 2 120 °C (248 °F) Cooling is effected by the air stream. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.
14 COOLING SYSTEM – 71 3 Position the corresponding radiator cover and attach the radiator shield at holding lugs . Attach mounting points at the radiator. 4 2 L01813-10 14.4 Removing the radiator cover – Detach radiator shield cover . 1 at mounting points 2 and remove it. Remove radiator 3 L01812-10 – Attach the radiator shield at holding lugs ator. 4. Attach mounting points 2 at the radi- L01814-10 14.
14 COOLING SYSTEM » 72 If the level of the coolant does not meet specifications: – Correct the coolant level. Alternative 1 Coolant ( p. 100) Alternative 2 Coolant (mixed ready to use) ( – 14.6 p. 100) Mount the radiator cap. Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot.
14 COOLING SYSTEM 73 (125 TC EU) – Remove screw 1. Take off radiator cap 2. – Completely drain the coolant. – Mount and tighten screw 1 with a new seal ring. Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) L01924-11 (250 TC EU) – Remove screw 1. Take off radiator cap 2. – Completely drain the coolant. – Mount and tighten screw 1 with a new seal ring. Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) L01810-11 14.
14 COOLING SYSTEM – 74 Move the vehicle into the position shown and prevent it from rolling away. Height difference must be reached. A Guideline Height difference 75 cm (29.5 in) A Info For all of the air to be able to escape from the cooling system, the vehicle must be raised at the front. If the cooling system is poorly de-aerated, its cooling power will be reduced and the engine may overheat. 400677-10 L01926-10 – Return the vehicle to the horizontal position.
15 TUNING THE ENGINE 15.1 Checking the play in the throttle cable 75 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back and forth slightly to determine the play in throttle cable . A Play in throttle cable » 2… 3 mm (0.08… 0.12 in) If the throttle cable play does not meet specifications: – Adjust the play in the throttle cable. x( p.
15 TUNING THE ENGINE 15.3 Carburetor - idle 76 The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. This means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly. Info The carburetor and its components are subject to increased wear caused by engine vibration. Wear can result in malfunctioning. The factory setting for the carburetor is set for the following values.
15 TUNING THE ENGINE 77 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Adjust the idle speed with adjusting screw 1. Guideline Choke function deactivated – The choke lever is pushed in to the stop. ( Idle speed p.
15 TUNING THE ENGINE 78 Main work – Place a cloth beneath the carburetor to soak up emerging fuel. – Remove plug – Completely drain the fuel. – Mount and tighten the plug. 1. L01657-10 15.6 Plug-in connection, ignition timing map (125 TC EU) Plug-in connection 1 is located under the fuel tank on the frame. Possible states • Performance – The plug-in connection is connected to achieve higher performance. • Soft – The plug-in connection is disconnected to achieve better rideability.
15 TUNING THE ENGINE 15.9 Adjusting the basic position of the shift lever 79 x – Remove screw – Clean gear teeth – Mount the shift lever on the shift shaft in the required position and engage the gearing. 1 and take off shift lever 2. 401950-12 A of the shift lever and shift shaft. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure. 401951-10 – Mount and tighten the screw.
15 TUNING THE ENGINE 80 – Take cap , adjusting spring the clutch cover. – Pull both springs off of the spring insert. – Mount the required auxiliary spring the clutch cover together. 2 3, auxiliary spring 4, and spring insert 5 out of B00056-11 4 and adjusting spring 3 and slide them into Auxiliary spring with yellow marking (54637072300) Auxiliary spring with green marking (54837072100) Auxiliary spring with red marking (54837072000) The recess in spring insert 5 engages in the angle lever.
16 SERVICE WORK ON THE ENGINE 16.1 Checking the gear oil level 81 Info The gear oil level must be checked while the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work (125 TC EU) – Remove screw – 1 from the opening used to check the gear oil level. Check the gear oil level. A small quantity of gear oil should flow out of the opening. » If gear oil does not flow out: – – L01711-10 Add gear oil. x( p.
16 SERVICE WORK ON THE ENGINE 16.3 Draining the gear oil 82 x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
16 SERVICE WORK ON THE ENGINE 83 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Start the engine and check that it is oil-tight. Finishing work – Check the gear oil level. ( 16.5 Adding gear oil p.
16 SERVICE WORK ON THE ENGINE – Start the engine and check that it is oil-tight.
17 CLEANING, CARE 17.1 Cleaning the motorcycle 85 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.
18 STORAGE 18.1 Storage 86 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
19 TROUBLESHOOTING 87 Faults Possible cause Action Engine turns but does not start Operating error – Go through the steps of starting the engine. ( p. 20) Motorcycle was out of use for a long time and there is old fuel in the float chamber – Empty the carburetor float chamber. ( p. 77) Fuel feed interrupted – Check the fuel tank breather. – Clean the fuel tap. – Check/set the carburetor components. Spark plug oily or wet – Clean and dry the spark plug, or change it if necessary.
19 TROUBLESHOOTING Faults Possible cause Engine overheats Foam formation in cooling system 88 Action – Drain the coolant. – Refill with coolant. Damaged cylinder head or cylinder head gasket – Check the cylinder head or cylinder head gasket. Bent radiator hose – Change the radiator hose. Incorrect ignition point due to loose stator – Adjust the ignition.
20 TECHNICAL DATA 20.1 Engine 20.1.1 125 TC EU 89 Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast Piston rings 2 half keystone rings X (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.
20 TECHNICAL DATA 90 Transmission ratio First gear 14:28 Second gear 15:24 Third gear 18:24 Fourth gear 21:24 Fifth gear 22:21 Ignition Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan Ignition point (BTDC) 1.9 mm (0.075 in) Spark plug NGK BR 8 ECM Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kick starter 20.2 Engine tightening torques 20.2.1 125 TC EU Screw, inner membrane sheets EJOT DELTA PT® 35x25 1 Nm (0.
20 TECHNICAL DATA 91 Nut, rotor M12x1 60 Nm (44.3 lbf ft) – Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) – Spark plug M14x1.25 25 Nm (18.4 lbf ft) – Nut, primary gear M16LHx1.5 130 Nm (95.9 lbf ft) Loctite® 243™ Nut, inner clutch hub M18x1.5 130 Nm (95.9 lbf ft) Loctite® 243™ Cap nut, exhaust control M26x1 35 Nm (25.8 lbf ft) – Screw, inner membrane sheets EJOT DELTA PT® 35x25 1 Nm (0.7 lbf ft) – Screw, membrane support plate EJOT DELTA PT® 30x12 1 Nm (0.
20 TECHNICAL DATA 20.3 Capacities 20.3.1 Gear oil 92 Gear oil (125 TC EU) 0.70 l (0.74 qt.) engine oil (15W/50) ( p. 100) Gear oil (250 TC EU) 0.80 l (0.85 qt.) engine oil (15W/50) ( p. 100) 1.2 l (1.3 qt.) Coolant ( 20.3.2 Coolant Coolant p. 100) Coolant (mixed ready to use) ( 20.3.3 p. 100) Fuel Total fuel tank capacity, approx. 7.5 l (1.98 US gal) Super unleaded (98 octane) mixed with 2-stroke engine oil (1:40) ( p.
20 TECHNICAL DATA 20.5 Tires 93 Validity Front tires Rear tires (125 TC EU) 80/100 - 21 51M TT Dunlop GEOMAX MX51 FA 100/90 - 19 57M TT Dunlop GEOMAX MX51 (250 TC EU) 80/100 - 21 51M TT Dunlop GEOMAX MX51 FA 110/90 - 19 62M TT Dunlop GEOMAX MX51 Additional information is available in the Service section under: www.husqvarna-motorcycles.com 20.6 Fork 20.6.1 125 TC EU Fork part number 14.18.7N.
20 TECHNICAL DATA 94 Oil capacity per cartridge 195 ml (6.59 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 100) Oil capacity fork leg without cartridge 380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 100) 20.7 Shock absorber 20.7.1 125 TC EU Shock absorber part number 18.15.7N.51 Shock absorber WP Suspension 5018 BAVP DCC Compression damping, low-speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, high-speed Comfort 2.
20 TECHNICAL DATA Weight of rider: 85… 95 kg (187… 209 lb.) 95 57 N/mm (325 lb/in) Spring length 260 mm (10.24 in) Gas pressure 10 bar (145 psi) Static sag 30 mm (1.18 in) Riding sag 100 mm (3.94 in) Fitted length 486 mm (19.13 in) Shock absorber oil ( 20.8 p. 101) SAE 2.5 Chassis tightening torques Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Spoke nipple, rear wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, shock absorber adjusting ring M5 5 Nm (3.
20 TECHNICAL DATA 20.9 Carburetor 20.9.1 125 TC EU 96 Carburetor type KEIHIN PWK 38S AG Carburetor identification number BS5_0 Needle position 4th position from top Jet needle NOZH (NOZG, NOZI) Main jet 182 (180, 185) Idling jet 42 (40, 45) Starting jet 85 Idle air adjusting screw Open 2 turns Throttle slide 20.9.2 7 with cut-out Carburetor - basic setting for sandy surfaces (125 TC EU) Idle air adjusting screw Open 1.
20 TECHNICAL DATA 20.10 Carburetor tuning 97 20.10.
20 TECHNICAL DATA 98 20.10.
20 TECHNICAL DATA 20.10.3 General carburetor tuning x 1... 5 0 1 30 5 0 99 Needle position from top The five possible needle positions are shown here. The carburetor tuning depends on the defined ambient and operating conditions.
21 SUBSTANCES 100 Brake fluid DOT 4 / DOT 5.1 Standard/classification – DOT Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties. Coolant Guideline – Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming. – Use only coolant based on ethylene glycol.
21 SUBSTANCES 101 Shock absorber oil (SAE 2.5) (50180342S1) Standard/classification – SAE ( p. 103) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.
22 AUXILIARY SUBSTANCES High viscosity grease Recommended supplier SKF® – LGHB 2 Rubber grip adhesive (00062030051) Recommended supplier KTM-Sportmotorcycle AG – GRIP GLUE 102
23 STANDARDS 103 JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.
INDEX 104 Compression damping fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Air filter box cleaning . . . . . . . . . . . . . . . . . . . . . .
INDEX 105 Fork protector installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Frame checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Front fender installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Front wheel installing . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 106 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Steering head bearing greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Steering head bearing play adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Swingarm checking . . . . . . . . . . . . . . . .
*3402001en* 3402001en 11/2013 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 | 5230 Mattighofen Austria Photo: Mitterbauer/Husqvarna Motorcycles GmbH
