Husqvarna TC449 Manuel d'instructions

NTSC 4:3

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Free

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MOTORE

1 - Operazioni di manutenzione

2 - Gruppo testa

3 - Gruppo cilindri e pistoni

4 - Gruppo frizione

5 - Gruppo alternatore

6 - Gruppo carter

CICLISTICA

7 - Operazioni di manutenzione

ENGINE

1 - Maintenance

2 - Cylinder head assembly

3 - Cylinder and piston assembly

4 - Clutch assembly

5 -Alternator assembly

6 - Crankcase

CHASSIS

7 - Maintenance

MOTEUR

1 - Opérations d'entretien

2 - Ensemble culasse

3 - Ensemble cylindres et pistons

4 - Ensemble embrayage

5 - Ensemble alternateur

6 - Ensemble carter

PARTIE-CYCLE

7 - Opérations d'entretien

MOTOR

1 -Wartungsarbeiten

2 - Zylinderkopfeinheit

3 - Zylinder- Kolbeneinheit

4 - Kupplungseinheit

5 - Lichtmaschineneinheit

6 - Gehäuseeinheit

FAHRWERK

7 -Wartungsarbeiten

MOTOR

1 - Operaciones de mantenimiento

2 - Grupo cabezal

3 - Grupo cilindros y pistones

4 - Grupo embrague

5 - Grupo alternador

6 - Grupo cárter

CHASIS

7 - Operaciones de mantenimiento

www.husqvarna-motorcycles.com

Cod. 8000H5336 www.husqvarna-motorcycles.com

Husqvarna Motorcycles srl

Via Nino Bixio 8

21024 - Biandronno (VA) - Italy

Technical DVD

Workshop Manual

My 2011

Ed. 11-2010

HUSQVARNA MOTORCYCLES S.R.L. - Varese disclaims all liabilities

for any errors or omissions in this manual and reserves the right to make

changes to reect on-going product development. Illustrations in the ma-

nual may differ from actual components. No reproduction in full or in part

without written authorisation.

1st edition (08-2010) _Rev. 11-2010

a.1

TC 449: ZKHA600AABV050001

TC 449 (USA): ZKHTC443#BV000001

TE 449: ZKHA600AABV000001

TE 511: ZKHA601AABV000001

TE 449: (USA): ZKHKEEFM#BV000001

TE 511: (USA): ZKHKEEGM#BV000001

TXC 449: (USA): ZKHTX440#BV000001

TXC 511: (USA): ZKHTX510#BV000001

SMR 499: ZKHA600ABBV000001

SMR 499 (USA): ZKHLEEFM#BV000001

SMR 511: ZKHA601ABBV000001

SMR 511 (USA): ZKHLEEGM#BV000001

1st edition (08-2010) _Rev. 11-2010

FOREWORD, TABLE OF CONTENTS

1st edition (08-2010) - Rev. 11-2010

Printed in Italy

MODELS COVERED (from serial number onwards)

HUSQVARNA MOTORCYCLES S.R.L.

BMW Group

Technical Service

Via Nino Bixio, 8

21024

(Varese) - Italy

tel. ++39 0332 75.61.11

tel. ++39 0332 756 558

www.husqvarna-motorcycles.com

Workshop Manual

1. Chassis serial number

TC - TE - TXC 449 2011 I.E.

TE - TXC 511 2011 I.E.

SMR 449 - 511 2011 I.E.

a.2 1st edition (08-2010) _Rev. 11-2010

FOREWORD, TABLE OF CONTENTS

Foreword

This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance

and repair of the models covered in this manual. The technical information provided in this manual is a critical comple-

ment to operator training and operators should become thoroughly familiar with it.

For ease of understanding, diagrams and photographs are provided next to the text.

Notes with special signicance are identied as follows throughout the manual:

Accident-prevention rules for operator and persons working nearby.

Damage to vehicle and/or its components may result from incompliance with relevant instructions.

Additional information concerning the operation covered in the text.

Useful tips

To prevent problems and ensure effective service work, observe the following HUSQVARNA recommendations:

– before repair, evaluate the customer's description of the problem and ask the appropriate questions to clearly identify

problem symptoms;

– diagnose the problem and identify the causes clearly. This manual provides basic background information that must

be supplemented with the operator's expertise and specic training available through HUSQVARNA held at regular

periods;

– plan ahead before starting work: gather any spare parts and tools to avoid unnecessary delays;

– avoid unnecessary disassembly work to get to the part that needs repairing.

Always read the relevant instructions and follow the disassembly sequence outlined in this manual.

Recommended shop practices

1 Always replace gaskets, sealing rings and split pins with new ones.

2 When loosening or tightening nuts or bolts, always begin with the bigger ones or from the centre. Tighten to the speci-

ed torque and follow a cross pattern.

3 Always mark any parts or positions that might be confused upon assembly.

4 Use genuine HUSQVARNA parts and the recommended lubricant brands.

5 Use special tools where specied.

6 Technical Bulletins might contain more up-to-date setting data and procedures than this manual. Be sure to read

them.

a.31st edition (08-2010) _Rev. 11-2010

FOREWORD, TABLE OF CONTENTS

NOTES

Unless otherwise specied, data and specications apply to all models.

Table of Contents

Title Section

Foreword, Table of Contents ...............................................................................a

Important Notices ................................................................................................ b

General Information .............................................................................................A

Maintenance ........................................................................................................B

Troubleshooting .................................................................................................. C

Settings and Adjustments ................................................................................... D

General Procedures ............................................................................................E

Adjustments - Engine ..........................................................................................F

Engine Disassembly /Reassembly ....................................................................F1

Front Suspension ................................................................................................. I

Rear Suspension ................................................................................................. J

Brakes ................................................................................................................. L

Electrical system................................................................................................. M

Engine Cooling ................................................................................................... N

Hydraulically Controlled Clutch............................................................................P

Fuel injection system ...........................................................................................S

Tightening Torque Figures ...................................................................................X

Chassis and Wheels ............................................................................................Y

Notes for USA/CDN Models ................................................................................Z

b.1

1st edition (08-2010) _Rev. 11-2010

IMPORTANT NOTICES

Section

b.2

H006104

H06374

SMR

H006106

TXC

H006105

1st edition (08-2010) _Rev. 11-2010

IMPORTANT NOTICES

1) TC and TXC models are RACING motorcycles and are warranted to be free

from operating defects; a scheduled maintenance chart for racing use is provided

in Section B.

2) The TE and SMR models are for ROAD USE; it is warranted to free from

defects and covered by legal warranty, provided that the STANDARD CON-

FIGURATION IS MAINTAINED and the maintenance chart provided in Section

B is observed.

* This motorcycle has not been designed to travel over long distances with the

engine at top rpm, as in long-distance road or highway travel. Riding over long

distances at full throttle may result in severe engine damage.

* ALWAYS remember that these motorcycles are specically designed for

racing, i.e. for usage conditions signicantly different from those experienced

in regular road use.

* In order to maintain the vehicle’s “Guarantee of Functionality”, the client must

follow the maintenance programme indicated in Section B by having the required

maintenance inspections carried out at authorised HUSQVARNA dealers. The

cost for changing parts and for the labour necessary in order to comply with

the maintenance plan is charged to the Client. The warranty becomes NULL

AND VOID if the motorcycle is rented.

Notes

Left and right side is determined when seated on motorcycle.

Z: number of teeth

A: Austria

AUS: Australia

B: Belgium

BR: Brazil

CDN: Canada

CH: Switzerland

D: Germany

E: Spain

F: France

FIN: Finland

GB: Great Britain

I: Italy

J: Japan

USA: United States of America

Unless otherwise specied, data and instructions apply to all market variants.

A.1

1st edition (08-2010) _Rev. 11-2010

GENERAL INFORMATION

Section

A.2 1st edition (08-2010) _Rev. 11-2010

GENERAL INFORMATION

Engine ..........................................................................................................A.3

Timing system ..............................................................................................A.3

Fuel system ..................................................................................................A.3

Lubrication ....................................................................................................A.3

Cooling .........................................................................................................A.3

Ignition system..............................................................................................A.3

Starter ..........................................................................................................A.3

Drive and Transmission ................................................................................A.3

Chassis .........................................................................................................A.4

Suspension ...................................................................................................A.4

Brakes ..........................................................................................................A.4

Wheels..........................................................................................................A.4

Tyres .............................................................................................................A.4

Electrical components location .....................................................................A.5

Supplies ........................................................................................................A.6

Overall dimensions - Weight .........................................................................A.7

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