Page 1 Workshop Manual TE 250-450-510/2008-I.E., TC 250-450-510/2008, TXC 250-450-510/2008 (only USA) SMR 450-510 2008-I.E. SMR 450-R/2008 Part. N. 8000 B0148 (02-2008)
Page 2 To the best knowledge of HUSQVARNA MOTORCYCLES S.R.L. - Varese, Inc. the material contained herein is accurate as of the date this pubblication was approved for printing. Cagiva Motor S.p.a. - Varese, Inc. reserves the right to change specifications, equipment, or designs at any time without notice and without incurring obligation. Illustrations in this manual are merely for demonstration purposes and could not exactly match the detail described.No part of this manual can de reproduced without permission...
Page 3 Print No. N° 8000 B0148 VALIDITY (from vehicle identification number) TE 250: ZKHA200AA8V000001 TE 450: ZKHA202AA8V000001 TE 510: ZKHA203AA8V000001 TE 250 (USA): ZKHECECA*8V100001 TE 450 (USA): ZKHECENB8V100001 TE 510 (USA): ZKHECEHB8V100001 TC 250: ZKHA200AA8V050001 TC 450: ZKHA202AA8V050001 TC 510: ZKHA203AA8V050001...
Page 4 Additional information concerning the operation under way. Useful suggestions HUSQVARNA suggests, in order to prevent troubles and in order to have an excellent final result, to generically comply with the following instructions: – in case of repair work, weigh the impressions of the Customer who complains about the improper operation of the motorcycle, and formulate proper clearing questions about the symptoms of the trouble.
Page 5: Table Of Contents
FOREWORD, SUMMARY Summary Chapter Section Foreword, summary ............Important notices ............General ................. Maintenance ..............Troubles and remedies ..........Settings and adjustments ..........General operations ............Engine disassembly ............Engine overhauling ............Engine re-assembly ............Front suspension ............Rear suspension ............Brakes ................
Page 6 FOREWORD, SUMMARY Part. N. 8000 B0148 (02-2008)
Page 7: Important Notices
IMPORTANT NOTICES Section Part. N. 8000 B0148 (02-2008)
Page 8 IMPORTANT NOTICES 1) The TC, TXC and SMR 450-R models are guaranteed COMPETITION motorcycles exempt from functional defects, the suggested maintenance table for competition use is shown on chapter B. 2) TE and SMR are STREET LEGAL motorcycles (with LIMITED POWER ENGINE); they are guaranteed exempt from functional defects and covered with legal guarantee, if the STANDARD CONFIGURATION is maintained and the suggested maintenance table, shown on chapter B, is observed.
Page 9 B by carrying out maintenance checks at authorized HUSQVARNA dealers. The cost for substituting parts and for the labour necessary in order to respect the maintenance plan, is charged to the client. The guarantee is EXTINGUISHED in the case where the motorcycle is rented.
Page 10 IMPORTANT NOTICES Part. N. 8000 B0148 (02-2008)
Page 11: General
GENERAL Section Part. N. 8000 B0148 (02-2008)
Page 12 GENERAL Engine ................Timing system ..............Fuel feeding ..............Lubrication ..............Cooling ................Ignition ................Starting ................Transmission ............A.4-A.5 Frame ................Suspensions ..............Brakes ................Wheels ................Tires ................Ignition system- electric system ........Weights ................Overall dimensions ............Capacities ...............
Page 13: Timing System
GENERAL ENGINE 4-stroke, single cylinder Bore (250) ..................2.99 in. Bore (450- 510) ................3.81 in. Stroke (250) ..................2.17 in. Stroke (450) ..................2.39 in. Stroke (510) ..................2.67 in. Displacement (250) ..............15.22 cu. in. Displacement (450) ..............27.39 cu. in. Displacement (510) ..............
Page 14: Transmission
5 th gear ............0.954 (z 21/22) Final drive Drive between gearbox and rear wheel by 5/8" x 1/4" chain (with OR for TE 250-450-510 and SMR 450-510 models; excluded SMR 450-R). Transmission sprocket (TE 250-450-510; TXC 250-450-510; SMR 450-R) ... z 13 Transmission sprocket (TC 450) ..............
Page 15 GENERAL Total drive ratios 1st gear (TE-TXC 250) ..........28.205 1st gear (TE-TXC 450-510) ........19.806 1st gear (TC 250) ............26.055 1st gear (TC 450) ............18.261 1st gear (TC 510) ............17.159 1st gear (SMR 450-510) ..........16.435 1st gear (SMR 450-R) ..........
Page 16: Frame
GENERAL FRAME Steel single tube cradle (round, rectangular and ellipsoidal tubes, branching off into two parts approximately at the exhaust level), rear frame in light alloy Forward travel (in.) .............. 4.17 (TE-TXC); 4.10 (TC); 3.27 (SMR); 3.23 (SMR 450-R) SUSPENSIONS Front “MARZOCCHI”...
Page 17 GENERAL ELECTRICAL COMPONENTS LOCATION (TE-SMR) The ignition system includes the following elements: - Generator, in oil bath, on the inner side of L.H. crankcase cover; - Electronic ignition coil under the fuel tank; - Electronic power unit under the fuel tank; - Voltage regulator under the fuel tank;...
Page 19: Capacities
GENERAL CAPACITIES TYPE QUANTITY Fuel tank (reserve included) Unleaded gasoline (98 R.O.N.) 1.58 Imp. Gall./ 1.9 U.S. Gall. Fuel reserve 1.58 Imp. Qt./ 1.9 U.S. Qt. Change gear and main transmission oil AGIP RACING 4T (SAE 10W60) 1.5 Imp. Qt./ 1.8 U.S. Qt. (oil and oil filter replacement) Change gear and main transmission oil AGIP RACING 4T (SAE 10W60)
Page 20 GENERAL A.10 Part. N. 8000 B0148 (02-2008)
Page 21: Maintenance
MAINTENANCE Section Part. N. 8000 B0148 (02-2008)
Page 22 MAINTENANCE PRE -DELIVERY INSPECTION Description Operation Pre-delivery Engine oil Check level Coolant Check / Restore level Cooling system Check for leakage Elettroventole (TE-SMR) Controllo funzionamento Spark plugs Check / Replace Throttle body / Carburettor Check and adjust Brakes / Clutch fluid Check level Brakes / Clutch Check operation...
Page 23 MAINTENANCE PERIODIC MAINTENANCE SCHEDULE (SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES) TE-TC-TXC 250, 450, 510 -2008 COMPETITION MOTORCYCLE, RACING USE: with FULL POWER ENGINE COUPON COUPON COUPON COUPON COUPON AFTER FIRST EVERY EVERY EVERY EVERY EVERY REPLACE ITEM 3 HOURS...
Page 24 MAINTENANCE PERIODIC MAINTENANCE SCHEDULE (SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES) TE-TC-TXC 250, 450, 510 -2008 COMPETITION MOTORCYCLE, RACING USE: with FULL POWER ENGINE COUPON COUPON COUPON COUPON COUPON AFTER FIRST EVERY EVERY EVERY EVERY EVERY REPLACE ITEM 3 HOURS...
Page 25 MAINTENANCE PERIODIC MAINTENANCE SCHEDULE (SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES) TE-TC-TXC 250, 450, 510 -2008 COMPETITION MOTORCYCLE, RACING USE: with FULL POWER ENGINE COUPON COUPON COUPON COUPON COUPON AFTER FIRST EVERY EVERY EVERY EVERY EVERY REPLACE ITEM 3 HOURS...
Page 26 MAINTENANCE PERIODIC MAINTENANCE SCHEDULE (SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES) SMR 450, 510 - TE 250, 450, 510 / 2008 AFTER FIRST EVERY EVERY - STANDARD MOTORCYCLE, STREET LEGAL (with LIMITED 1000 KM 5000 KM 10000 KM POWER ENGINE):...
Page 27 MAINTENANCE PERIODIC MAINTENANCE SCHEDULE (SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES) SMR 450, 510 - TE 250, 450, 510 / 2008 AFTER FIRST EVERY EVERY - STANDARD MOTORCYCLE, STREET LEGAL (with LIMITED 1000 KM 5000 KM 10000 KM POWER ENGINE):...
Page 28 MAINTENANCE PERIODIC MAINTENANCE SCHEDULE (SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES) SMR 450, 510 - TE 250, 450, 510 / 2008 AFTER FIRST EVERY EVERY - STANDARD MOTORCYCLE, STREET LEGAL (with LIMITED 1000 KM 5000 KM 10000 KM POWER ENGINE):...
Page 29: Troubles And Remedies
TROUBLES AND REMEDIES Section Part. N. 8000 B0148 (02-2008)
Page 30 TROUBLES AND REMEDIES ENGINE Trouble Cause Remedy Engine don’t start or starts Inadequate compression with difficulty 1. Piston seizure Replace 2. Con-rod small or big end seized Replace 3. Piston rings worn Replace 4. Cylinder worn Replace 5. Low torque cylinder head nuts Tighten 6.
Page 31 TROUBLES AND REMEDIES Trouble Cause Remedy Clutch noise 1. Discs worn Replace 2. Excesive free play between clutch drum and driving discs Replace Gearbox noise 1. Gears worn Replace 2. Gear splines worn Replace Rear transmission chain noise 1. Chain stretched or badly adjusted Replace or adjust 2.
Page 32 TROUBLES AND REMEDIES FRAME, WHEELS AND SUSPENSION Trouble Cause Remedy Difficult to turn handlebars 1. Low tire pressure Inflate Steering head bearings’ adjustment ring nut or steering stem nut too tight Adjust 3. Bent steering head stem Replace steering bracket 4.
Page 33 TROUBLES AND REMEDIES ELECTRICS (see also chapter M) Trouble Cause Remedy Spark plug becomes dirty 1. Mixture too rich Adjust carburettor too frequently 2. Air filter dirty Clean 3. Piston rings worn Replace 4. Piston or cylinder worn Replace Spark plug overheats 1.
Page 34 TROUBLES AND REMEDIES Part. N. 8000 B0148 (02-2008)
Page 35: Settings And Adjustments
SETTINGS AND ADJUSTMENTS Section Part. N. 8000 B0148 (02-2008)
Page 36 SETTINGS AND ADJUSTMENTS Adjustment of valves play ......... Adjustment of starter decompression device ..... Throttle cable adjustment .......... Carburettor adjustment (TC, TXC, SMR 450-R) ..D.10 Idle adjustment (TC, TXC, SMR 450-R) ....D.10 Idle adjustment (TE, SMR) ........D.10 Clutch discs replacement (TC, TE, TXC, SMR) ..
Page 37 SETTINGS AND ADJUSTMENTS TC-TXC SMR 450-R Part. N. 8000 B0148 (02-2008)
Page 38 SETTINGS AND ADJUSTMENTS Adjusting the valve play To check the valve clearance, proceed as follows , WITH COLD ENGINE: First turn counterclockwise fastening rear pin (1) then remove the saddle. HOW TO REMOVE THE TANK (TC) Close the fuel tap (2) and loosen the strap (3) on the connecting pipe to the carburettor, pull the pipe out of the carburettor.
Page 39 SETTINGS AND ADJUSTMENTS HOW TO REMOVE THE TANK (TE-SMR) Remove the screws (1) and the side panels. Remove the locking screw (A) of the tank. Lift the tank, then disconnect the connector of the fuel pump from the main cabling. Disconnect the feeding pump (B) from the outlet coupling (C) on the fuel pump in the lower back section of the tank.
Page 40 SETTINGS AND ADJUSTMENTS HOW TO REMOVE THE SADDLE AND THE TANK (SMR 450-R) First turn counterclockwise fastening rear pin (1) then remove the saddle. Close the fuel tap (2) and loosen the strap (3) on the connecting pipe to the carburettor, pull the pipe out of the carburettor.
Page 41 SETTINGS AND ADJUSTMENTS PROCEDURE APPLYING TO ALL THE MODELS Remove the spark plug (5), the four cylinder head cover fastening screws (6) and the cylinder head cover. Engage second gear and, moving the vehicle forwards and backwards, bring the piston to Top Dead Center (in this condition , the mark on the cylinder head is aligned with the two marks on the idle gear of the camshafts, as illustrated in the figure).
Page 42: Adjustment Of Starter Decompression Device
SETTINGS AND ADJUSTMENTS Adjustment of starter decompression device In order to adjust the lever decompressor free play (approximately 3 mm - 0.12 in.): should the clearance be incorrect, unblock the counter ring-nut and turn the adjusting screw (by unscrewing it, the clearance is reduced, while by screwing screw it is increased);...
Page 43: Throttle Cable Adjustment
SETTINGS AND ADJUSTMENTS 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 (0.08 in.) 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 screw- ing screw (4) it is increased);...
Page 44: Carburettor Adjustment (Tc, Txc, Smr 450-R)
SETTINGS AND ADJUSTMENTS Carburettor adjustment (TC, TXC, SMR 450-R) Adjust the carburettor with warm engine and with the throttle in closed position. Work as follows: - turn slow running adjusting screw (1) on the left side of the bike, , until the engine is turning over at fairly high rpm (turn the screw clockwise to increase the rpm, and anticlockwise to descrease the rpm).
Page 45: Clutch Discs Replacement (Tc-Te-Txc-Smr)
SETTINGS AND ADJUSTMENTS Clutch discs replacement (TC-TE-TXC-SMR) This operation can be carried out by laying the motorcycle on the left side with- out draining the engine oil. Remove the five fastening screws (1) and the clutch cover (if necessary, lower the rear brake control pedal). Use a 5 mm allen wrench to loosen the six screws (2) that fasten clutch springs.
Page 46: Clutch Discs Replacement (Smr 450-R)
SETTINGS AND ADJUSTMENTS Clutch discs replacement (SMR 450-R) TOOLS Tilt the motorcycle to the left side without draining the engine oil. Remove the five locking screws (A) and remove the clutch cover (lower the rear brake pedal if necessary). Use a 4 mm Allen wrench to loosen the six screws (9) and their notched washers (8) and remove the support (30) along with the fifth wheel (33) and the thrust bearing (32).
Page 47 SETTINGS AND ADJUSTMENTS Part. N. 8000 B0148 (02-2008) D.13...
Page 48 SETTINGS AND ADJUSTMENTS Put the drum stop hub (22) on the clutch hub (1) with a small quantity of grease; - insert the toothed washer (23) with the convex side facing upward; TOOLS - mount the spring (7) in its seat inside the drum (1) with a small quantity of grease; - insert the plate (6) on the drum (1);...
Page 49 SETTINGS AND ADJUSTMENTS Part. N. 8000 B0148 (02-2008) D.15...
Page 50: Adjustment Of The Control Lever And Check Of The Clutch Fluid Level
SETTINGS AND ADJUSTMENTS Adjustment of the control lever and check of the clutch fluid level Free play (A) must be at least 3 mm (0.1 in.). The lever position can be adjusted for any driver hand size. To decrease the lever distance from the handle grip, rotate the adjuster (B) CLOCKWISE.
Page 51: Adjustment Of Front Brake Control Lever And Fluid Level Control (Te-Tc-Txc- Smr)
SETTINGS AND ADJUSTMENTS Adjustment of front brake control lever and fluid level control (TE-TC-TXC- SMR) On the SMR model the lever position can be adjusted (4 adjustments) for any driver hand size. To decrease the lever distance from the handle grip, turn the adjuster (B) CLOCKWISE.
Page 52: Adjustment Of Front Brake Control Lever And Fluid Level Control (Smr 450-R)
SETTINGS AND ADJUSTMENTS Adjustment of front brake control lever and fluid level control (SMR 450-R) The handlebar lever can be adjusted to the rider’s hand size. Turn the adjuster (1) ANTICLOCKWISE to reduce the distance between the lever and the grip or turn the adjuster (1) CLOCKWISE to increase the distance between the lever and the grip.
Page 53: Rear Brake Idle Stroke Adjustment
SETTINGS AND ADJUSTMENTS Rear brake idle stroke 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 proceed as follows: - loosen nut (3); - operate the pump rod (4) to increase or decrease the idle stroke;...
Page 54: Checking The Engine Oil Level
SETTINGS AND ADJUSTMENTS Checking the engine oil level By keeping the motorcycle on a flat surface, in vertical position, remove the control screw (1) and check the oil should just barely escape from the hole on the R.H. cover. To fill up, remove the filler cap (2). : Have this operation made with warmed-up engine.
Page 55: Engine Oil Replacement And Bag Filters-Cartridge Filter Cleaning Or Replacement
SETTINGS AND ADJUSTMENTS Engine oil replacement and bag filters-cartridge filter cleaning or replace- ment Drain the oil with WARM ENGINE; proceed as follows: - remove oil filler cap (2); - even if not necessary, remove the engine guard (A); - place an oil drain pan under the engine block; - remove the oil drain cap (3), drain the used oil completely then clean the mag- net on the cap;...
Page 56: Coolant Level Check
SETTINGS AND ADJUSTMENTS Coolant level check Check level (1) in right-hand radiator when engine is cold (place the motorcycle so that it is perpendicular to the ground). The coolant should be approximately 10 mm above cells and besides, on TE and SMR models, it doesn’t exceed the middle of the expansion tank (2) located in front of the rear shock absorber.
Page 57: Air Filter Check
SETTINGS AND ADJUSTMENTS Air filter check Turn rear pin (1) counterclockwise, remove it and release the saddle from the front fastening screw. To gain access to the air filter, lift a little the electronic power unit (2). Remove screw (3) and the filter (4). Separate filter (5) from frame (6). AIR FILTER AND CLEANING Wash filter with a specific detergent (AGIP”...
Page 58: Secondary Transmission Chain Adjustment
SETTINGS AND ADJUSTMENTS Secondary transmission chain adjustment Fig. B Chain should be checked, adjusted and lubricated as shown on the Mainte- nance Chart (page B.5-B.8) 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.
Page 59: Lubricating The Transmission Chain
SETTINGS AND ADJUSTMENTS Lubricating the chain Lubricate the chain following these instructions. : Never use grease to lubricate the chain. Grease helps to accumulate dust and mud, which act as abrasive and hepl to rapidly wear out the chain, the sprocket, and the crown.
Page 60: Adjusting The Suspensions According To Particular Track Conditions
SETTINGS AND ADJUSTMENTS Adjusting the suspensions according to particular track conditions The following information is a useful guide for setting up the suspensions according to the road conditions. Always start from the standard calibration before making any change on the suspensions.
Page 61: Adjusting The Shock Absorber
SETTINGS AND ADJUSTMENTS Adjusting the shock 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.
Page 62: Adjusting The Shock Absorber Spring Preload
SETTINGS AND ADJUSTMENTS Adjusting the shock absorber spring preload Follow the instructions below to perform the operation: 1. First turn the fastening rear pin (1) anticlockwise, then remove the saddle, loosen the screws (2) and remove the right side panel (3). 2.
Page 63: Shock Absorber Hydraulic Brake Adjustment
SETTINGS AND ADJUSTMENTS Shock absorber hydraulic brake adjustment Adjustment of the compression stroke is independent from the rebound stroke. A) COMPRESSION - Standard calibration: 1) Low damping speed: -15 clicks (± 2 clicks) (adjuster 1) 2) High damping speed: -15 clicks (± 2 clicks) (adjuster 3) To reset the standard calibration, turn upper adjusters (1) and (3) clockwise TC-TE-TXC-SMR...
Page 64: Shock Absorber Springs
SETTINGS AND ADJUSTMENTS Shock absorber springs STANDARD K=5.4 kg/mm (TE-TXC 250; code 8000 98504) K=5.6 kg/mm (TE-TXC 450/510; code 8000 H0076) K=6.4 kg/mm (SMR; code 8000 98520) TC-TE-TXC-SMR SMR 450-R D.30 Part. N. 8000 B0148 (02-2008)
Page 65: Adjusting The Front Fork
SETTINGS AND ADJUSTMENTS Adjusting the front fork a) COMPRESSION (LOWER REGISTER) Standard calibration: -12 clicks (TE-SMR); -15 clicks (TC-TXC-SMR 450-R). 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.
Page 66: Front Fork Springs
SETTINGS AND ADJUSTMENTS Front fork springs STANDARD K=4.5 N/mm (TE; A: spring + spacer code 8000 B1713) K=4.8 N/mm (TC-TXC 250; A: spring + spacer code 8000 B1690) K=5.0 N/mm (TC-TXC 450/510; A: spring + spacer code 8000 B1716) K=5.0 N/mm (SMR; A: spring + spacer code 8000 A7608) TC-TXC TE-SMR D.32...
Page 67: Steering Bearings Play Adjustment
SETTINGS AND ADJUSTMENTS Steering bearings play adjustment To ensure maximum safety, the steering should always be adjusted so that the handlebars rotate freely without play. To check steering adjustment, place kick stand or other support under the engine so that the front wheel is raised from ground.
Page 68: Handlebar Position And Height Change (Te-Tc-Txc-Smr)
SETTINGS AND ADJUSTMENTS Handlebar position and height change (TE-TC-TXC-SMR) The handlebar position (a) and height (b) can be changed for better suiting Your driving requirements. To effect these operations, remove the upper screw (3), upper clamp (1), lower screw (4) then lower clamp (2). a) Handlebar position change Turn the lower clamp (2) 180°...
Page 69: Handlebar Position Change (Smr 450-R)
SETTINGS AND ADJUSTMENTS Handlebar position change (SMR 450-R) The handlebar can be moved to suit your driving style. To effect these operations, remove the upper screw (3), upper clamp (1), lower screw (4) then lower clamp (2). Turn the lower clamp (2) 180° to move forward or backward (10mm- 0.04in.) the handlebar position with respect to the original setup.
Page 70: Checking The Fuel Hose
SETTINGS AND ADJUSTMENTS Checking the fuel hose Check the hose (1) for leaks and replace it, if necessary. Remove the fuel hose as shown on page E.23-E.24. D.36 Part. N. 8000 B0148 (02-2008)
Page 71: Replacing The Muffler Deadening Material (Tc-Te-Txc-Smr)
SETTINGS AND ADJUSTMENTS Replacing the muffler deadening material (TC-TE-TXC-SMR) First turn counterclockwise fastening rear pin (1) then remove saddle, screws (2) and L.H. side panel (3). Using an 8 mm T-shaped spanner on the outside and a 10 mm T-shaped spanner on the inside, remove the locking screw (4) of the muffler.
Page 72: Replacing The Muffler Deadening Material (Smr 450-R)
SETTINGS AND ADJUSTMENTS Replacing the muffler deadening material (SMR 450-R) Remove the saddle after turning the locking back pin (1) anticlockwise, loosen the screws (2) with an 8-mm T-shaped spanner and remove the side panel (3) (do the same on the right side). Using an 8 mm T-shaped spanner on the outside and a 10 mm T-shaped spanner on the inside, remove the locking screw (4) of the muffler.
Page 73: Checking The Exhaust System
SETTINGS AND ADJUSTMENTS Checking the exhaust system Remove the exhaust system components as shown on page E.20. Check the exhaust pipe (1), (2), (3), (4) and silencer (5) for wear or damages. Replace the component, if necessary. SMR 450-R SMR 450-R Part.
Page 74 SETTINGS AND ADJUSTMENTS D.40 Part. N. 8000 B0148 (02-2008)
Page 75: General Operations
GENERAL OPERATIONS Section Part. N. 8000 B0148 (02-2008)
Page 76 GENERAL OPERATIONS FOREWORD ............E. 3 REMOVAL OF ENGINE FROM MOTORCYCLE ..E. 4 PARTIAL DISMALTEMENTS Removal of saddle and battery ........E. 15 Removal of side panels ..........E. 16 Removal of rear frame with fender (TE- SMR: with tail light) and air filter box assy ..E.
Page 77: Foreword
GENERAL OPERATIONS FOREWORD The operations described in this section are referred to the removal of the engine from the motorcycle. Nevertheless, in the case is had to effect operations on some parts of the motorcycle (as the access to the rear shock absorber, to the electric parts, to the wiring harness etc.), it can be necessary to effect some partial dismantlements.
Page 78: Removal Of Engine From Motorcycle
GENERAL OPERATIONS Removal of engine from motorcycle 1) Pages E.4-E.5: turn counterclockwise the rear fastening pin (1) and remove the saddle. Loosen the screws (2) and remove the side panels (3) and (4). TE-SMR-TXC: first remove the BLACK negative cable, then the RED positive cable (when reassembling, first connect the RED positive cable, then the BLACK negative cable);...
Page 79 GENERAL OPERATIONS TC-TXC-SMR 450-R 2) Remove the breather hose (1) from the steering axle. Turn the ring nut of the fuel tap (2) anticlockwise to stop fuel flowing and loosen the clamp (3) on the carburettor fuel pipe; remove this pipe from the carburettor and pour the remain- ing fuel into a container.
Page 80 GENERAL OPERATIONS TE-SMR 2) Remove the vent pipe (1) from the steering pin. Remove the fastening screw (2) from the fuel tank by slightly pressing upward in the front area of conveyors and release the conveyors from spoilers on radiators. Disconnect the fuel pump connector from the main cable.
Page 81 GENERAL OPERATIONS 3) TE, TC, TXC, SMR: using an 8 mm T-shaped spanner on the outside and a 10 mm T-shaped spanner on the inside, remove the locking screw (1) of the muffler (4). Remove the spring (2) and with an 8 mm T-shaped spanner remove the screw (3);...
Page 82 GENERAL OPERATIONS 3) SMR 450-R: use an 8 mm T-wrench outside and a 10 mm T-wrench inside to remove the fastening screw (1) of silencers (3) and (4). Remove the spring (2) and extract silencers (3) and (4). Remove the springs (5) that retain front pipes (6) and (7) to intermediate pipe (8).
Page 83 GENERAL OPERATIONS 4) TC-TXC: Loosen the clamps (3) and (4) that fasten the carburetor to the intake manifold and air filter box manifold. Pull back the carburetor to free it from the intake manifold and extract the carburetor from the right side of the motorcy- cle.
Page 84 GENERAL OPERATIONS 5) Place a vessel on the right side of the motorcycle, under the coolant draining screw (1). Using a 8 mm wrench, FIRST remove the screw (1) then SLOWLY open the R.H. radiator cap (2); slope the motorcycle on the right side to drain the coolant easily in the vessel.
Page 85 GENERAL OPERATIONS 6) Even if not essential, it is advisable to remove the engine lower guard (A) then place a vessel under the engine and remove the oil filler cap (1); using a 8 mm Allen wrench, remove the oil draining plug (2) and eliminate the used oil; on the L.H.
Page 86 GENERAL OPERATIONS 7) Remove the cap (1) from the spark plug. Remove the clamp (2) and detach the hose (3) from the cylinder head cover. On the L.H. side, using a 6 mm wrench, remove the rear transmission sprocket cover screws (4) and, using a 6 mm Allen wrench, remove the screws (5) that fasten guide-chain plate.
Page 87 GENERAL OPERATIONS 8) TE-SMR: disconnect the cooling fan (1) from the main wiring harness. Detach the thermoswitch (2) from the main wiring harness. Remove the two screws (3) and the coolant expansion tank (4). Part. N. 8000 B0148 (02-2008) E.13...
Page 88 GENERAL OPERATIONS 9) For the rear chain disassembling (both of the chain type without O-Rings that with rings O-Rings), remove the clip (1), the master link (2) then the chain. Using a 12 mm wrench on the L.H. side and a 10 mm wrench on the R.H. side, remove fastening bolts (3) (engine-frame).
Page 89: Removal Of Saddle And Battery
GENERAL OPERATIONS Removal of saddle and battery Turn counterclockwise the rear fastening pin (1) and remove the saddle. TE-SMR-TXC: First remove the BLACK negative cable, then the RED positive cable (when reassembling, first connect the RED positive cable and then the BLACK negative cable);...
Page 90: Removal Of Side Panels
GENERAL OPERATIONS Removal of side panels Turn rear pin (A) counterclockwise and remove the saddle from the front fasten- ing screw. Loosen the screws (2) and remove the side panels (3) and (4). E.16 Part. N. 8000 B0148 (02-2008)
Page 91: Removal Of Rear Frame With Fender
GENERAL OPERATIONS Removal of rear frame with fender (TE- SMR: with tail light) and air filter box assy. Remove the saddle and disconnect the battery (A) from the electric system as shown on page E.14. Remove the side panels as shown on page E.15. Remove the fuel tank as shown on page E.23.
Page 92 GENERAL OPERATIONS SMR 450-R: use an 8 mm T-wrench and a 10 mm T-wrench inside to remove the fastening screw (1) of silencers (3) and (4). Remove the spring (2) and ex- tract silencers (3) and (4). On the left side disconnect the electric connections from the starting motor [use an 8 mm wrench to remove the earth cable (5) and a 10 mm wrench for the nut under the rubber cap (6)], remove the clamps (A) that hold the clutch pipe and the alternator cable.
Page 93 GENERAL OPERATIONS On the right side, remove the clamp (B) from the vent pipe from the filter box; remove the pipe (C) from the cylinder head cover. Disconnect the start remote control switch (7) and the connector of the rear light from the cabling system (TE-SMR).
Page 94: Removal Of Exhaust System
GENERAL OPERATIONS Removal of exhaust system Remove the saddle as shown on page E.15. Remove the R.H. side panel as shown on page E.16. E.20 Part. N. 8000 B0148 (02-2008)
Page 95 GENERAL OPERATIONS TE, TC, TXC, SMR: use an 8 mm T-wrench outside and a 10 mm T-wrench inside to remove the fastening screw (1) of silencer (4). Remove the spring (2) and use an 8 mm T-wrench to remove also the screw (3); then extract the si- lencer (4).
Page 96 GENERAL OPERATIONS 3) SMR 450-R: use an 8 mm T-wrench outside and a 10 mm T-wrench inside to remove the fastening screw (1) of silencers (3) and (4). Remove the spring (2) and extract silencers (3) and (4). Remove the clamps (A) that the hold front pipes (6) and (7) to the intermediate pipe (8).
Page 97: Removal Of Fuel Tank, Conveyors And Spoiler
GENERAL OPERATIONS Removal of fuel tank, conveyors and spoiler Remove the saddle as described on page E.15. TC-TXC-SMR 450 R Remove the vent pipe (1) from the steering pin. Turn the ring nut of the fuel tap (2) anticlockwise to stop fuel flowing and loosen the clamp (3) on the carburettor fuel pipe;...
Page 98 GENERAL OPERATIONS TE-SMR Remove the vent pipe (1) from the fuel tank cap. Unscrew the fastening screw (6) of the fuel tank. Remove the screws (4) holding the conveyors to the tank; remove the conveyors (7), the screws (5) holding spoilers (8) to radiators. Re- move the spoilers.
Page 99: Removal Of Cooling Fan (Te-Smr), Radiators And Coolant Expansion Tank (Te-Smr)
GENERAL OPERATIONS Removal of cooling fan (TE-SMR), radiators and coolant expansion tank (TE-SMR) TE-SMR: disconnect the cooling fan (1) from the main wiring harness; remove the fan from its holding plate. Detach the thermoswitch (2) from the main wiring harness. Remove the grid (3), detach the breather hose (4), the other hoses (A) from the radiators, remove the three screws (5) and the R.H.
Page 100: Removal Of Electronic Power Unit C.d.i., Electronic Coil, Voltage Regulator And Clutch Hose
GENERAL OPERATIONS Removal of electronic power unit CDI, ignition coil, voltage regulator and clutch hose Remove: saddle, battery, side panels and fuel tank as shown on pages E.15, E.16, E.23. Remove the connector from electronic power unit CDI (1) and the electronic power unit complete with elastic holder from the frame.
Page 101: Engine Disassembly
ENGINE DISASSEMBLY Section Part. N. 8000 B0148 (02-2008)
Page 102 ENGINE DISASSEMBLY Cylinder head cover disassembly ......Camshaft disassembly ..........Water pump body disassembly ......... Cylinder head disassembly ........Valve disassembly ............ Cylinder disassembly ..........F.10 Piston disassembly ........... F.10 Flywheel disassembly ..........F.11 Kick start pedal disassembly (TC, TE, TXC) ....F.12 Transmission cover disassembly ......
Page 103 ENGINE DISASSEMBLY SMR 450 R Part. N. 8000 B0148 (02-2008)
Page 104: Cylinder Head Cover Disassembly
ENGINE DISASSEMBLY Cylinder head cover disassembly Remove the four fastening screws (8 mm wrench) and the cylinder head cover together with the relative gasket. Camshaft disassembly Remove the six fastening screws (8 mm wrench) and the alternator cover. Using a 17mm wrench, position the piston at T.D.C. at the end of the compression stroke (in this condition, the mark on the cylinder head is aligned with the two marks on the idle gear of the camshafts, as shown in the figure on page F.7).
Page 105 ENGINE DISASSEMBLY Excluded SMR 450-R: Loosen the cam-chain tensioner (10 mm wrench) then remove the two fastening screws (8 mm wrench) and the cam-chain tensioner assembly. SMR 450-R: ease the tension of the chain adjuster (12 mm wrench) and remove it with its support by removing the two fastening screws (8 mm wrench).
Page 106: Water Pump Body Disassembly
ENGINE DISASSEMBLY Remove the retaining pin and the valve lifter. Water pump body disassembly Loosen the hose water pump-cylinder head clamp and remove the hose from cylinder head. Remove the two fastening screws (8 mm wrench) and the water pump body from the cylinder head. Remove the timing driven gear (Water pump rotor fastening nut: 3,9 Nm/ 0,4 Kgm/ 2.9 ft/lb+LOCTITE 243).
Page 107: Cylinder Head Disassembly
ENGINE DISASSEMBLY Cylinder head disassembly TE-SMR: remove the coolant fluid temperature sensor with its O-ring. Remove the two screws on the L.H.S (8 mm wrench) then the front nut under the cylinder head (13 mm wrench). Remove the four inner screws on the cylinder head (10 mm wrench) whilst following a cross-over pattern.
Page 108: Valve Disassembly
ENGINE DISASSEMBLY Valve disassembly Using a hook, remove the rocker-arm spacer clip. Remove the fastening screw (5 mm wrench) and the chain slider. Remove the fastening screws (6 mm wrench) then the rocker-arm axles and the rocker-arms themselves. Part. N. 8000 B0148 (02-2008)
Page 109 ENGINE DISASSEMBLY Using a tweezer, remove the valve adjusting pads. Use a valve spring compressor tool to remove the valves. Be careful not to damage the gasket surfaces or the combustion chamber. Make sure that the valve spring compressor is always straight, otherwise the valve stem can bend.
Page 110: Cylinder Disassembly
ENGINE DISASSEMBLY Cylinder disassembly After having removed the cylinder head gasket, remove the two dowel bushings and the cylinder itself. Piston disassembly Remove the piston pin clips then the piston pin and the piston. F.10 Part. N. 8000 B0148 (02-2008)
Page 111: Flywheel Disassembly
ENGINE DISASSEMBLY Flywheel disassembly Maintain the rotor immobilized and remove the rotor nut (17 mm wrench). Remove the rotor using the puller (code no. 8000 A1559 for TC-TXC and 8000 B0144 for TE-SMR). Remove the timing system chain. If the chain slider is worn, remove the fastening screw then the chain slider in order to replace it.
Page 112: Kick Start Pedal Disassembly (Tc-Te-Txc)
ENGINE DISASSEMBLY Kick start pedal disassembly (TC-TE-TXC) Remove kick start pedal fastening screw (4 mm wrench), washer and kick start pedal. F.12 Part. N. 8000 B0148 (02-2008)
Page 113: Transmission Cover Disassembly
ENGINE DISASSEMBLY Transmission cover disassembly Remove the twelve cover fastening screws (8 mm wrench) then the transmission cover. Remove gasket, dowel bushings and O-Rings. Clutch disassembly (TE-TXC-TC; SMR 450-510) Remove the six screws (12) that fasten the springs (11) (5 mm wrench, whilst following a cross-over pattern and in steps).
Page 114 ENGINE DISASSEMBLY Remove the clutch control rod (13). Bend back tabs of the hub washer (6) and holding the clutch hub nut (27 mm wrench), remove the nut (7) using the clutch disassembly tool (A) (code no. 8000 79015). Remove the washer (6), the clutch hub (5), the grooved washer (4), the clutch housing (3), the bushing (2) and the washer (1).
Page 115: Clutch Disassembly (Smr 450 R)
ENGINE DISASSEMBLY Clutch disassembly (SMR 450-R) Use a 4 mm hex wrench to loosen the six screws 9) and their notched washers (8) and remove the support (30) along with the washer (33) and the thrust bearing (32) Remove the clutch control pin (31), the nut (11) and the washer (12). Insert the tool provided (a) in the seat on the hub (29).
Page 116 ENGINE DISASSEMBLY F.16 Part. N. 8000 B0148 (02-2008)
Page 117: Kick Start Components Disassembly (Tc-Te-Txc)
ENGINE DISASSEMBLY Kick start components disassembly (TC-TE-TXC) Release spring (1) from seat on crankcase (A) and remove kick starter shaft assy (2). Remove circlip (3), washer (4) and starting idle gear (5). Part. N. 8000 B0148 (02-2008) F.17...
Page 118: Electric Starting System Disassembly (Te, Txc; Smr 450-510)
ENGINE DISASSEMBLY Electric starting system disassembly (TE, TXC; SMR 450-510) Remove the four fastening screws (8 mm wrench) and starting gears retaining plate. Extract the starting gear and starting idle gear. F.18 Part. N. 8000 B0148 (02-2008)
Page 119: Oil Pump Disassembly
ENGINE DISASSEMBLY Remove the two fastening screws (8 mm wrench) and extract the starting motor. Oil pump disassembly Using pointed pliers, remove the oil pump idle gear circlip, then the idle gear. Remove the three fastening screws (8 mm wrench) and extract: the oil pump body, the gasket, the two bushes and the oil pump.
Page 120: Gear Control Pedal And Gear Shifter Disassembly
ENGINE DISASSEMBLY Gear control pedal and gear shifter disassembly Make a mark on the shaft showing the position of the gear control pedal to make the reassembly easier. Remove the fastening screw (8 mm wrench) and the gear control pedal from the gear shifter shaft. Extract, from the R.H.S., the gear shifter shaft and the bushing from the ratchet wheel.
Page 121 ENGINE DISASSEMBLY Remove the gear shifter drum fastening bolt (5 mm wrench). Remove the fastening screw and the gears pawl together with its spring. Pay attention for not to lose the roller. Part. N. 8000 B0148 (02-2008) F.21...
Page 122: Primary Transmission Driving Gear Disassembly
ENGINE DISASSEMBLY Primary trasmission driving gear disassembly Place an aluminium shim between the teeth of the free-wheel gear (in order to prevent its rotation) and loosen the fastening nut (27 mm wrench, left side thread nut). Remove the driving gear and the free-wheel (mark the reassembly direction), the free-wheel gear, the needle bearing, the washer and the spacer.
Page 123: Crankcase Disassembly
ENGINE DISASSEMBLY Crankcase disassembly Remove the circlip from the secondary shaft (R.H.S.). Remove the drive sprocket circlip and the drive sprocket from the secondary shaft. Extract the drive sprocket spacer. Remove the twelve screws from the L.H. crankcase side (8 mm wrench). Part.
Page 124: Gearbox Disassembly
ENGINE DISASSEMBLY Fix the crankcase puller (code no. 1517 94702) in the holes of the flywheel cover and pull off the L.H. crankcase side. During this operation, lightly strike the secondary shaft at intervals using a rubber hammer to avoid the crankcase from getting stuck. Gearbox disassembly Remove the fork pins, the forks and the selector drum so they do not interfere with each other: the following pictures show the correct disassembling sequence.
Page 125 ENGINE DISASSEMBLY (Primary shaft fork pin). (Selector drum). (Primary shaft fork). Extract the primary and secondary shaft assemblies. Part. N. 8000 B0148 (02-2008) F.25...
Page 126: Crankshaft And Counter Balancing Shaft Disassembly (Smr 450-510)
ENGINE DISASSEMBLY Crankshaft and counter balancing shaft disassembly (SMR 450-510) Place the puller bushing on the R.H.S. of the crankshaft. Fix the puller on the crankcase half and push out th crankshaft (strike lightly the layshaft with a rubber hammer in order to avoid it from getting stuck). F.26 Part.
Page 127 ENGINE DISASSEMBLY Place the layshaft idle gear disassembly tool and extract the idle gear. Place the crankshaft in a suitable position and press the crankpin out of one of the crankshaft flywheels. Remove the connecting rod with the needle bearing from the flywheel then turn the flywheel over half and press out the crankpin.
Page 128 ENGINE DISASSEMBLY F.28 Part. N. 8000 B0148 (02-2008)
Page 129: Engine Overhauling
ENGINE OVERHAULING Cleaning of components ........... Assemblies ............... Cylinder head ............Recutting the valve seats .......... Valve guides ............. Replacement of valve guides ........Valve ................ Valve spring .............. Installation of valves ..........Inspection of rocker arm ..........Starter decompressor ..........Camshaft ..............
Page 130: Cleaning Of Components
ENGINE OVERHAULING Cleaning of components All component must be cleaned with petrol and dried with compressed air. During this operation inflammable vapours burst out and metal particles may be violently ejected. Consequently, it is recommended to work in a room free from bare flames or sparks and that the operator wears goggles. Assemblies For a good and efficient engine operation, it is essential that all assemblies are within the tolerances prescribed.
Page 131: Recutting The Valve Seats
ENGINE OVERHAULING Recutting the valve seats Clean carbon and deposits from the valves. Apply some “Prussian blue” to the valve face and lap it against the seat with a suitable lapping tool. Remove the valve and measure the width “X” of the contact surface. If the width exceeds 0.06 in.
Page 132 ENGINE OVERHAULING Check the valve seat, if there are any low spots or other damage, the seat must be recut. It is important that the contact surface on the valve is in the right place on the valve. Use marking colour to determine where is the contact surface. The contact surface should be 0.02 in.
Page 133: Valve Guides
ENGINE OVERHAULING Valve guides Carry out a careful visual check of the valve guides. The valve guides should be checked for wear by measuring the clearance be- tween the valve stem and valve guide; use a dial gauge and measure the clear- ances on the “x”...
Page 134: Valve
ENGINE OVERHAULING Use a suitable reamer and cutting oil when the valve guide is reamed. Turn the reamer when it is removed, so that no longitudinal scratches occur. When a valve guide is replaced, the valve seat must be refaced Valve Check that the valve stem and contact surfaces are in good condition.
Page 135: Installation Of Valves
ENGINE OVERHAULING Installation of valves Lubricate the valve guides and valve stem with oil when the valve is installed. Install the seal ring, the springs and the cup. Use tool code 8000 39521 to compress the valve springs and can install halves cones.
Page 136: Inspection Of Rocker Arm
ENGINE OVERHAULING Tap gently on the valve stem with a plastic hammer to make the cotters seat. Hit straight on the top of the valve stem so that the valve stem doesn’t get out of true. Inspection of rocker arm Check the clearance between the rockerarm and the rocker arm shaft.
Page 137: Camshaft
ENGINE OVERHAULING Camshaft Check that cam surfaces are scored, stepped, grooved etc. Insert the camshaft between two references and then check deviation using two comparators. Wear limit: 0.0039 in. Check that the cams are in good conditions, without wear or deformation. Cam height “H”...
Page 138: Camshaft Chain And Gearing
ENGINE OVERHAULING Camshaft chain and gearing At every engine overhaul the wear of the camshaft gear teeth and the chain rollers should be checked. If the teeth are badly worn then replace the three components. Hold the chain taut and check the length of 20 links (21 pins). If any one of three cam drive components is found to be worn then all three components should be replaced.
Page 139: Cylinder
ENGINE OVERHAULING Cylinder The cylinder liner bore should be completely smooth, without grooving or scor- ing. To obtain the taper and the ovality of the cylinder liner bore take measure- ments at three different heights and in two positions at 90° to each other. Max taper (wear limit): 0.0019 in.
Page 140: Cylinder-Piston Fitting
ENGINE OVERHAULING Cylinder piston fitting The cylinder and piston are supplied matched; if by chance cylinder liners and pistons become mismatched then measure their diameters as follows: Cylinder bore Use an internal micrometer (Dc) and take the reading at “A” distance from the top 0.80 in.
Page 141: Gudgeon Pin
ENGINE OVERHAULING Gudgeon pin The gudgeon pin should be perfectly smooth without scoring, grooving or bluish discoloration caused by overheating. Part. N. 8000 B0148 (02-2008) G.13...
Page 142: Piston Rings
ENGINE OVERHAULING Piston rings The piston rings should not show signs of excessive wear or scoring. Spacer pistons are supplied complete with rings and gudgeon pins. Piston rings/cylinder clearance Introduce the ring into the lower part of the cylinder. (i.e. where there is least wear), ensure that the ring is squared up and then check the ring end gap.
Page 143: Piston Ring/Piston Rings Groove Clearance
ENGINE OVERHAULING Piston ring/Piston rings groove clearance Use a feeler gauge to check the axial play (H) of the rings in the groove. The manufacturer mark, if it is present on the piston ring, must be turned upwards. PISTON RING CUT SETTING PISTON RING CUT SETTING Gudgeon pin/conrod small end clearance (A): 0.00047÷0.00106 in.
Page 144: Connecting Rod Big End Side Clearance
ENGINE OVERHAULING Connetting rod big end side clearance STANDARD LIMITE DI SERVIZIO 0,300÷0,677 mm 0,75 mm (0.012÷0.027 in) (0.03 in) Crankshaft Main joiurnals must not present any scores, or grooves; their threads, key seats and slots have to be in good conditions. Crankshaft run-out STANDARD WEAR LIMIT...
Page 145: Connecting Rod Small End Bush Replacement
ENGINE OVERHAULING Connecting rod small end bush replacement The bush should be replaced using a correct size punch and drift. Before the assembly, smear the bush outside surface with molybdenum disulfide grease. Insert the bush from the side marked with the elephant and check that the bush holes coincide with the ones of the rod.
Page 146: Clutch Unit
ENGINE OVERHAULING Clutch unit Check that all clutch unit components are in good condition. The clutch discs should not be burnt or scored. Check the thickness of the clutch lining discs. Thickness of new plate: 0.118 in. Wear limit: 0.114 in. Check the distortion of each plate (both lined and unlined) by resting on a flat surface;...
Page 147 ENGINE OVERHAULING Clutch checking 1- Clutch disc pressure plate, 2- Clutch plate, 3- Clutch disengagement rod, 4- Clutch slave cylinder: Check that these parts are not worn or broken. lf not, replace the part. 5- Clutch disc hub: check the housing grooves of discs without friction material for wear or failure. If worn or breaked, replace the part. 6- Clutch disc housing: Check the housing grooves of discs with friction material for wear or failure.
Page 148: Oil Pump
ENGINE OVERHAULING Oil pump If they were not previously removed, remove from pump: screw (1), cover (2), shaft (3), and rotors (4) and (5). Clean the rotors and ressemble the above mentioned elements. Check that the pump mounting surface is not scored, grooved or pitted.
Page 149: Selector Drum
ENGINE OVERHAULING Selector drum Check grooves "A" for wear or dents: if grooves are worn or dented, replace drum selector. Check drum selector for bent or damage: if bent, worn or damaged, replace Carburettor overhauling (TC-TXC-SMR 450 R) Thoroughly wash with petrol and dry with compressed air all carburetor componets. Thoroughly clean all jets and ducts with com- pressed air only.
Page 150: Keihin" Carburettor Adjustment (Tc-Txc-Smr 450 R)
ENGINE OVERHAULING "Keihin" carburettor adjustment (TC-TXC-SMR 450 R) Adjust the carburettor with warm engine and with the throttle in closed position. Work as follows: - Turn slow running adjusting screw (1) on the left side of the bike, , until the engine is turning over at fairly high rpm (turn the screw clockwise to increase the rpm, and anticlockwise to descrease the rpm).
Page 151 ENGINE OVERHAULING Carburettor checking 1. Inspect: - Carburetor body Contamination: Clean NOTE: - Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. - Never use a wire. 2. Inspect: - Main jet (1) - Pilot jet (2) - Needle jet (9) - Pilot screw (7)
Page 152 ENGINE OVERHAULING NEEDLE VALVE Inspect needle valve (9) and valve seat (c) Grooved wear (a): Replace. Dust (b): Clean. THROTTLE VALVE Check for free movement. Stick: Repair or replace. Insert the throttle valve (5) into the carburetor body, and check for free movement. JET NEEDLE Inspect jet needle (6).
Page 153 ENGINE OVERHAULING FLOAT HEIGHT Measure: - Float height (a). Out of specification: Adjust. Float height: 8 mm (0.31 in.) Measurement and adjustment steps: - Hold the carburetor in an upside down position. NOTE: - Slowly tilt the carburetor in the opposite direction, then take the measurement when the needle valve aligns with the float arm.
Page 154 ENGINE OVERHAULING Fuel draining (TC-TXC-SMR 450 R) As the fuel has to be drained from the float chamber, close the fuel tap by tightening the ring nut (A). Place the hose (3) in a vessel, loosen the drain screw (4) on the float chamber lower side, then tighten the screw again after the fuel drain.
Page 155: Engine Reassembly
ENGINE REASSEMBLY Section Part. N. 8000 B0148 (02-2008)
Page 156 ENGINE REASSEMBLY General directions ............. Instructions for assembly and lubrication ....H.4÷H.13 Reassembly of crankshaft ......... H.14 Reassembly of counter balancing shaft driving gear (SMR 450-510) ............H.16 Reassembly of transmission (TE-TXC-SMR) .... H.17 Reassembly of transmission (TC) ......H.18 Reassembly of crankcase .........
Page 157: General Directions
ENGINE REASSEMBLY General directions For a correct re-assembly follow in the adverse sense what shown for dismantling, however paying a special attention to every operation we specifically mention. We remind you that gaskets, oil rings, clamps and sealing washer in deformable material (as copper, aluminium, fibers, etc.) and self-locking nuts havealways to be renewed.
Page 158: Instructions For Assembly And Lubrication
ENGINE REASSEMBLY Instructions for assembly and lubrication CRANKSHAFT, COUNTER BALANCING SHAFT- ALTERNATOR- LUBRICATION- L.H. CRANKCASE Part. N. 8000 B0148 (02-2008)
Page 159 ENGINE REASSEMBLY Tightening torques M14x1 (+LOCTITE 243) 20 Nm- 2 Kgm- 14.5 ft/lb M6x1 11 Nm- 1,1 Kgm- 7.9 ft/lb M16x1,5 25 Nm- 2,55 Kgm- 18.4 ft/lb M14x1,5 25 Nm- 2,55 Kgm- 18.4 ft/lb M12x1 75 Nm- 7,65 Kgm- 55.3 ft/lb M6x1 (+LOCTITE 272) 8 Nm- 0,8 Kgm- 5.8 ft/lb M5x0,8 (+LOCTITE 272)
Page 160 ENGINE REASSEMBLY Instructions for assembly and lubrication TRANSMISSION, GEARSHIFT MECHANISM Part. N. 8000 B0148 (02-2008)
Page 161 ENGINE REASSEMBLY Tightening torques 22- M8x1,25 (+LOCTITE 243) 20 Nm- 2 Kgm- 14.5 ft/lb 23- M6x1 (+LOCTITE 243) 8 Nm- 0,8 Kgm- 5.8 ft/lb 24- M5x0,8 6 Nm- 0,6 Kgm- 4.3 ft/lb STANDARD ft/lb M5x0,8 6 Nm- 0,6 Kgm- 4.3 ft/l M6x1 8 Nm-0,8 Kgm- 5.8...
Page 162 ENGINE REASSEMBLY Instructions for assembly and lubrication CLUTCH- STARTING SYSTEM- LUBRICATION- R.H. CRANKCASE Part. N. 8000 B0148 (02-2008)
Page 163 ENGINE REASSEMBLY Tightening torques M18x1,25 180 Nm- 18 Kgm- 130 ft/lb M6x1 (+LOCTITE 272) 11 Nm- 1,1 Kgm- 7.9 ft/lb M6x1 8 Nm- 0,8 Kgm- 5.8 ft/lb M18x1 75 Nm- 7,6 Kgm- 55 ft/lb M6x1 (+LOCTITE 243) 8 Nm- 0,8 Kgm- 5.8 ft/lb STANDARD ft/lb M5x0,8...
Page 164 ENGINE REASSEMBLY Instructions for assembly and lubrication CLUTCH- STARTING SYSTEM- LUBRICATION- R.H. CRANKCASE H.10 Part. N. 8000 B0148 (02-2008)
Page 165 ENGINE REASSEMBLY Tightening torques M18x1,25 180 Nm- 18 Kgm- 130 ft/lb M6x1 (+LOCTITE 272) 11 Nm- 1,1 Kgm- 7.9 ft/lb M6x1 8 Nm- 0,8 Kgm- 5.8 ft/lb M18x1 75 Nm- 7,6 Kgm- 55 ft/lb M6x1 (+LOCTITE 243) 8 Nm- 0,8 Kgm- 5.8 ft/lb STANDARD ft/lb M5x0,8...
Page 166 ENGINE REASSEMBLY Instructions for assembly and lubrication CYLINDER HEAD - CYLINDER - PISTON - TIMING SYSTEM - WATER PUMP - SPARK PLUG H.12 Part. N. 8000 B0148 (02-2008)
Page 167 ENGINE REASSEMBLY Tightening torques M8x1,25 15 Nm- 1,5 Kgm- 10.8 ft/lb M10x1,5 (+MOLIKOTE HSC) 37 Nm+90°- 3.8 Nm+90°- 27.5 ft/lb+90° M6x1 12 Nm- 1,2 Kgm- 8.7 ft/lb M14x1,5 (+LOCTITE 243) 25 Nm- 2,55 Kgm- 18.4 ft/lb M6x1 8 Nm- 0,8 Kgm- 5.8 ft/lb M10x1 15 Nm- 1,5 Kgm- 10.8 ft/lb M6x1 (+LOCTITE 243)
Page 168 ENGINE REASSEMBLY Reassembly of crankshaft Carefully clean the lubrication ducts. Lubricate the crankpin with motor oil and place it in the flywheel. Fit the roller bearing and lubricate with engine oil. Fit the connecting rod and the second half-flywheel. See that the half-flywheels are aligned using a triangle. Join all the elements using a press.
Page 169 ENGINE REASSEMBLY Check the connecting rod side float into the flywheels. It must be 0,4÷0,5 mm A = 0,4 ÷ 0,5 mm (0.0157÷0.0197 in). (0,0157÷0,0197 in.) Check the alignment of the crankshaft between centers. Runout may not exceed 0.02 mm (0.0008 in) at the bearing positions. Make an initial alignment of the flywheel using a copper hammer.
Page 170: Reassembly Of Counter Balancing Shaft Driving Gear (Smr 450-510)
ENGINE REASSEMBLY Reassembly of counter balancing shaft driving gear (SMR 450-510) Put the flywheel on the press as shown in picture (with the left half-flywheel surface on the press plane) and assemble the layshaft driving gear (2) on the flywheel (use a 4 mm - 0.16 in.
Page 171: Reassembly Of Transmission (Te-Txc-Smr)
ENGINE REASSEMBLY Reassembly of transmission If the gear shafts have been disassembled, the following paragraphs show the reassembly sequence. 6 Speed transmission (TE, TXC, SMR) Main shaft Auxiliary shaft Main shaft complete Main shaft Mount the bushing, the 5th gear on the bushing and after that the washer and the circlip.
Page 172 ENGINE REASSEMBLY Auxiliary shaft Mount the plug and the bush. Mount 2nd gear, the washer and the circlip. Mount the 6th gear and the circlip. Mount the washer. Fit the washer into the 3rd gear. Mount the 3rd gear, the washer and the circlip. Apply “MOLYKOTE G-n plus” under 3rd gear. Mount the washer.
Page 173 ENGINE REASSEMBLY Auxiliary shaft Main shaft complete Main shaft Mount the bushing, the 5th gear on the bushing and after that the washer and the circlip. The washer should be between the gear and the circlip. Mount the 3rd gear, the circlip and the washer. Mount the 4th gear. Mount the spacer (only for 400-450-510 cc).
Page 174: Reassembly Of Crankcase
ENGINE REASSEMBLY Reassembly of crankcase Clean the faces between the half-cases then support the half-case using a suitable tool code no. 8A00 90662. Warm up at approx. 125°C (257°F), and fit the ball bearings into the two half-cases with a suitable tool (crankcase bearings plates screws: 11Nm/ 1,1 Kgm/ 7.9 ft-lb + LOCTITE 272).
Page 175 ENGINE REASSEMBLY Make sure that the mounting of the bushes is correct (apply grease on the bushes). Lubricate with motor oil the surfaces that fit in the gear wheels. Put the selector drum in its place. Part. N. 8000 B0148 (02-2008) H.21...
Page 176 ENGINE REASSEMBLY Install the gear striker shafts. Make sure that the gear strikers move easily on the shafts. Check gearbox operation by turning the gear selector drum. Lubricate with motor oil the crankshaft journal with grease and assemble the shaft in the right half-crankcase.
Page 177 ENGINE REASSEMBLY Mount contemporarily the crankshaft and the counter balancing shaft aligning the chasings on the gears (the contemporary assembling of the crankshaft and the counter balancing shaft is obligatory on 400-450-510models). Mount the distance washer on the crankshaft. Smear the union surface of the left half case with “LOCTITE 510”; warm the crankshaft bearing seat and fit the half case.
Page 178: Reassembly Of Gearshift Mechanism, Electric Starting System And Oil Pump
ENGINE REASSEMBLY Reassembly of gearshift mechanism, electric starting system and oil pump Assembly of the gearshift mechanism should be done in reverse order to disassembly. Tighten the driving gear on the crankshaft to the required torque (180 Nm-18 Kgm- 130 ft/lb + LOCTITE 243). Mount the starting driven gear.
Page 179 ENGINE REASSEMBLY Mount the oil pump (8 Nm-0,8 Kgm-5.8 ft/lb). Mount the oil pump driven gear and the circlip. Mount the circlip on the auxiliary shaft. Reassembly of gear shaft Check the shaft for wear in the gear shift mechanism groove. Mount the spring and lubricate the shaft with motor oil.
Page 180: Reassembly Of Kick Start Components (Te-Tc-Txc)
ENGINE REASSEMBLY Reassembly of kick start components (TE-TC-TXC) Assemble the shaft assy. (2) in the seat (B) on crankcase (A) then place the hook return spring (1) in the crankcase hole (D). Assemble idling gear (5), washer (4) and circlip (3). H.26 Part.
Page 181: Reassembly Of Clutch (Te-Txc-Tc; Smr 450-510)
ENGINE REASSEMBLY Reassembly of clutch (TE-TXC-TC; SMR 450-510) Mount the washer (1), the bush (2) and the clutch housing (3). Mount the toothed washer (4), the hub (5), the tab washer (6) and the nut (7). Tighten the nut to the required torque (75 Nm-7,6 Kgm- 55 ft/lb; place an aluminium shim between the teeth of the primary drive gears, in order to prevent its rotation).
Page 182: Reassembly Of Clutch (Smr 450-R)
ENGINE REASSEMBLY Reassembly of clutch (SMR 450-R) If the clutch group is completely disassembled, assemble it as follows: - preassemble the hub group (B) by placing the 6 balls (14) on the bottom of the hub splines (4), apply a small quantity of grease and fix the drum (1) on the hub in idle position with a M6x15 mm screw (A);...
Page 183 ENGINE REASSEMBLY TOOLS Part. N. 8000 B0148 (02-2008) H.29...
Page 184 ENGINE REASSEMBLY Reassemble the pinion spacer with the O-ring housing turned inwards. : Be careful not to damage O-Ring on the spline shaft. Mount the pinion and the circlip. H.30 Part. N. 8000 B0148 (02-2008)
Page 185: Reassembly Of Timing System Drive Gear And Chain
ENGINE REASSEMBLY Reassembly of timing system drive gear and chain The key for the cam chain sprocket must be installed with the cut end out towards the drive gear. Lubricate the cam-chain sprocket and install it on the crankshaft using a drift. Reassemble the cam drive chain.
Page 186: Reassembly Of Flywheel
ENGINE REASSEMBLY Reassembly of flywheel Clean the flywheel rotor removing any debris gathered in centrifugated oil and attracted to the magnets. Reassembly the Woodruff key and the rotor on the crankshaft. Holding the rotor (on the R.H. side place an aluminium shim between the teeth of the primary drive gears, in order to prevent its rotation), mount the nut and tighten it to 75 Nm-7,65 Kgm- 55.3 ft/lb.
Page 187: Reassembly Of Transmission Cover
ENGINE REASSEMBLY Reassembly of transmission cover If the centering bushes have been removed, reassemble them in the crankcase. Mount the gasket and the O-rings. : Check that the engine oil hole is not obstructed. Mount the transmission cover and tighten the twelve screws (8 Nm-0,8 Kgm- 5.8 ft/ lb).
Page 188 ENGINE REASSEMBLY Fit the piston rings as shown in the picture. The manufacturer mark, if it is present on the piston ring, must be turned upwards. PISTON RING CUT SETTING PISTON RING CUT SETTING *: "d" cut posistion Assembly of piston and cylinder Install a new base gasket.
Page 189 ENGINE REASSEMBLY Assembly of cylinder head For valves reassembly see page G.15. If the rocker arm pivots have been disassembled, tighten the pivots fastening screws to 25 Nm-2,55 Kgm-18.4 ft/lb (+LOCTITE 243), when reassembling. Always use a new gasket head when assembling: see “Cylinder head gasket selection chart”...
Page 190 ENGINE REASSEMBLY Tighten the two L.h. external screws (8 Nm-0,8 Kgm- 5.8 ft/lb) and the lower nuts (15 Nm-1,5 Kgm- 10.8 ft/lb). Reassemble the lubrication hose on the transmission cover (15 Nm-1,5 Kgm-10.8 ft/lb). If the intake manifold (A) of the cylinder head has been dismantled, tighten the two screws to 3 Nm-0,3 Kgm-2.2 ft/lb+LOCTITE 272.
Page 191 ENGINE REASSEMBLY Position the piston at TDC at the end of the compression stroke. Put the timing gear in seat without rotating the crankshaft and mount the chain. Mount the water pump (8 Nm-0,8 Kgm-5.8 ft/lb+LOCTITE 542), without rotating the crankshaft, in order to obtain the perfect alignement of the twin chasing on the gear to the spline on head face (see picture) (tighten water pump fastening screws to 8 Nm-0,8 Kgm- 5.8 ft/lb+LOCTITE 542).
Page 192 ENGINE REASSEMBLY Assembly of cam-chain tensioner (TE-TC-TXC-SMR) TE-TC-TXC-SMR Back the pin for tightening the chain, reassemble the cam-chain tensioner with its two screws (8 Nm-0,8 Kgm-5.8 ft/lb). Insert the spring, the washer and the rear bolt (5 Nm-0,5 Kgm-3.6 ft/lb). Assembly of cam-chain tensioner (SMR 450-R) Retreat the chain adjuster pin, reassemble the chain adjuster with the support by means of two fastening screws (8 Nm-0.8 Kgm-5.8 ft/lb).
Page 193 ENGINE REASSEMBLY Assembly of valve lifter Mount the valve lifter in the head and, turning it in lift position, insert the retaining pin. Reassemble the lubrication tube. Lubricate the cammes abundantly with motor oil. Reassemble the four U-bolts for fixing the camshaft and tight the screws to 12 Nm- 1,2 Kgm-8.7 ft/lb.
Page 194 ENGINE REASSEMBLY Turn the crankshaft a few times in order to set the timing elements, bring the piston to Top Dead Center (in this condition, the mark on the cylinder head is aligned with the two marks on the idle gear of the camshafts, as shown in the figure). Check, by means of a feeler gauge, that the valve clearance is 0,10-0,15 mm (0.004-0.006 in.) for INTAKE and 0,15-0,20 mm (0.006-0.008 in.) for EXHAUST.
Page 195: Reassembly Of Cylinder Head Cover, Spark Plug, Lubrication Hose
ENGINE REASSEMBLY Reassembly of cylinder head cover, spark plug, lubrication hose Mount the cylinder head cover and its gasket on the cylinder head. Tight the screws whilst following a cross-over pattern and in steps (8 Nm-0,8 Kgm-5.8 ft/lb). Assemble the spark plug (10÷12 Nm-1÷1,23 Kgm-7.2÷8.9 ft/lb) and the lubrication hose (15 Nm-1,5 Kgm-10.8 ft/lb).
Page 196: Reassembly Of Flywhel Cover
ENGINE REASSEMBLY Fit a new O-ring and remount the neutral indicator locking the two fastening screws (6 Nm-0,6 Kgm-4.3 ft/lb+LOCTITE 243). Reassembly of flywheel cover Mount the stator plate so its mark and stator cover mark are aligned and tighten the two stator fastening screws (8 Nm-0,8 Kgm- 5.8 ft/lb+LOCTITE 272).
Page 197: Reassembly Of The Engine Oil Filters And Drain Plug
ENGINE REASSEMBLY Reassembly of gearshift pedal and the kick start pedal Mount the gearshift pedal (tighten fastening screw to 8 Nm-0,8 Kgm- 5.8 ft/lb). Check that the control pedal is not damaged. Reassemble kick start pedal (TE-TC- TXC) (8 Nm-0,8 Kgm-5.8 ft/lb); verify that the start pedal does not touch the crankcase cover.
Page 198: Engine And Motorcycle Reassembly
ENGINE REASSEMBLY ENGINE AND MOTORCYCLE REASSEMBLY Reassemble the engine and the motorcycle components previously removed, according to the following order. Place the engine on the motorcycle. Insert the rear swing arm axle on the L.H. side then screw the respective nut using a 22 mm wrench (122,5 Nm-12,5 Kgm-90.3 ft/lb).
Page 199 ENGINE REASSEMBLY Part. N. 8000 B0148 (02-2008) H.45...
Page 200: Cylinder Head Gasket Selection Chart
ENGINE REASSEMBLY CYLINDER HEAD GASKET SELECTION CHART Position the piston to T.D.C. at the end of the compression stroke, measure the distance "A" between piston crown and cylinder head face then choose the gasket as shown in the table below. CONDITION (see picture) “A”...
Page 201: Front Suspension
FRONT SUSPENSION Section Part. N. 8000 B0148 (02-2008)
Page 202 FRONT SUSPENSION Front suspension (TE-SMR) ........Instructions for use of Ø45USD fork (TE-SMR) ..............Components of the fork ..........General rules for a proper overhauling ...... Instructions for clamping in the vice ......Problems - Possible causes - Solutions ....General maintenance operations ......
Page 203 FRONT SUSPENSION TC-TXC SMR 450-R Part. N. 8000 B0148 (02-2008)
Page 204: Front Suspension (Te-Smr)
FRONT SUSPENSION Front suspension (TE-SMR) The front suspension unit is a MARZOCCHI “U.S.D.” telescopic hydraulic fork with advanced axle; the diameter of the stem is 50 mm . The thermal excursion of the wheel on the legs axis is 300 mm (TE) e 250 mm (SMR). Part.
Page 205: Instructions For Use Of Ø45Usd Fork (Te-Smr)
FRONT SUSPENSION INSTRUCTIONS FOR USE OF Ø45USD FORK (TE-SMR) GENERAL Telehydraulic upside down fork, with advanced axle. This fork is based on a multivalve damping system and spring for static load. The compression hydraulic damping is made through a special valve located in each fork’s leg lower area, whereas the rebound hydraulic damping is made through a cartridge located inside each stanchion.
Page 206: Components Of The Fork
FRONT SUSPENSION COMPONENTS OF THE FORK The fork is based on a multivalve damping system that is exactly the same on both fork’s legs. Each fork’s leg is therefore a complete suspension system which you must refer to when adjusting any part of the fork. 5) Stanchi on tube 8) Lower sliding bushing 9) Spri ng cup...
Page 207: General Rules For A Proper Overhauling
FRONT SUSPENSION GENERAL RULES FOR A PROPER OVERHAULING • After a complete breakdown, always use new, original Marzocchi seals when reassembling. • To tighten two bolts or nuts that are near each other, always follow the sequence 1- 2- 1 using a torque wrench; respect the indicated tightening torques (see Table 1 - Tightening Torques).
Page 208: Problems - Possible Causes - Solutions
FRONT SUSPENSION Problems - Possible causes - Solutions This paragraph indicates some of the problems which may arise during the working life of the fork, as well as the possible causes of these problems and any solutions to the same. Always consult this Table before working on the fork. PROBLEM CAUSE SOLUTION...
Page 209: Cleaning The Dust Seal
FRONT SUSPENSION You can find the reference numbers of this chapter about the explored FIG. 5 view of the fork on pag. 6. CLEANING THE DUST SEAL (FIG. 5) This operation can be carried out with the fork installed on the motorcycle. Dismantling •...
Page 210: Draining The Oil
FRONT SUSPENSION Draining the oil WARNING This operation cannot be carried out with the fork installed on the motorcycle. We recommend loosening the fork cap a little before removing the fork leg from the fork yokes. • Remove the fork leg from the fork yokes according to the procedure in the motorcycle owner’s manual.
Page 211: Braking Down The Pumping Element And The Bottom Valve
FRONT SUSPENSION BRAKING DOWN THE PUMPING ELEMENT AND THE BOTTOM VALVE WARNING This operation must be done only after having drained all of the oil out of the fork leg. • Clamp the wheel axle clamp in the vice. • Insert the R5081AA tooling inside the fork leg in a way that you can block the body rotation;...
Page 212 FRONT SUSPENSION • In order to be able to act on the pumping element you will need to remove the foot buffer components: hold the foot buffer nut ( 26 ) using a 18 mm spanner and unscrew the push rod ( 29 ) with a 17 mm hexagonal spanner. •...
Page 213: Braking Down The Fork Leg - Slider And Removing The Oil Seals
FRONT SUSPENSION BRAKING DOWN THE FORK LEG – SLIDER AND REMOVING THE OIL SEALS • Remove the dust seal ( 12 ) from its seat, using a small flat- tip screwdriver. • With the same screwdriver remove the metal stop ring ( 11 ). •...
Page 214: Overhauling And Modifying The Cartridge And Bottom Valve Setting
FRONT SUSPENSION OVERHAULING AND MODIFYING THE CARTRIDGE AND BOTTOM VALVE SETTING CARTRIDGE OVERHAULING (REBOUND BRAKING) Dismantling • CLAMP IN THE VICE THE ROD ( 32 ) MILLED AREA. • Unscrew the nut ( 38 ) using a 12 or 13 mm spanner, according to the mounted nut. •...
Page 215: Bottom Valve Overhauling (Compression Braking)
FRONT SUSPENSION WARNING The piston must be oriented in a way that the holes having smaller diameter are placed towards the setting washers (37). • Tighten the nut ( 38 ) manually. • Clamp in the vice the damping rod ( 32 ) milled area. •...
Page 216: Re- Assembling The Fork Leg - Slider And Oil Seals
FRONT SUSPENSION Assembling: The washers (46) and the piston (45) are the ones causing the compression braking. It is possible, if needed, to modify the fork’s behaviour during the compression phase, by replacing the washers (46) and the piston (45) with other components having different characteristics.
Page 217 FRONT SUSPENSION • Insert the following components in the stanchion tube in this order: dust seal ( 12), stop ring ( 11 ), oil seal ( 10 ), spring cup ( 9 ) and bottom guide bushing ( 8 ). WARNING Make sure the oil seal (10) is correctly oriented in a way that the hollow side is turned towards the spring cup (9).
Page 218: Re- Assembling The Pumping Element Unit And The Bottom Valve
FRONT SUSPENSION • Mount the stop ring ( 11 ) using a small flat- tip screwdriver, checking it fits perfectly into its groove and being very careful not to scratch the stanchion tube. • Re- assemble the dust seal ( 12 ) in its seat, pressing it home with your hands. RE- ASSEMBLING THE PUMPING ELEMENT UNIT AND THE BOTTOM VALVE •...
Page 219 FRONT SUSPENSION • Insert the foot buffer push rod ( 29 ) into the rod ( 32 ); this must be done in a way that the spanner seizing side is oriented towards the body ( 30 ) and the metal ring seat ( F ) is exceeded.
Page 220 FRONT SUSPENSION • Push the pre- assembled pumping element ( 23 ) until it is in contact with the stanchion tube ( 5 ). • Tighten the bottom valve by hand. • Insert the R5081AA tooling inside the fork leg in a way that you can block the body rotation;...
Page 221: Filling With Oil
FRONT SUSPENSION FILLING WITH OIL The R5051AC is available as spare part: if you tighten it on the rod’s edge, you can make the rod extraction from the inner part of the slide easier. • Lift the slider completely on the stanchion tube. •...
Page 222: Fitting The Fork Back On Themotorcycle
FRONT SUSPENSION FITTING THE FORK BACK ON THEMOTORCYCLE WARNING Fit the fork back onto the frame following the instructions in the motorcycle manufacturer’s manual, as for the steering elements, brakes and wheel. The incorrect assembly of these elements can be dangerous for the rider. For the fork to work correctly, the wheel must be installed on the fork as follows: •...
Page 223: Adjustments
FRONT SUSPENSION ADJUSTMENTS REBOUND ADJUSTMENT The extension (or rebound) damping adjustment can be made by acting on the adjustment screw ( R ) you can see on the upper cap of both legs. To modify the rebound braking adjustment, always start from the “fully closed”...
Page 224: Removing The Front Fork
FRONT SUSPENSION Removing the front fork Take note of measure “A” which must be restored when reassembling. Set a support under the engine to lift the front wheel from the ground, working as follows: -remove,on the L.H. side, the screws (1) , the brake hose and the instrument cable clamp (TE-SMR) on the fork tube guard;...
Page 225 FRONT SUSPENSION - remove the fork legs. Assemble the front wheel following the instructions on page Y.8 and check the distance “B” between magnet (6) on the brake disc and sensor (7) on the brake caliper. Restore the starting measure “A”. B=2÷4 mm (0.08÷0.16 in.) I.25...
Page 226: Front Suspension (Tc-Txc-Smr 450-R)
FRONT SUSPENSION Front suspension (TC-TXC-SMR 450-R) The front suspension unit is a MARZOCCHI “U.S.D.” telescopic hydraulic fork with advanced axle;the diameter of the stem is 50 mm . The thermal excursion of the wheel on the legs axis is 300 mm (TE) e 250 mm (SMR). I.26 Part.
Page 227 FRONT SUSPENSION INSTRUCTIONS FOR USE OF Ø45USD FORK (TC-TXC-SRM 450-R) GENERAL The telehydraulic upside down fork,with advanced axle. The fork multivalve damping system allows rebound and compression to be controlled and adjusted,it also has a spring for static load. The compression hydraulic damping is made through a special valve located in each fork ’s leg upper area,whereas the rebound hydraulic damping is made through a sealed cartridge located inside each stanchion.
Page 228: Components Of The Fork
FRONT SUSPENSION COMPONENTS OF THE FORK The SHIVER 50 Factory Works fork is based on a multivalve damping system that is exactly the same on both fork legs. Each fork leg is therefore a complete suspension system which you must refer to when adjusting any part of the fork. 3)Compression adjustment screw 11)Outer spider 12)Lower sliding bushing...
Page 229: General Rules For A Proper Overhauling
FRONT SUSPENSION GENERAL RULES FOR A PROPER OVERHAULING • After a complete breakdown,always use new,original Marzocchi seals when reassembling. • To tighten two screws,bolts or nuts that are near each other,always follow the sequence 1-2-1 using a torque wrench;strictly follow the indicated tightening torques (see Table 5 -Tightening Torques).
Page 230 FRONT SUSPENSION Issues - Possible Causes - Solutions This section describes some of the issues that may arise during the working life of the fork. For each issue listed, a possible cause is identiﬁed and a possible solution is given. Always consult this table before working on the fork. ISSUE CAUSE SOLUTION...
Page 231: Cleaning The Fork Legs
FRONT SUSPENSION CLEANING THE FORK LEGS This operation can be carried out with the fork installed on the motorcycle. Marzocchi lubricates the dust seals of its forks with grease to help the stanchion tubes slide easier, particularly when the forks have not been used for a long period of time.
Page 232: Bleeding The Air
FRONT SUSPENSION Bleeding the air This operation must be carried out with the fork’s legs fully extended and fork dismantled or with fork installed on the motorcycle and with the front wheel off the ground. The pressure generated by the air that can get into the fork legs while the motorcycle is being used and which, due to the special shape of the sealing rings remains trapped inside, can cause the fork to malfunction.
Page 233: Draining The Oil
FRONT SUSPENSION Draining the oil WARNING This operation cannot be carried out with the fork installed on the motorcycle. We recommend loosening the fork cap a little before removing the fork leg from the fork yokes. • Remove the fork leg from the steering crowns according to the procedure in the motorcycle owner’s manual.
Page 234: Valve Setting
FRONT SUSPENSION REMOVING THE CARTRIDGE UNIT WARNING! This operation must be done only after having drained allof the oil out of the fork leg. • Clamp the wheel axle clamp (70) in the vice. • Unscrew the lower cartridge nut (48) with a 21 mm socket wrench. •...
Page 235 FRONT SUSPENSION • Fix the rebound adjuster set (24) with a 17 mm open-ended wrench and unscrew the locknut (27) with another 17 mm open-ended wrench. • Remove the rebound adjustment set (24) and the locknut (27) from the pumping element rod.
Page 236: Checking The Rebound Adjusting Unit
FRONT SUSPENSION CHECKING THE REBOUND ADJUSTING UNIT Dismantling • Push the rebound spring back from the end part of the rod. • Being very careful not to damage the washers, clamp the end of the rod (25) in the vice, exploiting the 17 mm spanner’s grip and without over-tightening. •...
Page 237: Compression Valve Overhauling
FRONT SUSPENSION COMPRESSION VALVE OVERHAULING Dismantling • Being very careful not to damage the washers, clamp the compression valve (43) into the vice, exploiting the parallel surfaces and without over-tightening. • With a 12 mm spanner, unscrew nut (36). • In sequence, remove the nut (36), the spring (37), the by-pass washer (38), the piston (39) with O-ring (40) and the washer or washers’...
Page 238: Re-Assembling The Cartridge Unit
FRONT SUSPENSION RE-ASSEMBLING THE CARTRIDGE UNIT • Insert the spring (23) in its seat on the rod. • Apply some stretched adhesive tape onto the end of the rod (39) in order to cover the rod threading. Do not apply thick adhesive tape. •...
Page 239 FRONT SUSPENSION Push the rod for a few times and the cartridge body with some oil up to approx.20 mm from the body top. Screw the oil draining screw (1)in the compression valve unit (43) Seal the cartridge end hermetically by screwing the compression valve (43)and make the rod (25)perform a full stroke;after completing this operation,when the rod is completely extended,you will see that the bladder tends to compress next to the 4 radial holes in the tube sleeve.
Page 240 FRONT SUSPENSION Pull the rod (25) to the position of maximum extension and top up oil to the edge Set the compression adjuster to 15 clicks from fully closed position. Unscrew the oil draining screw (1) in the compression valve unit (43) Screw the compression valve unit until the external O-ring seals inside the cap body.
Page 241: Breaking Down The Fork Leg - Slider And Removing The Sealing Rings
FRONT SUSPENSION BREAKING DOWN THE FORK LEG - SLIDER AND REMOVING THE SEALING RINGS Remove the dust seal (16) from its seat, using a small ﬂat-tip screwdriver. With the same screwdriver remove the metal stop ring (15). Pull the stanchion tube (44) out of the slider (11); to separate these two elements you will have to pull hard.
Page 242: Re-Assembling The Fork Leg - Slider And Sealing Rings
FRONT SUSPENSION RE-ASSEMBLING THE FORK LEG - SLIDER AND SEALING RINGS WARNING The old sealing rings and dust seals must not be used again. Before re- assembling, check the conditions of the guide bushings; replace them if they are scratched or grooved. Check the Teﬂon® coating of the guide bushings which must be in a good condition.
Page 243: Re-Assembling The Cartridge
FRONT SUSPENSION Mount the stop ring (15) using a small ﬂat-tip screwdriver, checking it ﬁts perfectly into its groove and being a careful not to scratch the stanchion tube. Re-assemble the dust seal (16) in its seat, pressing it home with your hands. RE-ASSEMBLING THE CARTRIDGE Insert the pre-load spacer (17) and the spring (19) inside the stanchion tube.
Page 244: Filling With Oil
FRONT SUSPENSION FILLING WITH OIL Because the oil level inside the fork is not known, topping up should be done only after disassembling and removing the fork (see par. 4.8). Clamp the fork leg in the vice in a vertical position. Lift the slider on the stanchion tube up to 50 mm from the cap.
Page 245: Adjustments
FRONT SUSPENSION ADJUSTMENTS Obtaining the maximum performance from your suspension system depends on using the correct settings and making the proper adjustments. This section describes how to properly set and make adjustments to your Marzocchi suspension system. In order to ﬁnd the best settings for you, you will need to try several times to understand where and how to make adjustments.
Page 246: Spring Preload Adjustment
FRONT SUSPENSION SPRING PRELOAD ADJUSTMENT The spring preload adjustment can be done following the procedure here below described, after disassembly of the cartridge set from the fork’s leg interior (see par. 4.6): Slide the preload adjustment set (7) towards the cartridge lower edge, so that the metal ring seat becomes uncovered.
Page 247: Compression Adjustment
FRONT SUSPENSION COMPRESSION ADJUSTMENT The compression adjustment can be made by by turning on the adjuster (C). WARNING If your fork “bottoms” out, immediately adjust thecompression adjustment or check the oil height of thefork. Incorrect compression adjust can result in forkdamage, an accident, personal injury or death.
Page 248: Removing The Front Fork
FRONT SUSPENSION Removing the front fork Take note of measure “A” which must be restored when reassembling. Set a support under the engine to lift the front wheel from the ground, working as follows: -remove,on the L.H. side, the screws (1) , the brake hose and the instrument cable clamp (TE-SMR) on the fork tube guard;...
Page 249 FRONT SUSPENSION - remove the fork legs. Assemble the front wheel following the instructions on page Y.8 and check the distance “B” between magnet (6) on the brake disc and sensor (7) on the brake caliper. Restore the starting measure “A”. I.49 Part.
Page 250 FRONT SUSPENSION I.50 Part. N. 8000 B0148 (02-2008)
Page 251: Rear Suspension
REAR SUSPENSION Rear suspension ............Removal of rear shock absorber ....... Disassembly, overhauling and reassembly of the rear shock absorber ........Overhaul the spring ........... Checking the shock absorber ........Removing the reservoir plug and the valve ....Checks on the piston unit .......... Replacing the gasket ..........
Page 252: Rear Suspension
REAR SUSPENSION Rear shock absorber TIGHTENING TORQUES 1, 2: 52.4 Nm/ 5.35 Kgm/ 38.6 ft-lb LUBRICATION POINTS (GREASE) Part. N. 8000 B0148 (02-2008)
Page 253 REAR SUSPENSION Rear suspension The suspension of this motorcycle is of the progressive type and consists of a shock absorber, a series of linkages and a swing arm. The pre-load of the shock absorber spring can be adjusted according to the driving and ground conditions. Even the hydraulic damping can be adjusted from outside.
Page 254 REAR SUSPENSION Removing the rear shock absorber Remove the saddle, the side panels and the silencer as described in chapter "E’"- General operations (pages E.15-E.16-E.17). Loosen the front clamp (1) of the fitting on the carburettor (TC-TXC-SMR 450 R) or on the throttle body (TE-SMR). Loosen the upper fastening screw (2) of the rear frame (4), remove the lower fastening screw (3) and turn the rear frame forward making sure not to damage electric cables.
Page 255: Disassembly, Overhauling And Reassembly Of The Rear Shock Absorber
REAR SUSPENSION Disassembly, overhauling and reassembly of the rear shock absorber Accurately clean the shock absorber before disassembly. OVERHAULING THE SPRING Measure the spring in its housing before disassembling. Disassembling the spring: when gripping the shock absorber in the vice take care that it gets not warped.
Page 256: Removing The Reservoir Plug And The Valve
REAR SUSPENSION Bleed the gas by pressing on the reservoir valve. To protect his eyes from possible particles, the operator must turn t h e valve away from his eyes. Removing the reservoir plug and the valve Fit a tool on the air chambre cover, then exert a pressure on both the cover and the tool to gain access to the snap ring.
Page 257 REAR SUSPENSION Lay the shock absorber on the working table. Loosen or dig ot the cover (according to the model). Once the plug is removed, push and drive the forkrod guide inside the body so as to free snap ring housing. Remove then the snap ring using a screwdriver. Part.
Page 258: Checks On The Piston Unit
REAR SUSPENSION Grip the shock absorber upper side in a vice using aluminium or bronze iaws. Insert a rod or a screwdriver into the connecting hole, and remove tthe piston and forkrod unit from the shock absorber body. Wrap the body in a cloth to prevent spreading the oil on the shock absorber body.
Page 259: Checking The Adjustment
REAR SUSPENSION Checking the adjustment In case of compression adjustment for operating defect, it is necessary to unscrew the knob stopping dowel (before unscrewing, heat with warm air). Proceed as follows: unscrew the ring nut with a suitable wrench, extract the parts paying attention to the dismantling sequence in order to correctly effect then the reassembly.
Page 260: Reservoir Replacement
REAR SUSPENSION After having completed the check, insert again the piston, the disk, the spring and the ring with slots. Remove the cone holding shaft from the plug, screw the ring and insert it in the slot applying a light pressure. Lock the assembly with the plug at a torque of 30 Nm (3 kgm;...
Page 261: Disassembling The Air/Oil Diaphragm Of The Reservoir
REAR SUSPENSION Tighten the reservoir usingf Loctite, and see that the O-Ring is undamaged. Use a 40 Nm (4 kgm; 39.2 ft/lb) torque. NOTE: When carriying out these operations see that the place of work and all the elements are well cleaned. Disassembling the air/oil diaphragm of the reservoir Always replace the diaphragm when changing the oil inside the shock absorber.
Page 262 REAR SUSPENSION Prepare the diaphragm with assembled OR (we advise using a new one for each replacement). Fill up the reservoir with oil and insert the diaphragm into the reservoir, (see photo). Quickly push the diaphragm downwards at the bottom of the reservoir holding fast the forkdìrod in the topping up position.
Page 263 REAR SUSPENSION Reassemble the reservoir plug and the valve, fit it inside the reservoir, then fit the snap ring into the throat. Insert the nitrogen valve - or the air valve if teh nitrogden valve is not an hand - using 10-12 bar pressure. Reassemble the cap on the valve and check to make sure that both air bleeds, or oil leaks, are not present.
Page 264: Shock Absorber Damping Adjustment
REAR SUSPENSION Shock absorber damping adjustment Adjustment of the compression stroke is independent from the rebound stroke. A) COMPRESSION – standard calibration: 1) low damping speed: -15 clicks (± 2 clicks) (adjuster 1) 2) high damping speed: -15 clicks (± 2 clicks) (adjuster 3) To reset the standard calibration, rotate upper adjusters (1) and (3) clockwise to the fully-closed position, then move back for the clicks specified above.
Page 265: Disassembly And Overhauling The Rear Swing Arm
REAR SUSPENSION Disassembling and overhauling the rear swing arm Set a stand or a block under the engine and see that the rear wheel is lifted from the ground. Remove the chain (1) of the secondary transmission and disengage the rear brake pipe (2) from the fork (A). Remove the two side guards (3) of the frame.
Page 266: Overhauling The Rear Swing Arm Axle
REAR SUSPENSION Overhauling the rear swing arm axle Using a comparator, check the swing arm axle for distortion. Position the axle on two identical contacts. Rotating the axle and moving it horizontally and take the distortion reading with the instrument. Distortion limit: 0,30 mm/ 0.012 in.
Page 267: Chain Tension Rollers, Chain Driving Roller, Chain Guide, Chain Runner
REAR SUSPENSION Chain tension rollers, chain driving roller, chain guide, chain runner Check the wear of the above mentioned elements and replace them when necessary. : Check the chain guide alignement, and remember that a bent element can cause a rapid wear of the chain. In this case, a chain fleeting from the sprocket may ensue.
Page 268 REAR SUSPENSION Part. N. 8000 B0148 (02-2008) J.18...
Page 269: Brakes
BRAKES Section Part. N. 8000 B0148 (02-2008)
Page 270 BRAKES Braking system ............Brake disc ..............Wear check and brake pads replacement ....Front braking system bleeding (TE-TC-TXC) .... Front braking system bleeding (SMR) ....... Rear braking system bleeding ........Fluid replacement ............. BRAKING SYSTEM The braking systems is divided into two completely independent circuits.Each system is provided with a caliper connected to a hydraulic control pump with tank for the fluid.
Page 271 BRAKES SMR 450 R SMR 450 R SMR 450 R SMR 450 R SMR 450 R Part. N. 8000 B0148 (02-2008)
Page 272 BRAKES Disc brake A regular check of brake disc condition is most important; the disc should be absolutely clean without any traces of rust, oil, grease or dirt and should not be excessively scored. Front brake disc diameter: 10.24 in. (TE, TC, TXC); 12.6 in. (SMR) Front brake disc thickness (when new): 0.118 in.
Page 273 BRAKES Wear check and replacement of brake pads Inspect pads for wear. Service limit “ A” TE, TC, TXC - 3,8 mm-0.15 in. (front and rear pads) If service limit is exceeded, always replace the pads in pairs. a) In front: thickness “A” must never be lower than the one pointed out by the wear control notches.
Page 274 BRAKES Front braking system bleeding (TE-TC-TXC) The braking system must be bleed when, due to air in the circuit, the lever stroke is long and spongy. To bleed the system: - Remove the rubber cap on the bleeding valve (1). - Attach a clear plastic hose to the bleeding valve on the brake caliper and turn the other end of the hose into a container (make sure that the end of the hose is submerged in brake fluid during the entire bleeding operation).
Page 275 BRAKES Front braking system bleeding (SMR) The braking system must be bleed when, due to air in the circuit, the lever stroke is long and spongy. Regarding the front braking system, first proceed to bleed the upper braking system control (bleeding valve 1), then the brake caliper (bleeding valve 1A). In both cases, proceed as follows: - Remove the rubber cap on the bleeding valve (1) or (1A).
Page 276 BRAKES Bleeding the rear breaking system The braking system must be bled when, due to air in the circuit, the pedal stroke is long and spongy. To bleed the system: - Remove the reservoir cover (A) (21 mm wrench) rubber boot and top up with (DOT 4) brake fluid.
Page 277 BRAKES Fluid change The brake fluid should be checked and changed in accordance with the Periodic Maintenance Chart (page B.9) or whenever it is contaminated with dirt or water. Don’t change the fluid in the rain or when a strong wind is blowing. Use only brake fluid from a sealed container (DOT 4).
Page 278 BRAKES TE-TC-TXC L.10 Part. N. 8000 B0148 (02-2008)
Page 279 BRAKES Periodically check the connecting hoses (C) and (D) (see “Periodical maintenance card”, page B.9): if the hoses are worned or cracked, their replacement is advised. Part. N. 8000 B0148 (02-2008) L.11...
Page 280 BRAKES L.12 Part. N. 8000 B0148 (02-2008)
Page 281 ELECTRIC SYSTEM, DIGITAL INSTRUMENT WIRING DIAGRAM (TE, SMR) .............. KEY TO WIRING DIAGRAM (TE, SMR) ..........Cable colour coding (TE, SMR) ............. WIRING DIAGRAM (TC, TXC 250) ............KEY TO WIRING DIAGRAM (TC, TXC 250) ......... Cable colour coding (TC, TXC 250) ............WIRING DIAGRAM (TC, TXC 450-510 - SMR 450 R) ......
Page 282 ELECTRIC SYSTEM, DIGITAL INSTRUMENT KEY TO ELECTRIC DIAGRAM (TE-SMR) 1. Electronic power unit 2. Alternator 3. Voltage regulator 4. Rear stop switch 5. Front stop switch 6. Injector 7. Instrument 8. R.H. front turn indicator 9. Front headlamp 10. Electric fan 11.
Page 283: Cable Colour Coding (Te-Smr)
ELECTRIC SYSTEM, DIGITAL INSTRUMENT Cable colour coding (TE-SMR) Blue B/Bk Blue/Black Black Brown Br/B Brown/Blue Br/Bk Brown/Black Br/R Brown/Red Br/W Brown/White Green G/Bk Green/Black Green/Red Green/Yellow Grey Gr/Bk Grey/Black Gr/G Grey/Green Orange O/Bk Orange/Black Pink R/Bk Red/Black Sky blue Violet White W/B White/Blue W/Bk White/Black...
Page 284: Cable Colour Coding (Tc, Txc 250)
ELECTRIC SYSTEM, DIGITAL INSTRUMENT KEY TO ELECTRIC DIAGRAM (TC-TXC 250) 1. Electronic power unit 2. Alternator 3. Voltage regulator 4. Condenser 5. Battery 6. Electric start remote control switch 7. Starting motor 8. Spark plug 9. Gear shift position sensor 10.
Page 285: Cable Colour Coding (Tc, Txc 450-510 - Smr 450 R)
ELECTRIC SYSTEM, DIGITAL INSTRUMENT KEY TO ELECTRIC DIAGRAM (TC-TXC 450-510; SMR 450-R) 1. Electronic power unit 2. Alternator 3. Voltage regulator 4. Condenser (TC-TXC) 5. Battery 6. Electric start remote control switch 7. Starting motor 8. Spark plug 9. Gear shift position sensor 10.
Page 286: Electrical Components Location (Te-Smr)
ELECTRIC SYSTEM, DIGITAL INSTRUMENT ELECTRICAL COMPONENTS LOCATION (TE-SMR) The ignition system includes the following elements: - Generator (1), in oil bath, on the inner side of L.H. crankcase cover; - Electronic ignition coil (2) under the fuel tank; - Electronic power unit C.D.I. (3) under the fuel tank; - Voltage regulator (4) under the fuel tank;...
Page 287 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Part. N. 8000 B0148 (02-2008)
Page 288: Electrical Components Location (Tc-Txc-Smr 450 R)
ELECTRIC SYSTEM, DIGITAL INSTRUMENT ELECTRICAL COMPONENTS LOCATION (TC-TXC-SMR 450-R) The ignition system includes the following elements: - Generator (1) on the inner side of L.H. crankcase cover; - Electronic coil (2) and condenser (11; TC-TXC) under the fuel tank; - Electronic power unit C.D.I. (3) under the fuel tank; - Voltage regulator (4) under the fuel tank;...
Page 289 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Part. N. 8000 B0148 (02-2008)
Page 290: Charging System (Te-Smr)
ELECTRIC SYSTEM, DIGITAL INSTRUMENT CHARGING SYSTEM (TE-SMR) The charging system consists of: - Alternator (2); - Voltage regulator-rectifier (3); - Battery (5). The AC current produced by the alternator is converted by the regulator-rectifier into DC current. The regulator-rectifier prevents overcharging of the battery and changes the AC current to the DC current.
Page 291 ELECTRIC SYSTEM, DIGITAL INSTRUMENT For the key to electrical cables see pages M.4÷M.5. Part. N. 8000 B0148 (02-2008) M.11...
Page 292: Charging System Checks
ELECTRIC SYSTEM, DIGITAL INSTRUMENT CHARGING SYSTEM CHECKS Battery current leakage To gain access to the battery (1), remove the saddle (see page E.15) and release elastic (2). Remove the BLACK negative cable from the battery. Measure the current between the NEGATIVE terminal of the battery and the NEGATIVE cable using a tester.
Page 293 ELECTRIC SYSTEM, DIGITAL INSTRUMENT 1) EXCITER - Resistance between BLACK-RED and RED-WHITE cables: 12,7 +/- 15% (TC-TXC-SMR 450-R) 1) TRIGGER - Resistance between WHITE and GREEN cables: +/- 15% (TE-SMR) 2) CHARGE- Resistance between YELLOW and WHITE cables: 0,16 +/- 15% (TC-TXC-SMR 450-R) 2) CHARGE- Resistance between then YELLOW cables: 0,65 +/- 15% (TE-SMR)
Page 294 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Generator no-load voltage performances 1- Secondary no load voltage 2- Charging current 3- Lighting voltage 4- Rotational frequency TC -TXC-SMR 450 R : EVERY ENGINE OVERHAUL, CLEAN THE FLYWHEL ROTOR REMOVING ANY DEBRIS GATHERED IN CENTRIFUGATED OIL AND ATTRACTED TO THE MAGNETS.
Page 295: Voltage Regulator-Rectifier Check (Te-Smr-Txc-Smr 450 R)
ELECTRIC SYSTEM, DIGITAL INSTRUMENT Voltage regulator-rectifier checking (TE-SMR-TXC-SMR 450 R) With the ignition definitely functional, whilst the battery is charged (12.5V-13V), start the engine: if the battery tension does not increase (14 V) after about two minutes, substitute the regulator. To access the regulator, remove the seat and fuel tank (pages E.15, E.23).
Page 296: Electric Starting System (Txc-Smr 450 R-Kit Su Tc)
ELECTRIC SYSTEM, DIGITAL INSTRUMENT ELECTRIC STARTING SYSTEM (TXC-SMR 450 R; kit on TC) The starter system consists of: - Battery (5); - Electric start remote control switch (6); - Starting motor (7); - Engine stop switch (12); - Engine start switch (13); - Clutch switch (14) (TC-TXC).
Page 297: Starter System Checks
ELECTRIC SYSTEM, DIGITAL INSTRUMENT STARTER SYSTEM CHECKS Starter motor disassembly Use a 10 mm wrench to remove the nut (1) under the rubber cap and a 8 mm wrench to remove the starting motor and ground cable screws (2). Remove the starting motor.
Page 298: Starter Motor Test Diagram
ELECTRIC SYSTEM, DIGITAL INSTRUMENT Starter motor test diagram 1- Output (W) 2- Torque (TQ) 3- Revolution (N: r.p.m. x 1000) 4- Terminal voltage (V) 5- Load current (A) Starter motor maintenance Maintenance operations on the starter motor involve checking the brushes for wear, that the stator and rotor do not touch, and that they are correctky insu- lated.
Page 299: Electronic Ignition System (Tc-Txc-Smr 450 R)
ELECTRIC SYSTEM, DIGITAL INSTRUMENT ELECTRONIC IGNITION SYSTEM (TC-TXC-SMR 450 R) In the C.D.I. system the electrical energy generated by the alternator charges the condenser. The energy is released in a single surge at the specified ignition timing and the current flows through the primary side of the ignition coil. A high voltage is induced in the secondary windings of the ignition coil, resulting a strong spark between the ignition spark plug gap.
Page 300: Electronic Ignition System (Te-Smr)
ELECTRIC SYSTEM, DIGITAL INSTRUMENT ELECTRONIC IGNITION SYSTEM (TE-SMR) The ignition system is controlled by the ECU (1). The system belongs to the category of the integrated systems of digital electronic ignition with advance and static distribution and gasoline electronic injection of intermittent sequential balanced type. This ignition system consists of a sensor of the crankshaft position (Pick-up), an ECU, an ignition coil and an air pressure sensor of the intake manifold.
Page 301 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Part. N. 8000 B0148 (02-2008) M.21...
Page 302 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Ignition coil resistance check To gain access to the electronic coil (1) remove the saddle and the fuel tank (see pages E.15-E.23). Detach the ignition coil from main wiring harness. Remove the fastening screws, the ignition coil then measure the resistance in the primary and secondary windings using a tester.
Page 303 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Electronic unit (ECU) To gain access to the electronic unit (1) remove the saddle and fuel tank (see pages E.15-E.23). This unit consists of a condensor, a pick-up signal rectifier circuit, and ignition advance circuit synchronised with the pick-up signal and a switching circuit for discharging the condensor.
Page 304: Electronic Power Unit Wiring Diagram (Ecu) (Te-Smr)
ELECTRIC SYSTEM, DIGITAL INSTRUMENT ELECTRONIC POWER UNIT WIRING DIAGRAM (ECU) (TE-SMR) 35 23 33 25 36 - Electronic power unit (1) (ECU); - W.T.S. (33) (Water Temperature Sensor); - Ignition coil (23); - Fuel pump (35); - Clutch switch (27); - Ignition switch (26);...
Page 305: Voltage Regulator (Te-Smr)
ELECTRIC SYSTEM, DIGITAL INSTRUMENT Voltage regulator (TE-SMR) The voltage regulator (1) contains the diodes to rectify the current produced by the generator. It contains also an electronic device operating in relation to the battery tension: if battery has a “low” charge, recharge current will be high; on the contary if battery will be charged the current will be lower.
Page 306: Smr 450-R
ELECTRIC SYSTEM, DIGITAL INSTRUMENT Spark plug Use "NGK" CR8EB spark plug (1) (excluded SMR 450 R) or "NGK" CR9EKB (SMR 450 R). Check distance "A" (0.6÷0.7 mm / 0.023÷0.027 in. excluded SMR 450 R) or 0.8 mm / 0.031 in. (SMR 450 R) between electrodes. A wider gap may cause difficulties in starting engine and in overloading coil.A gap that is too narrow may cause difficulties when accelerating, when idling the engine or when performing at low speeds.
Page 307: Gear Shift Position Sensor Check (Gps)
ELECTRIC SYSTEM, DIGITAL INSTRUMENT Gear shift position sensor checking (GPS: Gear Position Sensor) Set the tester on "Ohm" position then detach the 6 ways connector (1) from the main wiring harness (the gear shift position sensor is fastened on the alternator cable with a clamp).
Page 308 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Throttle Position Sensor checking (TPS: Throttle Position Sensor) (TC-TXC-SMR 450 R) Set the tester in “Ohm” position then detach the throttle position sensor cable (1) from the main wiring harness. Set the two tester terminals in corrispondence of YELLOW (A) and BLACK (B) cables and check for the correct values (see table).
Page 309: Battery Recharge
ELECTRIC SYSTEM, DIGITAL INSTRUMENT BATTERY (TE-SMR; kit on TC) The sealed battery (1) does not require any maintenance work. If the vehicle remains unused for long periods, it is recommended to remove battery from electrical system and store it in a dry place. After an intensive use of the battery, it’s advisable a standard low charge (12V-6Ah battery: 0.6A for 8 hours).
Page 310: Headlamp, Tail Lamp (Te-Smr)
ELECTRIC SYSTEM, DIGITAL INSTRUMENT HEADLAMP, TAIL-LAMP (TE-SMR) Headlamp adjustment The front headlamp is fitted a dipping bulb for main and dipped beams and a pilot/ side lamp bulb. Particular care should be taken to adjust the headlamp beam; adjust as follows: - position the motorcycle at 33 ft from a flat wall;...
Page 311: Rear Tail Light Bulb Replacement
ELECTRIC SYSTEM, DIGITAL INSTRUMENT Rear tail light bulb replacement To gain access to the tail light bulb (12V-5/21W), proceed as follows: - remove the two fastening screws (1) and the rear lens (2); - pull the lamp (3) inside, turn it counterclockwise then remove it from the lamp holder.
Page 312: Replacing The Licence Plate Light Lamp
ELECTRIC SYSTEM, DIGITAL INSTRUMENT Replacing the licence plate light lamp Remove the licence plate light support (4) by extracting it from the tail of the motorbike. Extract the lamp holder with the lamp from the support. Turn the lamp (5) to remove it from the lamp holder. After replacing the lamp, reassemble all the parts in the inverse order.
Page 313: Handlebar Commutators
ELECTRIC SYSTEM, DIGITAL INSTRUMENT HANDLEBAR COMMUTATORS Measure the commutators continuity using a tester. In case of anomalies, replace the defective part. 1- Engine start and stop switches TC-TXC-SMR 450 R 1. Engine ignition button 2. Engine stop button TE-SMR 2- R.H. Commutator 1.
Page 314 ELECTRIC SYSTEM, DIGITAL INSTRUMENT 3- L.H. Commutator TE-SMR High beam flash (self cancelling) Selection control high beam Selection control low beam Left turm signals (automatic return) Right turm signals (automatic return) To deactivate the turn signals, press the control lever after its returning to center.
Page 315: Notes
ELECTRIC SYSTEM, DIGITAL INSTRUMENT NOTES CONNECTORS • When a connector is connected, check that it clicks into position. • Check the connector for corrosion, dirt or a broken cover. COUPLINGS • Block couplings – ensure that the block is released before disconnecting it to push it completely home when connecting it.
Page 316: Fuses
ELECTRIC SYSTEM, DIGITAL INSTRUMENT FUSES • When a fuse burns out, always investigate why the fuse has burnt out. Find the cause, repair and then substitute the fuse. • Do not utilise a fuse of a different capacity from the original one. •...
Page 317: Digital Instrument, Warning Lights (Te-Smr)
- To select the instrument functions and to set to zero the functions, use the SCROLL knob (A). IMPORTANT: Functions of the GREEN warning light (4) “NEUTRAL” in case of FUEL INJECTION SYSTEM malfunction (contact your local HUSQVARNA Dealer) a) With the GEARBOX NOT in NEUTRAL position: the warning light FLASHES INTERMITTENTLY.
Page 318 ELECTRIC SYSTEM, DIGITAL INSTRUMENT 2- SPEED / H / RPM (figure 2) - SPEED: motorcycle speedmaximum value: 299 kmh or 299 mph; - H: shows the running hours of the engine (data are saved in permanent memory every 10 minutes)- Maximum value: 9999:59; - RPM: engine r.p.m.
Page 319 ELECTRIC SYSTEM, DIGITAL INSTRUMENT 6- SPEED / AVS 1 / RPM (figure 6) - SPEED: motorcycle speedmaximum value: 299 kmh or 299 mph; - AVS 1: shows the covered average speed of the motorcycle, according with a distance (TRIP 1) and a miles/kilometers covered time (STP 1) (the data will be lost after battery detachment).
Page 320 ELECTRIC SYSTEM, DIGITAL INSTRUMENT 10- SPEED /RPM (engine r.p.m. numerical value) (figure 10) - SPEED: motorcycle speedmaximum value: 299 kmh or 299 mph; - RPM: engine r.p.m.; both vertical LED indicator and numerical value are on. Instructions for the instrument setting Upon turning on the instrument, if the operation DID NOT already take place, it is necessary to set the instrument associating it with the relative motorcycle by selection of the codes illustrated in the figures shown.
Page 321: Instrument Replacement
ELECTRIC SYSTEM, DIGITAL INSTRUMENT Instrument replacement (TE-SMR) Remove the four elastic (1) and remove the headlamp holder (2); Remove the three fastening screws (3), deconnect the connector (4) and remove the instrument (5). Reassemble the instrument in the reverse order that was shown for disassembling. LOCATING OPERATING TROUBLES CHARGING SYSTEM Fast battery discharging:...
Page 322: Wire Harness Tc-Txc-Smr 450R
ELECTRIC SYSTEM, DIGITAL INSTRUMENT WIRE HARNESS TC-TXC-SMR 450R WIRE HARNESS TE-SMR M.42 Part. N. 8000 B0148 (02-2008)
Page 323: Cable Runway And Assembling Instructions For The 'Te/Smr' Electric Parts
ELECTRIC SYSTEM, DIGITAL INSTRUMENT CABLE RUNWAY AND ASSEMBLING INSTRUCTIONS FOR THE ‘TE/SMR’ ELECTRIC PARTS • A.T.coil positioning Make sure the coil cable is facing the rear part of the motorbike. • Relay positioning (3 parts) R.S. relay. L.S. relay. • Turn indicators flash device positioning Turn indicators flash device Part.
Page 324 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Fall sensor positioning (for SMR only). Fall sensor installed with connector facing the centre of the motorbike and ‘UP’ writing upward. • Injection central unit positioning. Injection central unit installed with flat side upward. • Remote control switch positioning Start remote control switch with battery-remote control switch cable and remote control switch-starting motor cable.
Page 325 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Voltage regulator positioning. Voltage regulator in place. It is recommended to fasten it only after connecting the system earth cable screwed with the A.T. coil screw (see the instructions below). 8000B0563 voltage regulator with 8000B1061 heat dissipation plate and 8000B1071 thermal compound.
Page 326 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Bolt the 8000B0254 battery negative cable and the 8000B0253 motor-frame earth cable as shown. • Connection of the frame earth cable and of the motor-frame earth cable. Earth cable wire Bolt the motor-frame earth cable and the electric system earth cable to the left coil harness 8000 B0252 screw.
Page 327 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Connect indistinctively the ‘FAN’ and ‘DC’ cables to the relays on the left side of the motorbike. • Connecting the electric fan. Connect the electric fan cable. Position the connectors connected as shown in the picture. Electric fan connector •...
Page 328 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Connecting the injector. Connect the injector connector. Injector connector • Connecting the central unit. Connect the central unit connector. Central unit connection • Connecting the ‘MAQS’ and the water temperature sensor. Connect the ‘MAQS’ and water temperature connectors as shown in the picture. The picture also shows the cable tray of these connections.
Page 329 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Rear frame cable runway. Tail light cable Place the rear cables as shown in the picture. The fuses/fall sensor cable branch runs between the remote control switch and the rear frame. The tail light cables runs between the rear frame and the remote control switch.
Page 330 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Connecting the tail light cable. Connect the rear light cable as shown in the picture. Tail lamp connector • Positioning fuses. Position the three fuses as shown in the picture by taking into consideration the code on each cable sheath.
Page 331 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Fastening the front cables. Fasten the front bundle of cables with the appropriate clip. Cables harness fastening clip • Connecting front cables. Connect the headlight connector as shown. Headlamp connector Connect the clutch connector and the key connector as shown. Clutch connector Key switch...
Page 332 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Connect the front stoplight as shown. Front stop switch connector Connect the connector of the left electric block as shown. Left electric block connector Connect the connector of the right electric block and of the dashboard as shown. Dashboard connector Right electric...
Page 333 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Connect turn indicators connectors as shown. Turn indicators connectors • Arranging clamps. Fasten the electric system to the frame as shown. Clamp Fasten the electric system, the rear light cable and battery cables to the frame as shown.
Page 334 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Fasten the rear stoplight cable to the frame as shown. Clamp Fasten the electric system to the clutch control cable as shown. Clamp Fasten the cables of clutch sensor, dashboard, diagnostics connector, horn, front stoplight, right and left turn indicators to the clutch control cable as shown. Clamp Mutually fasten the cables of the gear sensor, flywheel cables, motor-frame earth connection, battery negative and starter motor cable as shown.
Page 335 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Connecting the lambda sensor. Connect the lambda sensor connector by placing the cable between relay cables as shown in the picture. Lamda probe Lamda probe cable connector Place the lambda sensor connector between the two relays and the high voltage coil as shown in the picture.
Page 336: Important Recommendation
ELECTRIC SYSTEM, DIGITAL INSTRUMENT IMPORTANT RECOMMENDATION (pages M.62-M.63) Premised that, before the motorcycle washing, it is necessary to protect opportunely from the water the following parts: a) Rear opening of the muffler; b) Clutch and brake levers, hand grips, handlebar commutators; c) Air cleaner intake;...
Page 337 ENGINE COOLING SYSTEM Section Part. N. 8000 B0148 (02-2008)
Page 338 ENGINE COOLING SYSTEM Checking the cooling fluid level ......... Cooling system ............Engine cooling system overhauling ......Part. N. 8000 B0148 (02-2008)
Page 339 ENGINE COOLING SYSTEM Checking the cooling fluid level Cooling fluid absorbs the heat from the thermic group (piston, cylinder, head) and conveys it to the exterior atmosphere through radiator. For a correct operation of the cooling system it is of utmost importance the periodical check of fluid level. The lack of the heat exchange means (water) between thermic mass and radiant mass could cause overheating of the cylinder-piston assembly with consequent seizure and, the worst, damages to the crankshaft assembly.
Page 340 ENGINE COOLING SYSTEM Cooling system The cooling system is of the forced circulation type, with centrifugal pump located on the L.H. side of the cylinder head, and two cooolers with vertical flow. Radiator cap R. H. Radiator L. H. Radiator Union Water pump Water pump cover...
Page 341 ENGINE COOLING SYSTEM Engine cooling system overhauling Verifying too high temperatures of cooling fluid, check the radiant mass. Whether on fins are noticed obstructions to the air flux as leaves, bugs, mud etc., carry out removal of these obstructions taking care not to damage radiator. If distortions are noticed, it is advisable to straighten them so restoring the air passage.
Page 342 ENGINE COOLING SYSTEM Part. N. 8000 B0148 (02-2008)
Page 343 “KIT” ASSEMBLING INSTRUCTIONS R.H. crankcase guard (TE-TC-TXC-SMR 450 R) ..Engine guard ............Passenger footrest Kit (TE-SMR) ......Carburetor KEIHIN 37 kit (TC-TXC 250) and KEIHIN 41 kit (TC-TXC 450-510; SMR 450 R) ..Hand guards kit (TE) ..........Blinkers Kit (TE-SMR) ..........Hook Kit for race starting phase (TC-TXC-SMR 450 R) ..........
Page 344: Crankcase Guard (Te-Tc-Txc-Smr 450 R)
“KIT” ASSEMBLING INSTRUCTIONS 1- 8000 A1427 (TE, TC, TXC, SMR 450-R) R.H. crankcase guard (page O.3) 2- 8000 B0157 Engine guard (page O.3) 3- 8000 B0152 (TE-SMR) (*) Passenger footrest Kit (page O.4) 4- 8000 A4295 (TC-TXC 250) Carburetor KEIHIN 37 kit (page O.7) 4- 8000 A4296 (TC-TXC 450-510, SMR 450-R) Carburetor KEIHIN 37 kit (page O.7) 5- 80A0 A6211 (TE)
Page 345 “KIT” ASSEMBLING INSTRUCTIONS 1- R.H. crankcase guard (TE-TC-TXC-SMR 450 R); 2- Engine guard (TE-TC): assemble as shown in the figure; (O.4) (O.4) M6x30 mm M6x10 mm M8x25 mm M8x40 mm Ø6,5xØ18x18 mm Part. N. 8000 B0148 (02-2008)
Page 346 “KIT” ASSEMBLING INSTRUCTIONS 3- Passenger footrest (TE-SMR); To always have the rear frame (a) fastened in two points, assemble the footrests first on to one side of the motorcycle then on the other one. The description refers to the assembly of the left footrest (7), the assembly of the right footrest (8) is symmetrical. Proceed as follow: - Preliminarily mount the foot-rests (A) and (B) on the relevant supports (C) and (D);...
Page 347 “KIT” ASSEMBLING INSTRUCTIONS - Insert the plate (2) on the back frame; - Remove the frame lower screw (7); - Provisionally, fasten the foot-rest support in the front side by means of the M8x25 mm (4) screw supplied with the Kit (do not tighten fully); - Insert the spacer (5) into the plate and fasten the rear by means of the M8x40 mm (6) screw also supplied with the Kit;...
Page 348 “KIT” ASSEMBLING INSTRUCTIONS - Fully tighten also the front screw (4); -- Assemble back the rear fastening screws (1) of the air filter box; -- Assemble back the saddle and side panels. Part. N. 8000 B0148 (02-2008)
Page 349 “KIT” ASSEMBLING INSTRUCTIONS 4- KEIHIN 37 carburetor Kit (TC-TXC 250) and KEIHIN 41 (TC-TXC 450-510; SMR 450 R) - Remove the carburetor (page E.9). The kit consists of: TC-TXC 250 1- Idle jet: 40, 45 3- Main jet: 170, 180 TC-TXC 450-510;...
Page 350 “KIT” ASSEMBLING INSTRUCTIONS 5- Hand guards kit (TE) Remove the rubber guards and the fastening screws of the front brake (a) and clutch (b) control levers. Place the right hand guard (A) then fasten it with screw (1), washer (2) and nut (3). Place the left hand guard (B) then fasten it with screw (4), washer (5) and nut (6).
Page 351 “KIT” ASSEMBLING INSTRUCTIONS 6- Blinkers Kit (TE-SMR) FRONT TURN SIGNALS Remove the two fastening elastics (A) and the headlamp holder. Assemble the turn signal (1) on the plate (4) fastening with the nut (6) M6, then pass the cable (B) trough the plate front hole. Remove the steering head fastening screws (B) and assemble the plate complete with turn signal using the same screws (4) and the corresponding spacer (5) (R.H.
Page 352 “KIT” ASSEMBLING INSTRUCTIONS REAR TURN SIGNALS Remove the saddle and left side panel as shown on page E.15-E16. Assemble the flash device (8) on the metal tab (E) near the start remote control switch (D). Assemble the turn signal (2) on the hole of the frame tightening the nut (6). Remove the screws (9), the rear tail light then connect the turn signals and the flasher to the main wiring harness.
Page 353 “KIT” ASSEMBLING INSTRUCTIONS TE-SMR Part. N. 8000 B0148 (02-2008) O.11...
Page 354 “KIT” ASSEMBLING INSTRUCTIONS 7- The Kit Hook for race starting phase (TC, TXC: Code 8000 B1530) consists of: Part. No. Description Code Q.ty Ring (8000A6135) Hook (8000B1529) Screw (80B047053) Screw (60N407330) O.12 Part. N. 8000 B0148 (02-2008)
Page 355 “KIT” ASSEMBLING INSTRUCTIONS Preliminary operations Set a stand or a block under the engine and see that the front wheel is lifted from the ground. Loosen the four screws (1 fig.1) fixing the front wheel axle. Hold the head (3 fig.2) of the wheel axle in place, unscrew the bolt (2 fig. 1) on the opposite side;...
Page 356 “KIT” ASSEMBLING INSTRUCTIONS 9- Kick starter kit (34, for SMR, NOT for SMR 450-R) To effect the above mentioned operations, it is not necessary to remove the engine from the motorcycle. 6- Plate(1) 43- Pedal hub (1) 10- Washer(2) 44- Spring (1) 14- Spring(1) 45- O Ring (1) 15- Sliding gear(1)
Page 357 “KIT” ASSEMBLING INSTRUCTIONS Remove oil line bolt on R.H. crankcase cover (13 mm wrench ). Remove 12 cover fastening screws (8 mm wrench ), cover and gasket. Use a punch to remove the brass plug cap (A) and install oil seal (50). Remove the six screws (12) that fasten the springs (11) (5 mm wrench, whilst following a cross-over pattern and in steps).
Page 358 “KIT” ASSEMBLING INSTRUCTIONS Remove the circlip (13), the spacer (12) then fasten the plate (6) in the holes (A) on the R.H. crankcase (C) using the two screws (38) M6x14 (+LOCTITE 243). Assemble the shaft assy. (E) in the seat (B) then place the hook return spring (37) in the crankcase hole (D).
Page 359 “KIT” ASSEMBLING INSTRUCTIONS Reassemble: clutch disc housing (3), grooved washer (4), hub (5), lock washer (6) and fastening nut (7) (27 mm socket and tool "A" code no. 8000 79015; tighten at 75 Nm-7,5 kgm-55 ft/lb). Remember to bend locking tab over nut when tight.
Page 360 “KIT” ASSEMBLING INSTRUCTIONS Reassemble R. H. crankcase cover gasket, reassemble cover and tighten 12 fastening screws at 8 Nm-6 ft/lb (8 mm wrench). Reassemble oil line bolt on crankcase cover (13 mm wrench; tighten at 15 Nm-1,5 kgm-11 ft/lb). Assemble kick start pedal (42) tightening the screw (48) with 4 mm allen wrench; (tighten at 8 Nm-0,8 kgm-6 ft/lb);...
Page 361 “KIT” ASSEMBLING INSTRUCTIONS Pour the proper oil amount in the crankcase (1,5 l.-1.3 Imp. Quarts- 1.6 U.S. Quarts of AGIP RACING 4T/ 10W-60). Reassemble the rear brake control pedal (6 mm allen wrench; tighten fastening bolt at 42 Nm-4,2 kgm-31ft/lb+LOCTITE 243).
Page 362 “KIT” ASSEMBLING INSTRUCTIONS 10- Electric starter kit (TC: drawing A+B) To effect the above mentioned operations, it is not necessary to remove the engine from the motorcycle. The electric starter kit consists of: DRAWING "A" 1- Starting motor (1) 2- Screw M6x25 (2) 3- Gear Z=24 (1) 4- Free wheel (1) 5- Disc (1)
Page 363 “KIT” ASSEMBLING INSTRUCTIONS Part. N. 8000 B0148 (02-2008) O.21...
Page 364 “KIT” ASSEMBLING INSTRUCTIONS PRELIMINARY OPERATIONS Remove the seat (page E.15); - remove the side panels, the exhaust system, the fuel tank and the conveyors (pages E.16, E.20, E.23); - remove the front number holder (5) (remove the screw 1, the hose clamp 2 and the upper screw 4); - drain the engine oil (page D.17) and reassemble the engine oil drain plug (8 mm allen wrench;...
Page 365 “KIT” ASSEMBLING INSTRUCTIONS Remove the six screws (12) that fasten the springs (11) (5 mm wrench, whilst following a cross-over pattern and in steps). Remove the pressure plate (10) with the bearing and the clutch control cap (9). Remove clutch discs (8). Bend back tabs of the hub washer (6) and holding the clutch hub nut (27 mm wrench), remove the nut (7) using the clutch disassembly tool (A) (code no.
Page 366 “KIT” ASSEMBLING INSTRUCTIONS Remove the primary drive pinion (C) nut (27 mm wrench). Assemble: spacer (30), washer (29), needle bearing (28), free wheel gear (27), ring (5) and free wheel (4). O.24 Part. N. 8000 B0148 (02-2008)
Page 367 “KIT” ASSEMBLING INSTRUCTIONS Pages O.24- O.25 Reassemble the primary drive pinion (C) and lock it with the relevant nut (tighten at 180 Nm - 18 kgm - 130 ft/lb+LOCTITE 243). Assemble: spacer (33), washer (32), gear with clutch (31) then the second washer and the second spacer. Mount pin (7), gear (3), plate (9) then fasten it with the screws (11) (8 Nm - 0,8 kgm -5.8 ft/lb+LOCTITE 243).
Page 368 “KIT” ASSEMBLING INSTRUCTIONS Reassemble clutch discs (8), clutch control cap (9), pressure plate (10) and springs (11). Tight the clutch springs screws (12) whilst following a cross-over pattern and in steps (5 mm allen wrench: 8 Nm-0,8 Kgm- 5.8 ft/lb). Reassemble R.
Page 369 “KIT” ASSEMBLING INSTRUCTIONS On the right side of the panel, assemble the plate (12) by means of the relevant rivets (11) matching the holes already present in the frame. Insert the battery (7) into the frame. Insert the battery (7) into the holder. Assemble the solenoid starter (16) and fasten the cables (14) and (15) to the battery and to the solenoid starter using the screws (17) M6x8.
Page 370 “KIT” ASSEMBLING INSTRUCTIONS Assemble the voltage regulator (8) in the front side of the steering tube with the screws (10) M6x20. Assemble the ENGINE START (29) and ENGINE STOP (28) commutators on the handlebar and the clutch microswitch (24) on the clutch control.
Page 371 “KIT” ASSEMBLING INSTRUCTIONS TC 250 Blue Brown Black Green Grey Grey/Red Yellow Orange Pink Sky blue Violet White TC 450-510 Part. N. 8000 B0148 (02-2008) O.29...
Page 372: Kit "Racing" (Te-Smr)
“KIT” ASSEMBLING INSTRUCTIONS Kit "RACING" (TE-SMR) NOTE: All modifications reported below cause the registered vehicle to be non compliant and unsuitable for circulating on public roads: consequently it may be used only in “closed circuits” by authorised subjects hold- ing the relevant driving licence. Identify the cover of the throttle cable pulley of the throttle body located on the right side of the vehicle.
Page 373 “KIT” ASSEMBLING INSTRUCTIONS Remove the cover of the throttle cable pulley. Loosen the nuts of the throttle cables. Loosen the nuts of the throttle cables. Part. N. 8000 B0148 (02-2008) O.31...
Page 374 “KIT” ASSEMBLING INSTRUCTIONS Remove the throttle cables from their housings. Loosen both screws fastening the pulley locking plate. Remove the locking plate. Apply thread locking compound, e.g. Loctite 243, to the previously removed plate holding screws. O.32 Part. N. 8000 B0148 (02-2008)
Page 375 “KIT” ASSEMBLING INSTRUCTIONS Tighten both screws. Place the throttle cables into their housings. Tighten the throttle cables by means of the relevant nuts. Make sure that the cable has a certain clearance. Make sure that the cables are not tight or locked in any way.
Page 376 “KIT” ASSEMBLING INSTRUCTIONS Position the pulley cover into its housing. Anchor the pulley cover by means of the previously removed suitable screw. O.34 Part. N. 8000 B0148 (02-2008)
Page 377 “KIT” ASSEMBLING INSTRUCTIONS Cable routing the instructions to mount the racing cables racing (TE-SMR) INTRODUCTION Using the racing cables automatically implies the modification of the central unit mapping, thus operating the vehicle at full power. A vehicle equipped with racing cables should not be used with a catalysed silencer since this would prevent obtaining top performance levels and damage the catalysts.
Page 378 “KIT” ASSEMBLING INSTRUCTIONS Opened exhaust silencer 8000B0145 - DB killer 8000 B1546 (NOT for USA - CDN) - Spark Arrester 8000 B1306 (USA - CDN) Simplified wire harness 8000B0146 Light switch 800093221 O.36 Part. N. 8000 B0148 (02-2008)
Page 379 “KIT” ASSEMBLING INSTRUCTIONS Switch protection cover 800071755 Horn button 800094145 Licence plate holder kit 8000B1641 Part. N. 8000 B0148 (02-2008) O.37...
Page 380 “KIT” ASSEMBLING INSTRUCTIONS Removing original cables and components (TE-SMR) REMOVING THE SADDLE Remove the saddle REMOVING THE BATTERY Disconnect the battery: disconnect the negative cable first, then the positive cable (red sheath). REMOVING SIDE PANELS Remove both side panels. REMOVING THE HEADLIGHT SUPPORT Remove the headlight support.
Page 381: Cables (Te-Smr)
“KIT” ASSEMBLING INSTRUCTIONS DISCONNECTING THE HEADLIGHT Disconnect the 4-way connector connecting the headlight support to the main cables. REMOVING REAR VIEW MIRRORS AND FRONT TURN INDICATORS Remove the rear view mirrors. Remove the front turn indicators and assemble back the fastening screws on the steer head WITHOUT inserting the spacer.
Page 382 “KIT” ASSEMBLING INSTRUCTIONS Disconnect the 4-way connector located under the tank. Disconnect the petrol pipe located under the tank. Remove the tank WITH GREAT CAUTION AND MAKING SURE NOT TO DAMAGE THE FUEL PIPE CONNECTOR. REMOVING CLAMPS/EYELETS Remove all clamps anchoring the electric system to the motorbike frame. Open the eyelet anchoring the cables to the motorbike frame.
Page 383 “KIT” ASSEMBLING INSTRUCTIONS LOOSEN THE RADIATOR LEFT Remove the left radiator grid. Remove the three hexagonal screws holding the left radiator. REMOVING FUSE HOUSINGS Remove the three fuse housings located on the right side back frame. Before removing them from the support bracket, unfasten them by means of a screwdriver .
Page 384 “KIT” ASSEMBLING INSTRUCTIONS Disconnect the fall sensor from the main cables. REMOVING THE FUSE HOUSING BRACKET Remove the fuse/sensor housing bracket and by unscrewing it from the rear frame. REMOVING THE LEFT ELECTRIC SWITCH Remove the left electric switch from the handle bar. REMOVING THE SENSOR OPERATING THE CLUTCH LEVER Gently remove the clutch sensor by turning it anticlockwise.
Page 385 “KIT” ASSEMBLING INSTRUCTIONS REMOVING THE SPEED SENSOR Loosen the block holding the speed sensor cable onto the left rod protection. Disconnect the speed sensor connector by pushing the holding tab by means of a sharp tool. Gently loosen the sensor from the brake calliper support. Make sure to avoid twisting the electric cable.
Page 386 “KIT” ASSEMBLING INSTRUCTIONS Tighten the handle bar clamps and make sure that everything is assembled with the relevant spacers. TORQUE WRENCH SETTING: 21 N/m REMOVING FRONT CABLES Disconnect the front cable connectors Disconnect the system from the eyelet anchoring it to the frame. REMOVING THE DIAGNOSTIC PLUG Remove the diagnosis connector plug and store it for future applications.
Page 387 “KIT” ASSEMBLING INSTRUCTIONS REMOVING THE INJECTION CENTRAL UNIT CONNECTOR Disconnect the injection central unit connector. STATIC ELECTRICITY MAY DAMAGE THE ELECTRONIC CENTRAL UNIT PERMANENTLY. MAKE SURE THAT ANTISTATIC PROTECTIONS ARE WORN WHEN HANDLING THE CENTRAL UNIT. DISCONNECTING ENGINE CABLES Disconnect the gear sensor connector. Disconnect the pick-up connector.
Page 388 “KIT” ASSEMBLING INSTRUCTIONS DISCONNECTING THE LAMBDA SENSOR Disconnect the lambda connector. DISCONNECTING THE MAQS SENSOR Disconnect the MAQS connector located on the throttle body. STATIC ELECTRICITY MAY DAMAGE THE MAQS SENSOR PERMANENTLY. MAKE SURE THAT ANTISTATIC PROTECTIONS ARE WORN WHEN HANDLING THE MAQS SENSOR.
Page 389 “KIT” ASSEMBLING INSTRUCTIONS DISCONNECTING THE REMOTE CONTROL SWITCH Disconnect the remote control switch. Disconnect the rear light connector. REMOVING THE ORIGINAL LICENCE PLATE HOLDER Remove the original licence plate holder from the frame holding it. Remove the electric cables. DISCONNECTING THE INJECTORS Disconnect the injector connector.
Page 390 “KIT” ASSEMBLING INSTRUCTIONS DISCONNECTING THE REAR STOPLIGHT Disconnect the rear stoplight connector. DISCONNECTING THE HIGH VOLTAGE COIL Disconnect the high voltage coil pin. Press the lock metal tab to remove the pin. Remove the screw holding the two earth eyelets. REMOVING THE VOLTAGE REGULATOR Remove the voltage regulator located on the right side of the frame.
Page 391 “KIT” ASSEMBLING INSTRUCTIONS Disconnect the regulator. REMOVING THE HIGH VOLTAGE COIL Remove the second screw holding the coil to the frame. DISCONNECTING THE ELECTRIC FAN Disconnect the electric fan connector. DISCONNECTING RELAYS Disconnect the connectors from all three relays. Part. N. 8000 B0148 (02-2008) O.49...
Page 392 “KIT” ASSEMBLING INSTRUCTIONS REMOVING THE ELECTRIC SYSTEM Disconnect the connectors from all three relays, then remove the electric system. O.50 Part. N. 8000 B0148 (02-2008)
Page 393: Installing Racing Cables And Components (Te-Smr)
“KIT” ASSEMBLING INSTRUCTIONS Installing racing cables and components (TE-SMR) REMOVING THE LAMBDA PROBE Loosen the lambda probe from the exhaust pipe. DO NOT EXPOSE THE PROBE TO OIL OR SOLVENTS. INSTALLING THE LAMBDA PROBE PLUG Assemble the 8000A7724 probe plug with the 8000A7749 gasket. Tighten the lambda probe plug.
Page 394 “KIT” ASSEMBLING INSTRUCTIONS Install the 8000 B1546 DB killer (not in the USA - CDN) or 8000 B1306 Spark Arrester (USA - CDN). INSTALLING THE DB KILLER Install the 8000 B1546 DB killer (not in the USA - CDN) or 8000 B1306 Spark Arrester (USA –...
Page 395 “KIT” ASSEMBLING INSTRUCTIONS Install the 8000B0146 racing cables. CONNECTING THE INJECTOR Connect the injector connector. CONNECTING THE INJECTION CENTRAL UNIT CONNECTOR Connect the injection central unit connector. STATIC ELECTRICITY MAY DAMAGE THE ELECTRONIC CENTRAL UNIT PERMANENTLY. MAKE SURE THAT ANTISTATIC PROTECTIONS ARE WORN WHEN HANDLING THE CENTRAL UNIT.
Page 396 “KIT” ASSEMBLING INSTRUCTIONS INSTALLING THE RACING LIGHT Drill one 6.5 mm hole on the rear mudguard as shown in the picture, then two additional holes with the same diameter matching the holes of the Racing light. Use the available screws to anchor. Pass the licence plate holder cables along the rear frame.
Page 397 “KIT” ASSEMBLING INSTRUCTIONS CONNECTING THE REAR LIGHT CONNECTOR Connect the rear light connector. CONNECTING THE WATER TEMPERATURE SENSOR Connect the water temperature sensor connector. CONNECTING THE MAQS SENSOR Connect the MAQS connector located on the throttle body. STATIC ELECTRICITY MAY DAMAGE THE MAQS SENSOR PERMANENTLY. MAKE SURE THAT ANTISTATIC PROTECTIONS ARE WORN WHEN HANDLING THE MAQS SENSOR.
Page 398 “KIT” ASSEMBLING INSTRUCTIONS CONNECTING ENGINE CABLES Connect the gear sensor connector. Connect the pick-up sensor connector. Connect the generator connector. CONNECTING RELAYS Connect both relay connectors with no differences. O.56 Part. N. 8000 B0148 (02-2008)
Page 399 “KIT” ASSEMBLING INSTRUCTIONS CONNECTING THE ELECTRIC FAN Connect the connector electric fan. CONNECTING VOLTAGE REGULATOR Connect the voltage regulator connector. ANCHORING HIGH VOLTAGE COIL Screw the coil into the frame. TOGETHER WITH THE COIL, ALSO INSERT THE EARTH EYELET PROJECTING FROM THE VOLTAGE REGULATOR CONNECTOR. Screw the coil into the frame.
Page 400 “KIT” ASSEMBLING INSTRUCTIONS CONNECTING THE HIGH VOLTAGE COIL Connect both pins to the coil. BOTH PINS ARE DIFFERENT IN WIDTH AND CANNOT BE INVERTED. MAKE SURE THAT BOTH PINS MAY BE SECURELY INSERTED INTO THE COIL. ANCHORING THE VOLTAGE REGULATOR Screw the voltage regulator into the frame.
Page 401 “KIT” ASSEMBLING INSTRUCTIONS CONNECTING THE DIAGNOSTIC CONNECTOR PLUG Connect the diagnostic plug which was previously removed from the original system. CONNECTING THE HORN PUSHBUTTON Connect the 800094145 horn cable to the horn. Connect the 800094145 horn cable to the racing system. Connect the 800094145 horn cable pushbutton to the handle bar.
Page 402 “KIT” ASSEMBLING INSTRUCTIONS CONNECTING THE HEADLIGHT Connect the headlight connector. CONNECTING THE LIGHT SWITCH Connect the 800093221 light switch to both racing cable pins. POSITIONING THE LIGHT SWITCH Drill a hole in the area signalled on the headlight holding cowl and insert the 800093221 light switch, then screw in the 800071755 protection cap.
Page 403 “KIT” ASSEMBLING INSTRUCTIONS ANCHOR THE RACING CABLES Anchor the racing cables to the frame by means of clamps as explained. Anchor the racing cables to the frame by means of clamps as explained. Anchor the racing cables to the frame by means of the eyelet as explained. Anchor the racing cables to the hydraulic clutch control pipe bye means of a clamp as explained.
Page 404 “KIT” ASSEMBLING INSTRUCTIONS CONNECTING THE FUEL PUMP Connect the connector fuel pump to the racing system. Connect the fuel pump to the fuel delivery pipe. ANCHORING THE HEADLIGHT HOLDING COWL Anchor the headlight holding cowl. ANCHORING THE TANK Anchor the fuel tank. O.62 Part.
Page 405 “KIT” ASSEMBLING INSTRUCTIONS INSTALLING SIDE PANELS Place both side panels and screw them in. CONNECTING THE BATTERY Connect the battery and make sure to connect the positive cable first (red sheath) and then the negative cable. INSTALLING THE SADDLE Install the saddle into its housing. Part.
Page 406 “KIT” ASSEMBLING INSTRUCTIONS WIRING HARNESS RACING Cable colour coding 1. Tail light Blue (1÷7, 21, 55÷57) 2. Voltage regulator Black (28÷31) 3. Electronic device (ECU) Brown (23) 4. Alternator pick-up Br/R Brown/Red (38) 5. Alternator Br/W Brown/White (17÷20, 61) 6. H.T. Coil Green (27) 7.
Page 407 “KIT” ASSEMBLING INSTRUCTIONS Part. N. 8000 B0148 (02-2008) O.65...
Page 408 “KIT” ASSEMBLING INSTRUCTIONS WIRING HARNESS RACING Cable colour coding 1. Tail light Blue (1÷7, 21, 55÷57) 2. Voltage regulator Black (28÷31) 3. Electronic device (ECU) Brown (23) 4. Alternator pick-up Br/R Brown/Red (38) 5. Alternator Br/W Brown/White (17÷20, 61) 6. H.T. Coil Green (27) 7.
Page 409 “KIT” ASSEMBLING INSTRUCTIONS Part. N. 8000 B0148 (02-2008) O.67...
Page 410 “KIT” ASSEMBLING INSTRUCTIONS O.68 Part. N. 8000 B0148 (02-2008)
Page 411 HYDRAULIC CONTROL CLUTCH Hydraulic clutch system ..........Discharge of hydraulic system fluid ......Overhaul of the control pump for clutch release ..Bleeding of the hydraulic system ....... Section Part. N. 8000 B0148 (02-2008)
Page 412 HYDRAULIC CONTROL CLUTCH Part. N. 8000 B0148 (02-2008)
Page 413: Hydraulic Clutch System
HYDRAULIC CONTROL CLUTCH Hydraulic clutch system The hydraulic system consists of a pump with its own tank, placed on handlebar L.H. side, and a small piston, placed in the L.H. engine crankcase. The clutch desengagement is effectued by the slave cylinder (5) that, acting on the push rod, move the pressure disc (6).
Page 414: Discharge Of Hydraulic System Fluid
HYDRAULIC CONTROL CLUTCH Discharge of hydraulic system fluid Connect a small plastic hose to the discharge valve and unscrew it by one or two turns. Remove the reservoir cover and the diaphragm and act release control lever until all fluid is discharged. Overhaul of the control pump for clutch release Drain the system, detach the pump from the L.H.
Page 415: Bleeding Of The Hydraulic System
HYDRAULIC CONTROL CLUTCH Bleeding of the hydraulic system Proceed as follows: - remove screws (1), cap (2) and rubber pump diaphragm (4); - remove the rubber cap (3) and the bleeding nipple (5); - mount a syringe in the bleeding nipple hole, then refill with fresh fluid (see LUBRICATION TABLE on page A.9).
Page 416 HYDRAULIC CONTROL CLUTCH Part. N. 8000 B0148 (02-2008)
Page 417 OPTIONAL PARTS LIST Section Part. N. 8000 B0148 (02-2008)
Page 418 OPTIONAL PARTS LIST OPTIONAL PARTS LIST (TE) 1- Engine seals kit (TE 250) 8000 B0373 1- Engine seals kit (TE 450-510) 8000 B0364 2- Rear sprocket 8A00 96837 (Z=47) * (TE 450-510) 8B00 96837 (Z=48) 8C00 96837 (Z=49) 8D00 96837 (Z=50) * (TE 250)
Page 419 OPTIONAL PARTS LIST OPTIONAL PARTS LIST (TC-TXC) 1- Engine seals kit (TC-TXC 250) 8000 A5735 1- Engine seals kit (TC-TXC 450-510) 8000 A5736 2. Workshop manual 8000 B0148 3. Rear sprocket 8A00 96837 (Z=47) * (TC 250) (TXC 450-510) 8B00 96837 (Z=48) 8C00 96837 (Z=49) 8D00 96837 (Z=50) * (TC 450-510) (TXC 250) 4.
Page 420 OPTIONAL PARTS LIST OPTIONAL PARTS LIST (SMR) 1- Engine seals kit 8000 B0364 2- Rear sprocket 8000 A4859 (Z=42) * 8A00 A4859 (Z=43) 8B00 A4859 (Z=44) 8G00 A4859 (Z=45) 3- Drive sprocket 8000 63829 (Z=14) * 4- Workshop manual 8000 B0148 5- Front fork oil (1000 cm container) 8000 80260 6- Rear shock absorber oil (500 cm...
Page 421 SMR 450-R Equipment kits - Optional parts ......... Carbon components ..........Steering head tube adjusting instructions ....Preliminary operations ..........Removing the Front Wheel ........Removing the Front Fork .......... Removal of Bushes ........... Steering Head Tube Adjustment ....... Starting hook kit ............Assembling instructions for starting hook kit ....
Page 422 SMR 450-R STANDARD KIT-OPTIONAL PARTS ( 1- 8000 A4349 Spark plug wrench (1) 2- 8000 66802 Box wrench 15x27mm (1) 3- 8000 96997 Front wheel pin wrench (1) 4- 8000 56920 Front wheel pin setscrew wrench (1) 5- 8000 B1245 User and service manual (1) 6- 8000 B0157 Motor safety guard (1) 7- 8000 B0148 Shop manual (1) (CD) 8- 8000 B1247 Spare parts list (1)
Page 423 SMR 450-R Part. N. 8000 B0148 (02-2008)
Page 424 SMR 450-R Carbon parts 1- Cylinder head cap 2- Shock absorber guard 3- Right sump guard 4- Gearbox outlet pinion cap 5- Chain guide cap 6- Front fender stiffener 7- Air filter box NOTE: every 2 hours, check the locking screws of the carbon caps to make sure they are tight.
Page 425: Preliminary Operations
SMR 450-R STEERING HEAD TUBE ADJUSTING INSTRUCTIONS The supplied kit consist of 9 bushes (+2 standard, assembled onto the steering head tube) identified by the two marks “A” on bottom side: Part No. Q.ty Mark "A" 8000 B1781 80 (standard) 8A00 B1781 8B00 B1781 8C00 B1781...
Page 426: Removing The Front Fork
SMR 450-R Removing the Front Fork Take note of measure “B” which must be restored when reassembling. Loosen the eight screws (4) fastening the legs to the steering plates, remove the brake hose brackets (5) and (6), remove the fastening screw (7) and withdraw the number holder from the lower plate.
Page 427: Removal Of Bushes
SMR 450-R Remove the vent hose (8) and the steering pin nut (9). Extract the entire assem- bly “b: steering head-handlebar-controls” and place it having attention to keep the brake fluid tank ALWAYS in plane, then withdraw the fork legs. Loosen the steering pin ring nut (10), remove it and extract the steering base assy with pin from the steering head tube.
Page 428: Steering Head Tube Adjustment
SMR 450-R Steering Head Tube Adjustment The steering head adjustment is obtained by means of coupling 2 bushes, and consists of 5 forward positions and 3 angular settings, for a total of 15 different adjustments. The table below shows adjustments values (X) and (A°) corresponding to the use of a bush coupling, and the check dimensions (S1) and (S2) shown in the picture.
Page 429: Starting Hook Kit
SMR 450-R Reassemble the steering base complete with washer and lower bearing, the upper bearing, the dust cover (11 page 1-2) and the ring nut (10 page 1-2) tightening it to the prescribed torque. Reassemble the group “b: steering head- handlebar-controls”...
Page 430: Assembling Instructions For Starting Hook Kit
SMR 450-R Assembling instructions for starting hook kit Preliminary operations Set a stand or a block under the engine and see that the front wheel is lifted from the ground. Loosen the four screws (1 fig. 1) fixing the front wheel axle. Hold the head (3 fig.
Page 431: Assembling Instructions For Hand-Guards Kit
SMR 450-R Assembling instructions for hand-guards kit The kit consists of: 1- Screw M8x55 (2) 2- Collared bush (2) 3- Notched bush (2) 4- Spacer (2) 5- Threaded spacer (2) 6- Screw M6x40 (2) 7- Bush (2) 8- Washer (2) 9- Self-locking nut M6 (2) 10- Front tie rod (2) 11- Screw M6x30 (4)
Page 432: Handlebar
SMR 450-R Handlebar In order to effect a correct assembly, the handlebar is provided with reference marks, as shown in the figure. Fluids tank Check periodically the fluid level in the tank (1): if the level is approx. at 1/3 of the top level, remove the plug (2) and drain the fluid.
Page 433: Fuel Injection System
FUEL INJECTION SYSTEM Fuel injection system .............. S.2 Operating instructions for the "DIAGNOSIS SOFTWARE KIT" on the fuel injection ....S.3 Fuel pump check ..............S.5 Relay check ................S.6 Section Part. N. 8000 B0148 (02-2008)
Page 434: Fuel Injection System
FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM The fuel injection system consists of: fuel tank (1), electric pump (2), hose (3) and injector (4). The fuel in the tank is pumped by the fuel pump and the pressurized fuel flows into the injector installed in the throttle body (6). The fuel is injected into the throttle body with a conical dispersion when the injector opens according to the injection signal coming from the Electronic power unit (5) located under the fuel tank.
Page 435: Operating Instructions For The "Diagnosis Software Kit" On The Fuel Injection
FUEL INJECTION SYSTEM Operating instructions for the "DIAGNOSIS SOFTWARE KIT" on the fuel injection system Premised that the fuel injection system doesn’t need any programmed maintenance, the Diagnosis Software Kit code no. 8000 A9634 allows to effect the check of the components of the fuel injection system in case of malfunction. The neutral green warning light shows the malfunction, with the ignition key in ON position and the right commutator in RUN position, in the following way: a) With the GEARBOX NOT in NEUTRAL position: the warning light FLASHES...
Page 436 FUEL INJECTION SYSTEM This diagnosis software allows, besides the identification of the malfunctions in progress, also the memorization of those that are already occurred and that have been eliminated: for these last ones it is possible to effect the cancellation, following the instructions of the Operation Manual (page 29).
Page 437: Fuel Pump Check
FUEL INJECTION SYSTEM Fuel pump check Remove the pump as shown on page S.2. - A: reserve sensor Check that in the reserve sensor has not remained any gasoline therefore set the meter on "Impedance" position and effect the reading on the cables BLUE and WHITE.
Page 438: Relay Check
FUEL INJECTION SYSTEM Relay check Remove the saddle and the the fuel tank as shown on pages E.15-E.23. Re- move the relays (1) located on the frame, R.H. side (no. 1) and L.H. side (no. 2). A: set the meter on "Impedance" position and check that the exciter coil func- tions properly;...
Page 439: Specific Tools
SPECIFIC TOOLS Section Part. N. 8000 B0148 (02-2008)
Page 440 SPECIFIC TOOLS SPECIAL TOOLS 1- (1517 94702) Crankcase puller 2- (8000 A1580) Crankshaft guard 3- (8000 A1559) Flywheel extractor (TC-TXC) 3- (8000 B0144) Flywheel extractor (TE-SMR) 4- (8000 39521) Valves assembling and removing tool 5- (8A00 90662) Support for assy 6- (8000 A9634) Diagnosys kit (TE-SMR) 8- (8000 A1625) Dial gauge holding tool 10- (8000 91288) Jaw (front fork seal ring)
Page 441: Torque Wrench Settings
TORQUE WRENCH SETTINGS Section Tighten all nuts and bolts with a torque wrench at the correct setting. Insufficient tightening of nuts or bolts can cause them to become damaged or loose leading to vehicle damage or injury to the rider. Overtightening a nut or bolt can strip its thread or cause breakage.
Page 442 TORQUE WRENCH SETTINGS TIGHTENING TORQUES (+/- 5%) ENGINE Application Camshaft cap fastening screw M6x1 12 Nm 1,2 Kgm 8.7 ft/lb Rocker arm axle plug M14x1,5 (+LOCTITE 243) 25 Nm 2,55 Kgm 18.4 ft/lb Cylinder head cover fastening screw M6x1 0,8 Kgm 5.8ft/lb Cylinder head fastening nut M8x1,25...
Page 443 TORQUE WRENCH SETTINGS TIGHTENING TORQUES (+/- 5%) CHASSIS Application Rear frame lower fastening screw M8x1,25 25,5 Nm 2,6 Kgm 18.8 ft/lb Engine guard fastening screw M6x1 14,7 Nm 1,5 Kgm 10.8 ft/lb Rear chain roller fastening screw M8x1,25 26,95 Nm 2,75 Kgm 19.9 ft/lb Side stand fastening screw M8x1,25 (+LOCTITE 243) 11,75 Nm 1,2 Kgm 8.7 ft/lb...
Page 444 TORQUE WRENCH SETTINGS TIGHTENING TORQUES (+/- 5%) CHASSIS Application Frame to tie rod fastening nut M12x1,25 80 Nm 8,2 Kgm 59 ft/lb Rocker arm to tie rod lubricator M6x1 2,95 Nm 0,3 Kgm 2,2 ft/lb Rear shock absorber to frame fastening pivot M10x1,25 52,4 Nm 5,35 Kgm 38,6 ft/lb Rocker arm to frame fastening pivot...
Page 445 TORQUE WRENCH SETTINGS TIGHTENING TORQUES (+/- 5%) CHASSIS Application Air filter box flange fastening nut M5x0,8 3,45 Nm 0,35 Kgm 2.5 ft/lb Front brake caliper fastening screw (TE- TC) M8x1,25 25,5 Nm 2,6 Kgm 18.8 ft/lb Brake hoses lower fastening screw M10x1 19 Nm 1,95 Kgm 14 ft/lb...
Page 446 TORQUE WRENCH SETTINGS NOTE: If not otherwise specified, standard tightening torques for the following thread (+/- 5%) steel screws on plastic with metal spacer 2 Nm 0,2 Kgm 1.45 ft/lb steel screws on brass, copper, aluminium 2 Nm 0,2 Kgm 1.45 ft/lb steel screws on iron, steel 3 Nm...
Page 447 FRAME AND WHEELS Frame ............... Front wheel ............... Removing the front wheel ......... Reassembling the front wheel ........Rear wheel ............... Y.10 Removing rear wheel ..........Y.11 Wheels overhauling ..........Y.12 Bending the wheel pin ..........Y.12 Wheel spokes ............Y.13 Rims warpage ............
Page 449 FRAME AND WHEELS STANDARD mm (in.) AXIS “X” “Y” -576.7 +440.5 (22.7) (17.34) -460 +423 (18.11) (16.65) -442 +259 (17.40) (10.19) -394.2 +337.2 (15.52) (13.27) -311 +23.2 (12.24) (0.91) -302.4 +1.8 (11.9) (0.07) -262.5 -81.5 (10.33) (3.2) -240.8 -95.9 (9.48) (3.77) +65.5 +170...
Page 450 FRAME AND WHEELS Check the assemblies shown on the picture for wear or failure. If worn or breaked, replace them. A. ENGINE FASTENING BOLTS B. REAR FRAME FASTENING BOLTS C. CHAIN GUIDE ROLLER-BEARING D. FOOTRESTS-PIVOTS-SPRINGS E. SIDE STAND- SPRINGS Part. N. 8000 B0148 (02-2008)
Page 451: Front Wheel
FRAME AND WHEELS TE-TC-TXC Front wheel Hub and rim in light alloy with high tensile steel spokes. Rim make, type and dimension (TE, TC, TXC) "TAKASAGO"" Excel in light alloy: 1.6x21” (SMR) "SANREMO" in light alloy: 3.50x17” (SMR/R) "EXCEL" in light alloy: 3.50x16.5” Tire make, type and dimension (TE, TXC) "Michelin"...
Page 452 FRAME AND WHEELS Removing the front wheel (pages Y.6-Y.7) Set a stand or a block under the engine and see that the front wheel is lifted from the ground. SMR: remove the two screws (A) and the brake caliper. Loosen the screws (1) fastening the wheel axle (2) to the fork rod supports. TE-TC-TXC TE-TC-TXC Lock the wheel pin head and at the same time loosen the screw (3) on the...
Page 453 FRAME AND WHEELS Do not operate the front brake lever when the wheel has been removed; this causes the caliper piston to move outwards. After removal, lay down the wheel with brake disc on top. Part. N. 8000 B0148 (02-2008)
Page 454 FRAME AND WHEELS Reassembling the front wheel (pages Y.8-Y.9) Fit the L.H. spacer on the wheel hub. TE-TC-TXC TE-TC-TXC: Fit the wheel between the front fork legs so that the brake disc is fitted TE-TC-TXC into the caliper. SMR: Fit the wheel between the front fork legs. Fit the wheel axle (2) from the R.H.
Page 455 FRAME AND WHEELS Tighten the screw (3) on the fork L.H. side but DO NOT lock it. Now, pump for a while, TE-TC-TXC pushing the handlebar downwards until you are sure that the fork legs are perfectly aligned. Lock: the screws (1) on the R.H. leg (10,4 Nm/ 1,05 Kgm/ 7.7 ft-lb), the screw (3) on the L.H.
Page 456: Rear Wheel
FRAME AND WHEELS Rear wheel Hub and rim in light alloy with high tensile steel spokes. Rim make, type and dimension (TE, TXC) "TAKASAGO“ Excel in light alloy: 2,15x18” (TC) "TAKASAGO“ Excel” in light alloy: 1,85x19”(250); 2,15x19”(450-510) (SMR) "SANREMO" in light alloy: 4,25x17” (SMR/R) "EXCEL"...
Page 457 FRAME AND WHEELS Removing the rear wheel Set a stand or a block under the engine and see that the rear wheel is lifted from the ground. Unscrew the nut (1) of the wheel pin (3) and extract it. It is not necessary to unloose the chain adjusters (2);...
Page 458: Wheels Overhauling
FRAME AND WHEELS Wheels overhauling Check the wear state of the hub bearings. In case of excessive clearance (radial and axial), operate as follows: - lay the hub on a flat holder with hole, allowing for the passage of the removed bearing;...
Page 459: Wheel Spokes
FRAME AND WHEELS WHEEL SPOKES Check to make sure that all the nipples are tight (4,4 Nm/ 0,45 Kgm/ 3.2 ft-lb); 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.
Page 460 FRAME AND WHEELS Rear sprocket, transmission sprocket and drive chain The figure shows the outline of teeth in normal and excessive wear. 1- Normal consumption 2- Excessive consumption Should the sprocket be badly worn out, replace it by loosening the six fastening screws to the hub.
Page 461 FRAME AND WHEELS CHECKING THE WEAR OF CHAIN, PINION AND SPROCKET Proceed as follows: - Fully stretch the chain with the adjusting screws. - Mark 20 chain links. - measure the distance “A” between 1st pin center and 21 st pin center. Check the pinion damages or wear and replace it should the wear degree be as the one shown in figure.
Page 462 FRAME AND WHEELS Y.16 Part. N. 8000 B0148 (02-2008)
Page 463: Notes For Usa/Cdn-Aus Models
NOTES FOR USA/CDN- AUS MODELS Section Part. N. 8000 B0148 (02-2008)
Page 464 IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. THE BUYER OR TRANSFEREE INDEMNIFIES AND HOLDS HARMLESS HUSQVARNA Motorcycles s.r.l., THEIR AGENTS AND EMPLOYEES. FOR ANY FAILURE OF PERFORMANCE, COST OF SERVICE, OR REPAIR. THE BUYER FURTHER ACKNOWLEDGES THAT THIS MOTORCYCLE IS NOT INTENDED FOR USE ON PUBLIC STREETS, ROADS, HIGHWAYS, OR TRAILS UNDER PUBLIC JURISDICTION AND THAT USE ON SUCH MAY VIOLATE STATE AND FEDERAL LAW.
Page 465 Noise emission warranty HUSQVARNA Motorcycles s.r.l. 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.
Page 466 NOTES FOR USA/CDN- AUS MODELS SPARK ARRESTER The TE/TXC/SMR models are equipped with a U.S. Forest Service approved spark arrester for maximum efficienty and performance. "SPARK ARRESTER" MAINTENENCE AND CLEANOUT INSTRUCTIONS Proceed as follows: A: First turn counterclockwise fastening rear pin (1) then remove saddle, screws (2) and L.H.
Page 467 NOTES FOR USA/CDN- AUS MODELS NOTES FOR “AUS” MODEL 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.
Page 468 NOTES FOR USA/CDN- AUS MODELS KIT CANISTER (USA) Canister kit (1) Hose (45 mm/1.77 in.) (1) Clamp (1) Hose (715 mm/28.15 in.) (1) Hose (320 mm/12.6 in.) (1) Clamp (2) Clamp (L=188mm/7.4 in.) (1) Hose (420 mm/16.53 in.) (2) Canister (1) Clamp (1) Pad (1) Vent valve (1)
Page 469 NOTES FOR USA/CDN- AUS MODELS Part. N. 8000 B0148 (02-2008)
Page 470 NOTES FOR USA/CDN- AUS MODELS Part. N. 8000 B0148 (02-2008)

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Husqvarna TE 250 Workshop Manual

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General Operations

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Engine Overhauling

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