WR 250 - WR 250 USA 2013

WR 300 - WR 300 USA 2013

Manuale utente_Owner’s manual_Manuel d’utilisateur_Benutzerhandbuch_Manual del usuario

 WR 250

EN
WR 300

WR 250 - WR 250 USA 2013

WR 300 - WR 300 USA 2013

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 1

Ed. 05-2012 - Rev. 00
Unless specified, data and prescription are referred to all the models.
TABLE OF CONTENTS Page Note
• References to the “left” or “right” of the motorcycle are in
PRESENTATION........................................................................ 3 the sense of a person facing forwards.
IMPORTANT NOTICES............................................................... 3 • Z: number of teeth
IDENTIFICATION DATA. ............................................................ 5 • A: Austria
control location.................................................................6 AUS: Australia
TECHNICAL DATA..................................................................... 7 B: Belgium
LUBRICATION TABLE, SUPPLIES................................................ 8 BR: Brazil
CONTROLS. ............................................................................. 9 CDN: Canada
CH: Switzerland
RIDING................................................................................. 16 D: Germany
APPENDIX............................................................................. 45 E: Spain
PRE-DELIVERY INSPECTION. ................................................... 47 F: France
ALPHABETICAL INDEX. ........................................................... 48 FIN: Finland
PERIODIC MAINTENANCE -ADJUSTMENT.................... APPENDIX A GB: Great Britain
I: Italy
J: Japan
USA: United States of America

• Where not specified, all the data and the instructions are
referred to any and all Countries.

EN - 2 SPECIFICATIONS - OPERATION - MAINTENANCE

PRESENTATION IMPORTANT NOTICES
Welcome to the Husqvarna motorcycling Family! WR 250 ENDURO
Your new Husqvarna motorcycle is designed and manufac- WR are STREET LEGAL motorcycles (with
tured to be the finest in its field. LIMITED POWER ENGINE); they are guar-

EN
The instructions in this book have been prepared to provide anteed exempt from functional defects
a simple and understandable guide for your motorcycle’s and covered with legal guarantee, if the
operation and care. STANDARD CONFIGURATION is maintained
Follow the instructions carefully to obtain maximum per- and the suggested maintenance table,
formance and your personal motorcycling pleasure. Your shown on Appendix A is observed.
owner’s manual contains instructions for owner care and If WR are transformed in COMPETITION
maintenance. MOTORCYCLES (with FULL POWER ENGINE),
The main work of repair or maintenance requires the at- the suggested maintenance table for com-
tention of a skilled mechanic and the use of special tools petition use is shown on Appendix A.
and equipment.
WR 300
Your Husqvarna dealer has the facilities, experience and origi-
nal parts necessary to properly render this valuable service.
This “Owner’s Manual” is part and par-
cel of the motorcycle, hence, this had to
remain with the motorcycle even when
sold to another user.
This motorcycle uses components designed thanks to sys-
tems and state of the art technologies which are thereafter
tested in competition.
In competition motorcycles, every detail is verified after each
race in order to always guarantee better performance. For
correct functioning of the vehicle, it is necessary to follow the
maintenance and control table found on Appendix A.

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 3

IMPORTANT Important Notice WARNING*: After an upset, inspect the motor-
Read this manual carefully and pay special attention to state- cycle carefully. Make sure that the throttle,
The reference for recognition of the guarantee will be the MO- brake, clutch and all other systems are unda-
ments preceeded by the following words:
TORCYCLE CONFIGURATION, as shown below: maged. Riding with a damaged motorcycle can
lead to a serious crash.
A) STANDARD MOTORCYCLE, STREET LEGAL: with LIMITED POWER WARNING*: Indicates a possibility of severe
ENGINE personal injury or loss of life if instructions are
B) COMPETITION MOTORCYCLE, RACING USE: with FULL POWER not followed. WARNING*: Never attempt to start or operate
ENGINE CAUTION*: Indicates a possibility of personal your motorcycle unless you are wearing appro-
injury or equipment damage if instructions are priate protective clothing. Always wear a motor-
This motorcycles was not designed for long not followed. cycle helmet, motorcycle boots, gloves, goggles
trips with the engine always at maximum Note*: Gives helpful information. and other appropriate protective clothing.
rpm as can occur whilst travelling on roads
or highways. Long trips at full throttle can
cause severe damage to the engine. WARNING*: Do not attempt to start or ride
Parts Replacement this motorcycle until you have received expert
This motorcycles was not designed for urban When parts replacement is required, use only Husqvarna ORIGI-
use and is not equiped with a cooling fan and instruction and are in excellent physical condi-
thermostat. Long stops at the traffic lights NAL parts. tion.
can cause overheating and the boiling of
radiator water. This motorcycles is setup for
competition use and therefore guarantees PRECAUTIONS FOR CHILDREN
maximum performance with the rider alone. WARNING
It is thereby • Park the vehicle where it is unlikely to be
not recommended to use the vehicle on circu- bumped into or damaged. Even slight or
its or off-road with a passenger. involuntary bumps can cause the vehicle
to topple over, with subsequent risk of se-
rious harm to people or children.
In order to maintain the vehicle’s “Guaran- • To prevent the vehicle from tipping over,
tee of Functionality”, the client must follow never park it on soft or uneven ground,
the maintenance program indicated in the nor on asphalt strongly heated by the
user’s manual by carrying out maintenance sun.
checks at authorized HUSQVARNA dealers. • Engine and exhaust pipes become very hot
The cost for substituting parts and for the la- during riding. Always park your motorcycle
where people or children can not easily re-
bour necessary in order to respect the main- ach these parts, in order to avoid serious
tenance plan, is charged to the client. burns.
NOTE: the guarantee is EXTINGUISHED in the
case where the motorcycle is rented.

EN - 4 SPECIFICATIONS - OPERATION - MAINTENANCE

IDENTIFICATION DATA
The engine number is printed on the upper side of the engi-
ne case, whereas the frame number is printed on the steering
tube. 1

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Always state the number stamped on the frame
(and write it on this booklet), when placing orders for spare
parts, or when asking for information on your motorcycle.

FRAME NUMBER

2
VEHICLE IDENTIFICATION NUMBER (V.I.N.)

The full 17 digit serial, or Vehicle Identification Number, is

stamped on the steering head tube (R.H. side).

(l) = Model designation

(▲) = Model Year (2013)
(♦) = Progressive no.

1. Frame serial number

2. Engine serial number
WR 250 WR 300

ZKH3H02ABDV000001 ZKH3H02ACDV000001

(l) (▲) (♦) (l) (▲) (♦)

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 5

control location
1. Front brake lever 2 3
2. Throttle grip 7
3. L.H. commutator
4. Rear brake control pedal
5. Starting pedal 6
6. Clutch control lever
1
7. Fuel tank filler cap
8. Gearbox control pedal
9. Choke (L.H. side)
10. Fuel cock

10
4
9

8
5

EN - 6 SPECIFICATIONS - OPERATION - MAINTENANCE

 TECHNICAL DATA FUEL SYSTEM FINAL RATIOS
ENGINE Type........................................... Carburettor “Mikuni” TMX 38 1st gear.........................................................................20,220
Type............................................... single cylinder, 2 stroke Venturi diameter............................................1.49 in. (38 mm) 2nd gear........................................................................16,513
Cooling. ........................................................................ liquid High speed jet.....................................................................380 3rd gear........................................................................13,564

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Bore (250)..................................................2.61 in (66,4 mm) High speed jet (250 USA)....................................................430 4th gear.........................................................................11,422
High speed jet (300 USA)....................................................420 5th gear...........................................................................9,932
Bore (300).....................................................2.83 in (72 mm)
Stroke. ..........................................................2.83 in (72 mm) Low speed jet.....................................................................17,5
FRAME
Displacement (250).....................15.21 cu. in. (249,3 cm3) Low speed jet (250 USA).......................................................40
Type................................ Steel single tube cradle (roud tubes);
Displacement (300)..................... 17.87 cu. in. (293,1 cm3) Low speed jet (300 USA).......................................................35
light alloy rear frame.
Compression ratio Starting jet............................................................................80
(with closed ports) WR 250...............................................8,4:1 Main nozzle...............................................................R-8 (914)
(with closed ports) WR 300...............................................6,9:1 FRONT SUSPENSION
Floater (n° 2)...................................................................g 6,1 Type....................”Upside-down” telescopic hydraulic front fork
Starting .................................................................. kick start Throttle piston......................................................................5,0 with advanced axle (adjustable in compression and rebound
Throttle piston (USA)............................................................4,0 stroke); stanchions tubes Ø 1.89 in (48 mm).
TIMING SYSTEM Metering pin............................................................ 6BFY43-74 Legs axis stroke........................................11.8 in. (300 mm)
Type..................................................lamellar valve on suction Metering pin (300 USA)...........................................6GAY69-74
H.T.S. valve with mechanical control on the exhaust REAR SUSPENSION
Metering pin slot..................................................................3^
Idle mixture adjusting screw............................................ 1 + ½ Type...............progressive with hydraulic single shock absorber
LUBRICATION
Engine........................................... 3% (1:32) of oil-gasoline mix Wheel stroke.............................................12.6 in. (320 mm)
during running in; NOT LESS than 2% (1:50) when running in is PRIMARY DRIVE
over Drive pinion gear- Clutch ring gear ........................... Z 27- Z 69 FRONT BRAKE
Primary drive transmission/Gearbox.by the oil contained in the Transmission ratio . .........................................................2,555 Type............fixed disc Ø 10.23 in. (260 mm) “Wave” type with
crankcase hydraulic control and floating caliper
CLUTCH
IGNITION Type....... oil bath multiple disc clutch, mechanical control REAR BRAKE
Type................................. electronic digital capacitor-discharge Type.....................................floating disc, ø 8.66 in. (220 mm)
type, with variable advance TRANSMISSION
Spark plug type......................................................NGK BR8EG Type......................................... constant mesh gear type with hydraulic control and floating caliper
Gap....................................0.0236÷0.0275 in. (0,6 ÷ 0,7 mm) Transmission ratio
1st gear. .......................................................2,142 (z 30/14)
2nd gear.......................................................1,750 (z 28/16)
3rd gear. ......................................................1,437 (z 23/16)
4th gear........................................................1,210 (z 23/19)
5 th gear. .....................................................1,053 (z 20/19)
SECONDARY DRIVE
Transmission sprocket- Rear wheel sprocket............... Z 13- Z 48
Transmission ratio............................................................3,692

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 7

RIMS TABLE FOR LUBRICATION, SUPPLIES
Front...................................................... in light alloy: 1,6x21”
Rear.....................................................in light alloy: 2,15x18”
Engine lubricating oil
TYRES CASTROL A747
Front...................................................................... 90/90x21”
Rear................................................................... 140/80x18” Gearbox and primary drive lubricating oil
CASTROL POWER 1 RACING 10W-40
Cold tire pressure
(front) (*)..........................................................12.8÷14.2 psi Engine coolant
( front) (%)..................................................................15.6 psi CASTROL MOTORCYCLE COOLANT
rider and passenger
(rear) (*)............................................................11.4÷12.8 psi Brake system fluid
(rear) (%)....................................................................14.2 psi CASTROL RESPONSE SUPER DOT 4
(*) Racing use - (%) Road use
Grease lubrication
DIMENSION, WEIGHT, CAPACITY CASTROL PASTE TA GREASE
Wheelbase ............................................... .57.7in. (1465 mm)
Final drive chain lubrication
Overall length......................................... 87.79 in. (2230 mm)
CASTROL CHAIN LUBE RACING
Overall length (USA-CDN)............................. 86 in. (2185 mm)
Overall width............................................ 33.07 in. (840 mm) Front fork oil
Overall height .......................................... 51.8 in. (1310 mm) Kayaba KHL15-11
Saddle height ............................................ 38.4 in. (975 mm)
Minimum ground clearance . ................... 13.58 in. (345 mm ) Oil for rear shock absorber
Kerb weight, without fuel..............................227.1 lb (103 kg) TITAN SAF 5045 UE 137 RED
Kerb weight, without fuel (USA-CDN).............224.4 lb (102 kg)
Fuel tank capacity, 1.77 Imp. Quarts - 2.1 U.S. Quarts Electric contact protection
reserve included . ..................... 2.09 Imp. Gall. , 2.51 U.S. Gall. CASTROL METAL PARTS CLEANER
Coolant capacity.................................. 0.97÷1.14 Imp. Quarts , CASTROL MOTORCYCLE DWF
.............................................................1.16÷1.37 U.S. Quarts
Transmission oil................. 0.70 Imp. Quarts , 0.85 U.S. Quarts Fillers for radiator
AREXONS TURAFALLE LIQUIDO

EN - 8 SPECIFICATIONS - OPERATION - MAINTENANCE

 CONTROLS A fuel filter is incorporated in the fuel valves. Accumulation of SIDESTAND
dirt in the filter will restrict the flow of the fuel to the carburetor. A sidestand (1) is supplied with every motorcycle.
FUEL SUPPLY VALVES Therefore, the fuel filter should be serviced periodically.
To service: WARNING*: The stand is designed to sup-

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The cock (1) set on left side of tank has three positions:
OFF - closed; no fuel outlet; 1- Drain the fuel from the fuel tank. Disconnect the fuel line. port the weight of the MOTORCYCLE ONLY. Do
ON - open; fuel outflows from the main flow; 2- Remove the fuel valve by removing the screws. Wash the fuel not sit on the motorcycle using the stand for
RES - reserve; fuel outflows from the reserve flow. screen filter in cleaning solvent. support as this could cause structural failure
When running, should feed problem ensue, set cock lever on RES 3- Reassemble the fuel valve in the reverse order of removal. to the stand and could cause serious bodily
position. After filling up, take the cock in ON position again. Turn the fuel valve “ON” and check for leaks. injury.
WARNING*: Be careful not to touch the hot Periodically check the side stand (see “Periodical maintenance
engine while operating the fuel valve.
card”); check that the springs are not damaged and that the
side stand freely moves. If the side stand is noisy, lubricate the
fastening pivot (A).

1. Fuel cock
A. To carburettor

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 9

FUEL CARBURETOR CHOKE
The motorcycle is equipped with 2 stroke engine that requires
a gasoline-oil mixture. Recommended fuel: premium grade un- The starter knob (1), located on the left side of the carburetor, is
leaded fuel (R.O.N. 98). used to enrich the mixture during the engine start.
Pull out the knob to open the starter, and pull the lever upwards
Note*: Do not continue operation if the en- to close it.
gine pings or knocks. The engine will be
damaged and could seize.

WARNING*: If “knocking” or “pinging”

occurs, try a different brand of gasoline or
higher octane grade.

WARNING*: Gasoline is extremely flamma-

ble and can be explosive under certain con-
ditions. Always stop the engine and do not
smoke or allow flames or sparks in the area
where the motorcycle is refueled or gasoline
is stored.

WARNING*: Do not overfill the tank. After re-

fueling, make sure the tank cap (2) is closed
securely.

EN - 10 SPECIFICATIONS - OPERATION - MAINTENANCE

DIGITAL INSTRUMENT, WARNING LIGHTS - The instrument functions are the following, as shown below. 1- SPEED (Km/h or mph) / ODO

The motorcycle is equipped with a digital instrument; on the 1- SPEED / ODO - SPEED: motorcycle speed- maximum value: 299 Km/h or 299
instrument are located 2 warning lights too: high beam and 2- SPEED / CLOCK mph;

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blinkers. 3- SPEED / TRIP - ODO: odometer- maximum value: 99999 km;
4- SPEED / CHRONO
1- BLUE warning light “HIGH BEAM” 1- SPEED / ODO To replace kilometers with miles or miles with kilometers pro-
2- GREEN warning light “BLINKERS” ................. ceed as follows:
The instrument display illuminates (amber colour) when the 1) set to figure 1, stop the engine and push the knob SCROLL
engine started. (A);
2) Start the engine holding pushed the button SCROLL (A) until
NOTES the symbol “Km/h” will be displayed;
- Every time the engine starts, for the first 2 seconds, the 3) then the symbols “Km/h” and “Mph Miles” will be displayed
instrument shows the version of the checking SW; after the alternatively. Push again the SCROLL (A) button when the
check, the instrument shows the last planned function. unit you wish to use is displayed.
- When the motorcycle engine is OFF, the instrument doesn’t
also show its functions.
- To select the instrument functions and to set to zero the
functions, use the SCROLL knob (A).

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 11

2- SPEED / CLOCK 3- SPEED / TRIP 1 4- SPEED / CHRONO (STP)
- SPEED: motorcycle speedmaximum value: 299 Km/h o 299 - SPEED: motorcycle speedmaximum value: 299 Km/h o 299 - SPEED: motorcycle speedmaximum value: 299 Km/h o 299
mph; mph mph;
- CLOCK: clock- Reading from 0:00 to 23:59:59; - TRIP 1: distance- maximum value: 999.9 km (the data will be - STP 1: miles/kilometers covered time;
To reset the clock, push the knob SCROLL (A) for more than 3 lost with voltage lower than 6V). - Reading from 0:00 to 99:59:59 (the data will be lost with
seconds in order to increase the hours; release the knob and To setup the TRIP, push the SCROLL (A) button holding down voltage lower than 6V).
then, after 3 seconds, it is possible to increase the minutes; more than 3 seconds. To activate the function STP 1, push the knob SCROLL (A) for
more than 3 seconds.
- 1st step: function ON;
- 2nd step: stop to the counters;
- 3rd step: STP 1 zero-setting; TRIP 1 and AVS 1 data zero-
setting;
- 4th step: function ON;
- 5th step: stop to the counters;
.............................
and so following

EN - 12 SPECIFICATIONS - OPERATION - MAINTENANCE

THROTTLE CONTROL STEERING LOCK
The throttle knob (1), is located on the right hand side of the The motorcycle is equipped with a steering lock (1) on the R.H.
handlebar. The position of the throttle control can be adjusted side of the steering head tube.

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by loosening the two fastenig screws . To lock it, procede as follows: turn the handlebar leftwards,
place the key in lock and turn counterclockwise. Push the key
inwards (if necessary, turn to and from). Turn the key clockwise
CAUTION and remove it from the lock.
Do not forget to tighten the screws (A) after To unlock the steering lock, reverse the above procedure.
the adjustment.

FRONT BRAKE CONTROL

The brake control lever (2) is located on the right hand side of
the handlebar. The position of the throttle control can be ad-
justed by loosening the two fastenig screws (B).

CAUTION
Do not forget to tighten the screws (B) after
the adjustment.

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 13

HANDLEBAR COMMUTATOR CLUTCH CONTROL
The clutch lever is located on the left-hand side of the handlebar
1) Engine stop button ( )
and is protected against dirt filtering in. The lever support is pro-
vided with adjusting screw (1) to regulate clutch wire free play.
2) HI = ( ) Selection control High beam
The clutch lever can be adjusted to suit your driving position.
LO = ( ) Selection control of Low beam
CAUTION
Do not forget to tighten the screws (C) after
3) TURN 5 the adjustment.
= Activation of left turn indicators (self cancelling) 1
= Activation of right turn indicators (self cancelling) 4 A: To decrease clearance
To deactivate the indicator, press the control lever after its re-
turning to center. 2 B: To increase clearance
4) HORN = ( ) Warning horn
5) LIGHTS
= Lighting control of lowbeams and high beam.

= Lighting control of position lights.

3
= Off

USA

ENGINE STOP BUTTON (USA) 1

On the left side of the handlebar, near the clutch control, is lo-
cated the engine stop button (1).

EN - 14 SPECIFICATIONS - OPERATION - MAINTENANCE

REAR BRAKE CONTROL GEAR SHIFT CONTROL KICKSTART PEDAL
The kickstart pedal (1) is situated on the right-hand side of the
The rear brake control (1) is placed on the right-hand side of the The lever (1) is placed on the left-hand side of the engine. The
motorcycle.
motorcycle. On models TE and SMR as stop switch, during the operator must release the lever after each gear change to allow

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braking action, causes the rear light to come on. it to return to its central position before another gear change
can be made.
Neutral position (N) is between first (low) and second gears.
First gear is engaged by pushing the lever downwards; all the
other gears are engaged, by pushing the lever upwards.
The position of the gear shift lever on the shaft can be varied by:
loosening screw; pulling lever out; placing lever in new position
on the shaft when the operation is over tighten the screw and
then tightening the screw.
CAUTION*: Do not shift gears without disen-
gaging the clutch and closing the throttle. The
engine could be damaged by “overspeed”
and shock.
WARNING*: Do not downshift when traveling
at a speed that would force the engine to
overrev in the next lower gear, or cause the
rear wheel to lose traction.

N: Neutral

1
2

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 15

RIDING 9. Check torque avoid hard accelerations.
A. Spark plug. 6.Repeat cool down procedure.
BEFORE EVERY RIDE MAKE FOLLOWING CHECKS B. General check of torque 7. Full throttle operation must be avoided until the engine has
WARNING! 10. Check steering action reached operating temperature, even after the break in process
Before each ride, to prevent accidents or failures during ride, Check bearing play. is completed. When the above procedure is followed correctly,
make sure to go through following list. 11. Check the electric system engine durability and performance will be greatly enhanced.
  Start the engine and check that the front and rear lamps, the
  1. Check all fluids stop light, the turn signals the cluster warning lights and the
A. Transmission oil level horn are working correctly.
B. fuel level
C. coolant level WARNING*: Failure to perform these checks
Make sure all caps are properly adjusted. every day before you ride may result in se- CHECKS WHILE RUNNING IN
rous damage or a severe accident. When running in, the following should be checked out:
WARNING*: Don’t remove radiator cap when
- WHEELS SPOKES TENSION;
hot!
- TIGHTENING OF WHEELS
2. Check all controls
- FORK PIN TIGHTENING
A. Throttle handgrip
- CHAIN ADJUSTMENT;
B. Clutch lever
- STEERING BEARING PLAY;
Make sure cables are not damaged and turn smoothly.
RUNNING IN - HANDLEBAR TIGHTENING
3. Check brakes
To obtain the best settling of the engine moving elements, for - ENGINE GRIP TO FRAME
Look for brake fluid leaks and worn hoses. Check for proper
driving your motorcycle to the best of your capability, run in the - SUCTION FITTING GRIP
functioning.
engine for several hours, following these procedures: - HEAD AND CYLINDER NUTS GRIP
4. Check suspensions
1. FROM STOP POSITION. Start the engine and run at idle, but
Compress fork and rear suspensions. Look for oil leaks and
open the throttle periodically and briefly until the engine is tho- Note*: After break in, install a new spark
ensure proper functioning.
roughly warmed up. Within 3-4 minutes the coolant temperature plug and change the transmission oil.
5. Check wheels
will have reached approximately 60° C/140° F. (Do not ride
Check spokes and look for worn bearings.
the motorcycle).
Check rims and tyres.
2. Stop the engine, and let it cool down naturally until its tem-
Check tyre pressure.
perature is equal to the ambient air temperature. This will allow
6. Check chain rollers and sprockets
the piston to align itself to any imperfections which might exist
Check wear on chain rollers and sprockets
at the cylinder wall.
Ensure chain is correctly adjusted and lubricated.
3. Repeat steps 1 and 2. (Do not ride the motorcycle).
7. Check air filter and intake system
4. Bring the engine up to normal running temperature. Ride the
Check that air filter is clean
motorcycle approximately 10 minutes at moderate speeds. Then
Check all rubber connections and clamps.
repeat cool down procedure.AVOID HARD ACCELERATIONS.
8. Check exhaust system
5. Bring engine up to normal temperature. Ride motorcycle
Check hook up, look for cracks
approximately 15 minutes at moderate to high speeds. Again
Check muffler.
EN - 16 SPECIFICATIONS - OPERATION - MAINTENANCE
ENGINE START IMPORTANT NOTE IN CASE OF COLD STARTS IMPORTANT
For the correct start of a cold engine proceed as follows: AT LOW TEMPERATURES Never accelerate the engine after a cold start.
- shift the transmission into neutral; It is recommended to briefly warm-up
- set fuel valve (1) in ON position; the engine at idle until, after having dis- WARNING*: Exhaust contains poisonous car-

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- lift the knob lever (3) on the carburetor. engaged the starter, there is a normal bon monoxide gas. Never run the engine in a
Leaving the throttle in closed position operate kick-start (4). response from the engine when opening closed garage or in a confined area.
Take the knob lever in its initial position as soon as the engine the throttle.
is idling. This will enable the lubricant to reach
When starting with an already warmed up engine DO NOT USE
the starter. You can start the engine with the gear inserted, after the correct working temperature there-
by guaranteeing a correct functioning of WARNING*: This high performance motor-
disconnecting of the clutch. cycle can some times «kick back» strongly
If the carburetor is flooded, shut off the fuel supply and the all engine parts.
starter and operate the crank lever or the kick-start until the Avoid overheating the engine. when you are starting it.
engine starts. If necessary, remove the spark plug and dry it. Do not attempt to start this motorcycle unless
you are wearing high top heavy sided rid-
ing boots. You could seriously hurt you leg
if the kickstarter kicked back and your foot
slipped.

1
4

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 17

STOPPING THE MOTORCYCLE AND THE ENGINE - Press the engine stop button (3). - Close the fuel cock (4).

- Close the throttle (1) completely so that the engine will help When the bike is off, place it on its side stand.
slow down the motorcycle.
- For normal braking, gradually apply both front and rear
brakes while down shifting (for maximum deceleration, apply
the front and rear brakes firmly).
- When stopped, pull the clutch lever and shift gear lever (2) in
neutral position.

USA
4
2

3
EN - 18 SPECIFICATIONS - OPERATION - MAINTENANCE
TRANSMISSION OIL LEVEL CHECKING TRANSMISSION OIL CHANGE COOLANT LEVEL CHECK
Check level (1) in right-hand radiator when engine is cold (place
By keeping the motorcycle on a flat surface and in vertical position, To completely replace the oil, unscrew the plug (A) under the
the motorcycle so that it is perpendicular to the ground). The
remove the control screw (C), and check the level through the hole oil sump and let oil come out, then screw the plug again with its

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coolant should be approximately 10 mm above cells.
in the screw. gasket and pour fresh oil from the hole of the loading plug.
Use only the prescribed quantity and type of oil.
The radiator cap is provided of two unlocking positions, the
Note*: Have this operation made with war-
first being for the previous pressure discharge in the cooling
med-up engine. Note:
system.
Have this operation made with warmed-up
A: Draining plug engine.
WARNING
B: Filling cap
Avoid removing radiator cap when engine
C: Levelling screw A: Draining plug
is hot, as coolant may spout out and cause
scalding.

NOTE
Difficulties may arise in eliminating coolant
from varnished surfaces. If this occurs, wash
off with water.

10 mm
(0,39 in.)

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 19

REPLACEMENT OF COOLING FLUID WARNING*: Coolant on tires will make them
slippery and can cause an accident or injury.
The cooling liquid replacement must be performed with cold
motor, as follows:
Periodically check the connecting hoses (see “Periodical mainte-
- remove the R.H. radiator plug;
nance card”): this will avoid coolant leakages and consequent
- remove the drain screw (2) on the pump cover or the pump
engine seizure: If hoses show cracks, swelling or hardenings due
cover by loosening the two screws (1);
to sheats desiccation, their
- slope the motorbike on the left, to make the liquid come out
replacement shall be advisable. Check the correct tightening of
easily;
the clamps.
- let the liquid drain completely;
- reassemble the drain screw or the pump cover;
- pour the necessary quantity of liquid in the radiator;
- warm up the motor in order to eliminate any possible air bub-
ble;
- fit the motor in vertical position and check that the liquid in
the radiators must be 10 mm/0.4 in. over the radiant mas (if
not, top it up);
- screw the R.H. radiator plug.

EN - 20 SPECIFICATIONS - OPERATION - MAINTENANCE

THROTTLE CABLE ADJUSTMENT - if register (2) should not provide sufficient movement to allow IDLING ADJUSTMENT
for correct adjustment, then adjust register placed on carbu-
The throttle cable can be adjusted using the screw set on the retor. Idling should be adjusted only when the engine is hot and throt-
throttle, or using the adjusting screw set on the There should be approx. 1 mm play on latter register; should tle is closed, as follows:

EN
carburettor cover. To check for proper adjustment of throttle this not be the case, then loosen lock nut (3), and loosen or - Turn idle speed adjuster screw (1) to reach 1400 ÷ 1500
cable, proceed as follows: tighten screw (4), to respectively increase or decrease the rpm.
- remove rubber cap; play. - Air adjuster screw (2) standard calibration: from fully closed
- move transmission sheath to and fro to ensure a play of ap- position, loosen screw by 1+1/2 turns.
prox. 1 mm;
- should play be greater than 1 mm, loosen lock nut (1) and WARNING*: Operation with damaged throt- WARNING*: Exhaust gas contains poisonous
register (2); should play less than 1 mm, then tighten lock tle cable could result in an unsafe riding con- carbon monoxide gas. Never run the engine
nut and register; dition. in a closed area or in a confined area.

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 21

CLUTCH ADJUSTMENT The adjustment can be also effected with tightener (1) set on the
right of the frame. Take care to tighten properly the lock nut. If
The clutch is adjusted by stretching the cable using the adjusting the clutch slips under load or drags in disengaged position after
unit positioned on the handlebar. play has been
As a rule it is sufficient to operate on the handlebar register to adjusted, it must be taken apart for inspection. For this opera-
restore the clearance due to the flexible transmission stretch. tion apply to a Dealer.
The control lever must always have an empty stroke (C)
(3 mm) before starting clutch disengagement. To adjust this
clearance, act on register (2) after taking out rubber cap (1);
turn the register in the direction indicated by arrow A to reduce
the clearance (C); turn it in the direction indicated by arrow B to
increase the clearance.

1. Adjusting screw
1. Rubber cap 2. Locknut
2.Adjusting screw 3. Rubber cap

EN - 22 SPECIFICATIONS - OPERATION - MAINTENANCE

SPARK PLUG CHECK Correct heat rating: Before refitting the plug, thoroughly cle-
The tip of the insulator should be dry and the colour should be light an the electrodes and the insulator using a
Use NGK BR8EG spark plug (2); the gap is 0,6÷0,7 in. brown or grey. brass-metal brush.
A wider gap may cause difficulties in starting engine and in High heat rating:
Apply a little graphite grease to the spark

EN
overloading coil. In this case, the insulator tip is dry and covered with dark deposits.
Low heat rating: plug thread; fit and screw the spark plug by
A gap that is too narrow may cause difficulties when accelerat-
In this case, the spark plug is overheated and insulator tip is vitre- hand then tighten to the torque of 23,5÷25,5
ing, when idling the engine or when performing at low
ous, white or grey in colour. Nm- 17,3÷18,8 ft/lb.
speeds.
Spark plugs which have cracked insulators or
Clean the dirt away from the base of the spark plug before re- CAUTION*: Select a spark plug with a colder corroded electrodes should be replaced.
moving it from the cylinder after removing the cap (1). or hotter heat range carefully and cautiou-
It is very useful to examine the state of the spark plug just after it sly. A spark plug with too hot a heat range
has been removed from the engine since the deposits on the plug may lead to preignition and possible engine
and the colour of the insulator provide useful indications. damage. A spark plug with too cold a heat
range may foul as the result of too much car-
bon buildup.

2
SPECIFICATIONS - OPERATION - MAINTENANCE EN- 23
AIR FILTER CHECK AIR FILTER AND CLEANING ASSEMBLY
Turn rear pin (1) counterclockwise, remove the saddle from the Wash the filter with a specific detergent (CASTROL FOAM AIR To ensure tight fit, slightly (C) grease filter edge on side facing
front afstening screw. FILTER CLEANER or similar) then dry it fully (wash filter with filter housing.
gasoline only in case of necessity). While re-inserting the filter into its housing, make surs that piece
Remove screw (3) and the filter (4). Separate filter (5) from Plunge the filter in special oil for filters (CASTROL FOAM AIR (A) is turned upwards and edge (B) is on the left lower side of
frame (6). FILTER OIL or similar) then wring it to drain superfluous oil. the filter case. Reassemble the parts previously removed (bat-
tery: connect the positive cable first).
CAUTION*: Do not use gasoline or a low flash-
point solvent to clean the element. A fire or CAUTION*: If the element assembly is not
explosion could result. installed correctly, dirt and dust may enter
and the engine resulting in rapid wear of the
CAUTION*: Clean the element in a well ven- piston rings and cylinder.
tilated area, and do not allow sparks or
flames anywhere near the working area.

4 6 A

3
5 C B
EN - 24 SPECIFICATIONS - OPERATION - MAINTENANCE
STEERING WHEEL BALL PLAY ADJUSTMENT Stand in front of the motorcycle and grasp the lower end of
the fork rods sliders moving them in the direction of their axis.
To ensure maximum safety, the steering wheel should always be Se si avverte gioco occorrerà eseguire la regolazione operando
regulated so that the handlebars steering the motorcycle rotate come segue:

EN
freely without play. To check steering wheel adjustment, place - loosen steering sleeve nut (1).
kick stand or other support under the engine so that the front - Loosen screws that fix steering head to fork rods (3).
wheel is raised from ground. Turn the steering ring nut (2) clockwise of the steering sleeve
Place slight pressure on the tips of the handlebars to rotate steer- proper tool, to adjust play properly.
ing wheel; the handlebars should also rotate without effort. - Tighten steering sleeve nut (1) to a torque setting of 57,9÷65,1
Lb/ft; (78,4÷88,3 Nm).
- Tighten screws on the steering head (3) to a torque of
22,5÷26,5 Nm (16.6÷19.5 Lb/ft).

CAUTION*: Do not ride a motorcycle with

damaged steering stem bearings. An unsafe
handling condition can result.

3 2

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 25

ADJUSTMENT OF THE CONTROL LEVER AND A decrease of the fuel level will let air into the sustem, hence CAUTION*: Do not spill brake fluid on to any
CHECK OF THE FRONT BRAKE FLUID LEVEL an extension of the level stroke. painted surface or lenses.
CAUTION*:Do not mix two brands of fluid.
The adjuster (2), located on the control lever, allows adjusting WARNING*: If the brake lever feels mushy Change the brake fluid in the brake line if
of the free play (a). when it is applied, there may be air in you wish to switch to another fluid brand.
Free play (a) must be at least 3 mm (0.1 in.). the brake lines or the brake may be CAUTION*: Brake fluid may cause irritation.
The level of the fluid in pump reservoir must never be below defective. Since it is dangerous to operate Avoid contact with skin or eyes. In case of
the minimum value (1), which can be checked from the window the motorcycle under such conditions, have contact, flush thoroughly with water and call
on the rear side of the pump body. the brake checked immediately by an a doctor if your eyes were exposed.
authorized HUSQVARNA dealer.

A: to encrease clearance
B: to decrease clearance

1 2
+ A

B -
EN - 26 SPECIFICATIONS - OPERATION - MAINTENANCE
REAR BRAKE PEDAL POSITION ADJUSTMENT Rear brake idle stroke adjustment CHECKING THE FLUID LEVEL
The position of the rear foot brake pedal as to the footrest may The rear brake foot pedal should have a (B) 5 mm (0.2 in.) idle The level (A) must be set between the pump tank notches.
be adjusted according to the individual needs. For the adjusting stroke before starting the true braking action.

EN
proceed as follows:
- loosen the screw (1); Should this not happen, operate as follows:
- turn the cam (2) in order to adjust the brake pedal idle stroke - loosen nut (3);
(A); - operate the pump rod (4) to increase or decrease the idle stroke;
- the operation done, tighten the screw (1). - tighten nut (3) at the end of the operation.

The adjusting operation carried out, adjust the idle stroke of the WARNING
pedal as follows. When the idle stroke figures are not met, the
brake pads will be subjected to a fast wear
that may bring to the TOTAL BRAKE INEFFEC-
TIVENESS.

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 27

ADJUSTING THE SUSPENSIONS ACCORDING TO SANDY GROUND NOTE:
PARTICULAR TRACK CONDITIONS Fork: have a harder compression adjustment, or replace the When the fork results as either too soft or too hard for any ad-
standard spring with a harder one, and make a softer compres- justment conditions, check the oil level inside the forkrod.
The following information is a useful guide for setting up the sion adjustment and a harder extension adjustment at the same The level can either be too low or too high. Remember that too
suspensions according to the road conditions. time. much oil inside the fork will involve a more frequent air drain-
Always start from the standard calibration before making any Shock absorber: have a harder compression, and expecially a age. When the suspensions do not react to the changes of cali-
change on the suspensions. Afterwards, increase or decrease the harder extension adjustment. Work on the spring preload to bration, check that the adjusting units are not blocked.
adjusting clicks one at a time. lower the motorcycle rear side.

HARD GROUND MUDDY GROUND

Fork: softer compression adjustment. Fork: have a harder compression adjustment, or replace the
Shock absorber: softer compression adjustment. standard spring with a harder one.
The softer adjustment for the two suspensions is also used both Shock absorber: have a harder compression and extension ad-
in compression and in extension when driving at top speed, in justments, or replace the standard spring with a harder one.
order to have better grip of the tires. Work on the spring preload to lift the motorcycle rear side.
We advise replacing the springs of both suspensions to compen-
sate the weight increase due to the piling of the mud.

EN - 28 SPECIFICATIONS - OPERATION - MAINTENANCE

The standard calibrations and the adjustment procedures are c) AIR VENT (to carry out after each competition, or monthly). OIL FORK LEVEL
shown below. Set the motorcycle on a central stand and release the fork fully
For the regular fork operation, both legs must be provided with
and loosen the air vent valve (D). Once this operation is over,
ADJUSTING THE COMPRESSION FORK the necessary oil quantity. Remove the forkrods form the fork to
tighten the valve.

EN
check the oil level inside the forkrods. Work as follows:
a) COMPRESSION (LOWER REGISTER) - remove the power rod caps;
Standard calibration: -10 clicks . WARNING: Never force the adjusting screws
- remove springs from the stems letting the oil drop into the
beyond the maximum opening and closure
latter;
Remove plug (B) and turn register (A) clockwise until the posi- positions.
- bring forks to stroke end;
tion of fully closed is reached then, turn back by the mentioned - check that the level is at distance “A” below the upper limit of
clicks.To obtain a smoother braking action, turn the register rods.
anticlockwise. Reverse the operation in order to obtain a harder
action.
OIL QUANTITY IN EACH FORK LEG
b) EXTENSION (upper register)
Standard calibration: - 10 clicks. 643 cm3

To reset standard calibration turn register (C) clockwise to reach NOTE

the position of fully closed; then, turn back by the mentioned Flexibility index for the serial springs:
clicks. To obtain a smoother braking action, turn the register K=8,4 N/mm
anticlockwise. Reverse the operation in order to obtain a harder
action. NOTE
Always replace both the spring and the spacers to keep the
preload value unchanged .

a) b) D
A C

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 29

ADJUSTING THE SHOCK ABSORBER 4. The difference between these two measurements constitutes ADJUSTING THE SHOCK ABSORBER SPRING PRE-
the “SAG” of the motorcycle’s rear end. LOAD
The rear shock absorber must be adjusted according to the rider
Suggested SAG: 4 in. with cold shock absorber. 3.7 in. with Proceed as follows:
weight and track conditions.
warmed up shock absorber. 1. First turn counterclockwise fastening rear pin (1) then re-
Proceed as follows:
5. To get the right SAG according to your weight, adjust the move saddle, screws (2) and R.H. side panel (3).
1. With motorcycle on the stand, measure distance (A).
shock absorber spring preload as described at side.
2. Take the normal riding position on the motorcycle with all
your riding apparel.
WARNING*: Never disassemble shock ab-
3. With somebody’s help, take the new distance (A).
sorber, which contains highly compressed
nitrogen. Contact your Dealer for such major
service. Do not incinerate.
B: axis of the panel screw
C: axis of rear wheel pin

A 2

3
C
EN - 30 SPECIFICATIONS - OPERATION - MAINTENANCE
2. Clean ringnut (1) and adjusting nut (2) of the spring (3). SHOCK ABSORBER DAMPING ADJUSTMENT B) EXTENSION - Standard calibration:
3. Either with a hook wrench or an aluminium punch, loosen - 15 clicks (± 2 clicks)
the ringnut. Adjustment of the compression stroke is independent from the
4. Turn the adjusting nut as required. rebound stroke. To reset the standard calibration, turn lower register (5) clock-

EN
5. When the adjusting operation is over (according to your A) COMPRESSION - Standard calibration: wise until reaching fully closed position. Return then back for
weight and riding style), tighten the ringnut. (Torque for 1) Low damping speed: the mentioned clicks. In order to obtain a smooth braking ac-
both ringnuts: 5 Kgm; 49 Nm; 36.2 ft/lb). - 15 clicks (± 2 clicks) tion, turn the register anticlockwise. Reverse the operation in
6. Reassemble R.H. side panel and saddle. (register 4) order to obtain a harder braking action.

WARNING*:Be careful not to touch hot ex- 2) High damping speed:

haust pipe while adjusting the shock abosr- - all open
ber. (register 6)
To reset the standard calibration, turn upper registers (4) and
(6) clockwise until reaching fully closed position.
Return then back for the mentioned clicks. In order to obtain a
smooth braking action, turn the registers anticlockwise. Reverse
the operation in order to obtain a harder braking action.

1 - +

6 4
5

3 2
SPECIFICATIONS - OPERATION - MAINTENANCE EN- 31
CHAIN ADJUSTMENT (Fig. A) Fast adjustment (Fig. B.) CHECKING THE WEAR OF CHAIN, PINION AND
SPROCKET
Chain should be checked, adjusted and lubricated as per the Push the chain towards the final part of runner and check that Check the pinion damages or wear and replace it should the
Maintenance Chart to ensure security and prevent excessive between the two elements a distance “A” from 0 to 2 mm (0,08 wear degree be as the one shown in figure.
wear. If the chains becomes badly worn or is poorly adjusted in.) is present. If this is not the case, go on as follows: Remove the wheel and check the wear of the rear sproket teeth.
(i.e., if it is too loose or too taught), it could escape from sprock- - Unloose the fastening nut of the wheel pin (1) on the right The below figure shows the outline of teeth in normal and exces-
et or break. side; sive wear. Should the sprocket be badly worn out, replace it by
To adjust the rear chain it is necessary to lower the rear part of - Unloose the lock nuts (2) on both chain adjusters and turn the loosening the six fastening screws to the hub.
motorcycle so to line up the drive sprocket axle, the rear swing screws (3) to obtain the correct tension value;
arm axle and the rear wheel axle as shown on drawing. Than - Tighten the lock nuts.
let turn three times the rear wheel. Now the chain should not After adjustment check that the wheel is lined up and tighten WARNING*: Misalignment of the wheel will
be tight. its axle. result in abnormal wear and may result in
an unsafe riding condition.

Fig. A Note*: In muddy and wet conditions, mud

sticks to the chain and sprockets resulting
in an overtight chain. The pinion, the chain,
and the rear sprocket wheel wear increases
when running on muddy ground.
Drive sprocket axle

Rear swing arm axle Rear wheel axle

Normal consumption

Fig. B
3 2

Excessive consumption

1
EN - 32 SPECIFICATIONS - OPERATION - MAINTENANCE
LUBRICATING THE CHAIN Washing the chain with OR 6- Correctly adjust chain, as described in the relevant para-
Lubricate the chain following these instructions. Wash using oil, diesel oil, or paraffin oil. Never use gasoline, graph.
tricloroetilene, or solvents, as the OR may suffer damages. WARNING: The chain oil has NEVER to get in
WARNING * : Never use grease to lubricate Use instead special sprays for chains with OR. contact with the tires or the rear brake disk.

EN
the chain. Grease helps to accumulate dust
and mud, which act as abrasive and hepl to Lubricating the chain with OR Chain tension rollers, chain driving roller,
rapidly wear out the chain, the sprocket, and Lubricate all metallic and rubber (OR) elements using a brush, chain guide, chain runner
the crown. and use engine oil with SAE 80-90 viscosity for the internal and Check the wear of the above mentioned elements and replace
external parts. them when necessary.
Disassembling and cleaning Note * : As an alternative, you can use suitable spray lubri- WARNING*: Check the chain guide aligne-
When particularly dirty, remove and clean the chain before cants. ment, and remember that a bent element
lubrication. can cause a rapid wear of the chain. In this
Work as follows: 5 - Assemble the joint spring (a) by turning the closed side to the case, a chain fleeting from the sprocket may
1 - Set a stand or a block under the engine and see that the rear chain direction of rotation as shown in figure below. ensue.
wheel is lifted from the ground. NOTE*: Even if all the joints are reusable when in good con-
Remove: screws (1), transmission sprocket guard (2), clip ditions, for safety purposes we advise using new joints when
(3), master link (4) and transmission chain (5); reassembling the chain.
To reassemble, reverse the above procedure.
2 - Check that the chain is neither worn out nor damaged. If the
rollers or the links are damaged, replace the chain by fol-
lowing the instructions given in the Periodical Maintenance
Table. C
3 - Check that neither the sprocket nor the crown are damaged.
4 - Wash and clean the chain as described hereunder.

3
2 X

4
A- Chain tension roller
B- Chain guide

5 1 C- Chain slider
X- Joint spring
B A

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 33

Removing the front wheel NOTES
Do not operate the front brake lever when the wheel has been
Set a stand or a block under the engine and see that the front
removed; this causes the caliper piston to move outwards. After
wheel is lifted from the ground. Loosen the bolts (1) holding the
removal, lay down the wheel with brake disc on top.
wheel axle (2) to the front
fork stanchions.
Hold the head of the wheel axle (2) in place, unscrew the bolt
(3) on the opposite side; draw the wheel axle out.

1
1 3

EN - 34 SPECIFICATIONS - OPERATION - MAINTENANCE

Reassembling the front wheel Fit the wheel axle (2) from the R.H. side, after greasing it and NOTE
push it to the stop on the L.H. leg; during this operation, the After reassembly, pump the brake control lever until the pads
Fit the L.H. spacer (A) on the wheel hub.
wheel should be turned. Tighten the screw (3) on the fork L.H. are against the brake disc.
Fit the wheel between the front fork legs so that the brake disc
side but DO NOT lock it. Now, pump for a while, pushing the

EN
is fitted into the caliper.
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. side (51,45 Nm/ 5,25 Kgm/
38 ft-lb), the screws (1) on the L.H. leg (10,4 Nm/ 1,05 Kgm/
7.7 ft-lb).

2
1 3
SPECIFICATIONS - OPERATION - MAINTENANCE EN- 35
Removing the rear wheel NOTES

Do not operate the rear brake pedal when the wheel has been
Unscrew the nut (1) of the wheel pin (3) and extract it. It is
removed; this causes the caliper piston to move outwards.
not necessary to unloose the chain adjusters (2); in this way,
After removal, lay down the wheel with brake disc on top.
the chain tension will remain unchanged after the reassembly.
After reassembly, pump the brake control pedal until the pads
Extract the complete rear wheel, by taking care of the spacers
are against the brake disc.
located at the hub sides.
To reassemble, reverse the above procedure remembering to
insert the disc into the caliper.

Tightening torque figures

1= 142.1 Nm, 14.5 Kgm, 104.8 ft/lb

2
2 3

1
EN­3-636 SPECIFICATIONS - OPERATION - MAINTENANCE
TIRES BRAKES 4. Front brake caliper
5. Front brake disc
Care should be taken to keep the tyres properly inflated. See The mayor components are brake master cylinder with its lever
6. Rear brake oil tank
“Technical data” chart at the beginning of the manual for cor- (front) or pedal (rear), brakeline, caliper assembly and disc.
7. Rear brake hose

EN
rect tyre inflation pressure.
8. Rear brake caliper
LEGEND
9. Rear brake disc
1. Front brake control lever
10. Rear brake pump
2. Front brake pump with oil reservoir
11. Rear brake control pedal
3. Front brake hose

2 5 3

1 4

7 8
9 10 11

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 37

BRAKE PADS REMOVAL PADS WEAR
Inspect pads for wear.
- Remove springs (1). Service limit “ A” is: 3,8 mm (0.15 in.).
- Remove pins (2). If service limit is exceeded, always replace the pads in pairs.
- Remove pads.

CAUTION!
Don’t operate the brake lever or pedal while
removing the pads.

FRONT REAR

1
1

2
2 FRONT REAR

EN - 38 SPECIFICATIONS - OPERATION - MAINTENANCE

PADS CLEANING WARNING!
Do not attempt to ride the motorcycle until
Be careful that no disc brake fluid or any oil gets on brake pads
the brake lever or pedal are fully effective.
or discs. Clean off any fluid or oil that inadverently gets on the
Pump the brake lever or pedal until the pads

EN
pads or disc with alcohol.
are against the discs.
Replace the pads with new ones if they cannot be cleaned sat-
The brake will not function on the first ap-
isfactorily.
plication of the lever or pedal.
PADS INSTALLATION
- Install new brake pads.
- Reassemble the two pins (2) and the springs (1).

FRONT REAR

1
1

2
2
SPECIFICATIONS - OPERATION - MAINTENANCE EN- 39
BRAKE DISC WEAR DISC WARPAGE
Measure disc warpage. Service limit for both discs is 0,15 mm
Measure the thickness of each disc at the point where it has worn
(0.006 in.)
the most. Replace the disc if it has worn past the service limit.
Replace the disc if warpage is more than service limit.
Disc Thickness

SERVICE
DISC STANDARD
LIMIT

Front 3 mm 2,5 mm
0,12 in. 0,1 in.

Rear 4 mm 3,5 mm
0,16 in. 0,14 in.

EN - 40 SPECIFICATIONS - OPERATION - MAINTENANCE

DISC CLEANING
Poor braking can also be caused by oil on the disc. Oil or grease
on the disc must be cleaned off with a high flash-point oil free

EN
solvent, such as acetone or lacquer thinner.

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 41

HEADLAMP BULBS REPLACEMENT - remove the two filaments bulb connector (2) and the boot
To gain access to the healamp bulbs, proceede as follows: (3);
- remove the upper fastening screw of the the headlamp carrier to - release the bulb holder clips (4) and take out bulb (5);
the instrument panuel support (1);
- push forward the headlamp carrier (B) and pull it towards the To replace the parking light bulb (6) extract it from the inside
high (C) in order to uncouple from the two lower supports. cover.
- remove the headlamp carrier; After replacement, reverse operations for reassembly.

2
3

C 4 5
B

EN - 42 SPECIFICATIONS - OPERATION - MAINTENANCE

TAIL LIGHT REPLACING THE NUMBER PLATE BULB

The tail light (1) is a LED light; Replace it when it does not func- - loosen screw (1) and remove the number plate bulb (2) from
tion. the mudguard;

EN
- take bulb holder (3) and bulb (4) out of the support;
- pull the bulb (4) to detach it from bulb holder.
Once the bulb has been replaced, reverse the above procedure
to reassemble.

3
1

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 43

ADJUSTMENT OF HEADLIGHT Adjust the preadlamp aiming by turning screw (1) to lower or
lift the high beam.
When checking the proper orienting of headlight, inflate tires
at right pressure, sat a person on the saddle and place the mo-
torcycle perpendicular with its longitudinal axis 10 meter (33
ft) from a wall or screen. Then trace an horizontal line equal to
the height of headlight center and a vertical one in line with its
longitudinal axis.

If possibile, execute this operation in a shadowy place.

When the low beam is on, the upper boundary limit between
dark and lit zone should be 9/10 th of headlight center from
groud.

1
EN - 44 SPECIFICATIONS - OPERATION - MAINTENANCE
APPENDIX - Run the engine for about 5 minutes to warm the oil then drain
AFTER-RACE CHECK POINTS the oil.
After racing, first clean the motorcycle and then inspect the - Put in fresh transmission oil.
- Check all the points listed under the inspection and Adjustment

EN
entire motorcycle, with special attention to the items listed in
«MAINTENANCE» table (Appendix A), such as the air cleaner, Section (Appendix A).
carburetor, brakes, etc. - Lubricate the points (listed in the Lubrication Section (Appendix
Carry out general lubrication, and make adjustment as neces- A).
sary.

STORAGE
When the motorcycle is to be stored for any length of time, is CLEANING
should be prepared for storage as follows: IMPORTANT RECOMMENDATION
- Clean the entire motorcycle thoroughly.
- Empty the fuel from the fuel tank, and empty the carburetor Premised that, before the motorcycle washing, it is necessary to
float bowl. (If left in for a long time, the fuel will deteriorate). protect opportunely from the water the following parts:
a) Rear opening of the muffler;
WARNING b) Clutch and brake levers, hand grips, handlebar commuta-
Never litter the environment with fuel, and tors;
let the engine running in open air, never in c) Air cleaner intake;
closed rooms. d) Fork head, wheel bearings;
e) Rear suspension links.
- Lubricate the drive chain and all the cables.
- Spray oil on all unpainted metal surfaces to prevent rusting.
Avoid getting oil on rubber parts or in the brakes.
- Set the motorcycle on a box or stand so that both wheels are
raised off the ground. (If this cannot be done, put boards un-
der the front and rear wheels to keep dampness away from
the tire rubber).
- Tie a plastic bag over the exhaust pipe to prevent moisture
from entering.
- Put a cover over the motorcycle to keep dust and dirt from
collecting on it.

To put the motorcycle back into the use after storage.

- Make sure the spark plug is tight.
- Fill the fuel tank.

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 45

It is necessary ABSOLUTELY TO AVOID THAT After washing: After each cleaning, it is recommended the
HIGH PRESSURE JETS OF WATER OR AIR come - Lubricate the points listed in the Maintenance Table (Appendix A). use of a water-repellent product suitable for
to contact with THE ELECTRICAL PARTS, espe- - Start the engine and run it for 5 minutes. electrical contacts (see table for lubrications
cially the electronic control unit (1) and the - Test the brakes before riding the motorcycle. and supplies) on all the electrical contacts,
dashboard (2). without disconnect them.
WARNING*: Never wax or lubricate the brake
disc. Loss of braking and an accident could
result. Clean the disc with an oilless solvent
such ans acetone. Observe the solvent warn-
ings.

EN - 46 SPECIFICATIONS - OPERATION - MAINTENANCE

 Trasmissioni e com. fless. Controllo / Regolazione � Collaudo generale �
Catena di trasmissione Controllo / Regolazione �
PRE-DELIVERY INSPECTION
PRE -DELIVERY INSPECTION
Description Operation Pre-delivery Description Operation Pre-delivery

EN
Engine oil Check level � Tyres Check pressure �
Two-stroke mix oil level Check level �� Side stand Check operation �
Coolant Check / Restore level � Side stand switch Check operation �
Cooling system Check for leakage � Electrical equipment Check operation �
Electric fans Check operation ��� Instrument panel Check operation �
Spark plugs Check / Replace � Lights / Visual signals Check operation �
Throttle body / Carburettor Check and adjust � Horn Check operation �
Brakes / Clutch fluid Check level � Headlight Check operation �
Brakes / Clutch Check operation � Ignition switch Check operation �
Brakes / Clutch Check lines for leakage � Locks Check operation �
Throttle control Check operation � Screws and nuts Check / Tighten �
Throttle control Check / Adjust play � Hose clamps Check / Tighten �
Choke control Check operation � General lubrication �
Flexible controls and transm. Check / Adjust � General test �
Drive chain Check / Adjust �
� : presenti solo sui motocicli con motore a 2 tempi � : only for motorcycles with 2 stroke engine
�� : presente solo su alcuni modelli �� : only for some models

279

SPECIFICATIONS - OPERATION - MAINTENANCE EN- 47

ALPHABETIC INDEX E Reassembling the front wheel.........................................................35
Page Engine start....................................................................................17 Removing the front wheel...............................................................34
A Engine stop button (usa)................................................................14 Removing the rear wheel................................................................36
Adjusting the compression fork........................................................29 Replacement of cooling fluid...........................................................20
Adjusting the shock absorber...........................................................30 F Replacing the number plate bulb . ..................................................43
Adjusting the shock absorber spring preload....................................30 Fuel................................................................................................10 Riding.............................................................................................16
Adjusting the suspensions according to particular track Fuel supply valves.............................................................................9 Running in......................................................................................16
conditions.......................................................................................28 Front brake control.........................................................................13
Adjustment of headlight .................................................................44 S
Adjustment of the control lever and check of the front G Shock absorber damping adjustment...............................................31
brake fluid level ............................................................................26 Gear shift control............................................................................15 Sidestand..........................................................................................9
After-race check points....................................................................45 Spark plug check ...........................................................................23
Air filter check.................................................................................24 H Steering lock...................................................................................13
Air filter and cleaning.....................................................................24 Handlebar commutator ..................................................................14 Steering wheel ball play adjustment................................................25
Appendix........................................................................................45 Headlamp bulbs replacement..........................................................42 Stopping the motorcycle and the engine..........................................18
Assembly........................................................................................24 Storage . ........................................................................................45
I
B Identification data.............................................................................5 T
Before every ride make following checks.........................................16 Idling adjustment............................................................................21 Table for lubrication, supplies............................................................8
Brake disc wear...............................................................................40 Important notices..............................................................................3 Tail light ........................................................................................43
Brake pads removal........................................................................38 Technical data...................................................................................7
Brakes............................................................................................37 K Throttle cable adjustment................................................................21
Kickstart pedal................................................................................15 Throttle control................................................................................13
C Tires...............................................................................................37
Carburetor choke ...........................................................................10 L Transmission oil change..................................................................19
Chain adjustment............................................................................32 Lubricating the chain.......................................................................33 Transmission oil level checking........................................................19
Checking the fluid level...................................................................27
Checking the wear of chain, pinion and sprocket.............................32 O
Checks while running in..................................................................16 Oil fork level...................................................................................29
Cleaning.........................................................................................45
Clutch adjustment...........................................................................22 P
Clutch control..................................................................................14 Pads cleaning..................................................................................39
Control location.................................................................................6 Pads installation.............................................................................39
Controls............................................................................................9 Pads wear . ....................................................................................38
Coolant level check..........................................................................19 Pre-delivery inspection....................................................................47
Presentation......................................................................................3
D
Digital instrument, warning lights...................................................11
Disc cleaning...................................................................................41 R
Disc warpage..................................................................................40 Rear brake control..........................................................................15
Rear brake idle stroke adjustment...................................................27
Rear brake pedal position adjustment ............................................27

EN - 48 SPECIFICATIONS - OPERATION - MAINTENANCE