Husqvarna SMR 511 2012 I.E. Gebrauchsanweisung

TC 449 2011/2012 I.E.

TE 449 - 511 2011/2012 I.E.

TXC 449 - 511 2011/2012 I.E.

SMR 449 2011 I.E.

SMR 511 2011/2012 I.E.

Workshop Manual Ed. 03-2012

Rev 02

Revision Record

Rev. No. Date Page Description

01 11/06/2012 Chapter B Inserted " Tables of periodic maintenance MY11".

01 11/06/2012 D.20 "Shock absorber adjustment": Inserted different values for models and Model

year

01 11/06/2012 D.21 "Shock absorber spring preload adjustment (TE-TC-TXC): Inserted different

values for models and Model year

01 11/06/2012 D.23 "Shock absorber damping adjustment"): Inserted different values for models

and Model year

01 11/06/2012 D.24 "KAYABAfork adjustment (TC - TE - TXC)": Inserted different values for models

and Model year

01 11/06/2012 D.25 "Fork oil level (TC - TE - TXC)": Inserted different values for models and

Model year

01 11/06/2012 D.26 "Fork oil level (SMR)": Inserted different values for models and Model year

01 22/06/2012 M.2 Updated index cause correction applied on page M.56

01 22/06/2012 M.3 Updated index cause corrections applied on pages M.58 - M.59

01 22/06/2012 M.56

M.57

M.58

M.59

"Digital dashboard, warning lights (TE - SMR)": Inserted different instructions

for models and Model year;

"Digital dashboard drawings": Applied correction;

"Instructions for the instrument setting": Inserted new note.

02 18/07/2012 D.12 "Engine oil level check": modied procedure in the paragraph.

02 18/07/2012 D.14 "Engine oil replacement and mesh lters-lter cartridge cleaning or replace-

ment": modied procedure in the paragraph.

HUSQVARNA MOTORCYCLES S.R.L. - Varese disclaims all liabilities for any errors or omissions in this manual and

reserves the right to make changes to reect on-going product development. Illustrations in the manual may differ from

actual components. No reproduction in full or in part without written authorisation.

1st edition (03-2012) - Rev. 02

a.1

simbolo

TC 449 2011/2012 I.E.

TE 449 - 511 2011/2012 I.E.

TXC 449 - 511 2011/2012 I.E.

SMR 449 2011 I.E.

SMR 511 2011/2012 I.E.

MY11

TC 449: ZKHA600AABV050001

TC 449 (USA): ZKHTC443#BV000001

TE 449: ZKHA600AABV000001

TE 511: ZKHA601AABV000001

TE 449: (USA): ZKHKEEFM#BV000001

TE 511: (USA): ZKHKEEGM#BV000001

TXC 449: (USA): ZKHTX440#BV000001

TXC 511: (USA): ZKHTX510#BV000001

SMR 499: ZKHA600ABBV000001

SMR 499 (USA): ZKHLEEFM#BV000001

SMR 511: ZKHA601ABBV000001

SMR 511 (USA): ZKHLEEGM#BV000001

TC 449 2011/2012 I.E.

TE 449 - 511 2011/2012 I.E.

TXC 449 - 511 2011/2012 I.E.

SMR 449 2011 I.E.

SMR 511 2011/2012 I.E.

MY12

TC 449: ZKHA600AABV050001

TC 449 (USA): ZKHTC443#BV000001

TE 449: ZKHA600AABV000001

TE 511: ZKHA601AABV000001

TE 449: (USA): ZKHKEEFM#BV000001

TE 511: (USA): ZKHKEEGM#BV000001

TXC 449: (USA): ZKHTX440#BV000001

TXC 511: (USA): ZKHTX510#BV000001

SMR 511: ZKHA601ABBV000001

SMR 511 (USA): ZKHLEEGM#BV000001

Workshop Manual Ed. 03-2012

FOREWORD, TABLE OF CONTENTS

1st edition (03-2012) - Rev. 02

Printed in Italy

MODELS COVERED (from serial number onwards)

HUSQVARNA MOTORCYCLES S.R.L.

BMW Group

Technical Service

Via Nino Bixio, 8

21024

(Varese) - Italy

tel. ++39 0332 75.61.11

tel. ++39 0332 756 558

www.husqvarna-motorcycles.com

Workshop Manual

1. Chassis serial number

a.2

simbolo

TC 449 2011/2012 I.E.

TE 449 - 511 2011/2012 I.E.

TXC 449 - 511 2011/2012 I.E.

SMR 449 2011 I.E.

SMR 511 2011/2012 I.E.

FOREWORD, TABLE OF CONTENTS

Workshop Manual Ed. 03-2012

Foreword

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

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

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

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

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

Accident-prevention rules for operator and persons working nearby.

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

Additional information concerning the operation covered in the text.

Useful tips

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

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

problem symptoms;

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

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

periods;

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

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

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

Recommended shop practices

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

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

ed torque and follow a cross pattern.

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

4 Use genuine HUSQVARNA parts and the recommended lubricant brands.

5 Use special tools where specied.

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

them.

a.3

simbolo

TC 449 2011/2012 I.E.

TE 449 - 511 2011/2012 I.E.

TXC 449 - 511 2011/2012 I.E.

SMR 449 2011 I.E.

SMR 511 2011/2012 I.E.

Workshop Manual Ed. 03-2012

FOREWORD, TABLE OF CONTENTS

NOTES

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

Table of Contents

Title Section

Foreword, table of contents a

Important notices ................................................................................................. b

General information .............................................................................................A

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

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

Settings and adjustments ................................................................................... D

General procedures .............................................................................................E

Adjustments - engine ...........................................................................................F

Engine disassembly/reassembly .......................................................................F1

Front suspension .................................................................................................. I

Rear suspension.................................................................................................. J

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

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

Engine cooling .................................................................................................... N

Hydraulically controlled clutch .............................................................................P

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

Tightening torque gures .....................................................................................X

Chassis and wheels.............................................................................................Y

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

b.1

TC 449 2011/2012 I.E.

TE 449 - 511 2011/2012 I.E.

TXC 449 - 511 2011/2012 I.E.

SMR 449 2011 I.E.

SMR 511 2011/2012 I.E.

Workshop Manual Ed. 03-2012

IMPORTANT NOTICES

Section

b.2

TC 449 2011/2012 I.E.

TE 449 - 511 2011/2012 I.E.

TXC 449 - 511 2011/2012 I.E.

SMR 449 2011 I.E.

SMR 511 2011/2012 I.E.

H006104

H06374

SMR

H006106

TXC

H006105

IMPORTANT NOTICES

Workshop Manual Ed. 03-2012

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

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

in Section B.

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

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

FIGURATION IS MAINTAINED and the maintenance chart provided in Section

B is observed.

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

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

distances at full throttle may result in severe engine damage.

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

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

in regular road use.

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

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

maintenance inspections carried out at authorised HUSQVARNA dealers. The

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

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

AND VOID if the motorcycle is rented.

Notes

Left and right side is determined when seated on motorcycle.

Z: number of teeth

A: Austria

AUS: Australia

B: Belgium

BR: Brazil

CDN: Canada

CH: Switzerland

D: Germany

E: Spain

F: France

FIN: Finland

GB: Great Britain

I: Italy

J: Japan

USA: United States of America

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

A.1

TC 449 2011/2012 I.E.

TE 449 - 511 2011/2012 I.E.

TXC 449 - 511 2011/2012 I.E.

SMR 449 2011 I.E.

SMR 511 2011/2012 I.E.

Workshop Manual Ed. 03-2012

GENERAL INFORMATION

Section

A.2

TC 449 2011/2012 I.E.

TE 449 - 511 2011/2012 I.E.

TXC 449 - 511 2011/2012 I.E.

SMR 449 2011 I.E.

SMR 511 2011/2012 I.E.

GENERAL INFORMATION

Workshop Manual Ed. 03-2012

Sommario

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

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

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

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

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

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

Starting .........................................................................................................A.3

Transmission ................................................................................................A.3

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

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

Brakes ..........................................................................................................A.5

Wheels..........................................................................................................A.5

Tyres .............................................................................................................A.5

Electrical components location (TC) .............................................................A.6

Electrical components location (TXC) ..........................................................A.6

Electrical components location (TE-SMR) ....................................................A.6

Supplies (reserve included) ..........................................................................A.7

Overall dimensions - Weight .........................................................................A.8

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