Husqvarna TC 449 2011 I.E. Workshop Manual
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Husqvarna TC 449 2011 I.E. Workshop Manual

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Table of Contents

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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

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Summary of Contents for Husqvarna TC 449 2011 I.E.

  • Page 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 Rev 02...
  • Page 2 : modified 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 reflect on-going product development. Illustrations in the manual may differ from actual components.

  • Page 3: Workshop Manual

    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. Copyright by HUSQVARNA MOTORCYCLES S.R.L. BMW Group Technical Service Via Nino Bixio, 8 21024 (Varese) - Italy tel.
  • Page 4 SMR 511 2011/2012 I.E. 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.
  • Page 5 FOREWORD, TABLE OF CONTENTS 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. Table of Contents Title Section Foreword, table of contents Important notices ....................b General information .....................A Maintenance ......................B Troubleshooting ....................
  • Page 7 IMPORTANT NOTICES 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. Section Workshop Manual Ed. 03-2012...
  • Page 8 * 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.
  • Page 9 GENERAL INFORMATION 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. Section Workshop Manual Ed. 03-2012...

  • Page 10: Table Of Contents

    GENERAL INFORMATION 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. 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...

  • Page 11: Timing System

    GENERAL INFORMATION 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. Engine Single cylinder, 4 stroke TC-TE-TXC-SMR 449 Bore ..................3.86 in (98 mm) Stroke ..................2.35 in (59.6 mm) Displacement .............

  • Page 12: Chassis

    GENERAL INFORMATION 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. Gear ratios (TE - TXC - SMR) 1st gear..................2.286 (32/14) 2nd gear ..................1.875 (30/16) 3rd gear ..................1.533 (23/15) 4th gear ..................1.250 (25/20) 5th gear ..................1.043 (24/23)

  • Page 13: Brakes

    GENERAL INFORMATION 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. Brakes Front (TC - TE - TXC) Fixed disc type “WAVE” Ø 10.24 in (Ø 260 mm) with hydraulic control and floating calliper. Brake pad surface area ........

  • Page 14: Electrical Components Location (Tc)

    GENERAL INFORMATION 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. Electrical components location (TC) The ignition system includes the following elements: Generator on the inner side of L.H. crankcase half cover; Electronic ignition coil with integrated spark plug cap positioned on cylinder head;...

  • Page 15: Supplies (Reserve Included)

    GENERAL INFORMATION 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. Supplies (reserve included) Type Quantity Fuel tank (TC) Unleaded fuel 95R0Z/R0N 2.25 gal (8.5 litres) Fuel tank (TE-SMR 499/511) Unleaded fuel 95R0Z/R0N 2.25 gal (8.5 litres)

  • Page 16: Overall Dimensions - Weight

    GENERAL INFORMATION 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. Overall dimensions - Weight Kerb weight, without fuel (TC): ..........108 Kg (238.1 lb) Kerb weight, without fuel (TE): ..........113 Kg (249.12 lb) Kerb weight, without fuel (TXC): ..........110 Kg (242.51 lb) Kerb weight, without fuel (SMR): ........
  • Page 17 GENERAL INFORMATION 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...
  • Page 18 GENERAL INFORMATION 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. 820 mm (32,28 inch) * 1460 mm (57,48 inch) 2170 mm (85,43 inch) H06375 Workshop Manual Ed.
  • Page 19 MAINTENANCE 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. Section Workshop Manual Ed. 03-2012...
  • Page 20 MAINTENANCE 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. INTENTIONALLY WHITE PAGE Workshop Manual Ed. 03-2012...
  • Page 21 MAINTENANCE 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. TABLES OF PERIODIC MAINTENANCE MY11 Workshop Manual Ed. 03-2012...
  • Page 22 TXC 449 - 511 2011/2012 I.E. SMR 449 2011 I.E. SMR 511 2011/2012 I.E. TE -TXC 449 /511 MY11 SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) COMPETITION MOTORCYCLE, RACING USE: WITH FULL POWER ENGINE ENGINE REPLACE IF...
  • Page 23 TXC 449 - 511 2011/2012 I.E. SMR 449 2011 I.E. SMR 511 2011/2012 I.E. TC 449 MY11 SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) COMPETITION MOTORCYCLE, RACING USE: WITH FULL POWER ENGINE ENGINE REPLACE IF EVERY 10 h...
  • Page 24 TXC 449 - 511 2011/2012 I.E. SMR 449 2011 I.E. SMR 511 2011/2012 I.E. TE-SMR 449/511 MY11 SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) STANDARD MOTORCYCLE, STREET LEGAL (WITH LIMITED POWER ENGINE) ENGINE CHECKS SERVICE COUPON...
  • Page 25 TXC 449 - 511 2011/2012 I.E. SMR 449 2011 I.E. SMR 511 2011/2012 I.E. TC 449 _TE -TXC 449 /511 MY11 SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) COMPETITION MOTORCYCLE, RACING USE: WITH FULL POWER ENGINE CHASSIS AFTER FIRST 3 HOURS...
  • Page 26 TXC 449 - 511 2011/2012 I.E. SMR 449 2011 I.E. SMR 511 2011/2012 I.E. TE-SMR 449/511 MY11 SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) STANDARD MOTORCYCLE, STREET LEGAL (WITH LIMITED POWER ENGINE) CHASSIS CHECKS SERVICE COUPON SERVICE COUPON SERVICE COUPON...
  • Page 27 MAINTENANCE 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. TABLES OF PERIODIC MAINTENANCE MY12 Workshop Manual Ed. 03-2012...
  • Page 28 TXC 449 - 511 2011/2012 I.E. SMR 449 2011 I.E. SMR 511 2011/2012 I.E. TE -TXC 449 /511 MY12 SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) COMPETITION MOTORCYCLE, RACING USE: WITH FULL POWER ENGINE ENGINE REPLACE IF...
  • Page 29 TXC 449 - 511 2011/2012 I.E. SMR 449 2011 I.E. SMR 511 2011/2012 I.E. TC 449 MY12 SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) COMPETITION MOTORCYCLE, RACING USE: WITH FULL POWER ENGINE ENGINE REPLACE IF EVERY 10 h...
  • Page 30 TXC 449 - 511 2011/2012 I.E. SMR 449 2011 I.E. SMR 511 2011/2012 I.E. TE/SMR 449/511 MY12 SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) STANDARD MOTORCYCLE, STREET LEGAL (WITH LIMITED POWER ENGINE) ENGINE CHECKS SERVICE COUPON...
  • Page 31 TXC 449 - 511 2011/2012 I.E. SMR 449 2011 I.E. SMR 511 2011/2012 I.E. TC 449 _TE -TXC 449 /511 MY12 SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) COMPETITION MOTORCYCLE, RACING USE: WITH FULL POWER ENGINE CHASSIS AFTER FIRST 4 HOURS...
  • Page 32 TXC 449 - 511 2011/2012 I.E. SMR 449 2011 I.E. SMR 511 2011/2012 I.E. TE-SMR 449/511 MY12 SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) STANDARD MOTORCYCLE, STREET LEGAL (WITH LIMITED POWER ENGINE) CHASSIS CHECKS SERVICE COUPON SERVICE COUPON SERVICE COUPON...
  • Page 33 TROUBLESHOOTING 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. Section Workshop Manual Ed. 03-2012...
  • Page 34 TROUBLESHOOTING 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. ENGINE Trouble Cause Remedy Engine does not start or Insufficient compression has starting trouble 1. Piston seized Replace 2.
  • Page 35 TROUBLESHOOTING 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. Trouble Cause Remedy Noise seems to come 1. Worn plates Replace from the clutch 2. Too much clearance between clutch housing and friction plates Replace Noise seems to 1.
  • Page 36 TROUBLESHOOTING 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. CHASSIS Trouble Cause Remedy Handlebar turns hard 1. Insufficient tyre pressure Inflate 2. Bearing adjuster ring nut or steering stem nut overtightened Adjust 3.
  • Page 37 TROUBLESHOOTING 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. ELECTRICAL SYSTEM (see also Section M) Trouble Cause Remedy Spark plug fouls 1. Dirty air filter Clean easily 2.
  • Page 39 SETTINGS AND ADJUSTMENTS 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. Section Workshop Manual Ed. 03-2012...
  • Page 40 SETTINGS AND ADJUSTMENTS 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. Sommario Saddle removal....................D.4 Side panel removal ..................D.4 Scoop removal....................D.6 Engine guard removal ..................D.6 Throttle cable adjustment ................
  • Page 41 SETTINGS AND ADJUSTMENTS 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 H006106 H006105 H06374 Workshop Manual Ed. 03-2012...

  • Page 42: Saddle Removal

    SETTINGS AND ADJUSTMENTS 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. Saddle removal Turn pin (1) counter clockwise, and remove saddle (2) from central retaining screw. H006109 H006110 Side panel removal...
  • Page 43 SETTINGS AND ADJUSTMENTS 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. Right-hand side panel: Loosen the five screws (3) using an 8 mm wrench, release side panel (4) from scoop (5) by disengaging retaining tabs (6).

  • Page 44: Scoop Removal

    SETTINGS AND ADJUSTMENTS 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. Scoop removal Remove the saddle and side panels, as described in the relevant para- graphs.
  • Page 45 SETTINGS AND ADJUSTMENTS 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. Throttle cable adjustment To check the correct adjustment of the throttle control cable, operate as follows: - loosen screws (1) and remove protective cap (2);...

  • Page 46: Idle Adjustment (Te - Txc - Smr)

    SETTINGS AND ADJUSTMENTS 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. Idle adjustment (TC) Adjust the carburettor with warm engine and with the throttle control in closed position.

  • Page 47: Hydraulic Clutch Lever Adjustment And Fluid Level Check

    SETTINGS AND ADJUSTMENTS 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. Hydraulic clutch lever adjustment and fluid level check Free play (A) shall be of at least 3 mm (0.12 in). The lever position can be adjusted to suit the rider hand size.

  • Page 48: Front Brake Lever Adjustment And Fluid Level Check (Smr)

    SETTINGS AND ADJUSTMENTS 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. Front brake lever adjustment and fluid level check (SMR) The lever (1) can be adjusted (4 settings available) to suit the rider's hand size. To decrease the lever (1) distance from the handgrip, turn the adjuster screw (2) COUNTER CLOCKWISE “A”.

  • Page 49: Rear Brake Pedal Position Adjustment

    SETTINGS AND ADJUSTMENTS 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. Rear brake pedal position adjustment The position of the rear brake pedal with respect to the footrest may be adjusted according to individual needs.

  • Page 50: Rear Brake Fluid Level Check

    SETTINGS AND ADJUSTMENTS 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. Rear brake fluid level check Level (A) must be between the MIN and MAX notches visible on the master cylinder reservoir.

  • Page 51: Engine Oil Replacement And Mesh Filters-Filter Cartridge Cleaning Or Replacement

    SETTINGS AND ADJUSTMENTS 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. Engine oil replacement and mesh filters-filter cartridge cleaning or repla- cement Be careful not to touch hot engine oil. Drain the oil with WARM ENGINE;...

  • Page 52: Coolant Level Check

    SETTINGS AND ADJUSTMENTS 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. - reassembly is a reverse of removal; - undo cap (7) and remove cartridge filter (8); (on reassembly, tighten plug (7) to a torque of 15 Nm / 1.5 Kgm / 11.6 ft/lb) - replace filter (8), lubricate O-ring (9), and screw cap (7);...

  • Page 53: Coolant Replacement

    SETTINGS AND ADJUSTMENTS 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. Coolant replacement Coolant shall be replaced with cold engine and coolant. - Remove the engine guard as indicated under the relevant paragraph. - Place a vessel on the R.H.

  • Page 54: Air Filter Check

    SETTINGS AND ADJUSTMENTS 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. Air filter check - Remove the saddle and right-hand side panel, as described in the relevant paragraphs.

  • Page 55: Chain Adjustment

    SETTINGS AND ADJUSTMENTS 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. Chain adjustment Chain should be checked, adjusted and lubricated as per the Maintenance Chart to ensure safety and prevent excessive wear.

  • Page 56: Chain Lubrication

    SETTINGS AND ADJUSTMENTS 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. Chain lubrication 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 help to rapidly wear out the chain, the front and rear sprockets.

  • Page 57: Suspension Setup According To Track Condition

    SETTINGS AND ADJUSTMENTS 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. Suspension setup according to track condition Following are a few guidelines to find the right suspension setup for different types of terrain.

  • Page 58: Shock Absorber Adjustment

    SETTINGS AND ADJUSTMENTS 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. Shock absorber adjustment The rear shock absorber must be adjusted to suit rider weight and terrain conditions. Proceed as follows: 1.

  • Page 59: Shock Absorber Spring Preload Adjustment (Te-Tc-Txc)

    SETTINGS AND ADJUSTMENTS 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. Shock absorber spring preload adjustment (TE-TC-TXC) Proceed as follows: 1. Remove the saddle and right-hand side panel, as described in the relevant paragraph.

  • Page 60: Shock Absorber Spring Preload Adjustment (Smr)

    SETTINGS AND ADJUSTMENTS 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. Shock absorber spring preload adjustment (SMR) Proceed as follows: 1. Remove the saddle and right-hand side panel, as described in the relevant paragraph.

  • Page 61: Shock Absorber Damping Adjustment

    SETTINGS AND ADJUSTMENTS 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. Shock absorber damping adjustment TC - TE - TXC Adjustment of the compression stroke is independent from the rebound stroke. MY11: A) COMPRESSION - Standard setting: 1) Low damping speed:...

  • Page 62: Kayaba Fork Adjustment (Tc - Te - Txc)

    SETTINGS AND ADJUSTMENTS 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. KAYABA fork adjustment (TC - TE - TXC) COMPRESSION (Fig. a) (TC - TXC: TOP ADJUSTER; TE: LOWER ADJUSTER) MY11 + MY12: TC-TXC= -11 clicks TE= -10 clicks...

  • Page 63: Fork Oil Level (Tc - Te - Txc)

    SETTINGS AND ADJUSTMENTS 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. Fork oil level (TC - TE - TXC) For regular fork operation, both legs must be provided with the necessary oil quantity.

  • Page 64: Marzocchi Fork Adjustment (Smr)

    SETTINGS AND ADJUSTMENTS 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. Marzocchi fork adjustment (SMR) a) COMPRESSION (LOWER ADJUSTER) Standard setting: -16 clicks (± 1 click) To reset standard calibration, turn adjuster screw (A) clockwise to reach the fully closed position;...

  • Page 65: Steering Bearing Clearance Adjustment

    SETTINGS AND ADJUSTMENTS 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. Steering bearing clearance adjustment For safety reasons, the steering should always be adjusted so that the handlebar turns freely and without play.

  • Page 66: Fuel Supply Hose Inspection

    SETTINGS AND ADJUSTMENTS 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. Fuel supply hose inspection MY11 Check fuel supply hose conditions; if cracked, swollen etc. it is necessary to change it as follows: - Remove the saddle and left-hand side panel, as described in the relevant paragraphs.

  • Page 67: Exhaust System Check

    SETTINGS AND ADJUSTMENTS 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. Exhaust system check Perform a visual inspection of the exhaust system first, in order to identify pos- sible gas leaks from the sealing elements (gaskets), and to ensure that the Silent-Blocks are not damaged.
  • Page 69 GENERAL PROCEDURES 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. Section Workshop Manual Ed. 03-2012...
  • Page 70 GENERAL PROCEDURES 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. Sommario Saddle removal.....................E.3 Side panel removal ..................E.3 Tail section removal (TC-TE-TXC MY12) .............E.4 Rear turning indicator removal ..............E.5 Front turn indicator removal................E.5 Number plate holder removal (TE MY12) .............E.6 Front mudguard removal ................E.7...

  • Page 71: Txc 449 - 511 2011/2012 I.e

    GENERAL PROCEDURES 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. Saddle removal Turn pin (1) counter clockwise, and remove saddle (2) from chassis fastening. H006109 H006110 Side panel removal...

  • Page 72: Tail Section Removal (Tc-Te-Txc My12)

    GENERAL PROCEDURES 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. Right-hand side panel: Loosen the five screws (3) using an 8 mm wrench, release side panel (4) from scoop (5) by disengaging retaining tabs (6).

  • Page 73: Rear Turning Indicator Removal

    GENERAL PROCEDURES 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. Rear turning indicator removal Disconnect the connectors (1). Loosen the screws (2) and remove the turning indicators (3). When reassembling, check that the water drainage hole (4) is placed underneath.

  • Page 74: Number Plate Holder Removal (Te My12)

    GENERAL PROCEDURES 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. Number plate holder removal (TE MY12) Remove the tail section and the rear turning indicators as described in the relevant paragraphs.

  • Page 75: Front Mudguard Removal

    GENERAL PROCEDURES 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. Front Mudguard Removal Loosen the two screws (1) securing headlamp fairing/number plate holder and mudguard. Loosen the four screws (2) with a 8 mm wrench, and remove front mudguard (3).

  • Page 76: Rear Mudguard Removal (Smr My11 / My 12 - Te-Txc-Tc My11)

    GENERAL PROCEDURES 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. Rear mudguard removal (SMR MY11 / MY 12 - TE-TXC-TC MY11) Remove the saddle, the two side panels and the number plate holder (TE - SMR) as described in the relevant paragraphs.

  • Page 77: Rear Mudguard Removal (Te - Txc - Tc My12)

    GENERAL PROCEDURES 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. Rear mudguard removal (TE - TXC - TC MY12) Remove the saddle, the side panels, the tail section and the number plate holder (TE) and the turning indicators (TE), as described in the relevant paragraphs.

  • Page 78: Battery Removal

    GENERAL PROCEDURES 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. Battery removal Remove the saddle as described in the relevant paragraph. First remove the BLACK negative cable (1), then the RED positive cable (2) (when reassembling, first connect the RED positive cable, then the BLACK negative cable);...
  • Page 79 GENERAL PROCEDURES 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. Undo the upper clamp (3) connecting fuel pump to throttle body. H06516 Disconnect pump supply connector (4). H02416 Slacken clamp (5) with long nose pliers, and disconnect breather hose (6) from tank.
  • Page 80 GENERAL PROCEDURES 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. Slacken clamp (7) with long nose pliers, and disconnect hose (8) between the two tanks. H02418 Loosen upper screw (8) using a 14 mm wrench;...
  • Page 81 GENERAL PROCEDURES 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. With a 8 mm socket wrench, undo screw (11), and remove the screw with rubbers and spacers.

  • Page 82: Fuel Pump Removal

    GENERAL PROCEDURES 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. Fuel Pump Removal Remove lower fuel tank as described in the relevant paragraph. Using a 8 mm Allen wrench, loosen the five screws (1) securing pump (2) to tank.

  • Page 83: Throttle Body Removal

    GENERAL PROCEDURES 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. Throttle body removal Remove lower fuel tank as described in the relevant paragraph. Remove the air filter as described in the relevant paragraph. Use a 4 mm Allen wrench to loosen the screw (1) and remove the cover (2) of the throttle body.
  • Page 84 GENERAL PROCEDURES 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. Disconnect injector connector (9). H02435 Detach the pressure sensor (10). H02436 H02437 From the right side: TE - TXC - SMR;...
  • Page 85 GENERAL PROCEDURES 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. disconnect TPS connector (14). H02439 Loosen intake manifold (16) upper screw (15). H02440 Working on bike right side, slightly lift throttle body and turn it clockwise by 90°, then remove it from bike left side.

  • Page 86: Exhaust System Removal (Smr)

    GENERAL PROCEDURES 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. Exhaust System Removal (SMR) H06518 Key (SMR) Silencer Clamp Seal Lambda sensor Manifold Seal Workshop Manual Ed.

  • Page 87: Exhaust System Removal (Te - Txc)

    GENERAL PROCEDURES 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. Exhaust System Removal (TE - TXC) TE-TXC H06517 Key (TE - TXC) 1. Silencer (Lanfranconi) 1a.
  • Page 88 GENERAL PROCEDURES 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. Working on the right side, loosen upper screw (1) using a 12 mm T- wrench.
  • Page 89 GENERAL PROCEDURES 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. Cut Lambda sensor cable clamps, and remove connector (6). H02446 Loosen the two screws (7) using a 12 mm Allen wrench, then remove manifold H02447 On reassembly, replace seal (9) H02449...

  • Page 90: Exhaust System Removal (Tc)

    GENERAL PROCEDURES 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. Exhaust system removal (TC) H02450 Silencer Spring Manifold Spring Flange Bushing Seal Workshop Manual Ed. 03-2012 E.22...
  • Page 91 GENERAL PROCEDURES 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. Working on the right side, loosen support clamp upper screw (1) using a 12 H02518 mm T-wrench.

  • Page 92: Rear Chassis Removal

    GENERAL PROCEDURES 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. Release springs (5), and remove manifold (6). Using a 12 mm Allen wrench, loosen the two nuts (7), then remove flange (8), bushing (9), and gasket (10).
  • Page 93 GENERAL PROCEDURES 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. Cut clamps (5) of the rear wiring harness. H02453 Make sure that fuel tank cocks are closed, then disconnect hose (6) from rear tank cock (7).

  • Page 94: Rear Tank Removal

    GENERAL PROCEDURES 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. Rear tank removal Remove the rear chassis, as described in the relevant paragraph. Loosen the two screws (1) securing tank (2) to rear chassis (3), and remove tank.

  • Page 95: Cdi Electronic Control Unit Removal

    GENERAL PROCEDURES 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. CDI electronic control unit removal Remove the saddle as described in the relevant paragraph. Remove the connector (1) from the CDI electronic control unit (2) and take the control unit together with its anti-vibration mount out of the chassis.

  • Page 96: Coil Removal And Spark Plug Check

    GENERAL PROCEDURES 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. Coil removal and spark plug check ÷ 0.031 in) Spark plug electrodes gap shall be 0.7 - 0.8 mm (0.028 A wider gap may cause difficulties in starting the engine and overload the coil.
  • Page 97 GENERAL PROCEDURES 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. turn spark plug cap (3) complete with coil through 90° and lift it to remove it; then remove spark plug.

  • Page 98: Clutch Hose Removal

    GENERAL PROCEDURES 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. Clutch hose removal Loosen screw (1) (with a 8 mm wrench), and move number plate holder or headlamp fairing.

  • Page 99: Horn Removal (Te - Smr)

    GENERAL PROCEDURES 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. Horn removal (TE - SMR) Loosen the two screws (1) (using a 8 mm wrench) Disconnect connector (2) and remove horn (3).

  • Page 100: Air Filter Box Removal

    GENERAL PROCEDURES 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. Air filter box removal Remove saddle, left and right side panels, filter, and voltage regulator, as indicated in the relevant paragraphs.
  • Page 101 GENERAL PROCEDURES 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. Disconnect Blow-by hose (5). H02475 Loosen the three screws (6) (with a 8 mm wrench) H02478 Lower filter box (7), and remove it from the bike right side.

  • Page 102: Engine Guard Removal

    GENERAL PROCEDURES 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. Engine guard removal Using a 8 mm socket wrench, loosen the three screws (1), and remove engine guard (2).

  • Page 103: Chain Slider Removal

    GENERAL PROCEDURES 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. Chain slider removal Remove chain and gear shift pedal as indicated in the relevant para- graphs.
  • Page 104 GENERAL PROCEDURES 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. Loosen screw (7) with a Phillips screwdriver. H02485 Loosen screw (9) (with a 8 mm wrench) and remove chain roller (8). H02486 Loosen screws (11) (with a 8 mm wrench) and remove sprocket guard (10).
  • Page 105 GENERAL PROCEDURES 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. Slide out the chain slider (5) as shown in figures “A” and “B”. H02489 H02490 Workshop Manual Ed.

  • Page 106: Engine Removal

    GENERAL PROCEDURES 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. Engine removal Remove lower tank, throttle body, chain, and exhaust system as described in the relevant paragraphs. Loosen screw (1) positioned onto pump body, and drain off cooling sys- tem.
  • Page 107 GENERAL PROCEDURES 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. Loosen screw (10) (with a 8 mm wrench), and remove cover (11). H02495 Loosen screw (12) (with a 8 mm wrench), and disconnect clamp (13) from engine.
  • Page 108 GENERAL PROCEDURES 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. Turn coil (16) by 90° so that connector is pointing to bike rear end, then remove it.
  • Page 109 GENERAL PROCEDURES 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. Remove rear brake pedal (26) by loosening screw (27) (with a 6 mm Allen wrench), and releasing spring (28).

  • Page 110: Radiator Removal

    GENERAL PROCEDURES 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. Radiator Removal Remove saddle, side panels, scoops, and radiator grids as described in the relevant paragraphs.
  • Page 111 GENERAL PROCEDURES 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. Disconnect temperature sensor connector (3). H02511 Disconnect electric fan connector (4) (TE - TXC - SMR). Loosen the four screws (5) (with a 8 mm wrench), and remove left-hand ra- H02512 diator (6) complete with fan (TE - TXC - SMR), and right-hand radiator (7).
  • Page 113 ADJUSTMENTS - ENGINE 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. Section Workshop Manual Ed. 03-2012...
  • Page 114 ADJUSTMENTS - ENGINE 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. Sommario Valve clearance check .................. F.3 Set valve clearance (cylinder head cover removed)........F.4 Engine positioning at ignition TDC ...............

  • Page 115: Txc 449 - 511 2011/2012 I.e

    ADJUSTMENTS - ENGINE 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. Valve clearance check Remove head cover as described in section F1 Check • Check valve clearance using a feeler gauge (1). Technical specifications Intake valve clearance with cold engine...

  • Page 116: Set Valve Clearance (Cylinder Head Cover Removed)

    ADJUSTMENTS - ENGINE 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. Set valve clearance (cylinder head cover removed) Engine positioning at ignition TDC • Turn engine until reaching TDC. •...

  • Page 117: Valve Clearance Adjustment

    ADJUSTMENTS - ENGINE 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. Valve clearance adjustment Bearing mount disassembly • Remove screws (1, 2). • Disassemble bearing mount (3). •...

  • Page 118: Bearing Mount Assembly

    ADJUSTMENTS - ENGINE 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. • Take special care to camshaft position: both shaft gears reference marks (ar- rows) shall be aligned with sealing surface.

  • Page 119: Valve Clearance Check

    ADJUSTMENTS - ENGINE 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. Valve clearance check Check • Check valve clearance using a feeler gauge (1). Technical specifications Intake valve clearance with cold engine...
  • Page 121 ENGINE DISASSEMBLY/REASSEMBLY 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. Section Workshop Manual Ed. 03-2012 F1.1...
  • Page 122 ENGINE DISASSEMBLY/REASSEMBLY 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. SOMMARIO OIL FILTER REPLACEMENT .................F1.7 Oil filter disassembly ..................F1.7 Oil filter assembly ..................F1.7 Engine oil filter disassembly ..............F1.8 Engine oil filter assembly ................F1.9 SPARK PLUG RECESS IGNITION COIL .............F1.10 Spark plug recess ignition coil disassembly ..........F1.10...
  • Page 123 ENGINE DISASSEMBLY/REASSEMBLY 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. Clutch hub disassembly ................F1.27 Clutch housing disassembly ..............F1.27 Clutch housing clearance check ..............F1.28 Clutch housing clearance reading ............F1.28 Clutch housing assembly .................F1.30 Clutch hub assembly ................F1.30 Fit clutch plates ..................F1.30...
  • Page 124 ENGINE DISASSEMBLY/REASSEMBLY 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. Rocker arm disassembly .................F1.47 Rocker arm shaft disassembly ..............F1.47 Valve seat width check ................F1.48 Valve guide clearance check ..............F1.48 Rocker arms shaft assembly ..............F1.49 Rocker arm assembly ................F1.50...
  • Page 125 ENGINE DISASSEMBLY/REASSEMBLY 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. Removing oil seal from gearbox shaft .............F1.67 Fitting gearbox shaft oil seal ..............F1.67 REPLACING OUTPUT SHAFT OIL SEAL ...........F1.68 Gearbox output shaft left oil seal disassembly ........F1.68 Gearbox output shaft right oil seal disassembly ........F1.68 Gearbox output shaft right oil seal assembly ...........F1.68...
  • Page 126 ENGINE DISASSEMBLY/REASSEMBLY 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. Disassembly/Reassembly of the gearbox (6 Speed) (TE-TXC-SMS) ..F1.88 Input shaft (6 speed) (TE-TXC-SMS) ............F1.89 Output shaft (6 speed) (TE-TXC-SMS) ............F1.89 Gearbox oil pipe disassembly ..............F1.90 Gearbox oil pipe assembly ..............F1.90...

  • Page 127: Oil Filter Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. OIL FILTER REPLACEMENT Oil filter disassembly • Remove plug (1) with O-Ring (2). • Disassemble oil filter (3). H01732 Oil filter assembly •...

  • Page 128: Engine Oil Filter Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Engine oil filter disassembly • Disassemble front oil mesh filter. • Disassemble the following parts: - screw (1) - Filter (3) - O-Rings (2, 4, 5)

  • Page 129: Engine Oil Filter Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Engine oil filter assembly • Assemble rear oil mesh filter. • Assemble the following parts: - O-Rings (5, 4, 2) - Filter (3) •...

  • Page 130: Spark Plug Recess Ignition Coil

    ENGINE DISASSEMBLY/REASSEMBLY 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. SPARK PLUG RECESS IGNITION COIL Spark plug recess ignition coil disassembly • Disassemble the following parts: - Screw (1) - Spark plug recess ignition coil (2) H01714...

  • Page 131: Spark Plug Recess

    ENGINE DISASSEMBLY/REASSEMBLY 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. SPARK PLUG RECESS Spark plug recess disassembly • Remove seal (1) and spark plug recess (2). H01728 Spark plug recess assembly •...

  • Page 132: Spark Plug

    ENGINE DISASSEMBLY/REASSEMBLY 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. SPARK PLUG Spark plug disassembly • Disassemble spark plug using a wrench / suitable tool H01729 Spark plug assembly •...

  • Page 133: Oil Pressure Adjustment Valve Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. OIL PRESSURE ADJUSTMENT VALVE REPLACEMENT Oil pressure adjustment valve disassembly • Disassemble the following parts: - screw (1) - Seal (2) - Spring (3)

  • Page 134: Cylinder Head Cover

    ENGINE DISASSEMBLY/REASSEMBLY 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. CYLINDER HEAD COVER Removing cylinder head cover • Remove screws with seal (1), and washers. •...

  • Page 135: Engine Positioning At Ignition Tdc

    ENGINE DISASSEMBLY/REASSEMBLY 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. ENGINE POSITIONING AT IGNITION TDC • Turn engine until reaching TDC. • Reference marks (arrows) parallel with cylinder head. H01727 Securing crankshaft at TDC •...

  • Page 136: Camshaft Removal

    ENGINE DISASSEMBLY/REASSEMBLY 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. CAMSHAFT REMOVAL Bearing mount disassembly • Remove screws (1, 2). • Disassemble bearing mount (3). •...

  • Page 137: Bearing Mount Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Bearing mount assembly • Assemble guide sleeves (4). • Lubricate mount (3) at camshaft sliding surfaces, then assemble it. Consumables Molykote D Paste Clear solid lubricant for metal part assembling...

  • Page 138: Engine Left Crankcase

    ENGINE DISASSEMBLY/REASSEMBLY 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. ENGINE LEFT CRANKCASE Engine left crankcase cover disassembly • Disassemble the following parts: - Screws (1) and (2) with sealing rings (3) - Cover (4) - Gasket (5) - Guide sleeves (6)

  • Page 139: Alternator Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. ALTERNATOR REPLACEMENT Preliminary operations Engine oil drainage Engine positioning at ignition TDC Securing crankshaft at TDC Engine left crankcase cover disassembly Flywheel disassembly •...

  • Page 140: Stator Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Stator disassembly • Disassemble the following parts: - Screws (1) and (2) - Cable retaining plate (3) - Rubber sheath (4) - Stator (5) H01919...

  • Page 141: Stator Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Stator assembly • Clean screw (1) and (5) threaded holes. • Position stator (6). •...

  • Page 142: Crankcase Left Cover Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. CRANKCASE LEFT COVER REPLACEMENT Preliminary operations Engine oil drainage Engine left crankcase cover disassembly Stator disassembly •...
  • Page 143 ENGINE DISASSEMBLY/REASSEMBLY 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. • Apply a layer of sealant onto rubber sheath (2) sealing surfaces. Consumables 3 - Bond 1209 Surface sealer •...

  • Page 144: Crankshaft Sensor Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. CRANKSHAFT SENSOR REPLACEMENT Preliminary operations Engine oil drainage Engine left crankcase cover disassembly Crankshaft sensor disassembly •...

  • Page 145: Freewheel Gear Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. FREEWHEEL GEAR REPLACEMENT Freewheel gear disassembly • Disassemble the following parts: - Screws (1) - Guide (2) - Gear (3) - Needle roller bearing (4)

  • Page 146: Clutch Disassembly And Reassembly Or Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. CLUTCH DISASSEMBLY AND REASSEMBLY OR REPLACEMENT H01987 Preliminary operations Engine oil drainage Securing crankshaft at TDC Brake pedal release Clutch actuator disassembly Clutch cover disassembly...

  • Page 147: Removing Clutch Plates

    ENGINE DISASSEMBLY/REASSEMBLY 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. Removing clutch plates • Remove clutch plates pack (1). Technical specifications Clutch plates number 6 steel plates 6 lined plates H01734...

  • Page 148: Clutch Housing Clearance Check

    ENGINE DISASSEMBLY/REASSEMBLY 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. Clutch housing clearance check • Fit clutch housing (1) with needle roller bearing cage and hub (2). •...
  • Page 149 ENGINE DISASSEMBLY/REASSEMBLY 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. Action: • Replace clutch thrust washer. If needed, repeat the procedure. Technical specifications Space washers 2.200 mm thickness for clutch 2.250 mm...

  • Page 150: Clutch Housing Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Clutch housing assembly • Lubricate bearing (3), and assemble it. Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling...

  • Page 151: Pressure Plate Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. • Make sure that the relief on the last steel washer is pointing outwards. •...

  • Page 152: Replacing Clutch Disengagement Bearing

    ENGINE DISASSEMBLY/REASSEMBLY 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. REPLACING CLUTCH DISENGAGEMENT BEARING Preliminary operations Engine oil drainage Clutch cover disassembly Mushroom-type disengagement element disassembly Clutch disengagement bearing disassembly •...

  • Page 153: Engine Right Crankcase

    ENGINE DISASSEMBLY/REASSEMBLY 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. ENGINE RIGHT CRANKCASE Preliminary operations Clutch cover disassembly Removing clutch pressure plate Removing clutch plates Clutch hub disassembly Clutch housing disassembly Coolant pump cover disassembly...
  • Page 154 ENGINE DISASSEMBLY/REASSEMBLY 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. • Fit screw (2). Tightening torque figures Engine and crankcase fairing, screw connections M6 x 30 11 Nm •...

  • Page 155: Clutch Thrust Washer

    ENGINE DISASSEMBLY/REASSEMBLY 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. CLUTCH THRUST WASHER Clutch thrust washer disassembly • Remove washer (1). H01742 Clutch thrust washer assembly •...

  • Page 156: Clutch Housing Axial Bearing

    ENGINE DISASSEMBLY/REASSEMBLY 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. CLUTCH HOUSING AXIAL BEARING Clutch housing axial bearing disassembly • Remove bearing (1). H01720 Clutch housing axial bearing assembly •...

  • Page 157: Coolant Pump Disassembly And Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. COOLANT PUMP DISASSEMBLY AND ASSEMBLY H01941 Coolant pump cover disassembly • Disassemble the following parts: - Screws (1, 2, 3) - Cover (5) - Seal (6)

  • Page 158: Coolant Pump Rotor Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Coolant pump rotor assembly • Fit rotor (2). • Fit screw (1). Tightening torque figures Coolant pump gear on pump shaft M5 x 10 - 10.9, Microincapsulated 6 Nm...

  • Page 159: Coolant Pump Inside Crankcase Oil Seal Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. COOLANT PUMP INSIDE CRANKCASE OIL SEAL REPLACEMENT (CRAN- KCASE COVER REMOVED) H01942 Coolant pump control rear oil seal disassembly •...

  • Page 160: Coolant Pump Drive Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. COOLANT PUMP DRIVE REPLACEMENT (CRANKCASE COVER REMO- VED) H01945 Slider loosening in the lower area •...

  • Page 161: Coolant Pump Shaft Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Coolant pump shaft assembly • Lubricate bearing (5), and shaft (3). Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling •...

  • Page 162: Chain Sprocket

    ENGINE DISASSEMBLY/REASSEMBLY 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. CHAIN SPROCKET Chain sprocket removal • Remove screws (1), and stop washer (2). • Remove chain sprocket (3). H01739 Sprocket assembly •...

  • Page 163: Chain Tensioner Disassembly And Reassembly Or Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. CHAIN TENSIONER DISASSEMBLY AND REASSEMBLY OR REPLACE- MENT H01933 Chain tensioner disassembly • Disassemble the following parts: - screw (1) - Chain tensioner (2) - O-Rings (3, 4)

  • Page 164: Cylinder Head Disassembly And Reassembly/Head Gasket Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. CYLINDER HEAD DISASSEMBLY AND REASSEMBLY/HEAD GASKET RE- PLACEMENT Preliminary operations Spark plug recess ignition coil disassembly Spark plug disassembly Removing cylinder head cover Spark plug recess disassembly...

  • Page 165: Cylinder Head Replacement (Cylinder Head Removed)

    ENGINE DISASSEMBLY/REASSEMBLY 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. CYLINDER HEAD REPLACEMENT (CYLINDER HEAD REMOVED) H01910 Valve removal • Mark bucket type tappets (1), and remove them with a suitable tool. •...

  • Page 166: Removing Valve Spring

    ENGINE DISASSEMBLY/REASSEMBLY 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. • Assemble cylinder head onto support plate (N. 8000H5015). • Fit supporting bracket (N. 8000H5017), spindle with handle (N.8000H5016), connector (N.

  • Page 167: Rocker Arm Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Rocker arm disassembly • Remove stop rings (1) and rocker arms (2). H01912 Rocker arm shaft disassembly •...

  • Page 168: Valve Seat Width Check

    ENGINE DISASSEMBLY/REASSEMBLY 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. Valve seat width check • Check that valve seat contact surface is neither damaged nor worn. Check •...

  • Page 169: Rocker Arms Shaft Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Rocker arms shaft assembly • Lubricate rocker arm shafts. Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling...

  • Page 170: Rocker Arm Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Rocker arm assembly • Lubricate rocker arm shafts. Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling...

  • Page 171: Valve Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Valve assembly • Assemble cylinder head onto support plate (N. 8000H5015). 8000H5016 • Fit supporting bracket (N. 8000H5017), spindle with handle (N.8000H5016), 8000H5017 connector (N.

  • Page 172: Chain Slider

    ENGINE DISASSEMBLY/REASSEMBLY 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. CHAIN SLIDER Chain tensioning slider disassembly • Remove screw (1). • Remove chain tensioning slider (2). H01749 Slider disassembly •...

  • Page 173: Slider Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Slider assembly • Assemble the following parts: - Slider (4) - Washer (2) • Fit screw (1). Tightening torque figures Slider onto cylinder head Calibrated screw, M8...

  • Page 174: Cylinder Disassembly And Reassembly Or Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. CYLINDER DISASSEMBLY AND REASSEMBLY OR REPLACEMENT H01908 Preliminary operations Spark plug recess ignition coil disassembly Spark plug disassembly Removing cylinder head cover Spark plug recess disassembly...

  • Page 175: Piston Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Piston disassembly • Watch stop rings correct position: ring opening shall be pointing up (arrow). •...

  • Page 176: Piston Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Piston diameter check Check • Measure piston diameter (A) crosswise to piston pin axis. •...

  • Page 177: Piston Ring Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Piston ring assembly • Fit piston ring and scraper ring inside annular grooves, offset by 180°. Warning Offset garter spring port by approx.

  • Page 178: Subsequent Actions

    ENGINE DISASSEMBLY/REASSEMBLY 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. • Remove the gasket protruding out of the flange used for cylinder connec- tion. •...

  • Page 179: Timing Chain Disassembly And Reassembly Or Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. TIMING CHAIN DISASSEMBLY AND REASSEMBLY OR REPLACEMENT H01932 Preliminary operations Clutch cover disassembly Spark plug recess ignition coil disassembly Removing cylinder head cover Spark plug recess disassembly Engine positioning at ignition TDC...

  • Page 180: Timing Chain Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Timing chain assembly • Lubricate timing chain (1), and fit it onto countershaft gear (2) working through crankcase from top.

  • Page 181: Preliminary Operations

    ENGINE DISASSEMBLY/REASSEMBLY 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. REPLACING OIL PUMP GEARS (CRANKCASE COVER REMOVED) Preliminary operations H01937 Idler gear disassembly Clutch housing axial bearing disassembly Clutch thrust washer disassembly Oil pump idler gear disassembly •...

  • Page 182: Disassembly Of Crankshaft Gear Pointing To Oil Pump Idler Gear

    ENGINE DISASSEMBLY/REASSEMBLY 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. Disassembly of crankshaft gear pointing to oil pump idler gear 8000H5014 • Fit presser (N. 8000H5014) onto crankshaft. Remove gear using puller (N.8000H5011), and jaws (N.
  • Page 183 ENGINE DISASSEMBLY/REASSEMBLY 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. Oil pump idler gear assembly • Lubricate bearing (4), and gear (3). Consumables Molykote D Paste Clear solid lubricant for metal part assembling and...

  • Page 184: Preliminary Operations

    ENGINE DISASSEMBLY/REASSEMBLY 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. OIL INTAKE PUMP REPLACEMENT (CRANKCASE COVER REMOVED) Preliminary operations Clutch housing axial bearing disassembly Clutch thrust washer disassembly Oil pump idler gear disassembly Oil pump control gear disassembly...

  • Page 185: Preliminary Operations

    ENGINE DISASSEMBLY/REASSEMBLY 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. REMOVING AND ASSEMBLING OR REPLACING PRESSURE OIL PUMP Preliminary operations Engine oil drainage Gear lever disassembly Engine left crankcase cover disassembly H01939 Oil force pump disassembly...

  • Page 186: Oil Pumps Shaft

    ENGINE DISASSEMBLY/REASSEMBLY 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. OIL PUMPS SHAFT Oil pumps shaft disassembly • Remove shaft (1) from crankcase. H01886 Oil pumps shaft assembly •...

  • Page 187: Replace Gearbox Control Shaft Radial Sealing Ring

    ENGINE DISASSEMBLY/REASSEMBLY 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. REPLACE GEARBOX CONTROL SHAFT RADIAL SEALING RING Preliminary operations Gear lever disassembly Removing oil seal from gearbox shaft •...

  • Page 188: Replacing Output Shaft Oil Seal

    ENGINE DISASSEMBLY/REASSEMBLY 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. REPLACING OUTPUT SHAFT OIL SEAL Gearbox output shaft left oil seal disassembly • Remove oil seal (1). H01998 Gearbox output shaft right oil seal disassembly •...

  • Page 189: Disassembling/Assembling Starter Motor

    ENGINE DISASSEMBLY/REASSEMBLY 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. DISASSEMBLING/ASSEMBLING STARTER MOTOR Removing starter motor • Disconnect positive cable (1). • Remove screws (2). •...

  • Page 190: Starter Idle Gear Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. STARTER IDLE GEAR REPLACEMENT Preliminary operations Engine oil drainage Gear lever disassembly Engine left crankcase cover disassembly Securing crankshaft at TDC Starter motor idle gear disengagement Flywheel disassembly...

  • Page 191: Freewheel Gear Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Freewheel gear disassembly • Disassemble the following parts: - Screws (1) - Guide (2) - Gear (3) - Needle roller bearing (4) H01743...

  • Page 192: Starter Motor Idle Gear Fitting

    ENGINE DISASSEMBLY/REASSEMBLY 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. Starter motor idle gear fitting • Lubricate bushing (5), and needle roller bearing (4), then assemble them. Consumables Molykote D Paste Clear solid lubricant for metal...

  • Page 193: Starter Motor Idle Gear

    ENGINE DISASSEMBLY/REASSEMBLY 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. STARTER MOTOR IDLE GEAR Starter motor idle gear disengagement • Loosen nut (1). Starter motor idle gear fitting •...

  • Page 194: Crankshaft Axial Clearance Check

    ENGINE DISASSEMBLY/REASSEMBLY 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. CRANKSHAFT AXIAL CLEARANCE CHECK Check • Measure crankshaft axial clearance (G) using a dial gauge. •...

  • Page 195: Control Gear Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Control gear disassembly • Lock control gear (1) using tool (N. 8000H5010) to prevent it from moving. •...

  • Page 196: Crankshaft Right Bearing Bushing Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Crankshaft right bearing bushing disassembly • Remove roller (1). H01789 Warning Burn hazard in case of contact with hot/heated parts. Should you have to touch hot parts, wear protective gloves.

  • Page 197: Crankshaft Left Bearing Bushing Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Crankshaft left bearing bushing disassembly Warning Burn hazard in case of contact with hot/heated parts. Should you have to touch hot parts, wear protective gloves.

  • Page 198: Crankshaft Wear Check

    ENGINE DISASSEMBLY/REASSEMBLY 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. Crankshaft wear check • Check crankshaft support pin (arrows). Result: Support pins are damaged or worn. Action: •...

  • Page 199: Crankshaft Axial Clearance Adjustment, Left Side

    ENGINE DISASSEMBLY/REASSEMBLY 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. Crankshaft axial clearance adjustment, left side • Measure left bearing (C) seat depth using a depth gauge. •...

  • Page 200: Crankshaft Left Bearing Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Crankshaft left bearing disassembly Caution Temperature differences as well as casing overheating may lead to struc- ture changes and to cracks due to internal stresses.

  • Page 201: Crankshaft Right Bearing Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Crankshaft right bearing assembly Caution Temperature differences as well as casing overheating may lead to struc- ture changes and to cracks due to internal stresses.

  • Page 202: Countershaft Left Bearing Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Countershaft left bearing assembly Caution Temperature differences as well as casing overheating may lead to struc- ture changes and to cracks due to internal stresses.

  • Page 203: Crankshaft Left Bearing Bushing Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Crankshaft left bearing bushing assembly • If necessary, fit space washer. Warning Burn hazard in case of contact with hot/heated parts. Should you have to touch hot parts, wear protective gloves.

  • Page 204: Crankshaft Right Bearing Bushing Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Crankshaft right bearing bushing assembly Warning Burn hazard in case of contact with hot/heated parts. Should you have to touch hot parts, wear protective gloves.

  • Page 205: Preliminary Operations

    ENGINE DISASSEMBLY/REASSEMBLY 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. GEARBOX UNIT - DISASSEMBLY / ASSEMBLY Preliminary operations Engine oil drainage Head disassembly Gear lever disassembly Engine left crankcase cover disassembly Engine right crankcase cover disassembly Securing crankshaft at TDC...

  • Page 206: Disassembly/Reassembly Of The Gearbox (5 Speed) (Tc)

    ENGINE DISASSEMBLY/REASSEMBLY 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. Result: Bearings do not move properly or they have increased clearance. Action: Replace primary shaft (removed shaft) bearings Replace output shaft (removed shaft) bearings •...

  • Page 207: Input Shaft (6 Speed) (Tc)

    ENGINE DISASSEMBLY/REASSEMBLY 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. Input shaft (6 speed) (TC) Z=14 Z=23 Z=15 Z=23 H06428 Z=16 Output shaft (6 speed) (TC) Z=32 Z=29 Z=23...

  • Page 208: Disassembly/Reassembly Of The Gearbox (6 Speed) (Te-Txc-Sms)

    ENGINE DISASSEMBLY/REASSEMBLY 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. Disassembly/Reassembly of the gearbox (6 Speed) (TE-TXC-SMS) Caution During operation, gear wheel sets slide one towards the other. If just one coupling gear is replaced, the load bearing capacity on gears may be- come significantly worse.

  • Page 209: Input Shaft (6 Speed) (Te-Txc-Sms)

    ENGINE DISASSEMBLY/REASSEMBLY 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. Input shaft (6 speed) (TE-TXC-SMS) TE - TXC - SMR Z=14 Z=23 Z=15/20 Z=24 H06430 Z=16 Output shaft (6 speed) (TE-TXC-SMS)

  • Page 210: Gearbox Oil Pipe Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Gearbox oil pipe disassembly • Remove oil pipe (1) Gearbox oil pipe assembly • Fit oil pipe (1) H01816 Gearbox input shaft right bearing disassembly Caution...

  • Page 211: Gearbox Output Shaft Right Bearing Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Gearbox output shaft right bearing disassembly • Remove oil seal (1). Caution Temperature differences as well as casing overheating may lead to struc- ture changes and to cracks due to internal stresses.

  • Page 212: Gearbox Shaft Right Bearing Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Gearbox shaft right bearing disassembly Caution Temperature differences as well as casing overheating may lead to struc- ture changes and to cracks due to internal stresses.

  • Page 213: Gearbox Input Shaft Idler Gear Bearing Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Gearbox input shaft idler gear bearing assembly Caution Temperature differences as well as casing overheating may lead to struc- ture changes and to cracks due to internal stresses.

  • Page 214: Gearbox Output Shaft Left Bearing Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Gearbox shaft right bearing assembly Caution Temperature differences as well as casing overheating may lead to struc- ture changes and to cracks due to internal stresses.

  • Page 215: Gearbox Input Shaft Left Bearing Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Gearbox input shaft left bearing assembly Caution Temperature differences as well as casing overheating may lead to struc- ture changes and to cracks due to internal stresses.
  • Page 216 ENGINE DISASSEMBLY/REASSEMBLY 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. • Remove idler gear (1) using a suitable tool. Technical specifications Release/connection 80 °C temperature H01805 Check...

  • Page 217: Idler Gear Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Idler gear disassembly Caution Temperature differences as well as casing overheating may lead to struc- ture changes and to cracks due to internal stresses.

  • Page 218: Gearbox Shaft Replacement (Crankcase Cover Removed)

    ENGINE DISASSEMBLY/REASSEMBLY 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. GEARBOX SHAFT REPLACEMENT (CRANKCASE COVER REMOVED) H02009 Complete selector shaft disassembly • Remove gearbox shaft (1) with spring (2), and washer (3). H02010 Gearbox shaft check Check...

  • Page 219: Selector Cylinder Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. SELECTOR CYLINDER REPLACEMENT Selector drum disassembly • Remove gearbox guides (1). • Turn forks (2) from selector cylinder (3). •...

  • Page 220: Gear Selector Fork Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. GEAR SELECTOR FORK REPLACEMENT Gear selector fork disassembly • Remove gearbox guides (1). • Remove gear selector forks (2). H02012 Check gear selector forks Check...

  • Page 221: Gearbox Assembly

    ENGINE DISASSEMBLY/REASSEMBLY 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. Gearbox assembly • Lubricate shafts, selector drum and forks. Consumables Molykote D Paste Clear solid lubricant for metal parts assembling and settling •...

  • Page 222: Preliminary Operations

    ENGINE DISASSEMBLY/REASSEMBLY 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. STOP LEVER REPLACEMENT Preliminary operations Clutch cover disassembly Removing clutch pressure plate Removing clutch plates Clutch hub disassembly Clutch housing disassembly Coolant pump cover disassembly...

  • Page 223: Gear Selector Lock Replacement

    ENGINE DISASSEMBLY/REASSEMBLY 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. GEAR SELECTOR LOCK REPLACEMENT Preliminary operations Clutch cover disassembly Removing clutch pressure plate Removing clutch plates Clutch hub disassembly Clutch housing disassembly Coolant pump cover disassembly...
  • Page 225 FRONT SUSPENSION 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. Section Workshop Manual Ed. 03-2012...
  • Page 226 FRONT SUSPENSION 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. Sommario Front fork removal ..................I.3 Service instructions for Ø48USD Kayaba fork..........I.5 Front suspension (TC - TXC) ............... I.6 Front fork disassembly (TC - TXC) ...............

  • Page 227: Txc 449 - 511 2011/2012 I.e

    FRONT SUSPENSION 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. Front fork removal Measure height "A" (it will need to be restored to original value on assembly). Set a block under the engine and see that the front wheel is lifted from the ground and then proceed as follows: H006207...
  • Page 228 FRONT SUSPENSION 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. remove the six screws (2) and the fork leg guards; TC - TE - TXC remove the brake calliper from the L.H.

  • Page 229: Service Instructions For Ø48Usd Kayaba Fork

    FRONT SUSPENSION 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. Front suspension Service instructions for Ø48USD Kayaba fork GENERAL The fork uses a multi-valve damping system with rebound and compression adjustment and spring preload adjustment for static load.
  • Page 230 FRONT SUSPENSION 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. Front suspension (TC - TXC) Front suspension is handled by a KAYABA upside-down telescopic hydraulic fork with advanced axle and 48 mm legs. Wheel travel is 300 mm.

  • Page 231: Front Fork Disassembly (Tc - Txc)

    FRONT SUSPENSION 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. Front fork disassembly (TC - TXC) Loosen the cap nut at the top of each outer tube. (Note: it is good practice to moderately slacken the cap nuts before removing the fork legs from the motorcycle).
  • Page 232 FRONT SUSPENSION 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. Take the cartridge out of the outer tube. Do not remove the nut at the bottom end of the cartridge. Remove the bottom valve assembly from the cartridge.
  • Page 233 FRONT SUSPENSION 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. If outer tube and inner tube are still assembled together, place the fork leg upside down and allow at least 20 minutes for oil to drain.
  • Page 234 FRONT SUSPENSION 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. Remove the sealing rings and the metal rings mounted on the inner tube. Do not reuse any metal parts after removal. Replace them with new components.
  • Page 235 FRONT SUSPENSION 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. Mount sealing rings and metal parts on the inner tube. See the figure below for the installation sequence. Note 1: Grease the edge of the sealing ring.
  • Page 236 FRONT SUSPENSION 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. Fit the dust seal to the outer tube. Make sure that there is not play between dust seal and outer tube. Refit the cartridge.
  • Page 237 FRONT SUSPENSION 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. Pull the piston rod until fully extended. Check oil level. It should be about 145 mm (5.7 in.). Push the piston rod all the way down and install the bottom valve assembly.
  • Page 238 FRONT SUSPENSION 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. Drain excess oil from the cartridge pushing the damper unit all the way home. Be careful not to distort or damage the piston rod or any other parts.
  • Page 239 FRONT SUSPENSION 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. Push down the inner tube. Slip the tool shown in the figure between wheel axle carrier and cartridge nut. Insert the rebound adjuster rod into the piston rod and tighten the adjuster screw.
  • Page 240 FRONT SUSPENSION 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. Clamp the wheel axle carrier in a vice and tighten the adjuster screw onto the carrier to 55 Nm (40.5 ft/lb).

  • Page 241: Front Suspension (Te)

    FRONT SUSPENSION 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. Front suspension Mod. TE /2010 Front suspension (TE) Front suspension is handled by a KAYABA upside-down telescopic hydraulic fork with advanced axle and 48 mm legs. Wheel travelis 300 mm.

  • Page 242: Front Fork Disassembly (Te)

    FRONT SUSPENSION 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. Front fork disassembly (TE) Loosen the cap nut at the top of each outer tube. (Note: it is good practice to moderately slacken the cap nuts before removing the fork legs from the motorcycle).
  • Page 243 FRONT SUSPENSION 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. Remove nut, spring guide, O-ring and collar bushing. Hold the cartridge top end steady. Loosen and remove the bottom valve assembly.
  • Page 244 FRONT SUSPENSION 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. Take the cartridge out of the outer tube. Remove the dust seal using a flat head screwdriver. Workshop Manual Ed.
  • Page 245 FRONT SUSPENSION 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. Remove the retaining ring using a flat head screwdriver. Pull the inner tube until separating it from the outer tube. Note: to facilitate removal, quickly (but carefully) pump the tubes back and forth until separating them.
  • Page 246 FRONT SUSPENSION 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. Check the spring. Replace it if: outside diameter is damaged or exceedingly worn. Free length is 457 mm (18 in.) or less. Check the inner tube.
  • Page 247 FRONT SUSPENSION 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. Fit metal bushing and washer to outer tube using an appropriate installer. Fit the oil seal to the outer tube and push it home using an appropriate in- staller.
  • Page 248 FRONT SUSPENSION 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. Insert the cartridge into the outer tube. Hold the cartridge top end into place. Tighten the bottom valve assembly to 55 Nm (40.5 ft/lb).
  • Page 249 FRONT SUSPENSION 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. Fit collar bushing, O-ring, spring guide and nut onto piston rod. Insert the rebound adjuster rod into the piston rod. Make sure that at least an 18 mm (0.71 in.) portion of the rebound adjuster rod protrudes from the piston rod.
  • Page 250 FRONT SUSPENSION 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. Filling oil to specific level Fill the damper unit with oil up to the top edge of the outer tube. Slowly pump the outer tube up and down to help oil flow equally into both inner and outer tube.

  • Page 251: Instructions For Use Of Ø50Usd Fork (Smr)

    FRONT SUSPENSION 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. Instructions for use of ø50USD fork (SMR) GENERAL Telehydraulic upside down fork, with advanced axle. This fork is based on a multivalve damping system and spring for static load.

  • Page 252: Front Suspension (Smr)

    FRONT SUSPENSION 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. Front suspension (SMR) Front suspension is handled by a MARZOCCHI “U.S.D.” upside-down telescopic hydraulic fork with advanced axle and 50 mm legs. Wheel travelis 258 mm.

  • Page 253: Components Of The Fork

    FRONT SUSPENSION 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. Components of the fork The fork is based on a multivalve damping system that is exactly the same on both fork’s legs.

  • Page 254: General Rules For A Proper Overhauling

    FRONT SUSPENSION 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 rules for a proper overhauling • After a complete breakdown, always use new, original Marzocchi seals when reassembling.

  • Page 255: Instructions For Clamping In The Vice

    FRONT SUSPENSION 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. Instructions for clamping in the vice For some maintenance procedures you may have to use the vice to clamp some components of the fork.

  • Page 256: Problems - Possible Causes - Solutions

    FRONT SUSPENSION 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. 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.

  • Page 257: Cleaning The Dust Seal

    FRONT SUSPENSION 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. You can find the reference numbers of this chapter about the explored view of the fork on pag. 6. Cleaning the dust seal (FIG.

  • Page 258: Draining The Oil

    FRONT SUSPENSION 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. Draining the oil This operation cannot be carried out with the fork installed on the motorcycle.

  • Page 259: Braking Down The Pumping Element And The Bottom Valve

    FRONT SUSPENSION 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. Braking down the pumping element and the bottom valve This operation must be done only after having drained all of the oil out of the fork leg.
  • Page 260 FRONT SUSPENSION 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. • 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 261: Braking Down The Fork Leg - Slider And Removing The Oil Seals

    FRONT SUSPENSION 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. 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. •...

  • Page 262: Overhauling And Modifying The Cartridge And Bottom Valve Setting

    FRONT SUSPENSION 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. Overhauling and modifying the cartridge and bottom valve setting Cartridge overhauling (rebound braking) Dismantling •...

  • Page 263: Bottom Valve Overhauling (Compression Braking)

    FRONT SUSPENSION 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. The piston must be oriented in a way that the holes having smaller diameter are placed towards the setting washers (37). •...

  • Page 264: Re- Assembling The Fork Leg - Slider And Oil Seals

    FRONT SUSPENSION 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. 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 wash- ers (46) and the piston (45) with other components having different characteristics.
  • Page 265 FRONT SUSPENSION 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. • 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 ).

  • Page 266: Re- Assembling The Pumping Element Unit And The Bottom Valve

    FRONT SUSPENSION 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. • 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.
  • Page 267 FRONT SUSPENSION 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. • Insert the tip (29) of stop buffer onto rod (32); it must be inserted so that the side with the flat is facing the case (30) and that you overcome the housing of the wire (F).
  • Page 268 FRONT SUSPENSION 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. • Push the pre- assembled pumping element ( 23 ) until it is in contact with the stanchion tube ( 5 ).

  • Page 269: Filling With Oil

    FRONT SUSPENSION 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. Filling with oil • Lift the slider completely on the stanchion tube. • Prepare the quantity of oil to pour into the fork leg (see Table 2 – Oil and quantity).
  • Page 271 REAR SUSPENSION 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. Section Workshop Manual Ed. 03-2012...
  • Page 272 REAR SUSPENSION 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. Rear shock absorber ..................J.3 Tightening torque ...................J.3 Lubrication points (grease) ................J.3 Rear suspension....................J.4 Rear shock absorber removal ...............J.5 Disassembling and servicing the swinging arm ..........J.6 Linkage disassembly ..................J.8 Chain roller, chain guide, chain slider ............J.9...

  • Page 273: Txc 449 - 511 2011/2012 I.e

    REAR SUSPENSION 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. Rear shock absorber Tightening torque figures 1, 2 = 50 Nm/ 5.0 Kgm/ 36.88 ft-lb H006175 H006176 Lubrication points (grease)

  • Page 274: Rear Suspension

    REAR SUSPENSION 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. Rear suspension The rising-rate rear suspension is made up of a shock absorber, a linkage system and a swinging arm.

  • Page 275: Rear Shock Absorber Removal

    REAR SUSPENSION 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. Rear shock absorber removal H006179 - Fit a support under the engine so that the rear wheel is raised off the ground. - Remove the saddle, the side panels and control unit as described in the cor- responding chapters.

  • Page 276: Disassembling And Servicing The Swinging Arm

    REAR SUSPENSION 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. H006192 Disassembling and servicing the swinging arm - Remove the chain and rear wheel, as described in the relevant chapters. - Remove the two side protections (A) from the chassis.
  • Page 277 REAR SUSPENSION 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. - Loosen the two screws (5) using an 8 mm wrench, and remove rear brake hose support (6) to slide out the pin (7).

  • Page 278: Linkage Disassembly

    REAR SUSPENSION 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. - Check bearings (11), seals and bushings for wear. H006191 - Upon reassembly, tighten nut (8) to 80 Nm - 8 Kgm - 59.00 ft-lb and pins (9) to 100 Nm - 10 Kgm - 73.76 ft-lb.

  • Page 279: Chain Roller, Chain Guide, Chain Slider

    REAR SUSPENSION 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. Chain roller, chain guide, chain slider Check the wear of the above-mentioned elements and replace them when necessary.
  • Page 281 BRAKES 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. Section Workshop Manual Ed. 03-2012...
  • Page 282 BRAKES 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. Sommario Braking system ..................... L.3 Brake disc ..................... L.5 Checking brake pads for wear / replacing the pads (TC-TE-TXC) ....L.6 Checking brake pads for wear / replacing the pads (SMR) ......

  • Page 283: Txc 449 - 511 2011/2012 I.e

    BRAKES 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. TC - TE - TXC Braking system The braking system uses two independent circuits. Each system is equipped with a brake calliper connected to a master cylinder with a fluid reservoir.
  • Page 284 BRAKES 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. 6. Rear brake fluid reservoir 7. Rear brake line 8. Rear brake calliper 9. Rear brake disc 10.
  • Page 285 BRAKES 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. Brake disc TC - TE - TXC Checking the brake disc is an important safety procedure; the disc must be spot- less, i.e.

  • Page 286: Checking Brake Pads For Wear / Replacing The Pads (Tc-Te-Txc)

    BRAKES 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. Checking brake pads for wear / replacing the pads (TC-TE-TXC) Check brake pad wear. Service limit ”A” 3.8 mm (0,15 in) (front and rear pads) If service limit is exceeded, always replace the pads in pairs.

  • Page 287: Checking Brake Pads For Wear / Replacing The Pads (Smr)

    BRAKES 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. Checking brake pads for wear / replacing the pads (SMR) Check brake pad wear. Service limit ”A” 3.8 mm (0,15 in) (front and rear pads) If service limit is exceeded, always replace the pads in pairs.

  • Page 288: Bleeding The Front Braking System (Tc-Te-Txc)

    BRAKES 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. Bleeding the front braking system (TC-TE-TXC) A long travel and mushy feel of the brake lever indicate that there is air in the system and the brake needs bleeding.
  • Page 289 BRAKES 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. Bleeding the front braking system (SMR) A long travel and mushy feel of the brake lever indicate that there is air in the system and the brake needs bleeding.

  • Page 290: Bleeding The Rear Braking System

    BRAKES 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. Bleeding the rear braking system A long travel and mushy feel of the brake pedal indicate that there is air in the system and the brake needs bleeding.

  • Page 291: Changing The Fluid

    BRAKES 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. TC - TE - TXC Changing the fluid Brake fluid should be checked and changed as per the "Maintenance Chart" (see Section B), or earlier if contaminated with debris or water.
  • Page 292 BRAKES 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. Remove the reservoir cap (2) or (2A) 21 mm wrench and the rubber gaiter. TC - TE - TXC Pull the lever (3) and hold it pulled, or press the pedal (3A) and hold it pressed so that the system is under pressure.
  • Page 293 BRAKES 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. Periodically check the connecting hoses (C) and (D) (see Scheduled Maintenance TC - TE - TXC Chart, Section B): replace worn or cracked hoses.
  • Page 295 ELECTRICAL SYSTEM 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. Section Workshop Manual Ed. 03-2012...
  • Page 296 ELECTRICAL SYSTEM 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. Engine wiring diagram (TC MY11 - MY12) ..........M.4 Engine wiring diagram (TE-TXC-SMR MY11 + SMR MY12) ...... M.6 Engine wiring diagram (TE-TXC MY12) ............
  • Page 297 ELECTRICAL SYSTEM 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. Dashboard replacement (TE - SMR) ............M.58 Instructions for the instrument setting............M.59 Troubleshooting ..................M.59 Charging system..................

  • Page 298: Txc 449 - 511 2011/2012 I.e

    ELECTRICAL SYSTEM 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. Engine wiring diagram (TC MY11 - MY12) Workshop Manual Ed. 03-2012...
  • Page 299 ELECTRICAL SYSTEM 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. Key to wiring diagram 1. Control unit 2. Neutral 3. Crankshaft pick up 4. Air temperature sensor 5.

  • Page 300: Engine Wiring Diagram (Te-Txc-Smr My11 + Smr My12)

    ELECTRICAL SYSTEM 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. Engine wiring diagram (TE-TXC-SMR MY11 + SMR MY12)    Workshop Manual Ed. 03-2012...
  • Page 301 ELECTRICAL SYSTEM 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. Key to wiring diagram Colour coding key 1. Control unit blge ....Blue/Yellow 2. Neutral blgn ....

  • Page 302: Engine Wiring Diagram (Te-Txc My12)

    ELECTRICAL SYSTEM 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. Engine wiring diagram (TE-TXC MY12) Workshop Manual Ed. 03-2012...
  • Page 303 ELECTRICAL SYSTEM 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. Key to wiring diagram 1. Coolant temperature sensor 2. Lambda sensor 3. Electronic control unit 4.

  • Page 304: Vehicle Wiring Diagram (Te My12)

    ELECTRICAL SYSTEM 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. Vehicle wiring diagram (TE MY12) Workshop Manual Ed. 03-2012 M.10...
  • Page 305 ELECTRICAL SYSTEM 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. Key to wiring diagram 1. Dashboard 2. L.H. switch 3. Clutch sensor 4. Fuses 5.

  • Page 306: Adapter (Txc)

    ELECTRICAL SYSTEM 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. Adapter (TXC) Workshop Manual Ed. 03-2012 M.12...
  • Page 307 ELECTRICAL SYSTEM 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. Key to wiring diagram 1. Adapter to engine wiring connector 2. Clutch connector 3. RH switch connector 4.

  • Page 308: Electrical Components Location (Tc)

    ELECTRICAL SYSTEM 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. Electrical components location (TC) The ignition system includes the following elements: Generator (1), on the inner side of L.H. crankcase half cover; H06284 MY11 Electronic ignition coil (2) with integrated spark plug cap positioned on...
  • Page 309 ELECTRICAL SYSTEM 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. Voltage regulator (4) located at the back of the steering tube. H06274 Starter motor (5) in front of engine cylinder; H06285 Solenoid starter (6) positioned under saddle, on rear chassis;...
  • Page 310 ELECTRICAL SYSTEM 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. The electrical system includes the following elements: Fuel pump (8) positioned inside the tank (9); H06271 12V - 4Ah Battery (10) under the saddle;...
  • Page 311 ELECTRICAL SYSTEM 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: MY12 Fuel pump relay (12a) positioned on the front right side, under the air box. Main starting relay (13a) positioned on the front right side, under the air box.

  • Page 312: Electrical Components Location (Te - Smr)

    ELECTRICAL SYSTEM 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. Electrical components location (TE - SMR) The ignition system includes the following elements: Generator (1) on the inner side of L.H. crankcase half cover; H06284 MY11 Electronic ignition coil (2) with integrated spark plug cap positioned on...
  • Page 313 ELECTRICAL SYSTEM 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. Voltage regulator (4) located at the back of the steering tube. H06274 Starter motor (5) in front of engine cylinder; H06285 Solenoid starter (6) positioned under saddle, on rear chassis;...
  • Page 314 ELECTRICAL SYSTEM 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. The electrical system includes the following elements: 12V - 6Ah Battery (9) under the saddle; H06287 H06287 H06287...
  • Page 315 ELECTRICAL SYSTEM 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: MY12 Fuel pump relay (12a) and main relay (13a) positioned on the front right side, under the air box;...
  • Page 316 ELECTRICAL SYSTEM 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. A 10A (lights) fuse (16) positioned below the headlamp fairing and a 30A MY11 (main) fuse (17) positioned on the solenoid starter;...
  • Page 317 ELECTRICAL SYSTEM 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. Coolant temperature sensor (18); Lambda sensor (19); H11194 Headlamp (20) with 12V-35W twin halogen bulb and 12V-5W parking light bulb;...
  • Page 318 ELECTRICAL SYSTEM 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. Odometer (25); MY11 + SMR MY12 H11195 TE MY12 H11196 Condenser (26) positioned on engine rear side. H06292 Workshop Manual Ed.

  • Page 319: Electrical Components Location (Txc)

    ELECTRICAL SYSTEM 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. Electrical components location (TXC) The ignition system includes the following elements: Generator (1), on the inner side of L.H. crankcase half cover; H06284 Electronic ignition coil (2) with integrated spark plug cap positioned on MY11...
  • Page 320 ELECTRICAL SYSTEM 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. Voltage regulator (4) located at the back of the steering tube. H06274 Starter motor (5) in front of engine cylinder; H06285 Solenoid starter (6) positioned under saddle, on rear chassis;...
  • Page 321 ELECTRICAL SYSTEM 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. The electrical system includes the following elements: Fuel pump (8) positioned inside the tank (9); H06271 12V - 6Ah Battery (10) under the saddle;...
  • Page 322 ELECTRICAL SYSTEM 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: MY11 Fuel pump relay (12) positioned on the front left side, under the air box; Main starting relay (13) positioned on the front left side, under the air box.
  • Page 323 ELECTRICAL SYSTEM 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. Coolant temperature sensor (16); H06377 Electric fan (17); H06378 Condenser (18) positioned on engine rear side. H06300 Workshop Manual Ed.

  • Page 324: Generator Stator Windings Resistance Inspection

    ELECTRICAL SYSTEM 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. Generator stator windings resistance (1) inspection Disconnect the stator coil connector from the wiring and measure resistance with a meter.

  • Page 325: Condenser Inspection

    ELECTRICAL SYSTEM 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. Condenser inspection The condenser (1) keeps the bike running in case of accidental disconnection of battery (loosening of cable fastening device).

  • Page 326: Ignition System (Tc My11)

    ELECTRICAL SYSTEM 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. Ignition system (TC MY11) Workshop Manual Ed. 03-2012 M.32...
  • Page 327 ELECTRICAL SYSTEM 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. The ignition system is controlled by the ECU (1). The ignition is an integrated digital electronic ignition system with static timing and advance using intermittent sequential phased electronic injection feed.

  • Page 328: Ignition System (Te - Txc - Smr My11 + Smr My12)

    ELECTRICAL SYSTEM 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. Ignition system (TE - TXC - SMR MY11 + SMR MY12)    Workshop Manual Ed.
  • Page 329 ELECTRICAL SYSTEM 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. The ignition system is controlled by the ECU (1). The ignition is an integrated digital electronic ignition system with static timing and advance using intermit- tent sequential phased electronic injection feed.

  • Page 330: Ignition System (Te - Txc My12)

    ELECTRICAL SYSTEM 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. Ignition system (TE - TXC MY12) Workshop Manual Ed. 03-2012 M.36...
  • Page 331 ELECTRICAL SYSTEM 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. The ignition system is controlled by the ECU (1). The ignition is an integrated digital electronic ignition system with static timing and advance using intermittent sequential phased electronic injection feed.

  • Page 332: Charging System

    ELECTRICAL SYSTEM 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. Charging system the charging system is composed of: - Alternator (1); - Voltage regulator/rectifier (2); - Solenoid starter (3);...

  • Page 333: Charging System Inspections

    ELECTRICAL SYSTEM 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. Charging system inspections Battery Remove the saddle (as described in the relevant paragraph) to gain access to the battery (1).

  • Page 334: Electric Starting System

    ELECTRICAL SYSTEM 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. Electric starting system the starting system is composed of: - Battery (1); - Solenoid starter (2); - Starter motor (3);...

  • Page 335: Starting System Inspection

    ELECTRICAL SYSTEM 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. Starting system inspection Starter motor inspection Remove the starter motor (1) as described in the relevant paragraph. Whenever a starter motor fault is detected, check the starter motor as follows: - connect a meter across ground and starter motor contact.

  • Page 336: Coil Windings Resistance Inspection

    ELECTRICAL SYSTEM 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. Coil windings resistance inspection Disconnect the connector (1) from the coil (2). Remove the coil (2) as described in the relevant paragraph. Measure primary and secondary winding resistance with a meter.

  • Page 337: Spark Plug

    ELECTRICAL SYSTEM 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. Spark plug Check the gap "A" (0.7 mm) between the electrodes. A wider gap may cause difficulties in starting the engine and overload the coil.

  • Page 338: Headlamp, Tail Light (Te - Smr)

    ELECTRICAL SYSTEM 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. Headlamp, tail light (TE - SMR) Headlamp adjustment The headlamp features a twin bulb for low and high beam and a festoon bulb for the city or parking light.
  • Page 339 ELECTRICAL SYSTEM 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. - loosen the two lower screws (2) using a Phillips screwdriver; H06313 - move headlight unit (3) aside; H06314 - release connector (4);...
  • Page 340 ELECTRICAL SYSTEM 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. - release the bulb holder clips (6) and take out bulb (7); NOTE*: Headlamp bulb (7) is of the halogen type; be careful when replacing it since the glass part shall not be touched with bare hands.

  • Page 341: Turning Indicator Bulb Replacement (Te - Smr)

    ELECTRICAL SYSTEM 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. Turning indicator bulb replacement (TE - SMR) - Loosen screw (1) using a Phillips screwdriver; H06320 - remove lens (2) and replace bulb (3) pushing it inside, and turning it to remove Once the bulb has been replaced, reverse the above procedure to reassem-...

  • Page 342: Tail Light Replacement (Te - Smr)

    ELECTRICAL SYSTEM 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 Tail light replacement (TE - SMR) Remove the tail light as follows: - Loosen the two screws (1) under the rear mudguard. H11206 MY12 H11207...

  • Page 343: Number Plate Bulb Replacement (Te - Smr)

    ELECTRICAL SYSTEM 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. Number plate bulb replacement (TE - SMR) - Loosen screw (1) and remove the number plate bulb (2) from the mud- guard.

  • Page 344: Left-Hand Switch (Te - Smr)

    ELECTRICAL SYSTEM 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. Left-hand switch (TE - SMR) High beam flasher (self-cancelling) High beam switch Low beam switch Left-hand turning indicators (self-cancelling) Right-hand turning indicators (self-cancelling) To deactivate the turning indicators, press the control lever after it is returned...

  • Page 345: Right-Hand Switch (Te - Txc - Smr)

    ELECTRICAL SYSTEM 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. Right-hand switch (TE - TXC - SMR) 1. Engine start button 2. Engine start/stop switch B/Bk H06453 Colour coding key...

  • Page 346: Right-Hand Switch (Tc)

    ELECTRICAL SYSTEM 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. Right-hand switch (TC) 1. Engine start button 2. Double map push-button Bk/G Bk/G B/Bk H06453 Colour coding key Bk ....

  • Page 347: Fuses

    ELECTRICAL SYSTEM 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. Fuses • When you find a blown fuse, always investigate and eliminate the cause before replacing it.

  • Page 348: Relay Test

    ELECTRICAL SYSTEM 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. Relay test MY11 Gain access to the relays as indicated in the relevant paragraph; then, remove them.
  • Page 349 ELECTRICAL SYSTEM 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. A: Set the meter to the "Impedance" scale and check the energiser coil for proper operation.

  • Page 350: Digital Dashboard, Warning Lights (Te - Smr)

    H11264 the word FAIL appears on the right side of the dashboard display: When this is the case, contact your HUSQVARNA dealer. 1- SPEED (km/h or mph) / ODO - SPEED: vehicle speed - maximum value: 299 Km/h or 299 mph;...
  • Page 351 ELECTRICAL SYSTEM 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. TE MY12 To change unit from kilometres to miles or miles to kilometres, proceed as follows: 1) with the engine off, press and hold the "SCROLL"...
  • Page 352 ELECTRICAL SYSTEM 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. 5- SPEED - SPEED: speed - maximum value: 299 Km/h or 299 mph The display also provides a fuel injection system "Malfunction" indication; the latter takes priority over any other indication.
  • Page 353 ELECTRICAL SYSTEM 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. 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.The identification codes appear on the display of the instrument at 2 second intervals: when the required...
  • Page 354 ELECTRICAL SYSTEM 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. Connector position (TE - SMR) TE-SMR MY11 / SMR MY12 The following connectors are positioned on the front side, below the headlamp fairing: 1) Headlamp connector 2) Turning indicator flasher connector...
  • Page 355 ELECTRICAL SYSTEM 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. The following connectors are positioned on the bike right side: MY11 12) Temperature sensor connector 13) Electric fan relay connector 13a) Main starter relay connector (MY12) 13b) Fuel pump relay connector (MY12)
  • Page 356 ELECTRICAL SYSTEM 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. 19) Current generator connector H06456 20) Voltage regulator connector H06342 21) Injector connector H06344 22) Pressure sensor connector H06345 Workshop Manual Ed.
  • Page 357 ELECTRICAL SYSTEM 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. 23) Rear stop (brake) connector H06340 The following connectors are positioned on the bike rear side: 24) Tail light connector 25) Rear turning indicator connector 26) Number plate light connector...
  • Page 358 ELECTRICAL SYSTEM 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. 33) Electronic control unit connector MY11 34) Solenoid starter connector H11230 MY12 H11231 MY11 35) Diagnostics connector H11232 MY12...
  • Page 359 ELECTRICAL SYSTEM 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. Connector position (TC) The following connectors are positioned on the front side, below the number holder: 1) RH switch connector 2) Clutch sensor connector...
  • Page 360 ELECTRICAL SYSTEM 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. The following connectors are positioned on the bike left side: MY11 Main starting relay connector (MY11) 11a) Main starting relay connector (MY12) (on the right-hand side of the engi- (on the right-hand side of the engi- Fuel pump relay connector (MY11)
  • Page 361 ELECTRICAL SYSTEM 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. 18) Diagnostics connector MY11 H11237 MY12 H11238 Connector position (TXC) The following connectors are positioned under the number holder: 1) Speed sensor connector 2) Clutch connector 3) RH switch connector...
  • Page 362 ELECTRICAL SYSTEM 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. 8) 2 throttle connector 9) 2 throttle TPS connector 10) TPS connector H06457 11) Current generator connector H06527 12) Voltage regulator connector H06361...
  • Page 363 ELECTRICAL SYSTEM 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. The following connectors are positioned on the bike left side: Main starting relay connector (MY11) 14a) Main starting relay connector (MY12) Fuel pump relay connector (MY11) 15a) Fuel pump relay connector (MY12)
  • Page 364 ELECTRICAL SYSTEM 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. 22) Diagnostics connector MY11 H11242 MY12 H11243 Workshop Manual Ed. 03-2012 M.70...
  • Page 365 ELECTRICAL SYSTEM 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. Important MY11 Before washing the motorcycle, it is necessary to duly protect the following parts from water: a) Rear opening of the muffler;...
  • Page 367 ENGINE COOLING 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. Section Workshop Manual Ed. 03-2012...
  • Page 368 ENGINE COOLING 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. Sommario Coolant level check ..................N.3 Cooling circuit ....................N.4 Engine cooling system overhaul ..............N.5 Workshop Manual Ed. 03-2012...

  • Page 369: Txc 449 - 511 2011/2012 I.e

    ENGINE COOLING 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. Coolant level check Coolant takes the heat from the piston-cylinder-and-head assembly and transfers it to the radiator, where it is released to the atmosphere. Checking coolant level at regular periods is critical to ensuring proper operation of the cooling system.

  • Page 370: Cooling Circuit

    ENGINE COOLING 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. Cooling circuit H06390 TE-TXC-SMR The forced circulation cooling system uses a centrifugal pump (located to the left of the head) and two down-draft radiators.

  • Page 371: Engine Cooling System Overhaul

    ENGINE COOLING 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. Engine cooling system overhaul If the coolant runs too hot, check the radiators. Any foreign matter trapped between the fins (such as leaves, bugs, mud, etc.) will obstruct air flow and must be removed carefully to avoid damage to radiator.
  • Page 373 HYDRAULICALLY CONTROLLED CLUTCH 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. Section Workshop Manual Ed. 03-2012...
  • Page 374 HYDRAULICALLY CONTROLLED CLUTCH 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. Sommario Hydraulic clutch system ................P.3 Draining clutch fluid ..................P.4 Clutch master cylinder servicing ..............P.5 Bleeding the clutch system ................

  • Page 375: Hydraulic Clutch System

    HYDRAULICALLY CONTROLLED CLUTCH 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. H006204 Hydraulic clutch system The hydraulic circuit is composed of a master cylinder with its reservoir located on the left side of the handlebar, and a piston installed on the right crankcase half.

  • Page 376: Draining Clutch Fluid

    HYDRAULICALLY CONTROLLED CLUTCH 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. Draining clutch fluid Connect a plastic hose to the bleed valve (1) and the loosen the valve turning it back 1 or 2 turns.

  • Page 377: Clutch Master Cylinder Servicing

    HYDRAULICALLY CONTROLLED CLUTCH 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. Clutch master cylinder servicing Drain the circuit, detach the master cylinder from the left side of the handlebar and take it apart.

  • Page 378: Bleeding The Clutch System

    HYDRAULICALLY CONTROLLED CLUTCH 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. Bleeding the clutch system A long travel and mushy feel of the clutch lever indicate that there is air in the system and the clutch hydraulic system needs bleeding.
  • Page 379 FUEL INJECTION SYSTEM 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. Section Workshop Manual Ed. 03-2012...
  • Page 380 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. Sommario Fuel injection system ..................S.3 Instructions for using "HUSQVARNA SERVICE TOOL" for a fuel injection system ...............S.4 Fuel pump inspection ...................S.6 Workshop Manual Ed. 03-2012...

  • Page 381: Fuel Injection System Tc 449 2011/2012 I.e

    Fuel injection pulse width; MY11 Ignition coil; Lambda sensor heater; Rich or lean combustion mixture (LAMBDA sensor); "HUSQVARNA SERVICE TOOL" diagnostic software allows you to test the components listed above in the event of a fuel injection system malfunction. H11250 MY12 H11245 H06265 Workshop Manual Ed.
  • Page 382 The fuel injection system does not require any scheduled maintenance. The "HUSQVARNA SERVICE TOOL" part no. 8000 H3898 allows you to test injection system components in the event of a malfunction. TE MY11 = A malfunction is indicated by the word "FAIL" appearing in the right- hand portion of the tool display when the ignition key is set to ON.

  • Page 383: Fuel Injection System

    FUEL INJECTION SYSTEM 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. In addition to identifying any current malfunction, the software stores past malfunctions that have been resolved: store malfunc- tions can be deleted following the instructions provided in the Operation Manual.

  • Page 384: Fuel Pump Inspection

    FUEL INJECTION SYSTEM 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. Fuel pump inspection Remove the pump as described in Section "E". Connect the power supply unit positive pole (12V) to the red lead pin in the pump connector;...
  • Page 385 TIGHTENING TORQUE FIGURES 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. Section Tighten all nuts and screws to the specified torque using a torque wrench. If not tightened securely, a nut or a screw might become damaged or work itself loose, causing damage to motorcycle and injury to rider.
  • Page 386 TIGHTENING TORQUE FIGURES 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. Operation Description ft/lb BRAKE PEDAL ADJUSTING CAMS TO CHASSIS FASTENING 10,00 1,00 7,38 CHASSIS CHAIN SLIDER TO TRANSVERSAL LOWER TUBE FASTENING 1,00 0,10...
  • Page 387 TIGHTENING TORQUE FIGURES 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. Operation Description ft/lb SILENCER TO REAR CHASSIS FASTENING 25,00 2,50 18,44 MANIFOLD FLANGE NUT FASTENING 13,00 1,30 9,59...
  • Page 388 TIGHTENING TORQUE FIGURES 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. Operation Description ft/lb LEFT SWITCH FASTENING 2,50 0,25 1,84 CLUTCH MASTER CYLINDER FASTENING 5,00 0,50 3,69...
  • Page 389 TIGHTENING TORQUE FIGURES 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. NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows (+/- 5%) Steel screws on plastic, with metal spacers 2 Nm 0.2 Kgm...
  • Page 391 CHASSIS AND WHEELS 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. Section Workshop Manual Ed. 03-2012...
  • Page 392 CHASSIS AND WHEELS 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. Sommario Chassis ......................Y.3 Lubrication points (lubricant) ................ Y.4 Front wheel (TC - TE - TXC) ................ Y.5 Front wheel (SMR) ..................

  • Page 393: Txc 449 - 511 2011/2012 I.e

    CHASSIS AND WHEELS 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. Chassis The single frame branches off at the exhaust and is made of steel tubes with circular, rectangular and ellipsoidal section; the rear chassis is made from light alloy.

  • Page 394: Lubrication Points (Lubricant)

    CHASSIS AND WHEELS 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. Lubrication points (lubricant) 1 Steering bearings (grease) H006231 H006232 Check the assemblies shown in the figure C REAR CHASSIS MOUNTING BOLTS D CHAIN GUIDE ROLLER/BEARING for cracks or damage.

  • Page 395: Front Wheel (Tc - Te - Txc)

    CHASSIS AND WHEELS 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. Front wheel (TC - TE - TXC) H11251 Legend 1) Tyre 2) Inner tube 3) Rim 4) Spoke 5) Nipple...

  • Page 396: Front Wheel (Smr)

    CHASSIS AND WHEELS 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. Front wheel (SMR) H11252 Legend 1) Tyre 2) Inner tube 3) Rim 4) Spoke 5) Nipple 6) Wheel axle 7) Seal...

  • Page 397: Removing The Front Wheel

    CHASSIS AND WHEELS 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. Removing the front wheel Set a stand or a block under the engine and see that the front wheel is lifted from the ground.

  • Page 398: Reassembling The Front Wheel

    CHASSIS AND WHEELS 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. Hold the head of the wheel axle in place, and unscrew the bolt (3) on the op- TC - TE - TXC posite side;...
  • Page 399 CHASSIS AND WHEELS 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. Fit the wheel between the fork legs so as to set the brake disc into the calliper. TC - TE - TXC Fit the wheel axle (2) from the R.H.
  • Page 400 CHASSIS AND WHEELS 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. TE - TXC - SMR TE - TXC -SMR Check the gap “B” between magnet (6) on brake disc and sensor (7) on brake calliper.

  • Page 401: Rear Wheel (Tc - Te - Txc)

    CHASSIS AND WHEELS 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. Rear wheel (TC - TE - TXC) H11253 1) Tyre 2) Inner tube 3) Rim 4) Spoke 5) Nipple...

  • Page 402: Rear Wheel (Smr)

    CHASSIS AND WHEELS 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. Rear wheel (SMR) H11254 1) Tyre 2) Inner tube 3) Rim 4) Spoke 5) Nipple 6) Wheel axle 7) Spacer...

  • Page 403: Removing The Rear Wheel

    CHASSIS AND WHEELS 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. Removing the rear wheel Set a stand or a block under the engine and see that the rear wheel is lifted from the ground.

  • Page 404: Wheel Servicing

    CHASSIS AND WHEELS 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. Wheel servicing Check the wheel hub bearings for wear. If you find too much (radial or axial) clearance, replace the bearings as follows: place the hub on a flat surface with an appropriate hole (for when you knock out the bearing);...

  • Page 405: Wheel Spokes

    CHASSIS AND WHEELS 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. Wheel spokes Make sure all nipples are firmly tightened (4.4 Nm, 0.45 Kgm, 3.2 ft/lb). Re- tighten if needed.

  • Page 406: Rear Chain Sprocket, Secondary Drive Sprocket And Chain

    CHASSIS AND WHEELS 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. Rear chain sprocket, secondary drive sprocket and chain The figure at the side shows the profiles of a normally worn and an exceedingly worn sprocket.

  • Page 407: Checking Pinion And Sprockets For Wear

    CHASSIS AND WHEELS 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. Checking pinion and sprockets for wear Check the transmission sprocket for damage or wear. When worn down like the sprocket shown in the figure, it must be replaced.
  • Page 409 NOTES FOR USA/CDN 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. Section Workshop Manual Ed. 03-2012...
  • Page 410 NOTES FOR USA/CDN 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. Spark arrester (TE - TXC - SMR) The models are equipped with a U.S. Forest Service approved spark arrester for maximum efficienty and performance.
  • Page 411 NOTES FOR USA/CDN 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. - Unscrew the screw on the end cap then pull out the screen. H06434 H06435 H06436...
  • Page 412 NOTES FOR USA/CDN 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. Assembly - Mount the screen matching the 3 holes. - Tighten the screw and washer with a torque of 3Nm. For all screws check the proper torque every 500Km and tighten if necessary.
  • Page 413 NOTES FOR USA/CDN 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. KIT Canister (TE - TXC - SMR) SERBATOIO FUEL TANK RESERVOIR TANK DEPOSITO MOTORE ENGINE MOTEUR...

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