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HUSABERG TE 125 EU User Manual

HUSABERG TE 125 EU
129 pages
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OWNER'S MANUAL
TE 125 EU
TE 250 EU
TE 250 AUS
TE 250 USA
TE 300 EU
TE 300 AUS
TE 300 USA
2013
Art. no. 3802032en

Table of Contents

Questions and Answers:

HUSABERG TE 125 EU Specifications

General IconGeneral
Displacement124.8 cc
Bore x Stroke54 mm x 54.5 mm
Transmission6-speed
Fuel SystemCarburetor
Seat Height960 mm
StarterKick starter
Cooling SystemLiquid-cooled
Final DriveChain
Engine TypeSingle-cylinder, 2-stroke
Front Suspension48 mm
Rear SuspensionMonoshock
Front BrakeSingle 260 mm disc
Rear BrakeDisc brake
Front Tire90/90-21

Summary

Means of Representation

Symbols Used in the Manual

Explanation of symbols used to denote expected/unexpected reactions and specialized knowledge required.

Typographical Formats Used

Defines specific names, protected names, and branded names used within the manual.

Safety Advice for Husaberg Motorcycles

Intended Use of the Motorcycle

Defines the intended use for TE EU/AUS and TE USA models, emphasizing sport and endurance competition.

General Safety Guidelines

Instructions for safe operation, including adherence to manual warnings and labels.

Degrees of Risk and Symbols

Identifies danger levels (Danger, Warning, Caution, Note) and associated symbols for risk communication.

Tampering Warning

Prohibits tampering with the noise control system and related components.

Safe Operation

Covers accident prevention, poisoning hazards from exhaust, burn risks, and proper vehicle operation.

Protective Clothing Requirements

Emphasizes the importance of wearing appropriate protective gear for riding safety.

Work Rules and Procedures

Guidelines for maintenance, including use of special tools and replacement parts.

Environmental Considerations

Promotes responsible motorcycle use with environmental consciousness and respect for others.

Owner's Manual Importance

Highlights the necessity of reading the manual for operation, handling, and maintenance.

Important Notes for Husaberg Owners

Warranty Service Requirements

Details warranty conditions, requiring authorized workshop service to maintain claims.

Operating and Auxiliary Substances

Information on using specified fluids and the environmental hazard of improper fuel handling.

Spare Parts and Accessories

Recommends using HUSABERG-approved parts and professional installation for safety.

Service and Maintenance Importance

Stresses proper service for optimal operation, preventing wear and ensuring longevity.

Notes on Figures in the Manual

Clarifies that figures may show special equipment and components might be shown disassembled.

Customer Service and Support

Informs owners where to find authorized dealers and get questions answered.

View of Vehicle Components

Front Left View of Vehicle

Diagram identifying key components on the front left side of the motorcycle.

Rear Right View of Vehicle

Diagram identifying key components on the rear right side of the motorcycle.

Vehicle Identification Numbers

Chassis Number Location

Details the location of the chassis number stamped on the steering head.

Type Label Identification

Specifies the location of the type label fixed to the front of the steering head.

Key Number (TE EU/AUS)

Indicates the key number is stamped on the key strap.

Engine Number Location

Shows the engine number stamped on the left side of the engine under the sprocket.

Fork Part Number Location

Details the location of the fork part number stamped on the inner side of the fork stub.

Shock Absorber Part Number

Indicates the shock absorber part number is stamped on its upper part above the adjusting ring.

Motorcycle Controls and Switches

Clutch Lever Operation

Describes the clutch lever on the left handlebar, hydraulically operated and self-adjusting.

Hand Brake Lever

Locates the hand brake lever on the right handlebar for activating the front brake.

Throttle Grip Function

Identifies the throttle grip on the right side of the handlebar.

Kill Switch Operation (TE EU/AUS)

Explains the kill switch on the left handlebar for starting and stopping the engine.

Kill Switch Operation (TE USA)

Details the kill switch on the left handlebar for engine ignition control.

Horn Button (TE EU/AUS)

Describes the horn button on the left handlebar and its operation.

Light Switch (TE EU/AUS)

Explains the light switch on the left handlebar for controlling low and high beams.

Light Switch (TE USA)

Details the light switch near the speedometer for controlling lights.

Turn Signal Switch (TE EU/AUS)

Describes the turn signal switch on the left handlebar for signaling turns.

Emergency OFF Switch (TE AUS)

Locates the emergency OFF switch on the right handlebar for ignition control.

Electric Starter Button

Identifies the electric starter button on the right handlebar for starting the engine.

Indicator Lamps Overview (TE EU/AUS)

Shows the high beam and turn signal indicator lights on the dashboard.

Speedometer Functions

Overview of the speedometer, including activation, testing, and display modes.

Opening the Filler Cap

Instructions on how to open the fuel filler cap, including safety warnings.

Closing the Filler Cap

Procedure for securely closing the fuel filler cap.

Fuel Tap Operation

Explains the fuel tap positions (OFF, ON, RES) for controlling fuel supply.

Choke Operation

Details the choke knob for enriching the fuel-air mixture for cold starts.

Shift Lever

Location and function of the shift lever on the left side of the engine.

Kick Starter

Identifies the kick starter on the right side of the engine.

Foot Brake Lever

Locates the foot brake lever for activating the rear brake.

Side Stand

Describes the location and function of the side stand for parking the motorcycle.

Steering Lock (TE EU/AUS)

Explains the steering lock on the left of the steering head for securing the steering.

Locking the Steering (TE EU/AUS)

Step-by-step guide on how to lock the steering using the key.

Unlocking the Steering (TE EU/AUS)

Instructions on how to unlock the steering and regain control.

Preparing Your Husaberg for Use

Advice for First Use

Essential safety advice before the initial ride, including warnings and pre-ride checks.

Engine Running-In Procedure

Guidelines for running in the engine, specifying performance limits for initial operating hours.

Preparing for Difficult Riding Conditions

Advice on component wear and checks needed for challenging riding environments.

Preparing for Dry Sand Rides

Specific checks and preparations for riding in dry sand conditions.

Preparing for Wet Sand Rides

Recommendations for riding in wet sand, including radiator cap checks.

Preparing for Wet and Muddy Surfaces

Steps for riding on wet and muddy terrain, focusing on air filter and carburetor.

Preparing for High Temp/Slow Speed Rides

Adjustments for riding in high temperatures and at slow speeds, checking radiator cap.

Preparing for Low Temp/Snow Rides

Guidance for riding in low temperatures and snow, including air filter preparation.

Riding Instructions

Pre-Ride Checks and Maintenance

Comprehensive checklist of critical components to inspect before riding.

Starting the Engine

Procedure for starting the engine, including safety warnings and cold start steps.

Starting Off

Instructions on how to start moving from a standstill, including clutch and throttle use.

Shifting Gears and Riding

Guidance on gear shifting, throttle control, braking, and general riding techniques.

Braking Techniques

Advice on proper braking to avoid wheel lock-up and maintain efficiency.

Stopping and Parking

Procedures for safely stopping, parking, and securing the motorcycle.

Transporting the Motorcycle

Guidelines for securing the motorcycle during transport.

Refueling Procedures

Safe practices for refueling, including fire and poisoning warnings.

Service Schedule and Work

Regular Service Schedule (S20A/S40A)

Table detailing routine checks and maintenance tasks based on operating hours.

Service Work (Additional Orders)

List of additional service tasks available on request or as part of specific maintenance intervals.

Chassis Tuning and Adjustments

Basic Chassis Setting with Rider's Weight

How to adjust suspension settings based on rider weight for optimal handling.

Shock Absorber Compression Damping

Explanation of high-speed and low-speed compression damping adjustments.

Adjusting Low-Speed Compression Damping (Shock Absorber)

Procedure for adjusting the low-speed compression damping of the shock absorber.

Adjusting High-Speed Compression Damping (Shock Absorber)

Steps to adjust the high-speed compression damping of the shock absorber.

Adjusting Rebound Damping (Shock Absorber)

Guide to adjusting the rebound damping on the shock absorber.

Measuring Unloaded Rear Wheel Sag

Method for measuring the rear wheel sag when the motorcycle is unloaded.

Checking Static Sag of Shock Absorber

Procedure to check the static sag of the shock absorber.

Checking Riding Sag of Shock Absorber

How to measure the riding sag of the shock absorber with the rider on the bike.

Adjusting Spring Preload (Shock Absorber)

Detailed steps for adjusting the spring preload on the shock absorber.

Adjusting Riding Sag

Instructions on adjusting the riding sag, potentially involving spring replacement.

Checking Basic Fork Setting

Guidance on checking the fork's basic settings and considerations for spring replacement.

Adjusting Fork Compression Damping

Procedure for adjusting the compression damping on the front fork.

Adjusting Fork Rebound Damping

Guide to adjusting the rebound damping on the front fork.

Handlebar Position Adjustment

Options for mounting the handlebar in different positions for rider comfort.

Adjusting Handlebar Position

Step-by-step instructions for adjusting the handlebar position.

Chassis Service Procedures

Raising Motorcycle with Lift Stand

Instructions for safely raising the motorcycle using a lift stand.

Removing Motorcycle from Lift Stand

Procedure for safely removing the motorcycle from the lift stand.

Bleeding Fork Legs

Steps to bleed excess pressure from the fork legs.

Cleaning Fork Leg Dust Boots

Procedure for cleaning dust boots to prevent dirt ingress and seal leaks.

Loosening Fork Protection

Steps to loosen and remove fork protection components.

Positioning Fork Protection

Guide for correctly positioning and mounting fork protection.

Removing Fork Legs

Detailed instructions for removing the front fork legs.

Installing Fork Legs

Step-by-step guide for installing the front fork legs.

Removing Fork Protector

Procedure to remove the fork protector from the fork legs.

Installing Fork Protector

Instructions for correctly installing the fork protector.

Removing Lower Triple Clamp

Steps to remove the lower triple clamp assembly.

Installing Lower Triple Clamp

Procedure for installing the lower triple clamp and associated bearings.

Checking Steering Head Bearing Play

Guidance on checking for play in the steering head bearing.

Adjusting Steering Head Bearing Play

Instructions for adjusting the steering head bearing play to eliminate looseness.

Greasing Steering Head Bearing

Procedure for greasing the steering head bearing components.

Removing Front Fender

Steps to remove the front fender, including disconnecting brake lines.

Installing Front Fender

Procedure for installing the front fender and reconnecting lines.

Removing Shock Absorber

Detailed steps for removing the rear shock absorber.

Installing Shock Absorber

Procedure for installing the rear shock absorber with correct torque values.

Removing Motorcycle Seat

Instructions for removing the seat by unscrewing and lifting it off.

Mounting Motorcycle Seat

Procedure for attaching and securing the motorcycle seat.

Removing Air Filter Box Lid

Steps to release the catch and remove the air filter box lid.

Installing Air Filter Box Lid

Procedure for correctly positioning and engaging the air filter box lid.

Removing Air Filter

Instructions on how to remove the air filter, emphasizing engine protection.

Installing Air Filter

Procedure for mounting the clean air filter, ensuring correct fitment.

Cleaning Air Filter and Air Filter Box

Steps for washing the air filter and cleaning the air filter box.

Sealing the Air Filter Box

Instructions for sealing the air filter box in a marked area.

Removing Main Silencer

Procedure to remove the main silencer from the exhaust system.

Installing Main Silencer

Steps for mounting and tightening the main silencer.

Changing Main Silencer Filling

Guide to replacing the glass fiber yarn filling in the main silencer.

Removing Right Side Cover

Instructions for removing the right side cover of the motorcycle.

Installing Right Side Cover

Procedure for correctly positioning and securing the right side cover.

Removing Fuel Tank

Detailed steps for removing the fuel tank, including fuel hose disconnection.

Installing Fuel Tank

Procedure for installing the fuel tank, ensuring correct routing of hoses and cables.

Checking Chain for Dirt

Procedure to inspect the chain for dirt and soiling.

Cleaning the Chain

Instructions for cleaning and lubricating the chain for optimal service life.

Checking Chain Tension

Guidance on how to check the chain tension for correct operation.

Adjusting Chain Tension

Step-by-step instructions for adjusting the chain tension using adjuster screws.

Checking Chain, Sprockets, and Guide

Inspection of chain, sprockets, and chain guide for wear and damage.

Adjusting Chain Guide

Procedure for adjusting or replacing the chain guide components.

Checking the Frame

Inspection of the frame for cracks or deformation due to impacts.

Checking the Swingarm

Inspection of the swingarm for damage, cracking, or deformation.

Checking Throttle Cable Routing

Verification of correct throttle cable routing to prevent interference.

Checking Rubber Grip

Inspection of handlebar rubber grips for damage, wear, or looseness.

Securing Rubber Grip

Instructions for additionally securing the rubber grip with wire.

Adjusting Clutch Lever Basic Position

Procedure for adjusting the clutch lever position for rider comfort.

Checking/Rectifying Hydraulic Clutch Fluid Level

How to check and correct the fluid level in the hydraulic clutch reservoir.

Changing Hydraulic Clutch Fluid

Detailed steps for changing the hydraulic clutch fluid, including bleeding.

Removing Engine Guard

Instructions for removing the engine guard using quick release fasteners.

Installing Engine Guard

Procedure for installing the engine guard with quick release fasteners.

Brake System Maintenance

Checking Hand Brake Lever Free Travel

Guidance on checking free travel in the hand brake lever for proper function.

Adjusting Hand Brake Lever Free Travel (TE EU/AUS)

Steps to adjust the free travel of the hand brake lever using an adjusting screw.

Adjusting Hand Brake Lever Basic Position (TE USA)

Procedure to adjust the hand brake lever's basic position for rider preference.

Checking Brake Discs

Instructions for checking brake disc thickness, damage, and wear limits.

Checking Front Brake Fluid Level

Procedure for checking the front brake fluid level and identifying leaks.

Adding Front Brake Fluid

Steps to add front brake fluid to the correct level, with safety warnings.

Checking Front Brake Linings

Guidance on checking the minimum thickness and condition of front brake linings.

Changing Front Brake Linings

Detailed instructions for replacing worn front brake linings.

Checking Foot Brake Lever Free Travel

Procedure to check the free travel of the foot brake lever.

Adjusting Foot Brake Lever Basic Position

Steps to adjust the basic position of the foot brake lever.

Checking Rear Brake Fluid Level

Procedure for checking the rear brake fluid level and identifying leaks.

Adding Rear Brake Fluid

Steps to add rear brake fluid to the correct level, with safety warnings.

Checking Rear Brake Linings

Guidance on checking the minimum thickness and condition of rear brake linings.

Changing Rear Brake Linings

Detailed instructions for replacing worn rear brake linings.

Wheels and Tires Maintenance

Removing the Front Wheel

Step-by-step guide for removing the front wheel, including brake caliper and spindle.

Installing the Front Wheel

Procedure for installing the front wheel, ensuring correct alignment and spoke condition.

Removing the Rear Wheel

Detailed instructions for removing the rear wheel, including chain and spindle.

Installing the Rear Wheel

Procedure for installing the rear wheel, chain, and ensuring correct tension.

Checking Tire Condition

Guidance on inspecting tires for cuts, damage, wear, and tread depth.

Checking Tire Air Pressure

Instructions for checking tire pressure for both off-road and road use.

Checking Spoke Tension

Method for checking spoke tension by sound and adjusting if necessary.

Electrical System Maintenance

Removing the Battery (TE 250/300)

Steps for safely removing the battery, including disconnecting cables.

Installing the Battery (TE 250/300)

Procedure for installing the battery, ensuring correct connections.

Recharging the Battery (TE 250/300)

Instructions on how to recharge the battery safely.

Changing the Main Fuse (TE 250/300)

Procedure for replacing the main fuse to protect the electrical system.

Removing Headlight Mask with Headlight

Steps to remove the headlight mask assembly.

Installing Headlight Mask with Headlight

Procedure for installing the headlight mask assembly.

Changing Headlight Bulb

Instructions for replacing the headlight bulb.

Changing Turn Signal Bulb (TE EU/AUS)

Procedure for replacing the turn signal bulb.

Checking Headlight Setting

How to check the headlight's beam alignment against a wall.

Adjusting Headlight Range

Steps to adjust the headlight range for optimal visibility.

Changing Speedometer Battery

Instructions for replacing the battery in the speedometer.

Cooling System Maintenance

Cooling System Overview

Explains the function of the water pump and radiator cap in the cooling system.

Checking Antifreeze and Coolant Level

Procedure for checking coolant antifreeze concentration and level.

Checking Coolant Level

Instructions to check the coolant level in the radiator.

Draining the Coolant

Detailed steps for draining the coolant from the system.

Refilling with Coolant

Procedure for refilling the cooling system with coolant, including bleeding.

Engine Tuning and Adjustments

Checking Throttle Cable Play

Guidance on checking and adjusting the play in the throttle cable.

Adjusting Throttle Cable Play

Step-by-step instructions for adjusting the throttle cable play.

Carburetor Overview

Information on the carburetor's influence on starting, idling, and throttle response.

Carburetor - Adjusting Idle Speed

Procedure for adjusting the idle speed and idle air mixture.

Emptying Carburetor Float Chamber

Instructions for emptying the carburetor float chamber to remove old fuel.

Checking Shift Lever Basic Position

How to check and adjust the basic position of the shift lever.

Adjusting Shift Lever Basic Position

Procedure for adjusting the shift lever's position for optimal shifting.

Engine Characteristic - Auxiliary Spring (TE 250/300)

Explanation of the auxiliary spring's role in influencing engine performance.

Engine Characteristic - Setting Auxiliary Spring (TE 250/300)

Instructions for changing the auxiliary spring to alter engine characteristics.

Engine Service Procedures

Checking Gear Oil Level

Procedure for checking the gear oil level while the engine is cold.

Changing the Gear Oil

Instructions for draining and refilling the gear oil.

Draining the Gear Oil

Detailed steps for draining the gear oil, with safety warnings.

Refilling with Gear Oil

Procedure for refilling the transmission with the correct type and amount of gear oil.

Adding Gear Oil

Instructions on how to add gear oil if the level is low.

Cleaning and Care

Cleaning the Motorcycle

Guidelines for cleaning the motorcycle, emphasizing safe methods and avoiding pressure washers on components.

Checks and Maintenance for Winter Operation

Specific maintenance steps to protect against road salt corrosion during winter use.

Storage Procedures

Motorcycle Storage Guidelines

Steps for preparing the motorcycle for long-term storage, including fuel and battery care.

Preparing for Use After Storage

Instructions for bringing the motorcycle back into service after a storage period.

Troubleshooting Common Issues

Engine Cannot Be Cranked

Troubleshooting steps for when the engine fails to crank, covering battery and fuse issues.

Engine Turns But Does Not Start

Diagnostic steps for when the engine cranks but does not start.

Engine Has No Idle

Troubleshooting for lack of idle, relating to carburetor and spark plug issues.

Engine Does Not Speed Up

Diagnosing issues where the engine fails to accelerate properly.

Engine Has Too Little Power

Identifying causes for reduced engine power, such as fuel or air filter problems.

Engine Stalls or Pops Into Carburetor

Troubleshooting for engine stalling or backfiring into the carburetor.

Engine Overheats

Steps to diagnose and resolve engine overheating issues.

White Smoke Emission (Steam in Exhaust Gas)

Diagnosing white smoke from the exhaust, often indicating head gasket issues.

Gear Oil Exits at Vent Hose

Troubleshooting for gear oil exiting the vent hose, possibly due to overfilling.

Water in the Gear Oil

Diagnosing water contamination in the gear oil, indicating seal or pump issues.

Technical Data Specifications

Engine Specifications (TE 125)

Technical data for the TE 125 engine, including displacement, bore, stroke, and transmission ratios.

Engine Specifications (All TE 250)

Technical data for TE 250 engines, covering displacement, bore, stroke, and valve adjustments.

Engine Specifications (All TE 300)

Technical data for TE 300 engines, including displacement, bore, stroke, and valve adjustments.

Engine Tightening Torques (TE 125)

Torque specifications for various engine components on the TE 125.

Engine Tightening Torques (TE 250/300)

Torque specifications for various engine components on TE 250/300 models.

Capacities: Gear Oil, Coolant, Fuel

Specifies capacities for gear oil, coolant, and fuel tank volume.

Chassis Specifications

Details on frame, fork, shock absorber, brake system, and suspension geometry.

Electrical System Specifications

Information on battery types, bulbs, and indicator lamps for the electrical system.

Tire Specifications

Recommended tire sizes and types for different TE models.

Fork Specifications

Details on fork part numbers, damping settings, spring rates, and oil types.

Shock Absorber Specifications

Data for shock absorbers, including damping settings, spring preload, and sag measurements.

Chassis Tightening Torques

Torque values for various chassis components and fasteners.

Carburetor Specifications

Details on carburetor types, jetting, needle positions, and settings for various models.

Substances and Fluids

2-Stroke Engine Oil Recommendations

Specifies approved 2-stroke engine oils, recommending Motorex®.

Brake Fluid Types (DOT 4/5.1)

Guidance on using specified brake fluids and recommended brands like Castrol and Motorex®.

Coolant Recommendations

Advice on using suitable coolant, mixture ratios, and recommended Motorex® products.

Engine Oil (15W/50) Specifications

Details on approved engine oils, recommending Motorex® Top Speed 4T.

Fork Oil (SAE 4) Recommendations

Specifies approved fork oils and their compliance with standards.

Hydraulic Oil (15) Specifications

Information on approved hydraulic oils, recommending Motorex®.

Shock Absorber Oil (SAE 2.5) Specifications

Details on approved shock absorber oils and their compliance with standards.

Super Unleaded Fuel Requirements

Guidelines for using unleaded fuel, including ethanol content limits and prohibited fuels.

Mixed Fuel (Gasoline + 2-Stroke Oil)

Specifies the mixture ratio and recommended oils for unleaded gasoline.

Auxiliary Substances and Maintenance Products

Air Filter Cleaning Agent

Recommends Motorex® Twin Air Dirt Bio Remover for air filter cleaning.

Chain Cleaner

Recommends Motorex® Chain Clean for cleaning the drive chain.

Chain Spray

Recommends Motorex® Chainlube Offroad for chain lubrication.

Cleaning Materials for Metal, Rubber, Plastic

Recommends Motorex® Protect & Shine for cleaning and polishing various surfaces.

High Viscosity Grease

Recommends SKF® LGHB 2 for high viscosity grease applications.

Long-Life Grease

Recommends Motorex® Bike Grease 2000 for long-life lubrication.

Motorcycle Cleaner

Recommends Motorex® Moto Clean 900 for general motorcycle cleaning.

Oil for Foam Air Filter

Recommends Motorex® Twin Air Liquid Bio Power for foam air filters.

Rubber Grip Adhesive

Specifies GRIP GLUE from KTM-Sportmotorcycle AG / Division HUSABERG.

Universal Oil Spray

Recommends Motorex® Joker 440 Synthetic for universal oil spray.

Standards and Classifications

JASO FC Standard

Classification for 2-stroke engine oils developed for racing demands.

JASO T903 MA Standard

Specification for 4-stroke motorcycle oils, meeting engine, gearbox, and clutch needs.

SAE Viscosity Classification

Defines SAE viscosity classes for oils based on Society of Automotive Engineers standards.

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