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Husqvarna SMR 449 2011 I.E. User Manual

Husqvarna SMR 449 2011 I.E.
414 pages
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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

Table of Contents

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Husqvarna SMR 449 2011 I.E. Specifications

General IconGeneral
Year2011
ManufacturerHusqvarna
ModelSMR 449 I.E.
CategorySupermoto
Engine TypeSingle cylinder, 4-stroke
Compression Ratio12.5:1
Transmission6-speed
Fuel SystemElectronic Fuel Injection
StarterElectric
Front Tire120/70-17
Rear Tire150/60-17
Power53 hp (39 kW)
Torque40 Nm
Front SuspensionKayaba 48 mm USD forks
Rear SuspensionMonoshock
Front BrakeSingle disc. Brembo, 4-piston caliper
Rear BrakeSingle disc. Brembo, 1-piston caliper
Ground Clearance300 mm

Summary

IMPORTANT NOTICES

GENERAL INFORMATION

Engine

Details about engine specifications like bore, stroke, compression ratio, and timing system details.

Timing system

Information on double overhead camshaft, chain operated timing system.

Fuel system

Describes electronic injection feed and air filtering for the fuel system.

Lubrication

Details on lubrication system type, pumps, and filter.

Cooling

Information on liquid cooling with radiators and electric fan.

Ignition system

Details on electronic capacitive discharge ignition with adjustable advance.

Transmission

Information on clutch type, gears, and primary drive.

Gear ratios

Lists gear ratios for TC, TE-TXC-SMR models.

Chassis

Describes the twin beam steel chassis and rear aluminum alloy chassis.

Suspension

Details front and rear suspension types and travel.

Brakes

Information on front and rear disc brake systems, including specifications.

Wheels

Lists front and rear wheel rim specifications.

Tyres

Specifies front and rear tyre sizes for different models.

Cold tyre pressure

Provides cold tyre pressure values for various models and conditions.

Electrical components location (TC)

Identifies locations of electrical components for TC model.

Electrical components location (TXC)

Identifies locations of electrical components for TXC model.

Electrical components location (TE-SMR)

Identifies locations of electrical components for TE-SMR models.

Supplies (reserve included)

Lists required fluids and quantities for fuel, gearbox, fork, and cooling.

Overall dimensions - Weight

Provides kerb weight and overall dimensions for different models.

MAINTENANCE

TABLES OF PERIODIC MAINTENANCE MY11

Scheduled maintenance chart for MY11 models, covering competition/racing use.

TABLES OF PERIODIC MAINTENANCE MY12

Scheduled maintenance chart for MY12 models, covering competition/racing use.

TROUBLESHOOTING

Engine

Lists common engine-related problems, their causes, and remedies.

Chassis

Lists common chassis-related problems, their causes, and remedies.

Electrical System

Lists common electrical system problems, their causes, and remedies.

SETTINGS AND ADJUSTMENTS

Throttle cable adjustment

Procedure for checking and adjusting throttle control cable free play.

Idle adjustment (TE - TXC - SMR)

Steps to adjust idle speed for TE, TXC, and SMR models.

Hydraulic clutch lever adjustment and fluid level check

Instructions for adjusting clutch lever free play and checking fluid level.

Front brake lever adjustment and fluid level check (TC - TE - TXC)

Steps for adjusting front brake lever play and checking fluid level.

Front brake lever adjustment and fluid level check (SMR)

Procedure for adjusting SMR front brake lever and checking fluid level.

Rear brake pedal position adjustment

Instructions on how to adjust the rear brake pedal position.

Engine oil replacement and mesh filters-filter cartridge cleaning or replacement

Detailed procedure for replacing engine oil and cleaning/replacing filters.

Coolant replacement

Step-by-step guide for replacing the engine coolant.

Air filter cleaning

Procedure for cleaning the air filter element.

Chain adjustment

Steps for checking and adjusting the drive chain tension.

Suspension setup according to track condition

Guidelines for adjusting front and rear suspension based on terrain.

Shock absorber damping adjustment

How to adjust the compression and rebound damping.

KAYABA fork adjustment (TC - TE - TXC)

Instructions for adjusting KAYABA front forks for TC, TE, and TXC models.

Fork oil level (TC - TE - TXC)

Procedure for checking and filling fork oil for TC, TE, TXC models.

Marzocchi fork adjustment (SMR)

Instructions for adjusting Marzocchi front forks for SMR models.

Fork oil level (SMR)

Procedure for checking and filling fork oil for SMR models.

Steering bearing clearance adjustment

Steps to adjust steering head bearing clearance for safety.

Exhaust system check

Procedure for visually inspecting the exhaust system for leaks.

GENERAL PROCEDURES

Saddle removal

Step-by-step instructions for removing the motorcycle saddle.

Side panel removal

Instructions for removing the left-hand side panel.

Tail section removal (TC-TE-TXC MY12)

Procedure for removing the tail section on MY12 TC-TE-TXC models.

Front turn indicator removal

Instructions for removing the front turn indicators.

Number plate holder removal (TE MY12)

Procedure for removing the number plate holder on TE MY12.

Front Mudguard Removal

Steps to remove the front mudguard.

Rear mudguard removal (SMR MY11 / MY 12 - TE-TXC-TC MY11)

Instructions for removing rear mudguard on SMR MY11/12 and TE-TXC-TC MY11.

Battery removal

Steps for safely removing the motorcycle battery.

Tank Removal

Procedure for removing the fuel tank.

Fuel Pump Removal

Instructions for removing the fuel pump.

Throttle body removal

Procedure for removing the throttle body.

Exhaust System Removal (SMR)

Steps for removing the exhaust system on SMR models.

Engine removal

Detailed procedure for removing the entire engine from the motorcycle.

ADJUSTMENTS - ENGINE

Valve clearance check

Procedure for checking valve clearance using a feeler gauge.

Engine positioning at ignition TDC

Steps to position the engine at Top Dead Center for ignition timing.

Securing crankshaft at TDC

Instructions for securing the crankshaft at Top Dead Center.

Camshaft disassembly

Procedure for removing the intake and exhaust camshafts.

Cylinder disassembly

Steps for removing the cylinder.

Piston disassembly

Procedure for disassembling the piston and rings.

Piston assembly

Steps for assembling the piston into the cylinder.

Timing chain disassembly and reassembly or replacement

Procedure for removing and installing the timing chain.

Replacing oil pump gears (crankcase cover removed)

Steps for replacing oil pump gears with the crankcase cover removed.

Clutch disassembly and reassembly or replacement

Comprehensive guide for clutch disassembly and reassembly.

Gearbox shaft replacement (crankcase cover removed)

Procedure for replacing gearbox shafts with crankcase cover removed.

Selector cylinder replacement

Steps for replacing the selector cylinder components.

Gear selector fork replacement

Procedure for replacing gear selector forks.

Gearbox assembly

Steps for assembling the gearbox components.

ENGINE DISASSEMBLY/REASSEMBLY

Oil filter replacement

Procedure for replacing the oil filter.

Spark plug

Procedure for removing and installing the spark plug.

Cylinder head disassembly and reassembly/head gasket replacement

Comprehensive guide for cylinder head removal, reassembly, and gasket replacement.

Clutch disassembly and reassembly or replacement

Comprehensive guide for clutch disassembly and reassembly.

Gearbox shaft replacement (crankcase cover removed)

Procedure for replacing gearbox shafts with crankcase cover removed.

FRONT SUSPENSION

Front fork removal

Steps for removing the front fork legs from the motorcycle.

Front fork disassembly (TC - TXC)

Detailed procedure for disassembling the KAYABA front fork.

Front fork disassembly (TE)

Detailed procedure for disassembling the TE front fork.

Overhauling and modifying the cartridge and bottom valve setting

Guide to overhauling the cartridge and adjusting the bottom valve setting.

Filling with oil

Instructions for filling the fork leg with the specified oil and checking level.

REAR SUSPENSION

Rear shock absorber

Information on the rear shock absorber and its specifications.

Rear shock absorber removal

Steps for removing the rear shock absorber.

Disassembling and servicing the swinging arm

Procedure for disassembling and servicing the swinging arm.

Linkage disassembly

Steps for disassembling the rear suspension linkage components.

Chain sprocket removal

Steps for removing the rear chain sprocket.

BRAKES

Braking system

Overview of the dual independent brake circuits and their components.

Brake disc

Information on brake disc specifications, wear limits, and removal.

Checking brake pads for wear / replacing the pads (TC-TE-TXC)

Procedure for checking and replacing brake pads on TC-TE-TXC models.

Bleeding the front braking system (TC-TE-TXC)

Detailed steps for bleeding air from the front brake system on TC-TE-TXC.

Bleeding the rear braking system

Procedure for bleeding air from the rear brake system.

Changing the fluid

Instructions for changing the brake fluid, including precautions.

ELECTRICAL SYSTEM

Engine wiring diagram (TC MY11 - MY12)

Wiring diagram for TC models, MY11 and MY12.

Engine wiring diagram (TE-TXC-SMR MY11 + SMR MY12)

Wiring diagram for TE-TXC-SMR models, MY11 and MY12.

Electrical components location (TC)

Identifies locations of electrical components for TC models.

Electrical components location (TE - SMR)

Identifies locations of electrical components for TE-SMR models.

Charging system inspections

Procedures for inspecting battery and regulated voltage.

Spark plug

Information on checking spark plug gap and condition.

Fuses

Information on fuse identification, replacement, and protection.

Relay test

Procedure for testing relays.

Digital dashboard, warning lights (TE - SMR)

Explanation of the digital dashboard and warning lights for TE-SMR.

FUEL INJECTION SYSTEM

Fuel injection system

Overview of the fuel injection system components and operation.

Instructions for using "HUSQVARNA SERVICE TOOL" for a fuel injection system

Guide on using the diagnostic tool for fuel injection system testing.

Fuel pump inspection

Procedure for inspecting the fuel pump.

CHASSIS AND WHEELS

Chassis

Description of the motorcycle's frame construction and materials.

Lubrication points (lubricant)

Identifies key lubrication points on the chassis and engine mounting.

Front wheel (TC - TE - TXC)

Exploded view and legend for the front wheel of TC, TE, TXC models.

Rear wheel (TC - TE - TXC)

Exploded view and legend for the rear wheel of TC, TE, TXC models.

Removing the front wheel

Steps for safely removing the front wheel.

Reassembling the front wheel

Procedure for correctly reassembling the front wheel.

Removing the rear wheel

Steps for safely removing the rear wheel.

Wheel servicing

General instructions for servicing wheel hub bearings.

Chain sprocket removal

Steps for removing the rear chain sprocket.

Checking pinion and sprockets for wear

How to inspect pinion and sprockets for wear and damage.

NOTES FOR USA/CDN

Spark arrester (TE - TXC - SMR)

Information on the U.S. Forest Service approved spark arrester.

Assembly

Instructions for mounting the screen and tightening screws.

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