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Husqvarna TC449 - User Manual

Husqvarna TC449
385 pages
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NTSC 4:3
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MOTORE
1 - Operazioni di manutenzione
2 - Gruppo testa
3 - Gruppo cilindri e pistoni
4 - Gruppo frizione
5 - Gruppo alternatore
6 - Gruppo carter
CICLISTICA
7 - Operazioni di manutenzione
ENGINE
1 - Maintenance
2 - Cylinder head assembly
3 - Cylinder and piston assembly
4 - Clutch assembly
5 - Alternator assembly
6 - Crankcase
CHASSIS
7 - Maintenance
MOTEUR
1 - Opérations d'entretien
2 - Ensemble culasse
3 - Ensemble cylindres et pistons
4 - Ensemble embrayage
5 - Ensemble alternateur
6 - Ensemble carter
PARTIE-CYCLE
7 - Opérations d'entretien
MOTOR
1 - Wartungsarbeiten
2 - Zylinderkopfeinheit
3 - Zylinder- Kolbeneinheit
4 - Kupplungseinheit
5 - Lichtmaschineneinheit
6 - Gehäuseeinheit
FAHRWERK
7 - Wartungsarbeiten
MOTOR
1 - Operaciones de mantenimiento
2 - Grupo cabezal
3 - Grupo cilindros y pistones
4 - Grupo embrague
5 - Grupo alternador
6 - Grupo cárter
CHASIS
7 - Operaciones de mantenimiento
www.husqvarna-motorcycles.com
Cod. 8000H5336
www.husqvarna-motorcycles.com
Husqvarna Motorcycles srl
Via Nino Bixio 8
21024 - Biandronno (VA) - Italy
Technical DVD
Technical DVD
Technical DVD
Workshop Manual
My 2011
Ed. 11-2010

Table of Contents

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Summary

IMPORTANT NOTICES

TC and TXC models warranty

Warranty for racing motorcycles, free from operating defects.

TE and SMR models warranty

Warranty for road use, free from defects and legal warranty.

Motorcycle usage limitations

Not designed for long-distance travel at top RPM; may cause engine damage.

Guarantee of Functionality

Client must follow maintenance program at authorized dealers.

GENERAL INFORMATION

Engine specifications

Details bore, stroke, displacement, and compression ratios for 449 and 511 models.

Timing system specifications

Describes camshaft type and valve clearance specifications.

Fuel system

Specifies electronic injection feed and air filtering.

Lubrication

Describes wet sump lubrication with two lobe pumps and cartridge filter.

Cooling

Describes liquid cooling with double radiator and electric fan.

Ignition system

Details capacitive discharge ignition and spark plug specifications.

Transmission

Describes clutch type, control, and gearbox components.

Suspension

Details front and rear suspension types and travel.

Brakes

Describes front and rear brake disc types, calipers, and pad surface area.

Cold tyre pressure

Provides cold tyre pressure specifications for various models and conditions.

Electrical components location

Illustrates the location of electrical components for TC, TXC, and TE-SMR models.

Supplies

Lists fuel tank capacity, gearbox oil, fork oil, and other fluids.

MAINTENANCE

Scheduled Maintenance Chart (TE-TXC 449;511) - Engine

Details engine maintenance tasks and intervals for TE-TXC 449/511 in competition use.

Scheduled Maintenance Chart (TC 449) - Engine

Details engine maintenance tasks and intervals for TC 449 in competition use.

Scheduled Maintenance Chart (TE-SMR 449;511) - Engine

Details engine maintenance tasks and intervals for TE-SMR 449/511 in standard street use.

Scheduled Maintenance Chart (TC 449 - TE -TXC 449;511) - Chassis

Details chassis maintenance tasks and intervals for TC/TE-TXC 449/511 in competition use.

Scheduled Maintenance Chart (TE-SMR 449;511) - Chassis

Details chassis maintenance tasks and intervals for TE-SMR 449/511 in standard street use.

TROUBLESHOOTING

Engine troubleshooting

Covers problems related to engine starting, spark, stalling, and noise.

Clutch troubleshooting

Addresses issues like clutch slip and difficulty in operation.

Gearbox troubleshooting

Covers problems with gear engagement, shift pedal, and transmission jumping.

Chassis troubleshooting

Addresses handlebar, damping, wheel, and suspension issues.

Electrical System troubleshooting

Covers issues with spark plug, generator, battery, and starter motor.

SETTINGS AND ADJUSTMENTS

Saddle and panel removal

Details the procedure for removing the saddle and side panels.

Throttle cable adjustment

Explains how to check and adjust the throttle control cable.

Idle adjustment

Details idle adjustment procedures for TC and TE-TXC-SMR models.

Hydraulic clutch lever adjustment and fluid level check

Covers hydraulic clutch lever adjustment and fluid level check.

Front brake lever adjustment and fluid level check

Covers front brake lever adjustment and fluid level check.

Rear brake pedal adjustment

Details rear brake pedal position and free play adjustments.

Engine oil level check and replacement

Explains how to check and replace engine oil and filters.

Coolant level check and replacement

Details coolant level check and replacement procedures.

Air filter check and cleaning

Outlines procedures for checking and cleaning the air filter.

Chain adjustment and lubrication

Details chain adjustment, lubrication, and wear checks.

Suspension setup

Provides guidelines for setting up suspension based on terrain conditions.

Shock absorber adjustment

Details rear shock absorber adjustment procedures.

Shock absorber spring preload adjustment

Details spring preload adjustment for TE-TC-TXC and SMR models.

Shock absorber damping adjustment

Details compression and rebound damping adjustments.

KAYABA fork adjustment

Details adjustment procedures for KAYABA forks (TC-TE-TXC).

Marzocchi fork adjustment

Details adjustment procedures for Marzocchi forks (SMR).

Steering bearing clearance adjustment

Details how to adjust steering bearing clearance.

Fuel supply hose inspection

Details inspection of fuel supply hose conditions.

GENERAL PROCEDURES

Saddle and panel removal

Details the procedure for removing the saddle and side panels.

Front Mudguard and Number Plate Holder Removal

Describes removal of the front mudguard and number plate holder.

Rear Mudguard Removal

Details the procedure for removing the rear mudguard.

Battery removal

Details the procedure for removing the battery.

Tank Removal

Details the procedure for removing the fuel tank.

Fuel Pump Removal

Details the procedure for removing the fuel pump.

Throttle body removal

Details the procedure for removing the throttle body.

Exhaust System Removal

Details the procedure for removing the exhaust system for various models.

Rear chassis removal

Details the procedure for removing the rear chassis.

Solenoid starter removal

Details the procedure for removing the solenoid starter.

CDI electronic control unit removal

Details the procedure for removing the CDI electronic control unit.

Voltage regulator removal

Details the procedure for removing the voltage regulator.

Coil removal and spark plug check

Details ignition coil removal and spark plug check.

Clutch hose removal

Details the procedure for removing the clutch hose.

Engine removal

Details the procedure for removing the engine.

Radiator Removal

Details the procedure for removing the radiators.

ADJUSTMENTS - ENGINE

Valve clearance check

Details how to check valve clearance and technical specifications.

Set valve clearance

Details procedures for setting valve clearance, engine positioning, and securing crankshaft.

Camshaft disassembly;assembly

Details camshaft removal, checking, and assembly procedures.

Crankshaft disconnection

Details procedures for crankshaft disconnection and reassembly.

ENGINE DISASSEMBLY;REASSEMBLY

Oil filters replacement

Details procedures for disassembling and assembling oil filters.

Spark plug

Details spark plug disassembly and assembly with tightening torques.

Cylinder head cover

Details removal and installation of the cylinder head cover with tightening torques.

Engine positioning at ignition TDC

Details engine positioning at ignition TDC.

Securing crankshaft at TDC

Details securing the crankshaft at TDC.

Camshaft disassembly;assembly

Details camshaft disassembly, checking, and assembly.

Engine left crankcase

Details left crankcase cover disassembly and assembly.

Alternator replacement

Details alternator replacement including flywheel disassembly.

Clutch disassembly and reassembly or replacement

Details clutch disassembly, reassembly, and replacement procedures.

Engine right crankcase

Details right crankcase cover disassembly and assembly.

Coolant pump disassembly and assembly

Details coolant pump disassembly and assembly procedures.

Crankshaft, countershaft, and relevant bearings

Covers crankshaft and bearing procedures, including wear checks and replacements.

Gearbox unit - disassembly; assembly

Details gearbox unit disassembly and assembly procedures.

Cylinder disassembly and reassembly or replacement

Details cylinder disassembly and reassembly procedures.

Piston disassembly;assembly

Details piston disassembly and assembly procedures.

Timing chain disassembly and reassembly or replacement

Details timing chain disassembly and reassembly.

Removing and assembling or replacing pressure oil pump

Details pressure oil pump removal and assembly.

Disassembling;assembling starter motor

Details starter motor disassembly and assembly.

Crankshaft, countershaft, and relevant bearings

Covers crankshaft and bearing procedures, including wear checks and replacements.

Gearbox unit - disassembly; assembly

Details gearbox unit disassembly and assembly procedures.

FRONT SUSPENSION

Front fork removal

Details the procedure for removing the front fork legs.

Service instructions for Ø48 USD Kayaba fork - TC-TXC

Provides general service instructions for Kayaba forks used on TC-TXC models.

Front suspension (TC - TXC)

Describes the TC-TXC front suspension setup and travel.

Front fork disassembly (TC - TXC)

Details the step-by-step disassembly of the TC-TXC front fork.

Front suspension (TE)

Describes the TE front suspension setup and travel.

Front fork disassembly (TE)

Details the step-by-step disassembly of the TE front fork.

Front suspension (SMR)

Describes the SMR front suspension setup and travel.

INSTRUCTIONS FOR USE OF Ø50 USD FORK (SMR)

Provides general instructions for using the SMR Marzocchi forks.

Components of the fork

Lists and illustrates the components of the front fork.

GENERAL RULES FOR A PROPER OVERHAULING

Provides essential rules and precautions for fork overhauling.

Problems - Possible causes - Solutions

Lists common fork problems, their causes, and solutions.

Draining the oil

Details the procedure for draining the fork oil.

Braking down the pumping element and the bottom valve

Details dismantling the pumping element and bottom valve.

Re- assembling the fork leg - slider and oil seals

Details reassembly of the fork leg, slider, and oil seals.

Filling with oil

Details the procedure for filling the fork with oil.

REAR SUSPENSION

Rear shock absorber

Details the rear shock absorber and its tightening torque figures.

Lubrication points (grease)

Illustrates the lubrication points for the rear suspension components.

Rear suspension

Provides a general description of the rear suspension system.

Rear shock absorber removal

Details the procedure for removing the rear shock absorber.

Disassembling and servicing the swinging arm

Details the disassembly and servicing of the swinging arm.

Linkage disassembly

Details the disassembly of the rear suspension linkage components.

Chain sprocket removal

Details the procedure for removing the rear chain sprocket.

BRAKES

Braking system

Describes the dual-circuit braking system with master cylinders and calipers.

Brake disc

Details brake disc specifications, including diameter, thickness, and warpage limits.

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

Details checking and replacing front and rear brake pads for TC-TE-TXC.

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

Details the procedure for bleeding the front brake system for TC-TE-TXC.

Bleeding the front braking system (SMS)

Details the procedure for bleeding the front brake system for SMS.

Bleeding the rear braking system

Details the procedure for bleeding the rear brake system.

Changing the fluid

Provides instructions for changing brake fluid, including precautions.

ELECTRICAL SYSTEM

Engine wiring diagram (TC)

Provides the electrical wiring diagram for TC models.

Engine wiring diagram (TE-TXC-SMR)

Provides the electrical wiring diagram for TE-TXC-SMR models.

Electrical components location (TC)

Illustrates the location of electrical components for TC models.

Electrical components location (TE - SMR)

Illustrates the location of electrical components for TE-SMR models.

Electrical components location (TXC)

Illustrates the location of electrical components for TXC models.

Generator stator windings resistance (1) inspection

Details how to inspect generator stator windings resistance.

Ignition system (TC)

Details the ignition system for TC models.

Ignition system (TE - TXC - SMR)

Details the ignition system for TE-TXC-SMR models.

CHARGING SYSTEM INSPECTIONS

Details inspections for the charging system, including battery.

Regulated voltage

Details how to check regulated voltage.

Voltage regulator;rectifier inspection

Details voltage regulator/rectifier inspection.

ELECTRIC STARTING SYSTEM

Details the components of the electric starting system.

Starter motor inspection

Details starter motor inspection procedures.

Solenoid starter inspection

Details solenoid starter inspection procedures.

Coil windings resistance inspection

Details coil windings resistance inspection.

Electronic control unit (ECU)

Details the electronic control unit.

Spark plug

Details spark plug check and replacement.

BATTERY

Provides battery information and charging procedures.

FUSES

Details fuse types, locations, and protections.

Relay test

Details relay testing procedures.

DIGITAL DASHBOARD, WARNING LIGHTS (TE)

Details dashboard functions and warning lights for TE models.

ENGINE COOLING

Coolant level check

Details how to check coolant level and safety precautions.

Cooling circuit

Describes the components of the cooling system.

Engine cooling system overhaul

Details radiator and hose maintenance procedures.

HYDRAULICALLY CONTROLLED CLUTCH

Hydraulic clutch system

Describes the hydraulic clutch system components and operation.

Draining clutch fluid

Details the procedure for draining the clutch fluid.

Clutch master cylinder servicing

Details servicing the clutch master cylinder.

Bleeding the clutch system

Details the procedure for bleeding the hydraulic clutch system.

FUEL INJECTION SYSTEM

FUEL INJECTION SYSTEM

Describes the fuel injection system components and operating parameters.

Instructions for using HUSQVARNA SERVICE TOOL

Explains how to use the HUSQVARNA SERVICE TOOL for diagnostics.

Fuel pump inspection

Details the procedure for inspecting the fuel pump.

TIGHTENING TORQUE FIGURES

Assembly Cycle Operation Description

Lists Nm, Kgm, and ft/lb torque values for various assembly operations.

Assembly Cycle Operation Description

Continues the list of torque values for assembly operations.

CHASSIS AND WHEELS

Chassis

Describes the frame construction materials and types.

Lubrication points (lubricant)

Shows lubrication points on the chassis and checks for cracks.

Front wheel (TC - TE - TXC)

Details front wheel specifications for TC, TE, TXC models.

Front wheel (SMR)

Details front wheel specifications for SMR models.

Removing the front wheel

Details the procedure for removing the front wheel.

Reassembling the front wheel

Details the procedure for reassembling the front wheel.

Rear wheel (TC - TE - TXC)

Details rear wheel specifications for TC, TE, TXC models.

Rear wheel (SMR)

Details rear wheel specifications for SMR models.

Removing the rear wheel

Details the procedure for removing the rear wheel.

Wheel servicing

Details wheel hub bearing service and wheel balancing.

Wheel spokes

Details wheel spoke tightening and checks.

Wheel rim warpage

Details wheel rim warpage checks and limits.

Rear chain sprocket, secondary drive sprocket and chain

Details inspection and replacement of rear sprocket and chain.

Checking pinion and sprockets for wear

Details checking pinion and sprockets for wear and factors affecting wear.

NOTES FOR USA;CDN

SPARK ARRESTER (TE - TXC - SMR)

Describes the US Forest Service approved spark arrester.

“SPARK ARRESTER” MAINTENANCE AND CLEANOUT INSTRUCTIONS

Provides instructions for spark arrester maintenance and cleanout.

Assembly

Details the assembly procedure for the spark arrester.

Husqvarna TC449 Specifications

General IconGeneral
Displacement449 cc
Compression Ratio12.5:1
Fuel SystemElectronic Fuel Injection
StarterElectric
Transmission5-speed
Final DriveChain
Front Tire80/100-21
Rear Tire110/90-19
Engine TypeSingle-cylinder, four-stroke
Front SuspensionUSD fork, 48 mm
Rear SuspensionMonoshock
Front BrakeSingle disc, 260 mm
Bore x Stroke98 x 59.6mm
Rear BrakeDisc brake, 240 mm

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