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TR 650 TERRA 2013
Husqvarna TR 650 TERRA 2013 Workshop Manual
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TR 650 TERRA 2013
TR 650 STRADA 2013
Workshop Manual
Ed. 09-2012
Rev 01
2
Table of Contents
Tr 650 Terra 2013 - Tr 650 Strada 2013
5
Foreword, Table of Contents
3
Tr 650 Terra 2013 - Tr 650 Strada 2013
3
Tr 650 Terra 2013 - Tr 650 Strada 2013
4
Table of Contents
5
Tr 650 Terra 2013 - Tr 650 Strada 2013
5
Important Notices
7
Tr 650 Terra 2013 - Tr 650 Strada
7
Engine
8
Tr 650 Terra 2013 - Tr 650 Strada 2013
8
Tr 650 Terra 2013 - Tr 650 Strada 2013
9
Tr 650 Terra 2013 - Tr 650 Strada 2013
10
General Information
11
Tr 650 Terra 2013 - Tr 650 Strada 2013
11
Tr 650 Terra 2013 - Tr 650 Strada 2013
12
Clutch
13
Fuel System
13
Ignition
13
Lubrication
13
Primary Drive
13
Secondary Drive
13
Timing System
13
Transmission
13
Transmission Ratio
13
Chassis
14
Final Ratios
14
Front Brake
14
Front Suspension
14
Rear Brake
14
Rear Suspension
14
Tyres
14
Wheels
14
Electrical Components Location
15
Table for Lubrication, Supplies
15
Dimensions, Weight, Capacity
16
Maintenance
17
Troubleshooting
21
Settings and Adjustments
31
Tr 650 Terra 2013 - Tr 650 Strada 2013
32
Saddle Removal
33
Removal of Central Upper Cover
34
Side Panel Removal
34
Front Brake Control
35
Position Adjustment
35
Throttle Cable Adjustment
35
Throttle Control
35
Throttle Position Adjustment
35
Clutch Control
36
Front Brake Lever Adjustment and Fluid Level Check
36
Position Adjustment
36
Clutch Control Lever Distance Adjustment
37
Clutch Free Play Adjustment
37
Rear Brake Fluid Level Check
38
Rear Brake Pedal Free Play Adjustment
38
Engine Oil Replacement and Cartridge Filter Replacement
39
Oil Level Check
39
Replacement of Cartridge Filter
40
Coolant Level Check
41
Filling
41
Coolant Replacement
42
Air Filter Check
43
Chain Tension Adjustment
44
Lubricating the Chain
44
Shock Absorber Spring Preload Adjustment
45
Suspension
45
Fork Adjustment
46
Fuel Supply Hose Inspection and Replacement
46
Rebound Shock Absorber Hydraulic Damping Adjustment
46
Exhaust System Check
47
Checking and Adjustment of Valve Clearance
48
Idle Speed Adjustment
48
General Procedures
51
Tr 650 Terra 2013 - Tr 650 Strada 2013
52
Stand Removal / Replacement
53
Removal of Central Upper Cover
54
Saddle Removal
54
Removal of Luggage Rack
55
Side Panel Removal
55
Removal of Rear Panels
56
Removal of Tail Cover
56
Removal of Antitheft Device Compartment Cover
57
Replacement of the Saddle Lock Key Lock
58
Removal of Number Plate Holder
59
Removal of Saddle Lock
59
Removal of Rear Turning Indicators
62
Removal of Tail Light
62
Removal of Radiator Guards
63
Removal of Lower Tail Cover
64
Removal of Tail Chassis
66
Front Fairing Removal
67
Front Turning Indicator Removal
68
Combined Dashboard Removal
69
Removal of Front Mudguard
70
Removal of Fuel Tank
71
Fuel Pump Removal
74
Fuel Pump Inspection
76
Removal of Filter Box
77
Dismantling of Filter Box
79
Throttle Body Removal
80
Exhaust System Removal
81
Coil / Stick-Coil Removal and Spark Plug Test
84
Lambda Sensor Removal
84
Horn Removal
85
Radiator Removal
85
Removal of Electric Fan
87
Gearbox Lever Removal
88
Removal of Engine
89
Reassembly of Engine
92
Engine Settings and Adjustments
93
Tr 650 Terra 2013 - Tr 650 Strada 2013
94
Valve Clearance Check
95
Valve Clearance Measurement
95
Locking the Crankshaft
96
Pad Replacement
96
Chain Guide Disassembly
97
Chain Tensioner Disassembly
97
Camshaft Assembly
98
Camshaft Removal
98
Pad Replacement
98
Chain Guide Installation
99
Chain Tensioner Installation
99
Removal of Engine Block Screw
99
Timing Check
100
Engine Phasing
101
General Engine Procedures
103
Tr 650 Terra 2013 - Tr 650 Strada 2013
104
Clutch Cover Removal / Installation
105
Gearbox Lever Removal/Installation
105
Clutch Cover Removal
105
Remove the Left Engine Crankcase Cover
105
Coolant Pump Cover Removal
106
Left Engine Cover Removal
106
Gearbox Selector Shaft Oil Seal Removal/Installation
106
Clutch Engagement Lever Removal/Refitting
107
Clutch Disengagement Shaft Removal
107
Clutch Disengagement Shaft Oil Seal Removal
107
Clutch Disengagement Shaft Bearing Removal
108
Installation of both Clutch Disengagement Shaft Bearings
108
Clutch Disengagement Shaft Oil Seal Installation
108
Disengagement Shaft Installation
108
Left Engine Crankcase Cover Assembly
109
Ignition Cover Removal/Refitting
109
Crankshaft Sensor and Stator Removal
110
Crankshaft Sensor and Stator Installation
110
Mounting the Ignition Cover
111
Replacement of the Gearbox Output Shaft Oil Seal
111
Flywheel and Starter Motor Idle Gear Removal
112
Removal/Installation Of The Freewheel From/On The Flywheel
112
Starter Motor Idle Gear Removal/Installation
113
Installation Of The Flywheel With Freewheel Control Gear
113
Chain Sprocket Removal/Installation
114
Starter Motor Removal/Installation
114
Removal/Installation of the Complete Clutch
115
Clutch Pressure Plate Disassembly
118
Removing the Neutral Position Sensor
115
Pumps
119
Oil Pump Removal/Installation
119
Replacement of the Oil Pressure Valve and Unidirectional Valve
120
Coolant Fluid Pump Removal/Installation
121
Removal/Installation or Replacement of the Timing Chain
122
Cylinder Head Removal/Disassembly
123
Tr 650 Terra 2013 - Tr 650 Strada 2013
124
Cylinder Head Cover Removal/Installation
125
Removal of the Ignition Coils
125
Chain Tensioner Removal/Installation
126
Locking the Crankshaft
126
Camshaft Removal/Replacement
127
Crankshaft Locking Screw Removal
127
Checking the Decompression Lever
128
Installing the Decompression Lever
128
Removing the Decompression Lever
128
Camshaft Assembly
129
Timing Chain Slider Replacement
129
Cylinder Head Removal/Installation - Replacement of Cylinder Head Gasket
130
Valve Removal
132
Crankcase Disassembly
133
Crankcase Disassembly Tr 650 Terra 2013 - Tr 650 Strada 2013
134
Cylinder Disassembly/Installation
135
Piston Removal/ Installation
136
Crankcase Disassembly
137
Measurement of a Piston and Cylinder
137
Crankshaft Disassembly
140
Crankshaft and Countershaft Installation
142
Crankshaft Axial Clearance Check
142
Removal/Refitting the Countershaft and Checking Axial Clearance
143
Countershaft Clearance Check
144
Crankshaft and Countershaft Gear Removal
144
Gear Installation
144
Removal of the Countershaft Gear
144
Crankshaft Gear Removal
145
Gear Installation
145
Replacement of the Countershaft Bearings
145
Gearbox Shafts Removal
146
Gearbox Shafts Removal/Installation
146
Removal of the Gear Engage Forks
146
Engagement System Check
147
Fork Installation
147
Gearbox Shafts Installation
147
Disassembly/Assembly of the Gearbox Input Shaft (Shaft Removed)
148
Disassembly/Assembly of the Gearbox Output Shaft (Shaft Removed)
149
Engagement System Check
150
Replacement of the Gearbox Control Shaft (Engine Disassembled)
150
Iengagement System Check
151
Replacement of the Selector Drum (Engine Disassembled)
151
Mesh Oil Filter
152
Replacement of the Gearbox Shaft Bearings (Shafts Removed)
152
Engine Torque Figures
153
Engine Parts Wear Limits
175
Front Suspension
179
Rear Suspension
187
Tr 650 Terra 2013 - Tr 650 Strada 2013
188
Rear Shock Absorber Removal
189
Rear Suspension
189
Lubrication Points (Grease)
192
Servicing the Rear Suspension Drop and Drag Link
193
Removal of the Chain Guard
194
Removal of the Sprocket Guard Casing
194
Removal of the Rear Swinging Arm
195
Replacement of the Chain Slider
197
Servicing the Swinging Arm Shaft
197
Brakes
199
Brakes Tr 650 Terra 2013 - Tr 650 Strada 2013
200
Braking System (Versions Without ABS)
201
Braking System (Versions with ABS)
202
Brake Disc
204
Removing the Rear Brake System (Versions Without ABS)
204
Front Braking System Removal (Versions Without ABS)
206
Removing the Braking System (Versions with ABS)
207
Front Braking System Removal (Versions with ABS)
208
Removing the Front Brake Calliper
208
Replacing a Brake Line (Versions with ABS)
208
Removing the Front Master Cylinder
209
Removing the Rear Braking System (Versions with ABS)
209
Removing the Rear Master Cylinder
210
Removing the Rear Brake Calliper
211
Checking Brake Pads for Wear / Replacing the Pads
212
Brake Fluid Replacement
214
Fluid Replacement and System Bleeding
214
Changing the Front Braking System Fluid
215
Changing the Rear Braking System Fluid
216
Bleeding the Front Braking System
217
Bleeding the Rear Braking System
219
Electrical System
221
Tr 650 Terra 2013 - Tr 650 Strada 2013
222
Wiring Diagram (NON-ABS Version)
225
Wiring Diagram (ABS Version)
226
Key to Wiring Diagram
227
Electrical Component Location
229
Generator Performance
231
Neutral Position Sensor
232
Ignition and Injection System
234
Charging System
235
Battery
236
Charging System Inspections
236
Regulated Voltage
236
Voltage Regulator Inspection
236
Voltage Regulator/Rectifier Wiring Diagram
236
Electric Starting System
237
Solenoid Starter Inspection
238
Starter Motor
238
Starter Motor Inspection
238
Starter Relay Wiring Diagram
238
Starting System Inspection
238
Coil Windings / Stick-Coil Inspection
239
Electronic Control Unit (ECU)
239
Battery
240
Battery Charger
240
Spark Plug
240
Headlight Adjustment
241
Headlight, Tail Light
241
Front Headlamp Bulb Replacement
242
Headlight Removal
244
Tail Light Replacement
246
Turning Indicator Bulb Replacement
246
Number Plate Bulb Replacement
247
Left-Hand Switch
248
Right-Hand Handlebar Switch
250
Right-Hand Switch Removal
251
Left-Hand Switch Removal
252
Auxiliary Fuses
253
Fuses
253
General Fuse 30A
253
Relay Removal
254
Semiconductor Parts
254
Relay Test
255
Combined Dashboard
256
Warning Light Description
257
Clock Adjustment
258
Description of Multifunction Display
258
Setting Units of Measurement
259
Setting Parameters
260
Control Unit Removal
261
Ignition Removal
262
Rear Stop Microswitch Replacement
264
Clutch Microswitch Replacement
265
Front Stop Microswitch Replacement
266
Speed Sensor Replacement / Rear Wheel ABS
266
Stand Rotative Switch Replacement
267
Water Temperature Sensor Replacement
267
Replacement of Front Wheel ABS Sensor
268
Charging System
269
Electronic Ignition System
269
Starting System
269
Troubleshooting
269
Electrical Connectors Positioning
270
Important
274
Engine Cooling
276
Tightening Torque Figures
282
Chassis and Wheels
288
Lubrication Points (Lubricant)
290
Front Wheel
293
Removing the Front Wheel
295
Reassembling the Front Wheel
296
Rear Wheel
297
Removing the Rear Wheel (Procedure Valid for All Models)
299
Wheel Axle Warpage
300
Axle Runout over 100 MM
300
Wheel Rim Warpage
300
Rear Chain Sprocket, Secondary Drive Sprocket and Chain
301
Checking Sprocket Wear
301
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Husqvarna TR 650 TERRA 2013 Specifications
General
Brand
Husqvarna
Model
TR 650 TERRA 2013
Category
Motorcycle
Language
English
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