2013-2014 Husqvarna TR650 Strada Service & Repair Manual

TR 650 TERRA 2013 TR 650 STRADA 2013 Workshop Manual Ed. 09-2012 Rev 01

Revision Record Rev. No. Date Page Description 01 30/11/2012 a.1 Change revision. 01 30/11/2012 X.4 Tightening torque figures have been revised. 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. No reproduction in full or in part without written authorisation. 1 st edition (09-2012) - Rev. 01

a.1 simbolo TR 650 TERRA 2013 - TR 650 STRADA 2013 TR 650 TERRA (43 kW): ZKH0H11A#DV000001 TR 650 TERRA (43 kW - ABS): ZKH0H11C#DV000001 TR 650 TERRA (35 kW - ABS): ZKH0H11D#DV000001 TR 650 STRADA (43 kW - ABS): ZKH0H11E#DV000001 TR 650 STRADA (35 kW - ABS): ZKH0H11F#DV000001 TR 650 TERRA 2013 TR 650 STRADA 2013 H11657 1 Workshop Manual Ed. 09-2012 FOREWORD, TABLE OF CONTENTS 1 st edition (09-2012) - Rev. 01 Printed in Italy MODELS COVERED (from serial number onwards) Copyright by HUSQVARNA MOTORCYCLES S.R.L. BMW Group Technical Service Via Nino Bixio, 8 21024 (Varese) - Italy tel. ++39 0332 75.61.11 tel. ++39 0332 756 558 www.husqvarna-motorcycles.com Workshop Manual 1. Chassis serial number

a.2 simbolo TR 650 TERRA 2013 - TR 650 STRADA 2013 FOREWORD, TABLE OF CONTENTS Workshop Manual Ed. 09-2012 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. This publication is for the exclusive use of those HUSQVARNA technicians who have an adequate basic mechanical preparation and a good knowledge of the vehicles repair procedures. Thus much information has been intentionally omitted as it was considered superfluous. The technicians must adopt special safety procedures that they will deem necessary in order to prevent damages to the motorbike, to its components, and to people. For ease of understanding, diagrams and photographs are provided next to the text. Notes with special significance are identified as follows throughout the manual: Accident-prevention rules for operator and persons working nearby. Damage to vehicle and/or its components may result from incompliance with relevant instructions. Additional information concerning the operation covered in the text. Useful tips To prevent problems and ensure effective service work, observe the following HUSQVARNA recommendations: – before repair, evaluate the customer's description of the problem and ask the appropriate questions to clearly identify problem symptoms; – diagnose the problem and identify the causes clearly. This manual provides basic background information that must be supplemented with the operator's expertise and specific training available through HUSQVARNA held at regular periods; – plan ahead before starting work: gather any spare parts and tools to avoid unnecessary delays; – avoid unnecessary disassembly work to get to the part that needs repairing. Always read the relevant instructions and follow the disassembly sequence outlined in this manual.

a.3 simbolo TR 650 TERRA 2013 - TR 650 STRADA 2013 Workshop Manual Ed. 09-2012 FOREWORD, TABLE OF CONTENTS NOTES Unless otherwise specified, data and specifications apply to all models. Table of Contents Title Section Foreword, table of contents ................................................................................. a Important notices ................................................................................................. b General information ............................................................................................. A Maintenance ........................................................................................................B Troubleshooting .................................................................................................. C Settings and adjustments ................................................................................... D General procedures .............................................................................................E Engine settings and adjustments......................................................................... F General engine procedures ............................................................................... F1 Cylinder head removal/disassembly .................................................................. F2 Crankcase disassembly..................................................................................... F3 Engine torque figures ........................................................................................ F4 Engine parts wear limits .................................................................................... F5 Front suspension .................................................................................................. I Rear suspension.................................................................................................. J Brakes ................................................................................................................. L Electrical system................................................................................................. M Engine cooling .................................................................................................... N Tightening torque figures .....................................................................................X Chassis and wheels............................................................................................. Y

b.1 TR 650 TERRA 2013 - TR 650 STRADA 2013 b Workshop Manual Ed. 09-2012 IMPORTANT NOTICES Section

b.2 TR 650 TERRA 2013 - TR 650 STRADA 2013 IMPORTANT NOTICES Workshop Manual Ed. 09-2012 GENERAL SAFETY WARNINGS Read these general recommendations carefully before using the vehicle. Carbon monoxide Only run the engine in an open or very well ventilated area. If you do work in an enclosed area, make sure you use a fume extraction system. Exhaust emissions contain carbon monoxide, a poisonous gas which can cause loss of consciousness and even death if inhaled. Parts of the vehicle that become hot Before working on the engine and the exhaust unit, wait for them to cool down; while the vehicle is running, these parts become very hot and remain hot for some time after turning off the engine. Risk of burns - work with caution and wear suitable PPE if necessary. Fuel The fuel used to power internal combustion engines is highly flammable and explosive. Do all fuelling and maintenance operations with the engine switched off and in ventilated areas; do not smoke and avoid contact between the fuel and naked flames, sparks, etc. that may cause an explosion. Do not dispose of fuel in the environment. Keep out of reach of children. Do not tilt the vehicle excessively since this may cause fuel to leak. Engine In some cases, coolant may become inflammable and if burnt, produce invisible flames which cause burns. Do not spill coolant onto hot components like the engine or exhaust pipe, etc. since it may ignite. During maintenance work, wear latex gloves. Never leave the coolant in open containers in areas accessible to children and animals since it is toxic. DO NOT remove the radiator cap when the engine is hot; the coolant is pressurised and may cause scalding. Engine oil Do not dispose of oil in the environment since it is highly polluting. Keep out of reach of children. Wear latex gloves since prolonged contact with the skin can cause serious damage. Send used oil to special authorised recyclers in accordance with the legal requirements in force in the country where the vehicle will be used. Brake fluid Brake fluid is highly corrosive and may damage the rubber and painted parts of the vehicle. While performing maintenance work, protect your eyes by wearing special goggles and wear protective gloves. In the event of accidental contact with the eyes, rinse them with plenty of clean, running water and seek medical advice immediately. Keep out of reach of children.

b.3 TR 650 TERRA 2013 - TR 650 STRADA 2013 H11658 Workshop Manual Ed. 09-2012 IMPORTANT NOTICES Battery Recharge the battery in well ventilated areas since the battery produces toxic, highly inflammable gases when being recharged; do not smoke or use naked flames or sparks. The liquid in the battery is highly corrosive. If it comes into contact with the skin, rinse thoroughly with running water. It is extremely important to protect your eyes because even a small amount of liquid can cause irreversible damage to the eyes. If it comes into contact with the eyes, rinse thoroughly with clean, running water and if swallowed accidentally, drink plenty of water or milk. In all cases, seek medical advice immediately. The battery liquid is corrosive and should not be poured onto the painted or rubber parts. The battery liquid is highly polluting. DO NOT dispose in the environment; at the end of its service life, take the battery to the special authorised recycling centres in accordance with the legal requirements in force in the country where the vehicle will be used. Keep out of reach of children. TR 650 TERRA and TR 650 STRADA models are STREET LEGAL motorcycles; they are guaranteed exempt from functional defects and covered with legal guarantee, as far as the STANDARD CON- FIGURATION IS MAINTAINED and the suggested maintenance table shown in Section "B" is observed. * 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. The warranty becomes NULL AND VOID if the motorcycle is rented. Notes Left and right side is determined when seated on motorcycle. Z: number of teeth Unless otherwise specified, data and instructions apply to all market variants.

b.4 TR 650 TERRA 2013 - TR 650 STRADA 2013 IMPORTANT NOTICES Workshop Manual Ed. 09-2012 RECOMMENDED SHOP PRACTICES Before disassembling components or before performing repair operations, clean the motorbike removing possible mud, dust, or foreign bodies. - Put the vehicle in a well lit area; - Fasten the vehicle in a steady position so that it cannot overturn; use suitable stands and belts. - Use suitable equipment for lifting/removing heavy parts. - Use appropriate keys (not pliers) to loosen/tighten nuts and screws. - When loosening or tightening nuts or bolts, always begin with the bigger ones or from the centre. Tighten to the specified torque and follow a cross pattern or a dedicated pattern as outlined in the relevant section. - Always mark any parts or positions that might be confused upon assembly. - Use special tools where specified. - Clean thoroughly the removed components before refitting them - During the reassembly, make sure that the bearings turn freely without obstruction or without getting stuck, otherwise replace them - Always replace the seals, the sealing rings, the split pins, the screws with damaged thread, and the self-locking nuts with new parts. - Use genuine HUSQVARNA parts and the recommended lubricant brands. - At the end of a repair or periodic maintenance, test the vehicle before delivering it to the customer. Electrical parts - Disconnect the electrical component connectors by pressing the special safety hooks. - Make sure that inside the connector there is no dirt or rust; if need be, clean them with an air jet or suitable products. - Make sure that the cables are correctly seamed to the connector terminals. - When you reconnect the connectors, ensure the correct coupling. Do not disconnect the connectors by pulling the electrical cables. - Technical Bulletins might contain more up-to-date setting data and procedures than this manual. Be sure to read them. Where not specified, refit the previously removed components following the procedures in the reverse order with respect to the removal.

2013-2014 Husqvarna TR650 Strada Service & Repair Manual

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