Husqvarna TE 449 - 511 2012 I.E. Manuals

Manuals and User Guides for Husqvarna TE 449 - 511 2012 I.E.. We have 1 Husqvarna TE 449 - 511 2012 I.E. manual available for free PDF download: Workshop Manual

Husqvarna TE 449 - 511 2012 I.E. Workshop Manual (414 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 48.55 MB

Section 1

10
- Workshop Manual
  3
- Table of Contents
  10
- Timing System
  11
- Fuel System
  11
- Lubrication
  11
- Cooling
  11
- Ignition System
  11
- Transmission
  11
- Chassis
  12
- Suspension
  12
- Brakes
  13
- Wheels
  13
- Tyres
  13
- Electrical Components Location (TC)
  14
- Electrical Components Location (TXC)
  14
- Electrical Components Location (TE-SMR)
  14
  - General Information
    14
- Supplies (Reserve Included)
  15
- Overall Dimensions - Weight
  16
Section 2

40
Section 3

70
- Saddle Removal
  71
- Side Panel Removal
  71
- Txc 449 - 511 2011/2012 I.e
  71
- Tail Section Removal (TC-TE-TXC MY12)
  72
- Front Turn Indicator Removal
  73
- Rear Turning Indicator Removal
  73
- Number Plate Holder Removal (te MY12)
  74
- Front Mudguard Removal
  75
- Number Plate Holder Removal (te MY11 - SMR MY11 / MY12)
  75
- Rear Mudguard Removal (SMR MY11 / MY 12 - TE-TXC-TC MY11)
  76
- Rear Mudguard Removal (te - TXC - TC MY12)
  77
- Battery Removal
  78
- Tank Removal
  78
- Cock Removal
  82
- Fuel Pump Removal
  82
- Throttle Body Removal
  83
- Exhaust System Removal (SMR)
  86
- Exhaust System Removal (te - TXC)
  87
- Exhaust System Removal (TC)
  90
- Rear Chassis Removal
  92
- Rear Tank Removal
  94
- Solenoid Starter Removal
  94
- CDI Electronic Control Unit Removal
  95
- Voltage Regulator Removal
  95
- Coil Removal and Spark Plug Check
  96
- Clutch Hose Removal
  98
- Electric Cooling Fan Removal (te - TXC - SMR)
  99
- Horn Removal (te - SMR)
  99
- Air Filter Box Removal
  100
- Engine Guard Removal
  102
- Gear Shift Pedal Removal
  102
- Chain Slider Removal
  103
- Engine Removal
  106
- Radiator Removal
  110
Section 4

114
- Txc 449 - 511 2011/2012 I.e
  115
- Valve Clearance Check
  115
- Securing Crankshaft at TDC
  116
- Set Valve Clearance (Cylinder Head Cover Removed)
  116
- Bearing Mount Disassembly
  117
- Camshaft Assembly
  117
- Camshaft Disassembly
  117
- Valve Clearance Adjustment
  117
- Bearing Mount Assembly
  118
- Bearing Mount Securing
  118
- Valve Clearance Check
  119
Section 5

122
- Oil Filter Replacement
  
  127
  - Oil Filter Disassembly
    127
  - Oil Filter Assembly
    127
  - Engine Oil Filter Disassembly
    128
  - Engine Oil Filter Assembly
    129
- Spark Plug Recess Ignition Coil
  
  130
  - Spark Plug Recess Ignition Coil Disassembly
    130
  - Spark Plug Recess Ignition Coil Assembly
    130
- Spark Plug Recess
  
  131
  - Spark Plug Recess Disassembly
    131
  - Spark Plug Recess Assembly
    131
- Spark Plug
  
  132
  - Spark Plug Disassembly
    132
  - Spark Plug Assembly
    132
- Oil Pressure Adjustment Valve Replacement
  
  133
  - Oil Pressure Adjustment Valve Disassembly
    133
- Cylinder Head Cover
  
  134
  - Removing Cylinder Head Cover
    134
  - Fitting Cylinder Head Cover
    134
- Engine Positioning at Ignition Tdc
  
  135
  - Securing Crankshaft at TDCF
    135
- Camshaft Removal
  
  136
  - Bearing Mount Disassembly
    136
  - Camshaft Check
    136
  - Camshaft Assembly
    136
  - Bearing Mount Assembly
    137
  - Bearing Mount Securing
    137
  - Subsequent Actions
    137
- Engine Left Crankcase
  
  138
  - Engine Left Crankcase Cover Disassembly
    138
  - Engine Left Crankcase Cover Assembly
    138
- Alternator Replacement
  
  139
  - Preliminary Operations
    139
  - Flywheel Disassembly
    139
  - Stator Disassembly
    140
  - Freewheel Disassembly
    140
  - Freewheel Assembly
    140
  - Stator Assembly
    141
  - Flywheel Assembly
    141
- Crankcase Left Cover Replacement
  
  142
  - Preliminary Operations
    142
  - Stator Disassembly
    142
- Crankshaft Sensor Replacement
  
  144
  - Preliminary Operations
    144
  - Crankshaft Sensor Disassembly
    144
  - Crankshaft Sensor Assembly
    144
- Freewheel Gear Replacement
  
  145
  - Freewheel Gear Disassembly
    145
  - Freewheel Gear Assembly
    145
- Clutch Disassembly and Reassembly or Replacement
  
  146
  - Preliminary Operations
    146
  - Clutch Cover Disassembly
    146
  - Removing Clutch Pressure Plate
    146
  - Removing Clutch Plates
    147
  - Clutch Hub Disassembly
    147
  - Clutch Housing Disassembly
    147
  - Clutch Housing Clearance Check
    148
  - Clutch Housing Clearance Reading
    148
  - Clutch Housing Assembly
    150
  - Clutch Hub Assembly
    150
  - Fit Clutch Plates
    150
  - Pressure Plate Assembly
    151
  - Clutch Cover Assembly
    151
- Replacing Clutch Disengagement Bearing
  
  152
- Engine Right Crankcase
  
  153
- Clutch Thrust Washer
  
  155
  - Clutch Thrust Washer Disassembly
    155
  - Clutch Thrust Washer Assembly
    155
- Clutch Housing Axial Bearing
  
  156
  - Clutch Housing Axial Bearing Disassembly
    156
  - Clutch Housing Axial Bearing Assembly
    156
- Coolant Pump Disassembly and Assembly
  
  157
  - Coolant Pump Cover Disassembly
    157
  - Coolant Pump Rotor Disassembly
    157
  - Coolant Pump Rotor Assembly
    158
  - Coolant Pump Cover Assembly
    158
- Coolant Pump Inside Crankcase Oil Seal Replacement
  
  159
- Coolant Pump Drive Replacement
  
  160
  - Slider Loosening in the Lower Area
    160
  - Coolant Pump Shaft Disassembly
    160
  - Coolant Pump Shaft Assembly
    161
  - Slider Assembly in the Lower Area
    161
- Chain Sprocket
  
  162
  - Chain Sprocket Removal
    162
  - Sprocket Assembly
    162
- Chain Tensioner Disassembly and Reassembly or Replacement
  
  163
  - Chain Tensioner Disassembly
    163
  - Chain Tensioner Assembly
    163
- Cylinder Head Disassembly and Reassembly/Head Gasket Replacement
  
  164
  - Preliminary Operations
    164
  - Cylinder Head Disassembly
    164
  - Cylinder Head Assembly
    164
- Cylinder Head Replacement (Cylinder Head Removed)
  
  165
  - Valve Removal
    165
  - Removing Valve Spring
    166
  - Removing Valve Stem Seal
    166
  - Rocker Arm Disassembly
    167
  - Rocker Arm Shaft Disassembly
    167
  - Valve Seat Width Check
    168
  - Valve Guide Clearance Check
    168
  - Rocker Arms Shaft Assembly
    169
  - Rocker Arm Assembly
    170
  - Fitting Valve Stem Seal
    170
  - Valve Spring Assembly
    170
  - Valve Assembly
    171
- Chain Slider
  
  172
  - Chain Tensioning Slider Disassembly
    172
  - Slider Disassembly
    172
  - Chain Sliding and Tensioning Sliders Check
    172
  - Slider Assembly
    173
  - Chain Tensioner Assembly
    173
- Cylinder Disassembly and Reassembly or Replacement
  
  174
  - Preliminary Operations
    174
  - Cylinder Disassembly
    174
  - Piston Disassembly
    175
  - Cylinder Check
    175
    
    Piston Assembly
    176
  - Piston Diameter Check
    176
  - Piston Stroke Clearance Definition
    176
  - Piston Ring Assembly
    177
  - Piston with Cylinder Assembly
    177
  - Subsequent Actions
    178
- Timing Chain Disassembly and Reassembly or Replacement
  
  179
  - Preliminary Operations
    179
  - Timing Chain Disassembly
    179
  - Timing Chain Assembly
    180
  - Subsequent Actions
    180
  - Chain, Chain Sprocket Check
    180
  - Timing Chain Check
    180
  - Preliminary Operations
    181
  - Disassembly of Crankshaft Gear Pointing to Oil Pump Idler Gear
    182
  - Assembly of Crankshaft Gear Pointing Oil Pump Idler Gear
    182
  - Oil Pump Control Gear Assembly
    182
  - Preliminary Operations
    184
  - Preliminary Operations
    185
- Oil Pumps Shaft
  
  186
  - Oil Pumps Shaft Disassembly
    186
  - Oil Pumps Shaft Assembly
    186
- Replace Gearbox Control Shaft Radial Sealing Ring
  
  187
  - Preliminary Operations
    187
  - Removing Oil Seal from Gearbox Shaft
    187
  - Fitting Gearbox Shaft Oil Seal
    187
- Replacing Output Shaft Oil Seal
  
  188
- Disassembling/Assembling Starter Motor
  
  189
  - Removing Starter Motor
    189
  - Starter Motor Assembly
    189
- Starter Idle Gear Replacement
  
  190
- Starter Motor Idle Gear
  
  193
  - Starter Motor Idle Gear Disengagement
    193
  - Starter Motor Idle Gear Fitting
    193
- Crankshaft Axial Clearance Check
  
  194
- Crankshaft, Countershaft, and Relevant Bearings
  
  194
- Gearbox Shaft Replacement (Crankcase Cover Removed)
  
  218
  - Complete Selector Shaft Disassembly
    218
  - Gearbox Shaft Check
    218
  - Gearbox Shaft Complete Assembly
    218
- Selector Cylinder Replacement
  
  219
  - Selector Drum Disassembly
    219
  - Selector Drum Check
    219
  - Selector Drum Assembly
    219
- Gear Selector Fork Replacement
  
  220
  - Gear Selector Fork Disassembly
    220
  - Check Gear Selector Forks
    220
  - Gear Selector Forks Assembly
    220
  - Gearbox Assembly
    221
  - Preliminary Operations
    222
  - Gear Selector Lock Disassembly
    222
  - Gear Selector Lock Assembly
    222
- Gear Selector Lock Replacement
  
  223
  - Preliminary Operations
    223
  - Gear Selector Disassembly
    223
  - Gear Selector Assembly
    223
Section 6

226
Section 7

272
- Lubrication Points (Grease)
  273
- Rear Shock Absorber
  273
- Tightening Torque
  273
- Txc 449 - 511 2011/2012 I.e
  273
- Rear Suspension
  274
- Rear Shock Absorber Removal
  275
- Disassembling and Servicing the Swinging Arm
  276
- Linkage Disassembly
  278
- Chain Roller, Chain Guide, Chain Slider
  279
- Chain Sprocket Removal
  279
Section 8

282
Section 9

296
- Engine Wiring Diagram (TC MY11 - MY12)
  298
- Txc 449 - 511 2011/2012 I.e
  298
- Engine Wiring Diagram (TE-TXC-SMR MY11 + SMR MY12)
  300
- Engine Wiring Diagram (TE-TXC MY12)
  302
- Vehicle Wiring Diagram (te MY12)
  304
- Adapter (TXC)
  306
- Electrical Components Location (TC)
  308
- Electrical Components Location (te - SMR)
  312
- Electrical Components Location (TXC)
  319
- Generator No-Load Performance
  324
- Generator Stator Windings Resistance Inspection
  324
- Condenser Inspection
  325
- Ignition System (TC MY11)
  326
- Ignition System (te - TXC - SMR MY11 + SMR MY12)
  328
- Ignition System (te - TXC MY12)
  330
- Charging System
  332
- Charging System Wiring Diagram
  332
- Battery
  333
- Charging System Inspections
  333
- Regulated Voltage
  333
- Voltage Regulator/Rectifier Inspection
  333
- Voltage Regulator/Rectifier Wiring Diagram
  333
- Electric Starting System
  334
- No-Load Test
  335
- Solenoid Starter Inspection
  335
- Solenoid Starter Wiring Diagram
  335
- Starter Motor
  335
- Starter Motor Inspection
  335
- Starting System Inspection
  335
- Coil Windings Resistance Inspection
  336
- Electronic Control Unit (ECU)
  336
- Battery
  337
- Battery Charger
  337
- Spark Plug
  337
- Headlamp Adjustment
  338
- Headlamp Bulb Replacement (te - SMR)
  338
- Headlamp, Tail Light (te - SMR)
  338
- Turning Indicator Bulb Replacement (te - SMR)
  341
- Tail Light Replacement (te - SMR)
  342
- Handlebar Switches
  343
- Left-Hand Switch (TC)
  343
- Number Plate Bulb Replacement (te - SMR)
  343
- Left-Hand Switch (te - SMR)
  344
- Right-Hand Switch (te - TXC - SMR)
  345
- Right-Hand Switch (TC)
  346
- Fuses
  347
- Semiconductor Parts
  347
- Relay Test
  348
- Digital Dashboard, Warning Lights (te - SMR)
  350
Section 10

368
- Coolant Level Check
  369
- Txc 449 - 511 2011/2012 I.e
  369
- Cooling Circuit
  370
- Engine Cooling System Overhaul
  371
  - Hydraulic Clutch System
    375
  - Draining Clutch Fluid
    376
  - Clutch Master Cylinder Servicing
    377
  - Bleeding the Clutch System
    378
  - Fuel Injection System Tc 449 2011/2012 I.e
    381
  - Txc 449 - 511 2011/2012 I.e
    381
    
    Smr 449 2011 I.e
    381
  - Smr 511 2011/2012 I.e
    381
    
    Fuel Injection System
    383
    
    Fuel Pump Inspection
    384
Section 11

392
- Chassis
  393
- Txc 449 - 511 2011/2012 I.e
  393
- Lubrication Points (Lubricant)
  394
- Front Wheel (TC - te - TXC)
  395
- Front Wheel (SMR)
  396
- Removing the Front Wheel
  397
- Reassembling the Front Wheel
  398
- Rear Wheel (TC - te - TXC)
  401
- Rear Wheel (SMR)
  402
- Removing the Rear Wheel
  403
- Axle Runout over 100 MM
  404
- Wheel Axle Warpage
  404
- Wheel Servicing
  404
- Wheel Rim Warpage
  405
- Wheel Spokes
  405
- Rear Chain Sprocket, Secondary Drive Sprocket and Chain
  406
- Tightening Torque
  406
- Checking Pinion and Sprockets for Wear
  407

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Husqvarna TE 449 - 511 2012 I.E. Manuals

Husqvarna TE 449 - 511 2012 I.E. Workshop Manual (414 pages)

Table of Contents

Section 1

Section 2

Section 3

Section 4

Section 5

Oil Filter Replacement

Spark Plug Recess Ignition Coil

Spark Plug Recess

Spark Plug

Oil Pressure Adjustment Valve Replacement

Cylinder Head Cover

Engine Positioning at Ignition Tdc

Camshaft Removal

Engine Left Crankcase

Alternator Replacement

Crankcase Left Cover Replacement

Crankshaft Sensor Replacement

Freewheel Gear Replacement

Clutch Disassembly and Reassembly or Replacement

Replacing Clutch Disengagement Bearing

Engine Right Crankcase

Clutch Thrust Washer

Clutch Housing Axial Bearing

Coolant Pump Disassembly and Assembly

Coolant Pump Inside Crankcase Oil Seal Replacement

Coolant Pump Drive Replacement

Chain Sprocket

Chain Tensioner Disassembly and Reassembly or Replacement

Cylinder Head Disassembly and Reassembly/Head Gasket Replacement

Cylinder Head Replacement (Cylinder Head Removed)

Chain Slider

Cylinder Disassembly and Reassembly or Replacement

Timing Chain Disassembly and Reassembly or Replacement

Oil Pumps Shaft

Replace Gearbox Control Shaft Radial Sealing Ring

Replacing Output Shaft Oil Seal

Disassembling/Assembling Starter Motor

Starter Idle Gear Replacement

Starter Motor Idle Gear

Crankshaft Axial Clearance Check

Crankshaft, Countershaft, and Relevant Bearings

Gearbox Shaft Replacement (Crankcase Cover Removed)

Selector Cylinder Replacement

Gear Selector Fork Replacement

Gear Selector Lock Replacement

Section 6

Section 7

Section 8

Section 9

Section 10

Section 11

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