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SMR 449 2011 I.E.
Husqvarna SMR 449 2011 I.E. User Manual
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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
2
Table of Contents
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
Saddle Removal
42
Side Panel Removal
42
Engine Guard Removal
44
Scoop Removal
44
Idle Adjustment (te - TXC - SMR)
46
Front Brake Lever Adjustment and Fluid Level Check (TC - te - TXC)
47
Hydraulic Clutch Lever Adjustment and Fluid Level Check
47
Front Brake Lever Adjustment and Fluid Level Check (SMR)
48
Rear Brake Pedal Free Play Adjustment
49
Rear Brake Pedal Position Adjustment
49
Engine Oil Level Check
50
Rear Brake Fluid Level Check
50
Engine Oil Replacement and Mesh Filters-Filter Cartridge Cleaning or Replacement
51
Coolant Level Check
52
Coolant Replacement
53
Air Filter Check
54
Air Filter Cleaning
54
Chain Adjustment
55
Chain Lubrication
56
Disassembling and Cleaning
56
Lubricating Chain with O-Rings (te - TXC - SMR)
56
Lubricating Chain Without O-Rings (TC)
56
Washing Chain with O-Rings (te - TXC - SMR)
56
Washing Chain Without O-Rings (TC)
56
Suspension Setup According to Track Condition
57
Shock Absorber Adjustment
58
Shock Absorber Spring Preload Adjustment (TE-TC-TXC)
59
Shock Absorber Spring Preload Adjustment (SMR)
60
Shock Absorber Damping Adjustment
61
KAYABA Fork Adjustment (TC - te - TXC)
62
Fork Oil Level (TC - te - TXC)
63
Fork Oil Level (SMR)
64
Marzocchi Fork Adjustment (SMR)
64
Steering Angle Adjustment
65
Steering Bearing Clearance Adjustment
65
Fuel Supply Hose Inspection
66
Exhaust System Check
67
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
Preliminary Operations
152
Clutch Disengagement Bearing Disassembly
152
Clutch Disengagement Bearing Assembly
152
Checking the Clutch Pack Thickness
152
Engine Right Crankcase
153
Preliminary Operations
153
Engine Right Crankcase Cover Disassembly
153
Engine Right Crankcase Assembly
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 Control Rear Oil Seal Disassembly
159
Coolant Pump Control Shaft Check
159
Coolant Pump Control Rear Oil Seal Assembly
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
Gearbox Output Shaft Left Oil Seal Disassembly
188
Gearbox Output Shaft Right Oil Seal Disassembly
188
Gearbox Output Shaft Right Oil Seal Assembly
188
Gearbox Output Shaft Left Oil Seal Assembly
188
Disassembling/Assembling Starter Motor
189
Removing Starter Motor
189
Starter Motor Assembly
189
Starter Idle Gear Replacement
190
Preliminary Operations
190
Gear Disassembly with Starter Motor Protected against Overload
190
Starter Motor Idle Gear Disassembly
190
Freewheel Gear Disassembly
191
Starter Motor Idle Gear Fitting
192
Gear Assembly with Starter Motor Protected against Overload
192
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
Preliminary Operations
194
Crankcase Left Half Disassembly
194
Control Gear Disassembly
195
Remove Crankshaft and Countershaft
195
Crankshaft Right Bearing Bushing Disassembly
196
Crankshaft for Countershaft Gear Disassembly
196
Crankshaft Left Bearing Bushing Disassembly
197
Crankshaft Axial Clearance Adjustment
197
Crankshaft Wear Check
198
Connecting Rod Wear Check
198
Crankshaft Replacement
198
Crankshaft Axial Clearance Adjustment, Left Side
199
Crankshaft Axial Clearance Adjustment, Right Side
199
Crankshaft Left Bearing Disassembly
200
Crankshaft Right Bearing Disassembly
200
Crankshaft Left Bearing Assembly
200
Crankshaft Right Bearing Assembly
201
Countershaft Right Bearing Disassembly
201
Countershaft Left Bearing Disassembly
201
Countershaft Left Bearing Assembly
202
Countershaft Right Bearing Assembly
202
Crankshaft Left Bearing Bushing Assembly
203
Oil Pump Gear Assembly Onto Crankshaft
203
Crankshaft Right Bearing Bushing Assembly
204
Control Gear Assembly
204
Assemble Crankshaft and Countershaft
204
Preliminary Operations
205
Gearbox Disassembly
205
Gearbox Check
205
Disassembly/Reassembly of the Gearbox (5 Speed) (TC)
206
Input Shaft (6 Speed) (TC)
207
Output Shaft (6 Speed) (TC)
207
Disassembly/Reassembly of the Gearbox (6 Speed) (TE-TXC-SMS)
208
Input Shaft (6 Speed) (TE-TXC-SMS)
209
Output Shaft (6 Speed) (TE-TXC-SMS)
209
Gearbox Oil Pipe Disassembly
210
Gearbox Oil Pipe Assembly
210
Gearbox Input Shaft Right Bearing Disassembly
210
Gearbox Input Shaft Left Bearing Disassembly
210
Gearbox Output Shaft Right Bearing Disassembly
211
Gearbox Output Shaft Left Bearing Disassembly
211
Gearbox Shaft Right Bearing Disassembly
212
Gearbox Shaft Left Bearing Disassembly
212
Gearbox Input Shaft Idler Gear Bearing Disassembly
212
Gearbox Input Shaft Idler Gear Bearing Assembly
213
Gearbox Shaft Left Bearing Assembly
213
Gearbox Output Shaft Left Bearing Assembly
214
Gearbox Output Shaft Right Bearing Assembly
214
Gearbox Shaft Right Bearing Assembly
214
Gearbox Input Shaft Left Bearing Assembly
215
Gearbox Input Shaft Right Bearing Assembly
215
Clutch Check Inside Primary Drive Unit
215
Idler Gear Disassembly
217
Idler Gear Assembly
217
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
Front Fork Removal
227
Txc 449 - 511 2011/2012 I.e
227
Front Suspension (TC - TXC)
229
Service Instructions for Ø48USD Kayaba Fork
229
Front Fork Disassembly (TC - TXC)
231
Front Suspension (TE)
241
Front Fork Disassembly (TE)
242
Instructions for Use of Ø50Usd Fork (SMR)
251
Front Suspension (SMR)
252
Components of the Fork
253
General Rules for a Proper Overhauling
254
Instructions for Clamping in the Vice
255
Problems - Possible Causes - Solutions
256
Bleeding the Air
257
Cleaning the Dust Seal
257
Draining the Oil
258
Braking down the Pumping Element and the Bottom Valve
259
Braking down the Fork Leg - Slider and Removing the Oil Seals
261
Cartridge Overhauling (Rebound Braking)
262
Overhauling and Modifying the Cartridge and Bottom Valve Setting
262
Bottom Valve Overhauling (Compression Braking)
263
Re- Assembling the Fork Leg - Slider and Oil Seals
264
Re- Assembling the Pumping Element Unit and the Bottom Valve
266
Filling with Oil
269
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
Braking System
283
Txc 449 - 511 2011/2012 I.e
283
Checking Brake Pads for Wear / Replacing the Pads (TC-TE-TXC)
286
Checking Brake Pads for Wear / Replacing the Pads (SMR)
287
Bleeding the Front Braking System (TC-TE-TXC)
288
Bleeding the Rear Braking System
290
Changing the Fluid
291
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
4
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Husqvarna SMR 449 2011 I.E. Specifications
General
Brand
Husqvarna
Model
SMR 449 2011 I.E.
Category
Motorcycle
Language
English
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