Husqvarna 2011 SMS 630 Instruction manual

TE 630 / 2011 I.E.
SMS 630 / 2011 I.E.
Part. N. 8000 H2051 (02-2010)
Workshop Manual

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 reect on-going product development. Illustrations in the ma-
nual may differ from actual components. No reproduction in full or in part
without written authorisation.
1st edition (02-2010)

a.1Part. N. 8000 H2051 (02-2010)
1
FOREWORD, TABLE OF CONTENTS
1st edition (02-2010)
Printed in Italy
Print no. 8000 H2051
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
TE 630: ZKHA4 01AA B V 000001
TE 630 (USA): ZKHKD EKP# B V 000001
SMS 630: ZKHA4 01AB B V 000001
SMS 630 (USA): ZKHLD EKP# B V 000001
1. Chassis serial number
TE 630 / 2011 I.E.
SMS 630 / 2011 I.E.

a.2 Part. N. 8000 H2051 (02-2010)
FOREWORD, TABLE OF CONTENTS
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 complement
to operator training and operators should become thoroughly familiar with it.
For ease of understanding, diagrams and photographs are provided next to the text.
Notes with special signicance are identied 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 specic 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.
Recommended shop practices
1 Always replace gaskets, sealing rings and split pins with new ones.
2 When loosening or tightening nuts or bolts, always begin with the bigger ones or from the centre. Tighten to the spe-
cied torque and follow a cross pattern.
3 Always mark any parts or positions that might be confused upon assembly.
4 Use genuine HUSQVARNA parts and the recommended lubricant brands.
5 Use special tools where specied.
6 Technical Bulletins might contain more up-to-date setting data and procedures than this manual. Be sure to read
them.
IMPORTANT: Where not specied, reassembled components must be tightened to the proper torque as indicated
in the tables provided in Chapter "x".

a.3Part. N. 8000 H2051 (02-2010)
FOREWORD, TABLE OF CONTENTS
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 Disassembly............................................................................................F
Engine Overhaul................................................................................................. G
Engine Reassembly............................................................................................ H
Front Suspension ................................................................................................. I
Rear Suspension................................................................................................. J
Brakes ................................................................................................................. L
Electrical System ................................................................................................ M
Engine Cooling ................................................................................................... N
Hydraulically Controlled Clutch............................................................................P
Optional Components......................................................................................... Q
Fuel Injection System ..........................................................................................S
Special Tools ......................................................................................................W
Tightening Torque Figures ...................................................................................X
Chassis and Wheels............................................................................................Y
NOTES
Unless otherwise specied, data and specications apply to all models.

b.1Part. N. 8000 H2051 (02-2010)
b
IMPORTANT NOTICES
Section

b.2 Part. N. 8000 H2051 (02-2010)
TE
SMS
IMPORTANT NOTICES
TE and SMS models are STREET LEGAL motorcycles; they are guaranteed
exempt from functional defects and covered with legal guarantee, as far as the
STANDARD CONFIGURATION IS MAINTAINED and the suggested maintenance
table shown in Section "B" is observed.
IMPORTANT
VEHICLE CONFIGURATION as outlined below is a prerequisite for the warranty
to remain valid:
A) STANDARD MOTORCYCLE, FOR ROAD USE.
* 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
A: Austria
AUS: Australia
B: Belgium
BR: Brazil
CDN: Canada
CH: Switzerland
D: Germany
E: Spain
F: France
FIN: Finland
GB: Great Britain
I: Italy
J: Japan
USA: United States of America
Unless otherwise specied, data and instructions apply to all market variants.

A.1Part. N. 8000 H2051 (02-2010)
A
GENERAL INFORMATION
Section

A.2 Part. N. 8000 H2051 (02-2010)
GENERAL INFORMATION
Engine ..........................................................................................................A.3
Timing system ..............................................................................................A.3
Fuel system ..................................................................................................A.3
Lubrication....................................................................................................A.3
Cooling .........................................................................................................A.3
Ignition system..............................................................................................A.3
Starter ..........................................................................................................A.3
Drive and Transmission................................................................................A.3
Chassis.........................................................................................................A.4
Suspension...................................................................................................A.4
Brakes ..........................................................................................................A.4
Wheels..........................................................................................................A.4
Tyres.............................................................................................................A.5
Electrical components location.....................................................................A.5
Overall dimensions - Weight.........................................................................A.6
Capacities.....................................................................................................A.7

A.3Part. N. 8000 H2051 (02-2010)
GENERAL INFORMATION
Engine
Type.............................................................................. single cylinder, 4 stroke
Cooling ............................................ Liquid with double radiator and heater fan
Bore.......................................................................................................100 mm
Stroke ...................................................................................................76.4 mm
Displacement..................................................................................... 600 cu.cm
Compression ratio ...................................................................................12.4:1
Starting .................................................................................................. electric
Timing system
Type ................................. double overhead camshaft chain operated; 4 valve
Valve clearance ( cold with engine)
Intake.........................................................................................0.10 ÷ 0.15 mm
Exhaust......................................................................................0.15 ÷ 0.20 mm
Fuel system
Type..............................................................................Electronic injection feed
Air cleaning: dry air lter
Lubrication
Type................. Dry sump with positive displacement pump and cartridge lter
Cooling
Liquid with double radiator and electric fan
Coolant capacity..................................................................................1.2 Litres
Ignition system
Type....................................................................................Electronic, inductive
with adjustable advance (digital control)
Spark plug type..............................................................................NGK CR8EB
Spark plug gap ............................................................................. 0.7 - 0.8 mm
Drive and transmission
Clutch: oil bath multiple disc clutch, hydraulic control
Transmission: constant mesh gear type
Motion is transmitted from engine to gearbox primary shaft through spur gears
Primary drive
Drive pinion gear ......................................................................................... Z 32
Clutch ring gear ..........................................................................................Z 75
Transmission ratio .................................................................................... 2.343
Gear ratios:
Type.............................................................................constant mesh gear type
Transmission ratio
(TE)
1st gear.......................................................................................2.615 (z 34/13)
2nd gear .....................................................................................1.812 (z 29/16)
3rd gear ...................................................................................... 1.350 (z 27/20)
4th gear ......................................................................................1.091 (z 24/22)
5th gear ......................................................................................0.916 (z 22/24)
6th gear ......................................................................................0.769 (z 20/26)
FINAL RATIOS (SMS)
1st gear.......................................................................................2.615 (z 34/13)
2nd gear .....................................................................................1.812 (z 29/16)
3rd gear ...................................................................................... 1.350 (z 27/20)
4th gear ......................................................................................1.091 (z 24/22)
5th gear ......................................................................................0.957 (z 22/23)
6th gear ......................................................................................0.880 (z 22/25)

A.4 Part. N. 8000 H2051 (02-2010)
GENERAL INFORMATION
Secondary drive
Motion is transmitted from gearbox to rear wheel by 5/8" x 1/4" nal drive chain ("D.I.D." 520 DS or "REGINA" 135 RX3)
Transmission sprocket ............................................................................... .Z 15
Rear wheel sprocket (TE)............................................................................ Z 42
Rear wheel sprocket (SMS)......................................................................... Z 38
Transmission ratio (TE) ............................................................................. 2.800
Transmission ratio (SMS) .......................................................................... 2.533
Transmission chain dimensions ...........................................................5/8”x1/4”
Final ratios
(TE)
1st gear.................................................................................................... 17.163
2nd gear .................................................................................................. 11.894
3rd gear ..................................................................................................... 8.859
4th gear ..................................................................................................... 7.159
5th gear ..................................................................................................... 6.016
6th gear ..................................................................................................... 5.048
(SMS)
1st gear.................................................................................................... 15.529
2nd gear .................................................................................................. 10.762
3rd gear ..................................................................................................... 8.016
4th gear ..................................................................................................... 6.477
5th gear ..................................................................................................... 5.679
6th gear ..................................................................................................... 5.225
Chassis
Type.................single frame, in circular sectioned tubes, in steel; rear chassis in squared sectioned tubes in light alloy.
Suspension
Front
Type “Upside-down” telescopic hydraulic front fork with advanced axle (adjustable in rebound stroke); tubes ø 45 mm
Leg axis stroke (TE) .............................................................................. 270 mm
Leg axis stroke (SMS) ........................................................................... 250 mm
Rear
Type.................progressive with hydraulic single shock absorber
(preload regulation of spring and hydraulic brake in compression and extension)
Wheel stroke (TE).................................................................................. 320 mm
Wheel stroke (SMS) .............................................................................. 290 mm
Brakes
Front
Type (TE).......................................................................... xed disc Ø 260 mm
with hydraulic control and oating calliper
Type (SMS).................................................................... oating disk Ø 320 mm
with hydraulic command and radial xed calliper
Rear
Type.................xed disc Ø 220 mm with hydraulic control and oating calliper
Wheels
Rims
Front (TE) ......................................................................... in light alloy: 1.6”x21”
Front (SMS).................................................................... in light alloy: 3.50”x17”
Rear (TE)........................................................................ in light alloy: 2.15”x18”
Rear (SMS)..................................................................... in light alloy: 4.25”x17”

A.5Part. N. 8000 H2051 (02-2010)
GENERAL INFORMATION
Tyres
Front
(TE)..................................................................................................... 90/90x21”
(SMS) ............................................................................................... 120/70x17”
Rear
(TE)................................................................................................... 140/80x18”
(SMS) ............................................................................................... 150/60x17”
Cold tyre pressure (TE)
Front
Rider only ..........................................................................................1.2 Kg/cm2
Rider and passenger ........................................................................1.5 Kg/cm2
Rear
Rider only ..........................................................................................1.5 Kg/cm2
Rider and passenger ........................................................................1.8 Kg/cm2
Cold tyre pressure (SMS)
Front
Rider only ..........................................................................................1.8 Kg/cm2
Rider and passenger .........................................................................2.0 Kg/cm2
Rear
Rider only ..........................................................................................2.0 Kg/cm2
Rider and passenger .........................................................................2.2 Kg/cm2
ELECTRICAL COMPONENTS LOCATION
The ignition system includes the following elements:
- Generator on the inner side of L.H. crankcase half cover;
- Electronic ignition coil under the fuel tank;
- Electronic control unit under the saddle;
- Voltage regulator on the R.H. side of the rear chassis;
- Spark plug on the R.H. side of the cylinder head;
- 12V-700W starter motor behind the engine cylinder;
- Solenoid starter located on the fuse holder plate, under the saddle;
- M.A.Q.S. sensor (pressure, throttle position, air temperature) on throttle body.
The electrical system includes the following elements:
- 12V-14Ah battery under the saddle;
- Turning indicators asher located on the utilities holder plate, under the saddle;
- Relays located on the utilities holder plate, under the saddle;
- Electric fan relay;
- Injector, Lambda sensor, fuel pump, coil relay;
- Horn, turning indicators, stop lights, low and high beam lights relay;
- Electric fan;
- Fuses located on the utilities holder plate, under the saddle;
- Fuse FP- 15A (cable sheath marked “P”): fuel pump, HT coil, lambda sensor heater, injector;
- Fuse FM- 15A (cable sheath marked “M”): 12V depending on ignition switch, (system voltage), parking lights;
- Fuse FDC- 20A (cable sheath marked “DC”): electric fan, rear stop light, high beam, low beam, turning indicators, horn, instru-
ment panel power supply (instrument functions display).
- Rollover sensor (SMS) located on the utilities holder plate, under the saddle;
- Coolant temperature sensor;
- Lambda sensor;
- Headlamp with 12V-60/55W twin halogen bulb and 12V-5W parking light bulb;
- LED tail light;
- 12V-10W turning indicator bulbs;
- Fuel pump inside the fuel tank.

A.6 Part. N. 8000 H2051 (02-2010)
GENERAL INFORMATION
Overall dimensions - Weight
Kerb weight, without fuel
(TE):.......................................................................................150 Kg (330.69 lb)
(SMS): ...................................................................................158 Kg (348.33 lb)
*: max. width

A.7Part. N. 8000 H2051 (02-2010)
GENERAL INFORMATION

A.8 Part. N. 8000 H2051 (02-2010)
GENERAL INFORMATION
Capacities Type Quantity
Fuel tank including reserve 98 octane unleaded fuel 12 litres (3.17 GAL)
Reserve fuel (warning light goes on) 2.5 litres (0.66 GAL)
Gearbox/engine oil CASTROL POWER 1 RACING 10W-50 2 litres (0.53 GAL)
(oil change and oil lter
replacement)
Gearbox/engine oil CASTROL POWER 1 RACING 10W-50 1.8 litres (0.48 GAL)
(oil change)
Front fork oil CASTROL SYNTHETIC FORK OIL 5W 610 cc (37.22 CU IN)
Rear shock absorber oil CASTROL SYNTHETIC FORK OIL 5W
Coolant CASTROL MOTORCYCLE COOLANT 1.2 litres (0.27 GAL)
Brake system uid CASTROL RESPONSE SUPER DOT 4
Clutch uid CASTROL FORK OIL 10W
Secondary drive chain lubrication CASTROL CHAIN LUBE RACING
Grease lubrication CASTROL LM GREASE 2
Electric contact protection CASTROL METAL PARTS CLEANER
Fillers for radiator AREXONS LIQUID FILLER
Air lter oil CASTROL FOAMAIR FILTER OIL
Air lter cleaner CASTROL FOAMAIR FILTER CLEANER
IMPORTANT - Do not add any additives to fuel or lubricants.

B.1Part. N. 8000 H2051 (02-2010)
B
MAINTENANCE
Section

B.2 Part. N. 8000 H2051 (02-2010)
MAINTENANCE
SCHEDULED MAINTENANCE CHART
(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
TE - SMS
- STANDARD MOTORCYCLE, FOR ROAD USE
(DERATED)
AFTER FIRST
1000 KM
AFTER FIRST
5000 KM
AFTER FIRST
10000 KM
AFTER FIRST
15000 KM
AFTER FIRST
20000 KM
REPLACE
AS
REQUIRED
PART SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
VALVES
C (*) C (*) C (*) C (*) C (*)
INTAKE/EXHAUST ROCKER ARMS C C
TIMING CHAIN S
TIMING CHAIN SLIDER S
TIMING DRIVEN GEAR S
SPARK PLUG P S P S
SPARK PLUG CAP CCCC
ENGINE OIL SSSSS
ENGINE OIL INTAKE FILTER PPP
CLUTCH CUSH DRIVE DAMPER C C
ENGINE OIL FILTER CARTRIDGE SSS
AIR FILTER P P/S (**) S P/S (**) S
CLUTCH AND BRAKE FLUIDS CCSCS
BRAKE HYDRAULIC CONTROLS CCCCC
BRAKE PADS WEAR C C S
BOWDEN CABLES CPPPP
THROTTLE CONTROL CCCCC
TYRE PRESSURE AND WEAR CCCCC
ELECTRIC FAN C C CC
HEADLAMP BEAM
HEIGHT
C
LIGHTS/INDICATIONS/HORN CCCCC
BATTERY CCCC
WHEEL SPOKES TENSION C C C C CC
STEERING BEARINGS PLAY
CCC
SECONDARY DRIVE CHAIN/TENSIONER
ROLLERS
CL CL S CL S
CHAIN
CL CL S CL S
SIDE STAND SCREWS CCCCC
REAR CHAIN SPROCKET/TRANSMISSION
SPROCKET
CSCS

B.3Part. N. 8000 H2051 (02-2010)
MAINTENANCE
SCHEDULED MAINTENANCE CHART
(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
TE - SMS
- STANDARD MOTORCYCLE, FOR ROAD USE
(DERATED)
AFTER FIRST
1000 KM
AFTER FIRST
5000 KM
AFTER FIRST
10000 KM
AFTER FIRST
15000 KM
AFTER FIRST
20000 KM
REPLACE
AS
REQUIRED
PART SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
WHEEL HUB BEARINGS
C C
FRONT FORK OIL
S/R S/R
OVERALL TIGHTENING OF NUTS AND BOLTS
CCCCC
LUBRICATION/GREASING
LLLLL
LEGEND
C: CHECK
C (*): CHECK CLEARANCE
P: CLEAN
P/S (**): CLEAN OR CHANGE (depending on the conditions of use of the motorcycle)
S: REPLACE
L: LUBRICATION
R: FORK OVERHAUL
NOTES:
- REPLACE GASKETS AND SEALS AFTER EACH REMOVAL;
- REPLACE SCREWS AND BOLTS IF DAMAGED;
- PERFORM A GENERAL INSPECTION AFTER RIDING ON MUDDY OR SANDY TERRAIN.