Husqvarna SMR 511 2012 I.E. Instruction manual

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

Revision Record
Rev. No. Date Page Description
01 11/06/2012 Chapter B Inserted " Tables of periodic maintenance MY11".
01 11/06/2012 D.20 "Shock absorber adjustment": Inserted different values for models and Model
year
01 11/06/2012 D.21 "Shock absorber spring preload adjustment (TE-TC-TXC): Inserted different
values for models and Model year
01 11/06/2012 D.23 "Shock absorber damping adjustment"): Inserted different values for models
and Model year
01 11/06/2012 D.24 "KAYABAfork adjustment (TC - TE - TXC)": Inserted different values for models
and Model year
01 11/06/2012 D.25 "Fork oil level (TC - TE - TXC)": Inserted different values for models and
Model year
01 11/06/2012 D.26 "Fork oil level (SMR)": Inserted different values for models and Model year
01 22/06/2012 M.2 Updated index cause correction applied on page M.56
01 22/06/2012 M.3 Updated index cause corrections applied on pages M.58 - M.59
01 22/06/2012 M.56
M.57
M.58
M.59
"Digital dashboard, warning lights (TE - SMR)": Inserted different instructions
for models and Model year;
"Digital dashboard drawings": Applied correction;
"Instructions for the instrument setting": Inserted new note.
02 18/07/2012 D.12 "Engine oil level check": modied procedure in the paragraph.
02 18/07/2012 D.14 "Engine oil replacement and mesh lters-lter cartridge cleaning or replace-
ment": modied procedure in the paragraph.
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 manual may differ from
actual components. No reproduction in full or in part without written authorisation.
1st edition (03-2012) - Rev. 02

a.1
simbolo
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.
MY11
TC 449: ZKHA600AABV050001
TC 449 (USA): ZKHTC443#BV000001
TE 449: ZKHA600AABV000001
TE 511: ZKHA601AABV000001
TE 449: (USA): ZKHKEEFM#BV000001
TE 511: (USA): ZKHKEEGM#BV000001
TXC 449: (USA): ZKHTX440#BV000001
TXC 511: (USA): ZKHTX510#BV000001
SMR 499: ZKHA600ABBV000001
SMR 499 (USA): ZKHLEEFM#BV000001
SMR 511: ZKHA601ABBV000001
SMR 511 (USA): ZKHLEEGM#BV000001
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.
MY12
TC 449: ZKHA600AABV050001
TC 449 (USA): ZKHTC443#BV000001
TE 449: ZKHA600AABV000001
TE 511: ZKHA601AABV000001
TE 449: (USA): ZKHKEEFM#BV000001
TE 511: (USA): ZKHKEEGM#BV000001
TXC 449: (USA): ZKHTX440#BV000001
TXC 511: (USA): ZKHTX510#BV000001
SMR 511: ZKHA601ABBV000001
SMR 511 (USA): ZKHLEEGM#BV000001
Workshop Manual Ed. 03-2012
FOREWORD, TABLE OF CONTENTS
1st edition (03-2012) - Rev. 02
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
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.
FOREWORD, TABLE OF CONTENTS
Workshop Manual Ed. 03-2012
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.
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 speci-
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.

a.3
simbolo
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
FOREWORD, TABLE OF CONTENTS
NOTES
Unless otherwise specied, data and specications 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
Adjustments - engine ...........................................................................................F
Engine disassembly/reassembly .......................................................................F1
Front suspension .................................................................................................. I
Rear suspension.................................................................................................. J
Brakes ................................................................................................................. L
Electrical system................................................................................................. M
Engine cooling .................................................................................................... N
Hydraulically controlled clutch .............................................................................P
Fuel injection system ...........................................................................................S
Tightening torque gures .....................................................................................X
Chassis and wheels.............................................................................................Y
Notes for USA/CDN .............................................................................................Z

b.1
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.
b
Workshop Manual Ed. 03-2012
IMPORTANT NOTICES
Section

b.2
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.
H006104
TC
H06374
SMR
H006106
TXC
H006105
TE
IMPORTANT NOTICES
Workshop Manual Ed. 03-2012
1) TC and TXC models are RACING motorcycles and are warranted to be free
from operating defects; a scheduled maintenance chart for racing use is provided
in Section B.
2) The TE and SMR models are for ROAD USE; it is warranted to free from
defects and covered by legal warranty, provided that the STANDARD CON-
FIGURATION IS MAINTAINED and the maintenance chart provided in Section
B is observed.
* This motorcycle has not been designed to travel over long distances with the
engine at top rpm, as in long-distance road or highway travel. Riding over long
distances at full throttle may result in severe engine damage.
* ALWAYS remember that these motorcycles are specically designed for
racing, i.e. for usage conditions signicantly different from those experienced
in regular 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.1
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.
A
Workshop Manual Ed. 03-2012
GENERAL INFORMATION
Section

A.2
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.
GENERAL INFORMATION
Workshop Manual Ed. 03-2012
Sommario
Engine ..........................................................................................................A.3
Timing system ..............................................................................................A.3
Fuel system ..................................................................................................A.3
Lubrication ....................................................................................................A.3
Cooling .........................................................................................................A.3
Ignition system..............................................................................................A.3
Starting .........................................................................................................A.3
Transmission ................................................................................................A.3
Chassis .........................................................................................................A.4
Suspension ...................................................................................................A.4
Brakes ..........................................................................................................A.5
Wheels..........................................................................................................A.5
Tyres .............................................................................................................A.5
Electrical components location (TC) .............................................................A.6
Electrical components location (TXC) ..........................................................A.6
Electrical components location (TE-SMR) ....................................................A.6
Supplies (reserve included) ..........................................................................A.7
Overall dimensions - Weight .........................................................................A.8