Husqvarna TR 650 TERRA 2013 Instruction 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 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 (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
1st 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

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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 superuous. 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 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.

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TR 650 TERRA 2013 - TR 650 STRADA 2013
Workshop Manual Ed. 09-2012
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
Engine settings and adjustments.........................................................................F
General engine procedures...............................................................................F1
Cylinder head removal/disassembly..................................................................F2
Crankcase disassembly.....................................................................................F3
Engine torque gures ........................................................................................F4
Engine parts wear limits ....................................................................................F5
Front suspension.................................................................................................. I
Rear suspension.................................................................................................. J
Brakes ................................................................................................................. L
Electrical system................................................................................................. M
Engine cooling.................................................................................................... N
Tightening torque gures.....................................................................................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 ammable 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 ames, 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 inammable and if burnt, produce invisible ames 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 uid
Brake uid 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.

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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 inammable gases when being
recharged; do not smoke or use naked ames 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 mainte-
nance 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 specied, data and instructions
apply to all market variants.

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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 specied 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 specied.
- Clean thoroughly the removed components before retting 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 specied, ret the previously removed components following the procedures in the reverse order with
respect to the removal.