Husqvarna TR 650 TERRA 2013 Instruction manual

TR 650 TERRA 2013
TR 650 STRADA 2013
Workshop Manual Ed. 09-2012
Rev 00

Revision Record
Rev. No. Date Page Description
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. 00

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. 00
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
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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.

a.3
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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.

b.3
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.

b.4
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.

A.1
TR 650 TERRA 2013 - TR 650 STRADA 2013
A
Workshop Manual Ed. 09-2012
GENERAL INFORMATION
Section

A.2
TR 650 TERRA 2013 - TR 650 STRADA 2013
GENERAL INFORMATION
Workshop Manual Ed. 09-2012
Sommario
Engine ..........................................................................................................A.3
Timing system ..............................................................................................A.3
Lubrication....................................................................................................A.3
Ignition..........................................................................................................A.3
Fuel system ..................................................................................................A.3
Primary drive ................................................................................................A.3
Clutch ...........................................................................................................A.3
Transmission ................................................................................................A.3
Transmission ratio ........................................................................................A.3
Secondary drive............................................................................................A.3
Final ratios....................................................................................................A.4
Chassis.........................................................................................................A.4
Front suspension..........................................................................................A.4
Rear suspension...........................................................................................A.4
Front brake ...................................................................................................A.4
Rear brake....................................................................................................A.4
Wheels..........................................................................................................A.4
Tyres.............................................................................................................A.4
Table for lubrication, supplies .......................................................................A.5
Electrical components location.....................................................................A.5
Dimensions, weight, capacity .......................................................................A.6

A.3
TR 650 TERRA 2013 - TR 650 STRADA 2013
Workshop Manual Ed. 09-2012
GENERAL INFORMATION
Engine
Single cylinder, 4 stroke engine with four valves
Cooling .............................................................................liquid and electric fan
Bore...................................................................................... 3,937 in (100 mm)
Stroke ..................................................................................... 3,268 in (83 mm)
Displacement..................................................................... 39,787 in3(652 cm3)
Compression ratio ..................................................................................12,3:1
Starting .................................................................................................. electric
Type of fuel ............................................................. unleaded fuel 95ROZ/RON
Timing system
Double overhead camshaft chain operated; 4 valves
Valve clearance (with engine cold)
Intake............................................................0,009 ÷ 0,011 in (0,23 ÷ 0,28 mm)
Exhaust........................................................ 0,015 ÷ 0,017 in (0,38 ÷ 0,43 mm)
Lubrication
Dry sump with tank integrated in the chassis and cartridge oil lter.
Ignition
Electronic with adjustable advance (digital control)
Spark plug type................................................................ “NGK” MAR9A-J-G06
Spark plug electrode gap....................................................0,024 in (± 0,004 in)
0,6 mm (± 0,1 mm)
Fuel system
Electronic injection feed
Primary drive
Drive gear on crankshaft ............................................................................ Z 37
Driven gear on clutch housing.................................................................... Z 72
Transmission ratio ....................................................................................1.946
Clutch
Multidisc in oil bath with mechanical control
Transmission
With front couplings always engaged
Transmission ratio
1st gear......................................................................................... 2.750 (33/12)
2nd gear ....................................................................................... 1.750 (28/16)
3rd gear ........................................................................................ 1.313 (21/16)
4th gear ........................................................................................ 1.045 (23/22)
5th gear ........................................................................................ 0.875 (21/24)
Secondary drive
Transmission sprocket ............................................................................... Z 16
Rear wheel sprocket................................................................................... Z 47
Transmission ratio ....................................................................................2.938
Drive chain dimensions ..........................................................520KR0 112 links
Sommario
Engine ..........................................................................................................A.3
Timing system ..............................................................................................A.3
Lubrication....................................................................................................A.3
Ignition..........................................................................................................A.3
Fuel system ..................................................................................................A.3
Primary drive ................................................................................................A.3
Clutch ...........................................................................................................A.3
Transmission ................................................................................................A.3
Transmission ratio ........................................................................................A.3
Secondary drive............................................................................................A.3
Final ratios....................................................................................................A.4
Chassis.........................................................................................................A.4
Front suspension..........................................................................................A.4
Rear suspension...........................................................................................A.4
Front brake ...................................................................................................A.4
Rear brake....................................................................................................A.4
Wheels..........................................................................................................A.4
Tyres.............................................................................................................A.4
Table for lubrication, supplies .......................................................................A.5
Electrical components location.....................................................................A.5
Dimensions, weight, capacity .......................................................................A.6

A.4
TR 650 TERRA 2013 - TR 650 STRADA 2013
GENERAL INFORMATION
Workshop Manual Ed. 09-2012
Final ratios
1st gear....................................................................................................15.722
2nd gear ..................................................................................................10.005
3rd gear ....................................................................................................7.506
4th gear .....................................................................................................5.974
5th gear .....................................................................................................2.898
Chassis
Single frame, in round, rectangular and ellipsoidal steel pipes; rear steel chassis
Front suspension
Upside down type hydraulic fork..............................ø 1.81 in (46 mm) fork legs
Wheel travel ........................................................................... 7.48 in (190 mm)
Rear suspension
Hydraulic monoshock (adjustment of spring preload and rebound hydraulic
damping)
Wheel travel ........................................................................... 7.48 in (190 mm)
Front brake
Ø 11,811 in (300 mm) xed disc with hydraulic control and oating calliper
Rear brake
Ø 9,449 in (240 mm) oating wave disc with hydraulic control and oating calliper
Wheels
TR 650 STRADA
Front .................................................................................in light alloy: 2.5”x19”
Rear.....................................................................................in light alloy: 3”x17”
TR 650 TERRA
Front ................................................ with spokes and aluminium rim: 1.85”x21”
Rear.......................................with spokes and aluminium rim: 3”x18” (no ABS)
with spokes and aluminium rim: 3”x17” ( ABS)
Tyres
TR 650 STRADA
Front ............................................................................... 110/80 R19” M/C 59 V
Rear................................................................................140/80 R17” M/C 59 V
Cold tyre pressure (Rider only)
Front ................................................................................2.2 kg/cm2(31.29 psi)
Rear.................................................................................2.0 kg/cm2(28.45 psi)
Cold tyre pressure (Rider and passenger)
Front ................................................................................2.2 kg/cm2(31.29 psi)
Rear.................................................................................2,5 kg/cm2(35.56 psi)
TR 650 TERRA
Front ....................................................................90/90 21” M/C 54 H TL (ABS)
90/90 21” M/C 54 S (no ABS)
Rear........................................................................140/80 17” M/C 59 H (ABS)
140/80 18” M/C 70 S (no ABS)
Cold tyre pressure (Rider only)
Front ................................................................................2.0 kg/cm2(28.45 psi)
Rear.................................................................................2.5 kg/cm2(35.56 psi)
Cold tyre pressure (Rider and passenger)
Front ................................................................................2,0 kg/cm2(28.45 psi)
Rear.................................................................................2,8 kg/cm2(39.82 psi)

A.5
TR 650 TERRA 2013 - TR 650 STRADA 2013
Workshop Manual Ed. 09-2012
GENERAL INFORMATION
Table for lubrication, supplies
Engine, gearbox and primary drive
lubricating oil................................ CASTROL POWER1 RACING SAE 10W-50
Engine coolant ..................................... CASTROL MOTORCYCLE COOLANT
Brake uid ...........................................CASTROL RESPONSE SUPER DOT 4
Grease lubrication ....................................................CASTROL LM GREASE 2
Secondary drive chain lubrication................ CASTROL CHAIN LUBE RACING
Electric contact protection ......................CASTROL METAL PARTS CLEANER
Electrical components location
The ignition system includes the following elements:
- Generator on the inner side of R.H. crankcase half cover;
- Electronic ignition coil with integrated spark plug cap positioned on cylinder head;
- Electronic control unit on rear chassis under saddle;
- Spark plug on cylinder head;
- Starter motor in front of cylinder block;
- Solenoid starter on rear chassis under saddle;
- Potentiometer on throttle body;
- Voltage regulator on right-hand side of engine;
- Neutral position sensor on right-hand side of engine.
The electrical system includes the following elements:
- 12V - 10Ah battery in the central part;
- Turning indicator asher integrated in the digital instrument;
- Fuel pump relay, main relay and fan on rear chassis under saddle;
- Electric fan;
- Auxiliary fuses on rear chassis under saddle; two 30A main fuses on solenoid starter;
- Coolant temperature sensor on cylinder head;
- Lambda sensor;
- Headlamp with H4-12V-55/60W HD halogen bulb and 12V-5W parking light bulb;
- LED tail light with stop light bulb;
- 12V-RY10W turning indicator bulbs;
- Fuel pump inside the tank.
- Multifunction digital instrument.

A.6
TR 650 TERRA 2013 - TR 650 STRADA 2013
H11659
1500 mm
885 mm
A
C
D
B
GENERAL INFORMATION
Workshop Manual Ed. 09-2012
Dimensions, weight, capacity
Wheelbase ............................................................................................................................55,055 in (1500 mm)
Total length (STRADA) ........................................................................................................ 88,504 in (2248 mm)
Total length (TERRA)............................................................................................................ 89,252 in (2267 mm)
Overall width ...........................................................................................................................34,843 in (885 mm)
Max. height (STRADA)......................................................................................................... 47,441 in (1205 mm)
Max. height (TERRA) ............................................................................................................. 48,15 in (1223 mm)
Saddle height (STRADA).........................................................................................................33,858 in (860 mm)
Saddle height (TERRA)..............................34,449 in (875 mm) (no ABS - 18”) / 34,055 in (865 mm) (ABS - 17”)
Minimum height off ground (STRADA) .....................................................................................9,843 in (250 mm)
Minimum height off ground (TERRA) ............. 10,472 in (mm 266) (no ABS 18”) / 10,118 in (257 mm) (ABS 17”)
Weight, without fuel (STRADA). ..............................................................................................390,218 lb (177 kg)
Weight without fuel. (TERRA)......................................................................................................383,604 (174 kg)
Fuel tank capacity including reserve ......................................................... 3,08 Imp. Gall. / 3,698 U.S. Gall. / l 14
Fuel reserve................................................................................... approx. 0,55 Imp. Gall. / 0,66 U.S. Gall. / 2.5 l
Coolant tank capacity ........................................................................... 0,255 Imp. Gall. / 0,306 U.S. Gall. / 1.16 l
Oil and oil lter replacement.................................................................... 0,44 Imp. Gall. / 0,528 U.S. Gall. / 2.0 l
Topping up oil between minimum and max. level ................................. 0,055 Imp. Gall. / 0,066 U.S. Gall. / l 0.25

B.1
TR 650 TERRA 2013 - TR 650 STRADA 2013
B
Workshop Manual Ed. 09-2012
MAINTENANCE
Section

B.2
TR 650 TERRA 2013 - TR 650 STRADA 2013
MAINTENANCE
Workshop Manual Ed. 09-2012
TR 650 STRADA
TR 650 TERRA
SCHEDULED MAINTENANCE CHART
(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
ENGINE
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
AFTER
THE FIRST
1.000 Km
EVERY
10.000 Km
EVERY
20.000 Km
EVERY
30.000 Km
EVERY
40.000 Km
Check engine oil level C S S S S EVERY
1.000 Km
Replace engine oil together with oil lter,
clean magnetic plug
S S S S S
EVERY
10.000 Km
or
ONCE A
YEAR
Check / adjust valve play C/R C/R C/R C/R
Replace spark plugs S S EVERY
20.000 Km
Oil lter (on oil return pipe from chassis) P/S P/S
Replace coolant EVERY 2 YEARS
Check / adjust clutch play C/R C/R C/R C/R C/R
C: Check
S: Change
R: Reset

B.3
TR 650 TERRA 2013 - TR 650 STRADA 2013
Workshop Manual Ed. 09-2012
MAINTENANCE
TR 650 STRADA
TR 650 TERRA
SCHEDULED MAINTENANCE CHART
(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
CHASSIS
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
AFTER THE
FIRST
1.000 Km
EVERY
10.000 Km
EVERY
20.000 Km
EVERY
30.000 Km
EVERY
40.000 Km
Check and lubricate secondary chain Lubricate the secondary drive chain at least once every 1,000 km.
If used on dusty or wet roads, do this more frequently
Second.Drive chain: check tension and
wear C/L/S C/L/S C/L/S C/L/S
Check front/rear sprockets for wear: if nec-
essary, replace along with the secondary
drive chain
C/L/S C/L/S C/L/S C/L/S
Air lter S S
If the vehicle is used in very dusty conditions/on very dusty roads, reduce this service
to 10,000 km
Transmission cables and controls C/R/L C/R/L C/R/L C/R/L C/R/L
Steering bearings and steering clearance C/R C/R C/R C/R
Emptying the intake silencer hose C/P C/P C/P C/P
Brake discs C/S C/S C/S C/S
Brake pad wear C/S C/S C/S C/S
Front fork (oil change) S S
General vehicle operation C C C C C
Braking systems (check pipes) C/R C/R C/R C/R C/R
Cooling system (check level) C/S C/S
Lights / warnings C/R C/R C/R C/R C/R
Safety switches C/R C/R C/R C/R
Brake uid (3) C/R C/R C/R C/R C/R
Coolant (1) C/R C/R C/R C/R C/R
Checking battery charge level C/R C/R C/R C/R
Tyres: Pressure / Wear C/R C/R C/R C/R
Wheels (checking spoke tension - terra
version) C/R C/R C/R C/R
Control unit diagnosis C/R C/R C/R C/R C/R
Side stand C/R/L C/R/L C/R/L C/R/L
Checking function and clearance of ac-
celerator cable C/R C/R C/R C/R
Fuel hoses (2) C/S
Check cooling-water tubes and water
pump for condition and leakage / replace
if necessary
CCCC
S: Change
L: Lubricate
P: Clean
R: Reset
C: Check
(1): Replace every 2 years
(2): Replace every 4 years
(3): Replace every year