HUSQVARNA TE 150I 2022 (01) PDF DOCUMENT

The meaning of specific symbols is described below:

This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations.

TE 150i EU:

This vehicle is only authorized for operation on public roads in the homologated (restricted) version. The derestricted version of this vehicle must only be operated in closed off areas away from public highway traffic. This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross.

TE 150i US:

Only operate this vehicle in closed-off areas remote from public road traffic. This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross.

The vehicle must only be used as intended. Dangers can arise for people, property and the environment through use not as intended. Any use of the vehicle beyond the intended and defined use constitutes misuse. Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respective use.

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Note (Environmental)

Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

1. The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or

2. the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

1. Removal or puncturing of the main silencers, baffles, header pipes or any other components which conduct exhaust gases.

2. Removal or puncturing of parts of the intake system.

3. Lack of proper maintenance.

4. Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those specified by the manufacturer.

Danger of accidents: A rider who is not fit to ride poses a danger to him or herself and others.

– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.

– Do not operate the vehicle if you are physically or mentally impaired.

Danger of poisoning: Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

– Always make sure there is sufficient ventilation when running the engine.

– Use effective exhaust extraction when starting or running the engine in an enclosed space.

Danger of burns: Some vehicle components become very hot when the vehicle is operated.

– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.

– Let the vehicle parts cool down before you perform any work on the vehicle.

Warning – Risk of injury: Missing or poor protective clothing presents an increased safety risk.

– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides.

– Always wear protective clothing that is in good condition and meets the legal regulations.

In the interest of your own safety, Husqvarna Motorcycles recommends that you only operate the vehicle while wearing protective clothing.

Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).

Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the number in parentheses.

Unless otherwise noted, normal conditions apply to all tasks and descriptions.

During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, expansion screws, seals, sealing rings, O-rings, pins, and lock washers).

In the case of certain screws, a screw adhesive is required. Observe the manufacturer’s instructions.

If thread locker has already been applied to a new part, do not apply any additional thread locker.

After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.

After completing a repair or service work, check the operating safety of the vehicle.

Clutch lever: Fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automatically.

Hand brake lever: Fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever.

Throttle grip: Fitted on the right side of the handlebar.

Stop button (TE 150i EU and US): Fitted on the left side of the handlebar.

– In the basic position, the ignition circuit is closed and the engine can be started.

– When pressed, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

Horn button (TE 150i EU): Fitted on the left side of the handlebar. The horn is operated when the button is pressed.

Light switch (TE 150i EU): Fitted on the left side of the handlebar.

– Low beam on: Light switch is in the central position.

– High beam on: Light switch is turned to the left.

Light switch (TE 150i US): Located to the left of the combination instrument.

– Light off: Light switch is pressed in up to the stop.

– Light on: Light switch is pulled out to the stop.

Turn signal switch (TE 150i EU): Fitted on the left side of the handlebar.

– Off: The turn signal switch is in the central position.

– Left turn signal on: The turn signal switch is turned to the left.

– Right turn signal on: The turn signal switch is turned to the right.

Emergency OFF switch (TE 150i EU): Fitted on the right side of the handlebar.

– Ignition off: In this position, the ignition circuit is interrupted.

– Ignition on: In this position, the ignition circuit is closed and the engine can be started.

Start button (TE 150i EU and US): Fitted on the right side of the handlebar. The starter motor is actuated when the button is pressed.

The map switch is fitted on the right side of the handlebar. The engine characteristic can be altered with the map switch. The map switch has no function in the homologated (restricted) condition of the motorcycle.

Possible states:

– Map switch in position I: The ignition timing map Performance is active in this position.

– Map switch in position II: The ignition timing map Soft is active in this position.

TE 150i EU:

TE 150i US:

Opening:

– Press release button, turn the fuel tank filler cap counter-clockwise, and lift it off.

Closing:

– Mount the fuel tank filler cap and turn it clockwise until the release button engages.

– Route fuel tank breather hose without kinks.

Opening:

– Fold the loop upward.

– Turn the 2-stroke oil tank cap counterclockwise and pull it up.

Closing:

– Put the 2-stroke oil tank cap on and turn it clockwise.

– Fold the loop down.

The 2-stroke oil tank cap engages.

The cold start button is fitted on the side of the throttle valve body. If the engine is cold and the ambient temperature is low, the electronic fuel injection system extends the injection time. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pulling the cold start button. If the engine is warm, the cold start button must be deactivated.

Possible states:

– The cold start button is activated: The cold start button is pulled out all the way and turned by a ¼ turn.

– The cold start button is deactivated: A further ¼ turn returns the cold start button back to the basic position.

The idle setting of the throttle valve body substantially influences the vehicle’s starting behavior, a stable idle speed, and the vehicle’s response when the throttle is opened. The idle speed is adjusted using the idle speed adjusting screw.

– If the idle speed is high, the engine is slow to run, the engine brake is low and the throttle response is aggressive, the adjustment screw must be turned clockwise.

– If the idle speed is low, the engine is running fast, the engine brake is high and the throttle response is not clean, the adjusting screw must be turned counterclockwise.

The shift lever is mounted on the left side of the engine. The neutral or idle position is between the first and second gears. The gear pattern is 1 – N – 2 – 3 – 4 – 5 – 6.

The side stand is located on the left of the vehicle and is used for parking the motorcycle. When you are riding, the side stand must be folded up and secured with the rubber strap.

The steering lock is fitted on the left side of the steering head. It is used to lock the steering, preventing riding.

Locking the steering:

1. Park the vehicle on a firm and level surface.

2. Turn the handlebar as far as possible to the right.

3. Insert the key for the steering lock into the steering lock, turn it to the left, press it in, and turn it to the right. Pull out the key for the steering lock.

Steering is no longer possible. Never leave the key for the steering lock in the steering lock.

Unlocking the steering:

1. Insert the key for the steering lock into the steering lock, turn it to the left, pull it out, and turn it to the right. Pull out the key for the steering lock.

The handlebar can now be moved again. Never leave the key for the steering lock in the steering lock.

Activation: The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.

Messages:

Entering Setup Menu:

With the motorcycle stationary, press both buttons for 3-5 seconds. The Setup menu is displayed.

Setting Kilometers or Miles:

In the setup menu, the UNIT display flashes. Press one of the buttons to select UNIT for the speed in kilometers KM/H or miles M/H.

Setting the Clock:

1. In the setup menu, wait for the menu of the clock to flash.

2. Press one of the buttons to select the 24h or 12h display of the clock.

3. Wait for 5 seconds. The combination instrument changes to the time setting, and the clock symbol flashes.

4. To reset the time, press the left button (value decreases). To advance the time, press the right button (value increases).

Setting the Service Display:

1. In the setup menu, wait for the menu of the service display to flash.

2. To shorten the service interval, press the left button. To extend the service interval, press the right button.

3. To switch off the service interval display, press and hold the left button until ‘off’ appears on the display.

Using Display Modes:

Press one of the buttons repeatedly to cycle through the display modes:

– DST (Distance 1): Shows distance since last reset. To reset, press the right button for 3-5 seconds.

– DST2 (Distance 2): Shows distance 2 since last reset. To reset, press the right button for 3-5 seconds.

– AVG, ART, ODO: Shows average speed (AVG), operating hours (ART), and total distance covered (ODO). To reset AVG, press the right button for 3-5 seconds.

Before riding for the first time, read the entire Owner’s Manual carefully.

– Make sure that the pre-sale inspection work has been carried out by an authorized workshop.

– Get to know the controls.

– Adjust the basic position of the clutch lever.

– Adjust the basic position of the hand brake lever.

– Adjust the basic position of the foot brake lever.

– Adjust the basic position of the shift lever.

– Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more challenging trips.

– Try also to ride as slowly as possible and in a standing position to get a better feel for the motorcycle.

– Do not make any off-road trips that exceed your ability and experience.

– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.

– If you carry luggage, make sure you secure it firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels.

– Do not exceed the maximum permissible overall weight and axle loads.

– Check the spoke tension. The spoke tension must be checked after half an hour of operation.

– Run the engine in.

During the running-in phase, do not exceed the specified engine performance.

Guideline – Maximum engine performance

– Avoid fully opening the throttle!

– Check the idle speed regularly.

Guideline – Idle speed

The idle speed may change during the run-in time. If it changes, adjust the idle speed.

Lithium-ion batteries are lighter and have more starting power at temperatures over 15 °C (60 °F). At low temperatures, however, the starting power drops. Multiple starting attempts may be needed. Press the start button for 5 seconds, and wait 30 seconds between attempts. The pauses allow heat to distribute through the battery, increasing its starting power. If the battery is unable to actuate the starter motor below 15 °C (60 °F), it needs to be warmed up internally to increase its current output. The starting power increases as the battery warms up.

Use of the vehicle under difficult conditions (sand, wet/muddy surfaces) can result in significantly increased wear. It may be necessary to inspect or replace parts before the next scheduled service.

– Clean the air filter and air filter box. Check the air filter approx. every 30 minutes.

– Check the electrical connector for humidity and corrosion and to ensure it is firmly seated. If found, clean and dry the connector, or change it if necessary.

Specific preparations are needed for:

– Rides on dry sand

– Rides on wet sand

– Rides on wet and muddy circuits

– Rides at high temperatures or slow riding

– Riding at low temperatures and in snow

1. Check the radiator cap. The value on the cap should be 1.8 bar (26 psi). If not, change the radiator cap.

2. For dry sand, mount the air filter dust cover (79006920000) and air filter sand cover (79006922000).

3. For wet sand, mount the air filter rain cover (79006921000).

4. Clean the chain.

5. Mount the steel sprocket.

6. Grease the chain with Universal oil spray.

7. Clean the radiator fins and straighten any bent fins carefully.

8. For regular use in sand, change the piston every 10 operating hours.

– Mount the air filter rain cover (79006921000).

– Mount the steel sprocket.

– Clean the motorcycle.

– Straighten the bent radiator fins carefully.

1. Check the radiator cap. The value on the cap should be 1.8 bar (26 psi). If not, change the radiator cap.

2. Adjust the secondary drive to the road conditions.

3. Clean the chain.

4. Clean the radiator fins.

5. Straighten bent radiator fins carefully.

6. Check the coolant level.

Mount the air filter rain cover (79006921000). Observe the fitting instructions for the technical accessory.

Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition.

– Check the gear oil level.

– Check the electrical system.

– Check the front brake fluid level.

– Check the rear brake fluid level.

– Check the front brake linings.

– Check the brake linings of the rear brake.

– Check that the brake system is functioning properly.

– Check the coolant level.

– Check the chain for dirt.

– Check the chain, rear sprocket, engine sprocket, and chain guide.

– Check the chain tension.

– Check the tire condition.

– Check tire pressure.

– Check the spoke tension. (Incorrect spoke tension will strongly impair riding safety).

– Clean the dust boots of the fork legs.

– Bleed the fork legs.

– Check the air filter.

– Check the settings of all controls and ensure that they can be operated smoothly.

– Check all screws, nuts, and hose clamps regularly for tightness.

– Check the fuel level.

– Check 2-stroke oil level.

1. Take the motorcycle off the side stand and secure the side stand with the rubber strap.

2. Shift the transmission into neutral.

3. (TE 150i EU) Turn the emergency OFF switch to the ‘on’ position.

4. If the ambient temperature is below 10 °C (50 °F), pull the cold start button out all the way and turn it by a ¼ turn. If the engine is warm, the cold start button must be deactivated.

5. Press the start button or press the kick starter lever forcefully all the way. Do not open the throttle. Press the start button for a maximum of 5 seconds and wait 30 seconds between attempts.

Starting Off:

– Switch on the light before riding. Pull the clutch lever, shift into first gear, release the clutch lever slowly and at the same time open the throttle carefully.

Shifting and Riding:

– Do not change into a low gear at high engine speed.

– If the oil level warning light comes on, add 2-stroke oil at the next opportunity.

– To shift up, release the throttle, pull the clutch lever, shift, release the clutch lever, and open the throttle.

– If the cold start function was activated, deactivate it after the engine has warmed up.

– To shift down, apply the brakes, close the throttle, pull the clutch lever, shift into a lower gear, and slowly release the clutch lever.

– Avoid frequent or lengthy slipping of the clutch.

Braking:

– Adjust application of the brakes to the riding situation and surface conditions.

– On sandy, wet, or slippery surfaces, use the rear brake.

– Complete braking before entering a bend.

Stopping and Parking:

1. Apply the brakes.

2. Shift the transmission into neutral.

3. Press and hold the stop button while the engine is idling until it stops.

4. Park the motorcycle on firm ground. Do not park near flammable materials and allow the vehicle to cool before covering it.

– Park the vehicle on a firm and level surface.

– Do not park the vehicle near to materials which are highly flammable or explosive.

– Allow the vehicle to cool down before covering it.

– Switch off the engine.

– Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away.

Refueling:

1. Open the fuel tank filler cap.

2. Fill the fuel tank with Super unleaded (ROZ 95) fuel up to the specified level (35 mm / 1.38 in from the top).

3. Do not refuel using pre-mixed fuel.

4. Close the fuel tank filler cap.

Adding 2-stroke Oil:

1. Open the 2-stroke oil tank cap.

2. Fill the 2-stroke oil tank up to the lower edge of the filler neck. Use only 2-stroke oil appropriate for separate lubrication.

3. Close the 2-stroke oil tank cap.

○ One-time interval ● Periodic interval

For optimal riding characteristics, the basic settings of the suspension components must match the rider’s weight. When adjusting, first adjust the shock absorber and then the fork.

As delivered, Husqvarna motorcycles are adjusted for a standard rider weight (with full protective clothing) of 75 to 85 kg (165 to 187 lb.).

If your weight is above or below this range, the basic setting must be adjusted accordingly. Small weight differences can be compensated by adjusting the spring preload, but for large weight differences, the springs must be replaced.

Low-Speed Compression Damping:

1. Turn the adjusting screw clockwise with a screwdriver to the last perceptible click.

2. Turn counterclockwise by the number of clicks corresponding to the desired setting. Turn clockwise to increase damping; turn counterclockwise to reduce damping.

High-Speed Compression Damping:

1. Using an open end wrench, turn the adjusting screw clockwise all the way.

2. Turn counterclockwise by the number of turns corresponding to the desired setting.

Rebound Damping:

1. Turn the adjusting screw clockwise up to the last perceptible click.

2. Turn counterclockwise by the number of clicks corresponding to the desired setting. Turn clockwise to increase damping; turn counterclockwise to reduce damping when the shock absorber rebounds.

Spring Preload:

1. Raise the motorcycle, remove the shock absorber, and clean it.

2. Loosen the screw on the adjusting ring and turn the ring until the spring is no longer under tension.

3. Measure the total spring length.

4. Tension the spring by turning the adjusting ring to the specified spring preload of 10 mm (0.39 in).

5. Tighten the screw on the adjusting ring to 5 Nm (3.7 lbf ft).

6. Install the shock absorber.

1. Measure Rear Wheel Unloaded (Dimension A):

– Raise the motorcycle with a lift stand so the rear wheel is off the ground.

– Position a sag gauge in the rear axle and measure the distance to the SAG marking on the rear fender. Note this value as dimension A.

2. Check Static Sag:

– Remove the motorcycle from the lift stand. Hold the motorcycle upright with the help of an assistant.

– Measure the distance again between the rear axle and the SAG marking. Note this value as dimension B.

– The static sag is the difference between A and B. It should be 37 mm (1.46 in). If it’s incorrect, adjust the spring preload.

3. Check Riding Sag:

– With an assistant holding the motorcycle, the rider (in full gear) sits in a normal position and bounces up and down a few times.

– Another person measures the distance between the rear axle and the SAG marking. Note this value as dimension C.

– The riding sag is the difference between A and C. It should be 110 mm (4.33 in). If it’s incorrect, adjust the riding sag by choosing a suitable spring.

If the riding sag is incorrect, you must mount a suitable spring for your weight.

1. Raise the motorcycle and remove the shock absorber.

2. Choose and mount a suitable spring based on the rider’s weight.

3. Install the shock absorber.

4. Re-check static and riding sag, and adjust the rebound damping of the shock absorber.

Compression Damping:

1. The adjuster is at the upper end of the left fork leg (COMP, white adjuster).

2. Turn the white adjuster clockwise as far as it will go.

3. Turn counterclockwise by the number of clicks for your desired setting.

Rebound Damping:

1. The adjuster is at the upper end of the right fork leg (REB, red adjuster).

2. Turn the red adjuster clockwise as far as it will go.

3. Turn counterclockwise by the number of clicks for your desired setting.

Spring Preload:

1. Raise the motorcycle with a lift stand.

2. Turn the T-grips on both fork legs counterclockwise all the way until the +0 marking aligns.

3. Turn the T-grips clockwise to the desired setting. Make the same adjustment on both fork legs by hand only.

The handlebar can be mounted in four different positions.

1. Remove screws and take off the handlebar clamps. Lay the handlebar to one side, covering components to protect them from damage.

2. Remove screws and take off the handlebar supports.

3. Place the handlebar supports in the required position. Mount and tighten the screws to 40 Nm (29.5 lbf ft) using Loctite® 243™. Position the supports evenly.

4. Position the handlebar, ensuring cables and wiring are positioned correctly.

5. Position the handlebar clamps. Mount and tighten the screws evenly to 20 Nm (14.8 lbf ft). Ensure the gap widths are even.

Bleeding the Fork Legs:

1. Raise the motorcycle with a lift stand.

2. Release the bleeder screws on top of the fork legs. Any excess pressure will escape.

3. Tighten the bleeder screws.

4. Remove the motorcycle from the lift stand.

Cleaning the Dust Boots:

1. Raise the motorcycle and remove the fork protectors.

2. Push the dust boots of both fork legs downward.

3. Clean and oil the dust boots and inner fork tubes. Use Universal oil spray.

4. Press the dust boots back into their installation position and remove excess oil.

5. Install the fork protectors and remove the motorcycle from the lift stand.

Removal:

1. Remove the headlight mask and raise the motorcycle on a lift stand.

2. Remove the front wheel.

3. Remove screws to take off the brake line clamp, then remove the cable tie and screws to take off the brake caliper.

4. Loosen the screws on the top and bottom triple clamps.

5. Remove the left and right fork legs.

Installation:

1. Position the fork legs. The bleeder screws should be positioned toward the front. The second milled groove from the top of the fork leg must be flush with the upper edge of the upper triple clamp.

2. Tighten the top triple clamp screws to 17 Nm (12.5 lbf ft).

3. Tighten the bottom triple clamp screws to 15 Nm (11.1 lbf ft).

4. Position the brake caliper, mount and tighten its screws to 25 Nm (18.4 lbf ft) using Loctite® 243™.

5. Mount cable ties and position the brake line, wiring harness, and clamp. Tighten the clamp screw.

6. Install the front wheel and headlight mask.

7. Check the headlight setting.

Checking:

1. Raise the motorcycle with a lift stand.

2. Move the handlebar to the straight-ahead position. Move the fork legs to and fro. There should be no detectable play in the steering head bearing.

3. Move the handlebar to and fro over the entire steering range. It should move easily with no detectable detent positions.

4. If there is play or detents are detected, adjust the bearing.

Adjusting:

1. Raise the motorcycle with a lift stand.

2. Loosen the top triple clamp screws and remove the top steering stem screw.

3. Loosen and retighten the top steering head screw to 12 Nm (8.9 lbf ft).

4. Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.

5. Tighten the top triple clamp screws to 17 Nm (12.5 lbf ft).

6. Mount and tighten the top steering stem screw to 17 Nm (12.5 lbf ft) using Loctite® 243™.

7. Re-check the bearing play and remove the motorcycle from the lift stand.

Removal:

1. Raise the motorcycle on a lift stand.

2. Remove cable ties, then screws to detach the frame protector.

3. Remove the screw and fitting from the linkage. Raise the link fork slightly to help.

4. Press the angle lever and linkage lever to create space.

5. (TE 150i EU) Disconnect the plug-in connector of the brake light switch.

6. Remove screws and pull off the foot brake cylinder from the push rod.

7. Remove the connecting link of the chain and take off the chain.

8. Remove the nut and pull out the swingarm pivot. Push the link fork back.

9. Hold the shock absorber and remove the top mounting screw. Remove the shock absorber from the bottom.

Installation:

1. Carefully position the shock absorber from the bottom. Mount and tighten the top screw to 60 Nm (44.3 lbf ft) using Loctite® 2701™.

2. Position the link fork and mount the swingarm pivot. Mount and tighten the nut to 100 Nm (73.8 lbf ft).

3. Mount and connect the chain.

4. (TE 150i EU) Join the brake light switch plug-in connector.

5. Position the foot brake cylinder. Mount and tighten its screws to 10 Nm (7.4 lbf ft).

6. Position the angle and linkage lever. Mount and tighten the fitting to 60 Nm (44.3 lbf ft).

7. Mount and tighten the bottom shock absorber screw to 60 Nm (44.3 lbf ft) using Loctite® 2701™.

8. Attach the frame protector and tighten its screws to 3 Nm (2.2 lbf ft).

9. Mount new cable ties and remove the motorcycle from the lift stand.

Removing the Seat:

1. First, remove the air filter box cover.

2. Remove the screw at the rear of the seat.

3. Raise the rear of the seat, pull the seat back, and lift it off.

Mounting the Seat:

1. Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket.

2. Push the seat forward. Make sure it is correctly latched.

3. Mount and tighten the screw to 10 Nm (7.4 lbf ft).

4. Install the air filter box cover.

Removing the Air Filter Box Cover:

– Pull off the air filter box cover sideways and take it off toward the rear.

Installing the Air Filter Box Cover:

1. Attach the catch of the air filter box and push it forward.

2. Engage the air filter box cover at the side points.

Removing the Air Filter:

1. Remove the air filter box cover.

2. Detach the retaining tab. Remove the air filter with its support.

3. Remove the air filter from the air filter support.

Cleaning the Air Filter and Box:

1. Wash the air filter thoroughly in special air filter cleaner and allow it to dry properly. Only press the air filter to dry it, never wring it out.

2. Oil the dry air filter with a high-grade oil for foam air filters.

3. Clean the air filter box and the intake flange.

Installing the Air Filter:

1. Mount the clean air filter on the air filter support.

2. Grease the air filter in the sealing area with long-life grease.

3. Insert the air filter and position the retaining pin in the bushing. Ensure the air filter is correctly positioned.

4. Insert the retaining tab to secure the retaining pin.

5. Install the air filter box cover.

1. Remove the main silencer from the motorcycle.

2. Remove the screws. Pull out the inner tube with its O-ring.

3. Pull the old glass fiber yarn filling from the inner tube.

4. Clean the parts that need to be reinstalled and check for damage.

5. Mount new glass fiber yarn filling on the inner tube.

6. Push the outer tube over the inner tube with the new filling and the O-ring.

7. Mount and tighten all screws to 7 Nm (5.2 lbf ft).

8. Install the main silencer.

Removal:

1. Remove the air filter box cover, seat, and right side cover.

2. Unplug the fuel pump connector. Clean the quick release coupling with compressed air.

3. Disconnect the quick release coupling. Mount a wash cap set to prevent spills.

4. Remove the screws with collar bushings. (TE 150i EU: Hang the horn and bracket to one side).

5. Remove the central screw with the rubber bushing and pull the fuel tank breather hose off the fuel tank lid.

6. Pull both spoilers laterally off the radiator and lift off the fuel tank.

Installation:

1. Check the throttle cable routing. Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracket.

2. Attach the fuel tank breather hose. Mount and tighten the central screw with rubber bushing to 10 Nm (7.4 lbf ft).

3. (TE 150i EU: Position the horn with bracket). Mount and tighten the side screws to 10 Nm (7.4 lbf ft).

4. Plug in the fuel pump connector. Remove the wash cap set.

5. Clean the quick release coupling, lubricate the O-ring with silicone spray, and join the coupling.

6. Attach the fuel tank breather hose.

7. Install the right side cover and the seat.

Checking:

1. Raise the motorcycle with a lift stand.

2. Pull the chain upward at the end of the chain sliding piece. The lower chain section must be taut.

3. Measure the chain tension. The distance between the chain and the swingarm should be 55 to 58 mm (2.17 to 2.28 in). Repeat at different chain positions.

Adjusting:

1. Loosen the rear wheel spindle nut and the chain adjuster nuts.

2. Adjust the chain tension by turning the adjusting screws on the left and right.

3. Ensure the markings on the left and right chain adjusters are in the same position relative to the reference marks for proper wheel alignment.

4. Tighten the chain adjuster nuts.

5. Make sure that the chain adjusters are fitted correctly on the adjusting screws.

6. Tighten the rear wheel spindle nut to 80 Nm (59 lbf ft).

7. Remove the motorcycle from the lift stand.

– Check the chain, rear sprocket, and engine sprocket for wear. If any component is worn, change the entire drivetrain kit (chain, sprockets).

– To check chain wear, pull on the top section of the chain with a weight of 10 to 15 kg (22 to 33 lb.).

– Measure the distance of 18 chain rollers in the lower chain section. If the maximum distance of 272 mm (10.71 in) is exceeded, change the drivetrain kit.

– Check the chain sliding guard for wear. If the lower edge of the chain pins is in line with or below the guard, change it. If loose, tighten the screw to 10 Nm (7.4 lbf ft) with Loctite® 243™.

– Check the chain sliding piece for wear. If the lower edge of the chain pins is in line with or below the piece, change it. If loose, tighten the screw to 15 Nm (11.1 lbf ft).

– Check the chain guide for wear. If the light part of the guide is worn, change it. If loose, tighten the screws/nuts to 10 Nm (7.4 lbf ft).

Checking Brake Linings (Front and Rear):

– Visually inspect the brake linings for minimum thickness. The minimum thickness should be ≥ 1 mm (≥ 0.04 in).

– If the thickness is less than specified, change the linings.

– Check the linings for damage and cracking. If found, change the linings.

Changing Front Brake Linings:

1. Move the brake fluid reservoir to a horizontal position. Remove the cover screws, cover, and membrane.

2. Manually press the brake caliper toward the brake disc to push back the pistons.

3. Remove the cotter pin and pull out the retaining pin.

4. Remove the old brake linings.

5. Clean the brake caliper and check the spring plate and sliding plate.

6. Insert the new brake linings. Always change linings in pairs.

7. Mount the retaining pin (the spring plate should engage in the groove).

8. Mount new cotter pins.

9. Operate the hand brake lever repeatedly until the linings are in contact with the disc.

10. Add brake fluid up to 5 mm (0.2 in) below the reservoir rim and reinstall the cover.

Changing Rear Brake Linings:

1. Position the vehicle vertically. Remove the screw cap, membrane, and shim from the rear brake fluid reservoir.

2. Manually press the brake caliper toward the disc to push back the piston.

3. Remove the cotter pins and pull out the retaining pin.

4. Remove the old brake linings.

5. Clean the caliper and check the spring plate.

6. Insert the new brake linings and mount the pin. The spring plate must engage in the groove.

7. Mount new cotter pins.

8. Operate the foot brake lever repeatedly until the linings contact the disc.

9. Correct the brake fluid level to the MAX marking and reinstall the cap.

Removing the Front Wheel:

1. Raise the motorcycle with a lift stand.

2. Manually press the brake caliper to push back the pistons.

3. Loosen the wheel spindle screw and the axle clamp screws.

4. Press on the wheel spindle screw to push the spindle out, then remove the screw completely.

5. Hold the front wheel and remove the wheel spindle. Take the wheel out of the fork.

6. Remove the spacers.

Installing the Front Wheel:

1. Check the wheel bearing for damage/wear. Clean and grease the shaft seal rings and spacers.

2. Insert spacers. Clean and grease the wheel spindle.

3. Jack up the front wheel into the fork, position it, and insert the wheel spindle.

4. Mount and tighten the wheel spindle screw to 35 Nm (25.8 lbf ft).

5. Operate the hand brake lever until linings are seated. Remove the motorcycle from the lift stand.

6. Operate the front brake and compress the fork firmly. The fork legs will straighten.

7. Tighten the axle clamp screws to 15 Nm (11.1 lbf ft).

Removing the Rear Wheel:

1. Raise the motorcycle with a lift stand.

2. Manually press the brake caliper to push back the piston.

3. Remove the nut from the wheel spindle.

4. Take off the chain adjuster and pull out the wheel spindle far enough to push the wheel forward. Remove the chain from the sprocket.

5. Hold the rear wheel and remove the wheel spindle. Take the wheel out.

6. Remove the spacers.

Installing the Rear Wheel:

1. Check the wheel bearing. Clean and grease the shaft seal rings and spacers.

2. Insert spacers. Clean and grease the wheel spindle.

3. Position the rear wheel and insert the wheel spindle. Mount the chain.

4. Position the chain adjuster and mount the nut, but do not tighten it yet.

5. Adjust the chain tension.

6. Tighten the wheel spindle nut to 80 Nm (59 lbf ft).

7. Operate the foot brake lever until linings are seated. Remove the motorcycle from the lift stand.

Tire Condition:

– Check front and rear tires for cuts, run-in objects, and other damage. Change tires if damaged.

– Check the tread depth. It must be ≥ 2 mm (≥ 0.08 in). If less, change the tires.

– Check the tire age via the DOT number. It is recommended to change tires after 5 years at the latest.

Tire Pressure:

– Remove the protection cap and check pressure when tires are cold.

– Correct the pressure if needed and mount the protection cap.

Spoke Tension:

– Strike each spoke briefly with a screwdriver blade. You should hear a high note. Different tones indicate different tensions.

– If tension differs, correct it.

– Check the spoke torque.

Removal:

1. Remove the air filter box cover and the seat.

2. Disconnect the negative cable from the 12-V battery.

3. Pull back the positive terminal cover and disconnect the positive cable.

4. Pull the EFI control unit upward off its rubber lugs and hang it to the side.

5. Pull off the starter relay and fuse box from the battery compartment and hang them to the side.

6. Detach the wiring harness, disconnect relays and plugs, and hang to the side.

7. Remove the screw and detach the battery compartment.

8. Lift out the 12-V battery.

Installation:

1. Insert the 12-V battery into the compartment with terminals facing forward and secure with the holding bracket.

2. Mount and tighten the screw to 10 Nm (7.4 lbf ft).

3. Place relays and connectors on the battery compartment and attach the wiring harness.

4. Attach the starter relay and fuse box to the battery compartment.

5. Secure the EFI control unit with its rubber lugs.

6. Connect the positive cable to the battery. Tighten the screw to 2.5 Nm (1.84 lbf ft).

7. Slide the positive terminal cover over the positive terminal.

8. Connect the negative cable to the battery. Tighten the screw to 2.5 Nm (1.84 lbf ft).

9. Mount the seat and install the air filter box cover.

1. Remove the 12-V battery.

2. Check the battery voltage. If it is less than 9 V, do not charge the battery. Replace it.

3. If the voltage is ≥ 9 V, charge the 12-V battery using a suitable charger.

4. Switch off the battery charger after charging and disconnect from the 12-V battery.

5. Install the 12-V battery.

Changing the Main Fuse:

1. Remove the air filter box cover and seat.

2. Pull the EFI control unit upward and hang to the side.

3. Pull the starter relay from its holder.

4. Take off the protection caps and remove the faulty main fuse (20 A).

5. A spare fuse is located in the starter relay. Insert a new main fuse.

6. Check that the electrical system is functioning properly.

7. Reassemble the components.

Changing Individual Fuses:

1. The fuse box is located under the seat. Remove the air filter box cover and seat.

2. Open the fuse box cover and remove the faulty fuse. A faulty fuse has a burned-out fuse wire.

3. Insert a spare fuse with the correct rating.

4. Close the fuse box cover and reassemble.

Changing the Headlight Bulb:

1. Remove the headlight mask with the headlight.

2. Turn the protection cap with the underlying bulb socket counterclockwise and remove it.

3. Pull the position light bulb socket out of the reflector.

4. Pull out the old headlight bulb.

5. Insert the new headlight bulb (HS1/socket BX43t).

6. Insert the protection cap with the bulb socket and turn it clockwise all the way.

7. Insert the position light bulb socket into the reflector.

8. Reinstall the headlight mask and check the headlight setting.

Changing the Turn Signal Bulb (TE 150i EU):

1. Remove the screw on the rear of the turn signal housing and carefully remove the turn signal glass.

2. Lightly squeeze the orange cap and take it off.

3. Press the old turn signal bulb lightly into the socket, turn it counterclockwise about 30°, and take it out.

4. Press the new turn signal bulb (R10W/socket BA15s) into the socket and turn it clockwise until it stops.

5. Mount the orange cap, position the glass, and tighten the screw lightly.

Checking:

1. Park the vehicle on a horizontal surface in front of a light-colored wall. Make a mark at the height of the center of the low beam headlight.

2. Make another mark 5 cm (2 in) below the first mark.

3. Position the vehicle vertically at a distance of 5 m (16 ft) from the wall.

4. The rider sits on the motorcycle. Switch on the low beam.

5. The boundary between light and dark must be exactly on the lower mark.

Adjusting:

1. Loosen the screw on the side of the headlight mask.

2. Adjust the headlight range by pivoting the headlight.

3. Tighten the screw.

1. Ensure the engine is cold. Position the motorcycle upright.

2. Place an appropriate container under the water pump cover.

3. Remove the screw on the water pump cover and take off the radiator cap to completely drain the coolant.

4. Mount and tighten the water pump cover screw with a new seal ring to 10 Nm (7.4 lbf ft).

5. Pour in new coolant up to 10 mm (0.39 in) above the radiator fins.

6. Bleed the system: Push the protection cap upward over the coolant temperature sensor. Unplug the connector. Remove the sensor with its O-ring and wait until coolant escapes without bubbles.

7. Mount and tighten the coolant temperature sensor with O-ring to 12 Nm (8.9 lbf ft). Plug in the connector and position the protection cap.

8. Pour coolant in again up to 10 mm (0.39 in) above the radiator fins.

9. Mount the radiator cap.

10. Allow the engine to warm up and cool down again. Check the cooling system for leaks and re-check the coolant level.

Checking:

1. Turn the handlebar as far as possible to the right. Turn the throttle grip back and forth slightly.

2. The play in the throttle cable should be 3 to 5 mm (0.12 to 0.2 in).

3. Start the engine and let it run at idle. Move the handlebar to and fro over the entire steering range. The idle speed must not change. If it does, there is an issue to be addressed.

Adjusting:

1. Move the handlebar to the straight-ahead position. Push back the sleeve on the throttle cable housing.

2. Loosen the lock nut and turn the adjusting screw in as far as possible.

3. Loosen the lower lock nut and turn its adjusting screw in as far as possible.

4. Turn the upper adjusting screw to set the throttle cable play to the specified value (3-5 mm).

5. Unscrew the lower adjusting screw until the smooth operation of the throttle cable is worsened, then turn it back approx. two turns.

6. Tighten both lock nuts, slide on the sleeve, and re-check the play.

1. Run the engine until warm. The cold start button must be deactivated.

2. Adjust the idle speed by turning the idle speed adjusting screw. The idle speed should be 1,400 to 1,500 rpm.

– Turn clockwise to decrease the idle speed.

– Turn counterclockwise to increase the idle speed.

If the vehicle is transported over great height differences, the ambient pressure must be reprogrammed.

1. Start up the vehicle at the new height above sea level and switch off the engine again.

2. Wait for at least five seconds.

3. Start the vehicle again and check the response of the vehicle.

4. If the response has not improved, repeat the procedure.

Drain the gear oil while the engine is at operating temperature.

1. Park the motorcycle on a level surface and position a container under the engine.

2. Remove the gear oil drain plug with magnet and the second gear oil drain plug. Let the oil drain fully.

3. Clean the drain plug with magnet and the engine sealing surface.

4. Mount and tighten the drain plug with magnet and a new seal ring to 20 Nm (14.8 lbf ft).

5. Mount and tighten the second drain plug with a new seal ring to 15 Nm (11.1 lbf ft).

6. Remove the filler plug with O-ring and fill up with 0.80 L (0.85 qt.) of Engine oil (15W/50).

7. Mount and tighten the filler plug with O-ring.

8. Start the engine, check for leaks, and then check the gear oil level.

When using a pressure cleaner, maintain a minimum distance of 60 cm (23.6 in) from components. Do not direct the water jet directly on electrical components, connectors, cables, or bearings.

1. Close off the exhaust system to keep water from entering.

2. Remove coarse dirt particles with a gentle water jet.

3. Spray heavily soiled parts with a commercial motorcycle cleaner and clean using a brush. Use warm water and a soft sponge. Never apply cleaner to a dry vehicle.

4. After rinsing with a gentle spray of water, allow it to dry thoroughly.

5. Remove the closure of the exhaust system.

6. After cleaning, ride the vehicle a short distance until the engine warms up to evaporate water from inaccessible locations.

7. After the motorcycle has cooled down, lubricate all moving parts and pivot points.

8. Clean the chain.

9. Treat bare metal (except brake discs and exhaust) with a corrosion inhibitor.

10. Treat plastic and powder-coated parts with a mild cleaning and care product.

1. Clean the motorcycle.

2. Change the gear oil.

3. Check the antifreeze and coolant level.

4. When refueling for the last time, add fuel additive.

5. Check tire pressure.

6. Remove and charge the 12-V battery. The ideal storage temperature for the lithium-ion battery is 10 to 20 °C (50 to 68 °F).

7. Store the vehicle in a dry location that is not subject to large fluctuations in temperature.

8. Raise the motorcycle with a lift stand.

9. Cover the vehicle with a tarp or a similar cover that is permeable to air.

Possible Cause: Operating error

Action: Carry out start procedure.

Possible Cause: 12-V battery discharged

Action: Charge the 12-V battery. Check the charging voltage. Check the open-circuit current. Check the stator winding of the alternator.

Possible Cause: Main fuse blown

Action: Change the main fuse.

Possible Cause: Starter relay faulty

Action: Check the starter relay.

Possible Cause: Starter motor faulty

Action: Check the starter motor.

Possible Cause: Operating error

Action: Carry out start procedure.

Possible Cause: Quick release coupling not joined

Action: Join quick release coupling.

Possible Cause: Idle speed is not set correctly

Action: Adjust the idle speed.

Possible Cause: Fuel supply interrupted

Action: Check the fuel tank breather.

Possible Cause: Spark plug sooty or wet

Action: Clean and dry the spark plug and spark plug connector, or change if necessary.

Possible Cause: Plug gap of spark plug too wide

Action: Adjust plug gap. Guideline: Spark plug electrode gap 1.20 mm (0.0472 in).

Possible Cause: Faulty ignition

Action: Ignition coil – check the primary winding. Check the spark plug connector. Check the stator winding of the alternator.

Possible Cause: Short-circuit cable in wiring harness frayed, stop button or emergency OFF switch faulty

Action: Check wiring harness (visual check). Check the electrical system.

Possible Cause: The connector or ignition coil is loose or oxidized

Action: Clean the connector and treat with contact spray.

Possible Cause: Malfunction in the electronic fuel injection

Action: Read out the fault memory using the diagnostics tool.

Possible Cause: Spark plug defective

Action: Change the spark plug.

Possible Cause: Faulty ignition

Action: Ignition coil – check the primary winding. Check the spark plug connector. Check the stator winding of the alternator.

Possible Cause: Idle speed is not set correctly

Action: Adjust the idle speed.

Possible Cause: Malfunction in the electronic fuel injection

Action: Read out the fault memory using the diagnostics tool.

Possible Cause: Faulty ignition

Action: Ignition coil – check the primary winding. Check the spark plug connector. Check the stator winding of the alternator.

Possible Cause: Ambient pressure is incorrectly stored

Action: Program ambient air pressure.

Possible Cause: Air filter very dirty

Action: Clean the air filter and air filter box.

Possible Cause: Fuel filter is very dirty

Action: Change the fuel filter.

Possible Cause: Fuel screen is very dirty

Action: Change the fuel screen.

Possible Cause: Malfunction in the electronic fuel injection

Action: Read out the fault memory using the diagnostics tool.

Possible Cause: Fuel supply interrupted

Action: Check the fuel tank breather.

Possible Cause: Exhaust system leaks, deformed or too little glass fiber yarn filling in the main silencer

Action: Check exhaust system for damage. Change the glass fiber yarn filling of the main silencer.

Possible Cause: Faulty ignition

Action: Ignition coil – check the primary winding. Check the spark plug connector. Check the stator winding of the alternator.

Possible Cause: Diaphragm or reed valve housing damaged

Action: Check the diaphragm and reed valve housing.

Possible Cause: Ambient pressure is incorrectly stored

Action: Program ambient air pressure.

Possible Cause: Lack of fuel

Action: Refuel.

Possible Cause: The engine takes in false air

Action: Check that the intake flange is firmly seated.

Possible Cause: The connector or ignition coil is loose or oxidized

Action: Clean the connector and treat with contact spray.

Possible Cause: Ambient pressure is incorrectly stored

Action: Program ambient air pressure.

Possible Cause: Too little coolant in cooling system

Action: Check the cooling system for leakage. Check the coolant level.

Possible Cause: Too little air stream

Action: Switch off engine when stationary.

Possible Cause: Radiator fins very dirty

Action: Clean the radiator fins.

Possible Cause: Foam formation in cooling system

Action: Drain the coolant. Refill with coolant.

Possible Cause: Damaged cylinder head or cylinder head gasket

Action: Check the cylinder head and cylinder head gasket.

Possible Cause: Bent radiator hose

Action: Change the radiator hose.

Possible Cause: Thermostat defective

Action: Check the thermostat. Guideline: Opening temperature: 70 °C (158 °F).

Fault: White smoke emission (steam in exhaust gas)

Possible Cause: Damaged cylinder head or cylinder head gasket

Action: Check the cylinder head and cylinder head gasket.

Fault: Gear oil exits at the vent hose

Possible Cause: Too much gear oil added

Action: Check the gear oil level.

Fault: Water in the gear oil

Possible Cause: Damaged radial shaft seal ring or water pump

Action: Check the radial shaft seal ring and the water pump.

Fault: Malfunction indicator lamp lights up or flashes

Possible Cause: Malfunction in the electronic fuel injection

Action: Check wiring for damage and electrical plug-in connectors for corrosion and damage. Read out the fault memory using the diagnostics tool.

Fault: 12-V battery discharged

Possible Cause: The 12-V battery is not being charged by the alternator

Action: Check the charging voltage. Check the stator winding of the alternator.

Fault: 12-V battery discharged

Possible Cause: Unwanted electrical power consumer

Action: Check the open-circuit current.

Fault: Values in combination instrument deleted (time, stopwatch, lap times)

Possible Cause: The combination instrument battery is empty

Action: Change combination instrument battery.

The blink codes are only displayed by the derestricted version of the vehicle.

Engine

Capacities

Chassis

Tires

Electrical System