HUSQVARNA TE 300I 2022 (01) PDF DOCUMENT

This document is valid for the following models:

TE 250i EU (F2303V7)

TE 250i US (F2375V7)

TE 250i CN (F2387V7)

TE 300i EU (F2403V7)

TE 300i US (F2475V7)

TE 300i AR (F2442V7)

TE 300i ROCKSTAR EDITION EU (F2403V8)

TE 300i ROCKSTAR EDITION US (F2475V8)

The meaning of specific symbols is described below.

✓: Indicates an expected reaction (e.g., of a work step or a function).

✗: Indicates an unexpected reaction (e.g., of a work step or a function).

👨‍🔧: Indicates work that requires expert knowledge and technical understanding. In the interest of your own safety, have this work performed by an authorized Husqvarna Motorcycles workshop.

📖: Indicates a page reference.

ℹ️: Indicates information with more details or tips.

»: Indicates the result of a testing step.

🔚: Indicates the end of an activity, including potential reworking.

This vehicle has been designed and built to withstand the normal stresses and strains of racing and complies with the currently valid regulations and categories of the top international motorsports organizations. It is designed for use in offroad endurance competition, and not primarily for use in motocross.

(All EU/AR/CN models)

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.

(All US models)

Only operate this vehicle in closed-off areas remote from public road traffic.

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 (Environment)

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.

Warning – 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.

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).

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 (e.g. Loctite®) is required. Observe the manufacturer’s instructions.

If thread locker (e.g., Precote®) 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.

Note – Environmental hazard: Improper handling of fuel is a danger to the environment.

– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Use fuels and auxiliary substances in accordance with the specifications in the Owner’s Manual.

Vehicle identification number (VIN): Stamped on the right side of the steering head.

Type label (All EU/AR/CN models): Fixed to the front of the steering head.

Key number (All EU/AR models): Stamped on a tag on the key ring for the steering lock.

Engine number: Embossed on the left side of the engine above the engine sprocket.

Fork article number: Stamped on the inside of the axle clamp.

Shock absorber article number: Stamped on the top of the shock absorber above the adjusting ring towards the engine side.

Clutch Lever: Located on the left handlebar. It is activated hydraulically and adjusts itself automatically.

Hand Brake Lever: Located on the right handlebar. It engages the front brake.

Throttle Grip: Located on the right handlebar. It controls engine speed.

Stop Button (All models): Located on the left side of the handlebar. Pressing it interrupts the ignition circuit, stopping a running engine and preventing a non-running engine from starting.

Horn Button (All EU/AR models): Located on the left handlebar. Press it to operate the horn.

Light Switch (All EU/AR/CN models): Located on the left handlebar. It has positions for low beam and high beam.

Light Switch (All US models): Located to the left of the combination instrument. It can be pushed in to turn the light off or pulled out to turn the light on.

Turn Signal Switch (All EU/AR models): Located on the left handlebar. It has positions for left turn, right turn, and off (central position).

Emergency OFF Switch (All EU/AR/CN models): Located on the right handlebar. It has an “Ignition off” position and an “Ignition on” position.

Start Button (All models): Located on the right side of the handlebar. Pressing it actuates the starter motor.

Map Switch (All TE special models): Located on the right handlebar. It allows switching between ignition timing maps: Position I for Performance and Position II for Soft.

Turn signal indicator lamp (Green): Flashes when the turn signal is switched on.

High beam indicator lamp (Blue): Lights up when the high beam is switched on.

Malfunction indicator lamp (Yellow): Lights up or flashes when the On-Board Diagnostics (OBD) has detected a malfunction in the vehicle electronics. Come safely to a halt and contact an authorized workshop.

Fuel level warning lamp (Yellow): Lights up when the fuel level has reached the reserve mark.

Oil level warning lamp (Red): Lights up when the oil level has reached the MIN marking. Ride for no more than until the remaining fuel in the tank is depleted and at the next opportunity refuel with 2-stroke oil.

High beam indicator lamp: Inoperative.

Malfunction indicator lamp (Yellow): Lights up or flashes when the On-Board Diagnostics (OBD) has detected a malfunction in the vehicle electronics. Come safely to a halt, and contact an authorized workshop.

Fuel level warning lamp (Yellow): Lights up when the fuel level has reached the reserve mark.

Oil level warning lamp (Red): Lights up when the oil level has reached the MIN marking. Ride for no more than until the remaining fuel in the tank is depleted and at the next opportunity refuel with 2-stroke oil.

Opening Fuel Tank Filler Cap:

1. Press the release button.

2. Turn the fuel tank filler cap counter-clockwise and lift it off.

Closing the Fuel Tank Filler Cap:

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

2. Ensure the fuel tank breather hose is routed without kinks.

Opening 2-Stroke Oil Tank Cap:

1. Fold the loop upward.

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

Closing 2-Stroke Oil Tank Cap:

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

2. Fold the loop down. The cap will engage.

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.

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.

If the engine is warm, the cold start button must be deactivated.

The idle speed is adjusted using the idle speed adjusting screw on the throttle valve body.

– 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.

Note: Park the vehicle on a firm and level surface to prevent it from rolling away or falling over.

Locking the steering:

1. Park the vehicle.

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.

Steering is no longer possible. Never leave the key 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.

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

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

Messages on the Combination Instrument:

– Battery icon: Indicates the battery voltage of the combination instrument is too low. The battery needs to be changed.

– Wrench icon: A service is due. Contact an authorized workshop.

Adjusting the Combination Instrument (motorcycle stationary):

1. Press both buttons for 3-5 seconds to enter the Setup menu. The UNIT display flashes.

2. Press one of the buttons to select units for speed: KM/H or M/H.

3. Wait for 5 seconds. The clock symbol (🕘) flashes. Press one of the buttons to select 24h or 12h display.

4. Wait for 5 seconds. The clock display flashes. Use the left button to decrease the time and the right button to increase the time.

5. Wait for 5 seconds. The service interval symbol (🔧) flashes. Use the left button to shorten the interval and the right button to extend it. To switch off the service interval display, press and hold the left button until “off” appears.

Press the left or right buttons briefly to cycle through the display modes.

Speed, time, and DST (distance 1):

– Press a button until DST appears. It shows the distance since the last reset (e.g., between refueling stops).

– To reset DST to 0.0, press and hold the right button for 3-5 seconds.

– To preset a value for DST, press and hold the left button for 3-5 seconds.

Speed, time, and DST2 (distance 2):

– Press a button until DST2 appears. It shows a second trip distance.

– To reset DST2 to 0.0, press and hold the right button for 3-5 seconds.

– To preset a value for DST2, press and hold the left button for 3-5 seconds.

AVG (average speed), ART (operating hours), and ODO (total distance):

– Press a button until AVG, ART, and ODO appear.

– AVG shows the average speed since the last reset.

– ART shows the total operating hours.

– ODO shows the total distance covered by the vehicle.

– To reset AVG to 0.0, press and hold the right button for 3-5 seconds.

– To view remaining operating hours until the next service, press and hold the left button for 3-5 seconds.

Before riding for the first time, read the entire Owner’s Manual carefully and get to know the controls.

– Ensure the pre-sale inspection has been carried out by an authorized workshop.

– Adjust the basic position of the clutch and brake levers.

– Get used to the handling characteristics on a suitable surface before challenging trips.

– Try riding slowly in a standing position to get a better feel for the motorcycle.

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

Guideline

Maximum permissible overall weight: 335 kg (739 lb.)

Maximum permissible front axle load: 145 kg (320 lb.)

Maximum permissible rear axle load: 190 kg (419 lb.)

– Check the spoke tension after half an hour of operation.

– Run in the engine according to the specified procedure.

During the running-in phase, do not exceed the specified engine performance and avoid fully opening the throttle.

Check the idle speed regularly. The idle speed may change during the run-in time.

If the idle speed changes, adjust it.

At low temperatures, the starting power of lithium-ion batteries drops. Multiple starting attempts may be needed. The pauses are necessary so that the heat created can distribute through the battery.

1. Press the start button for 5 seconds.

2. Wait 30 seconds between attempts.

The starting power increases as the battery warms up internally.

For Dry Sand:

– Check the radiator cap. The specified value is 1.8 bar (26 psi). If the value is incorrect, change the cap.

– Mount the air filter dust cover.

– Mount the air filter sand cover.

– Clean the chain.

– Mount a steel sprocket.

– Grease the chain.

– Clean and straighten any bent radiator fins.

– Change the piston every 10 operating hours for regular use in sand.

For Wet Sand:

– Check the radiator cap (1.8 bar / 26 psi).

– Change the radiator cap if the value is incorrect.

– Mount the air filter rain cover.

For Wet and Muddy Circuits:

– Mount the air filter rain cover.

– Mount a steel sprocket.

– Clean the motorcycle.

– Straighten any bent radiator fins.

For High Temperatures or Slow Riding:

– Check the radiator cap (1.8 bar / 26 psi) and change it if necessary.

– Adjust the secondary drive to the road conditions.

– Clean the chain, radiator fins, and straighten any bent fins.

– Check the coolant level.

– Mount the air filter rain cover.

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 and rear brake fluid levels.

– Check the front and rear brake linings.

– 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 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 they can be operated smoothly.

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

– Check the fuel level.

– Check 2-stroke oil level.

Danger of poisoning: Exhaust gases are toxic. Always ensure sufficient ventilation.

Note: High revving speed with a cold engine negatively impacts its lifespan. Always warm up the engine at a low speed.

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

2. Shift the transmission into neutral.

3. (All EU/AR/CN models) 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. Deactivate it once the engine is warm.

5. Press the start button. Do not open the throttle. Press for a maximum of 5 seconds, and wait 30 seconds before another attempt.

Starting off: 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:

– Warning: If you change down at high engine speed, the rear wheel blocks and the engine races. Do not change into a low gear at high engine speed.

– First gear is used for starting off and for steep inclines.

– Shift into a higher gear when conditions allow. To do so, release the throttle, pull the clutch lever, shift, release the clutch lever, and open the throttle.

– Deactivate the cold start button after the engine has warmed up.

– After reaching maximum speed, turn the throttle back to ¾ open to reduce fuel consumption.

– To shift down, apply the brakes and close the throttle at the same time. Pull the clutch lever, shift into a lower gear, release the clutch lever slowly, and then either open the throttle or shift again.

– Avoid frequent or lengthy slipping of the clutch (≥ 2 min) as this heats up the gear oil, engine, and cooling system.

Warning: Excessively forceful application of the brakes blocks the wheels. Adjust brake application to the riding situation and surface conditions.

Warning: A spongy pressure point on the front or rear brake reduces braking efficiency. Check the brake system and do not continue riding until the problem is eliminated.

Warning: Moisture and dirt impair the brake system. Brake carefully several times to dry out and remove dirt from the brake linings and brake discs.

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

– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.

Stopping and Parking:

– Apply the brakes and shift the transmission into neutral.

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

– Park the motorcycle on firm, level ground using the side stand.

– Do not park near highly flammable or explosive materials. Allow the vehicle to cool before covering it.

Transporting:

– Park the vehicle on a firm and level surface.

– Switch off the engine.

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

Refueling with Fuel:

Danger – Fire hazard: Fuel is highly flammable. Do not fuel near open flames or lit cigarettes. Switch off the engine. Wipe up spills immediately.

1. Open the fuel tank filler cap.

2. Fill the fuel tank with Super unleaded (ROZ 95) fuel up to the specified level.

Guideline

Total fuel tank capacity, approx.: 8.5 l (2.25 US gal)

Fuel level below lower edge of filler neck: 35 mm (1.38 in)

Do not refuel using pre-mixed fuel.

3. Close the fuel tank filler cap.

Adding 2-Stroke Oil:

Warning – Engine failure: The engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light comes on, add 2-stroke oil at the next opportunity before you refuel.

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.

Guideline

2-stroke oil tank content approx.: 0.6 l (0.6 qt.)

3. Close the 2-stroke oil tank cap.

○ One-time interval

● Periodic interval

○ One-time interval

● Periodic interval

The standard settings are for a rider weight of 75 … 85 kg (165 … 187 lb.). If your weight is outside this range, the suspension must be adjusted.

Adjusting Low-Speed Compression Damping:

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

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

Adjusting 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 for your desired setting.

Adjusting Rebound Damping:

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

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

Adjusting Spring Preload and Riding Sag:

This process involves measuring the rear wheel unloaded, with the bike’s own weight (static sag), and with the rider’s weight (riding sag) to determine if the spring preload or spring rate needs adjustment. The target for static sag is 37 mm (1.46 in) and for riding sag is 110 mm (4.33 in). If the sag is incorrect, adjust the spring preload using a hook wrench or change the spring to a different rate based on rider weight.

Adjusting Compression Damping (Left Fork Leg – White Adjuster):

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

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

Adjusting Rebound Damping (Right Fork Leg – Red Adjuster):

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

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

Adjusting Spring Preload:

1. Turn the T-grips on top of the forks counterclockwise all the way until marking +0 aligns.

2. Turn the T-grips clockwise to the desired setting. Make the same adjustment on both forks.

The handlebar can be mounted in four different positions. If the handlebar is bent or damaged, it must be changed.

1. Remove the screws and handlebar clamps. Lay the handlebar to one side, covering components to protect them from damage. Do not kink cables or lines.

2. Remove the screws and take off the handlebar supports.

3. Place the handlebar supports in the required position. The upper triple clamp has two sets of holes, and the handlebar supports are offset, allowing for four positions.

4. Mount and tighten the handlebar support screws.

Guideline: M10 screw, 40 Nm (29.5 lbf ft), Loctite® 243™

5. Position the handlebar, ensuring cables are routed correctly.

6. Position the handlebar clamps, and mount and tighten the screws evenly.

Guideline: M8 screw, 20 Nm (14.8 lbf ft)

1. Raise the motorcycle with a lift stand.

2. Release the bleeder screws on top of each fork leg.

3. Any excess pressure will escape from the interior of the fork.

4. Tighten the bleeder screws.

5. Remove the motorcycle from the lift stand.

Note: Unfiltered intake air will damage the engine. Only operate the vehicle with a correctly installed air filter.

Removing the air filter:

1. Remove the air filter box cover.

2. Detach the retaining tab and remove the air filter with its support.

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

Cleaning the air filter and air filter box:

1. Wash the foam air filter thoroughly in special air filter cleaning liquid and allow it to dry completely. Do not wring it out; only press it.

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

3. Clean the air filter box and the intake flange. Check the intake flange for damage and tightness.

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. Insert the retaining tab to secure the retaining pin.

4. Install the air filter box cover.

Warning: Incorrect chain tension damages components and can cause accidents. If too tight, components wear quickly. If too loose, the chain can fall off, locking the rear wheel or damaging the engine.

Checking the chain tension:

1. Raise the motorcycle on a lift stand.

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

Guideline – Chain tension: 55 … 58 mm (2.17 … 2.28 in)

3. Repeat this measurement at different chain positions as chain wear may not be even.

Adjusting the chain tension:

1. Loosen the nut on the rear wheel spindle.

2. Loosen the nuts on the chain adjuster screws.

3. Turn the adjusting screws on the left and right sides to set the correct chain tension. Ensure the markings on both chain adjusters are in the same position relative to the reference marks for correct wheel alignment.

4. Tighten the nuts on the chain adjuster screws.

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

6. Tighten the nut on the rear wheel spindle.

Guideline – Nut, rear wheel spindle: M20x1.5, 80 Nm (59 lbf ft)

1. Shift the transmission into neutral.

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

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

4. Measure the distance of 18 chain rollers in the lower chain section. Repeat at different positions.

Guideline – Maximum distance from 18 chain rollers: 272 mm (10.71 in)

If the distance is greater, change the drivetrain kit.

5. Check the chain sliding guard and chain sliding piece for wear. If the lower edge of the chain pins is in line with or below the guard/piece, change the part.

6. Check the chain guide for wear. If the light part of the guide is worn, change it.

Warning – Risk of injury: 12 V batteries contain harmful substances. Keep out of reach of children. Keep sparks and open flames away. Only charge in well-ventilated rooms.

The 12-V battery is maintenance-free. If the battery is depleted, it must be charged immediately to avoid deep discharge and damage.

1. Remove the 12-V battery from the motorcycle.

2. Check the battery voltage. If below 9 V, do not charge; replace the battery.

3. If voltage is ≥ 9 V, charge the 12-V battery.

A specific battery charger is recommended. This charger tests voltage retention and prevents overcharging. It is only suitable for lithium iron phosphate batteries.

4. Switch off the battery charger after charging and disconnect it from the battery.

5. Install the 12-V battery.

Warning – Fire hazard: Incorrect fuses overload the electrical system. Only use fuses with the required ampere value. Do not bypass or repair fuses.

Changing Main Fuse:

1. Remove the seat and air filter box cover.

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

3. Pull the starter relay from its holder.

4. Take off the protection caps.

5. Remove the faulty main fuse (20 A). A faulty fuse has a burned-out fuse wire.

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

7. Check that the electrical system is functioning.

8. Reassemble all components.

Changing Fuses of Individual Power Consumers:

The fuse box is located under the seat.

1. Remove the seat and air filter box cover.

2. Open the fuse box cover.

3. Remove the faulty fuse. Fuse assignments are listed below.

4. Insert a spare fuse with the correct rating (10 A or 5 A).

5. Check the function of the consumer and close the fuse box.

Fuse Assignment (All EU/AR models):

Fuse 1 – 10 A: EFI control unit, lambda sensor, oil pump, combination instrument, etc.

Fuse 2 – 10 A: horn, brake light, radiator fan (optional), turn signal

Fuse 3 – 10 A: high/low beam, position light, tail light, license plate lamp

Fuse 4 – 5 A: fuel pump

Fuse Assignment (All US/CN models):

Fuse 1 – 10 A: EFI control unit, oil pump, combination instrument, etc.

Fuse 2 – 10 A: radiator fan (optional)

Fuse 3 – 10 A: low beam, position light, tail light

Fuse 4 – 5 A: fuel pump

Checking the headlight setting:

1. Park the vehicle on a horizontal surface 5 m (16 ft) in front of a light-colored wall.

2. Make a mark on the wall at the height of the center of the low beam headlight.

3. Make a second mark 5 cm (2 in) below the first mark.

4. Have the rider sit on the motorcycle.

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

Adjusting the headlight range:

1. If the setting is incorrect, loosen the adjusting screw behind the headlight mask.

2. Adjust the headlight range by pivoting the headlight up or down.

3. Tighten the adjusting screw.

Warning: Coolant gets very hot and is under pressure. Allow the engine and cooling system to cool down completely before starting. Coolant is toxic; avoid contact with skin and eyes.

Draining the coolant:

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

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

Refilling with coolant:

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

2. Position the motorcycle upright and pour coolant in up to 10 mm (0.39 in) above the radiator fins.

3. To bleed the system, unplug the connector from the coolant temperature sensor. Remove the sensor with its O-ring and wait until coolant escapes without bubbles.

4. Mount and tighten the sensor (M10x1.25, 12 Nm / 8.9 lbf ft), plug in the connector, and top up the coolant again.

5. Mount the radiator cap.

6. Warm up the engine, let it cool down, and check the coolant level again.

Checking the gear oil level:

This must be done when the engine is cold.

1. Stand the motorcycle upright on a horizontal surface.

2. Remove the gear oil level monitoring screw. A small quantity of gear oil should run out.

3. If no oil runs out, add gear oil until it does.

4. Mount and tighten the gear oil level monitoring screw (M6, 8 Nm / 5.9 lbf ft).

Changing the gear oil:

Drain the oil when the engine is at operating temperature.

Warning: Engine and oil get very hot. Wear protective gloves.

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 let the oil drain fully.

3. Clean the drain plug and the sealing surface on the engine.

4. Mount and tighten the drain plug with a new seal ring (M12x1.5, 20 Nm / 14.8 lbf ft).

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

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

7. Start the engine and check for leaks.

This procedure is necessary if the 2-stroke oil hose has been removed or the tank has been fully depleted.

1. Ensure the engine is off and the motorcycle is upright on a horizontal surface. Check that there is sufficient 2-stroke oil in the tank.

2. Remove the seat and air filter box cover.

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

4. Pull the diagnostics connector off its holder.

5. Put the throttle grip into the full throttle position and secure it.

6. Plug the special wake-up connector into the diagnostics connector. The combination instrument lighting will activate.

7. Wait at least five seconds, then release the throttle grip. The oil pump is now timed and will run at various speeds, which is clearly audible.

8. Wait until you no longer hear the oil pump operating. Disconnect the wake-up connector.

9. Check the oil hose for visible air bubbles. If bubbles are present, repeat the entire procedure.

10. Reassemble all components.

Note: A high-pressure cleaner can damage components. Maintain a minimum distance of 60 cm (23.6 in) and do not direct the jet at electrical components, connectors, cables, or bearings.

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

2. Remove coarse dirt with a gentle water jet.

3. Spray heavily soiled parts with a commercial motorcycle cleaner and use a brush.

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

5. Remove the closure from 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 and clean the chain.

8. Treat bare metal (except brake discs and exhaust) with a corrosion inhibitor. Treat plastic and powder-coated parts with a care product.

1. Clean the motorcycle.

2. Change the gear oil.

3. Check the antifreeze and coolant level.

4. Refuel and add a fuel additive.

5. Check tire pressure.

6. Remove the 12-V battery and charge it. Store it in a location where the temperature is 10 … 20 °C (50 … 68 °F).

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

8. Raise the motorcycle with a lift stand so both wheels are off the ground.

9. Cover the vehicle with a tarp or similar cover that is permeable to air. Do not use non-porous materials as they trap humidity.

1. Remove the motorcycle from the lift stand.

2. Install the charged 12-V battery.

3. Perform all checks and maintenance measures as you would before any ride.

4. Make a short test ride.

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