First Look: 2016 Husqvarna Motocross Models 3

Here's the First Look at the 2016 Husqvarna models. We'll add a bit more in here (stuff is still downloading), so check back in a bit. – Vital MX

Husqvarna Introduce New Era Motocross Models

The new Husqvarna 2016 motocross line-up represents a revolutionary step forward. Beginning a new era, every detail of this new from the ground up motocross range has been specifically designed to improve performance. Featuring massive weight savings, totally new bodywork, new engine design and new carbon fibre subframes, the 2016 motocross bikes embrace Husqvarna’s rich racing heritage to ensure premium motorcycles with state-of-the-art technology.

Presenting the all-new FC 450, FC 350 and FC 250 4-stroke models, plus the all-new TC 125 machine, Husqvarna Motorcycles offers a range of bikes that effortlessly supports riders of all ages and abilities, in all situations. Husqvarna’s six-strong MY16 model range ensures racers and riders alike have the perfect machinery to achieve their goals.

LIKE NOTHING BEFORE IT
Rethinking torsional rigidity and longitudinal stiffness, the hydro-formed, laser-cut and robot welded chromium molybdenum steel frame is lighter and more compact to offer better handling and feeling than its predecessor. Coupled with its new three-piece carbon fibre subframe – 1 kg lighter than the previous subframe – and a new cast aluminium swingarm, it ensures a motorcycle with unrivalled rideability and ease of use.

Perfectly matching the new chassis characteristics, new CNC machined triple clamps, WP’s 4CS forks, a new shorter and 500 grams lighter WP rear shock are mated to a new rear link geometry, which improves both damping and balance. It ensures optimum traction and control across all riding situations and terrains.

THE FUTURE IS HERE
In the engine department the FC 450, FC 350 and FC 250 enjoy further developments and improvements and together with the TC 125 benefit from a significant reduction in engine weight. Smaller and lighter 4-stroke motors are completely reconfigured for optimal mass-centralisation.

Across all 4-stroke models a new Keihin engine management system processes data faster while a 44 mm throttle body – compact and 100 grams lighter – provides immediate throttle response thanks to the elimination of a throttle linkage. New for MY16 is launch control, integrated into the standard handlebar map switch. With the ability to alter engine characteristics, the launch control feature seeks out maximum traction to deliver consistently perfect starts as standard.

Overall weight savings have been significant. The FC 450 is now 5.2 kg lighter than the previous model, while the FC 350 is 4.7 kg less than the 2015 machine. The FC 250 has been lightened by 4.0 kg.

Importantly, the exhaust system has been completely redesigned to improve mass centralisation and reduce sound levels in keeping with FIM limits. Notably shorter and sleeker, the FC 450 sees its resonance chambers integrated into the header pipe.

Keeping in line with a more compact and sleeker generation of motorcycles, the distinctive and futuristic bodywork with striking pearl blue and electric yellow colours and graphics marks a new era in Swedish inspired design. The revised ergonomics and new seat provide greater comfort and superior control in all riding situations.

Finally, new GSK brake discs, Pro Taper handlebars, ODI lock-on grips, new WP radiators, new 7-litre polythene fuel tanks, a new airbox design with tool-less air filter access, as well as black DID alloy rims, CNC machined hubs and Dunlop MX52 tyres further ensure that the all-new MY16 motocross line-up is one of the most sophisticated on the market.

While considerable effort has gone into the release of the all-new 4-stroke models, the 2-stroke range also sees improvements – in particular the TC 125.

The eighth-litre machine receives a significantly smaller and lighter engine. Redesigned and repackaged with a new power valve and exhaust it has an increased power output from 38 hp to 40 hp. The 2016 TC 125 is 3.2 kg lighter compared to the previous model.

For the youngest racers in the Husqvarna family, the agile and powerful TC 85 is the ideal entry machine into motocross. Adorned with stylish colours and graphics, it is the perfect motorcycle for the champions of tomorrow.

Refinements to the TC 250, including new CNC triple clamps with rubber damping, new seat cover and new disc brakes, make it a formidable competitor to its 4-stroke brothers.

The new Husqvarna MY16 motocross range will be available from authorized Husqvarna Dealers Fall 2015.

2016 Husqvarna Model Year Introduction
In over a century of uninterrupted design, development and production, there have been several ground-breaking motorcycles in Husqvarna’s model history. The new MY16 motocross line-up marks one of those groundbreaking milestones.

Completely redesigned from the ground up, the new motocross range sets new standards for handling, agility, power, weight, technology and aesthetics. The new engines are more compact and lighter, and fit tightly in the redesigned frame. The new subframe is made of lightweight carbon fiber, and is extremely short and compact to keep weight as close as possible to the center of gravity. Every detail has been specifically designed to improve performance over the previous generation.

In 2015, Husqvarna Motorcycles have improved on the successful results of the first year in the Motocross World Championship thanks to the dedication of official teams and top pro riders. The spectacular first half of the season in the Motocross World Championship, with several wins and podiums in the MXGP class, and the positive debut in the AMA Supercross with two podium finishes coming in the first race in both 450 and 250 categories have sparked the passion for competing at the highest level in the most challenging championships.

With the new generation motocross models, Husqvarna Motorcycles is set to consolidate its position as a major brand in the motocross segment, increasing its market share and competing at the highest level on the world stage.

FEATURES AND BENEFITS

New frame
With years of experience in designing the most advanced steel frames in off-road, the engineers in Research and Development have designed a completely new chromium molybdenum steel frame that redefines every structural aspect in order to improve handling, ergonomics and packaging. The torsional rigidity and longitudinal stiffness have been completely rethought. The 6 mm wider and 2 mm lower steel tubes offer 20% more torsional rigidity and 30% less longitudinal stiffness compared to the previous generation frame design. These characteristics, matched to the new engine stays, improve handling precision while at the same time increasing bump-absorption and feeling.

The hydro-formed, laser-cut and robot-welded frame has been tightly packaged around the new engines. The new design, high quality materials and the high-tech production processes by WP Performance Systems add-up to a weight saving of 380 grams.

• Completely redesigned frame → 380 g lighter and more compact
• Improved mechanical characteristics → better handling and feeling
• Produced by WP Performance Systems → guarantee of high quality standards

New carbon fiber subframe
The use of carbon fiber strips away weight, improving weight distribution and bringing weight closer to the center of gravity for precise handling. The composition of the material is now 30% carbon fiber and the overall 3-piece construction is 1 kg lighter than the previous subframe, for an overall weight of 1.4 kg. It is also more compact as well as being shorter, for greatly improved ergonomics.

• New 3-piece subframe → more compact for better ergonomics and mass-centralization
• Carbon fiber construction → 1 kg lighter than outgoing model

New swingarm
The new cast aluminum swingarm has been redesigned for optimum stiffness, improving traction and feeling. With new signature Husqvarna machining on the sides, the swingarm is also 250 g lighter while maintaining structural integrity and reliability.

• Redefined stiffness → improved traction and feeling, 250 g weight reduction

Updated WP 4CS front fork
WP’s 4CS fork has a revised setup to match the new chassis characteristics of the MY16 generation motocross. As with all 4CS forks by WP, the clicker settings can be easily and quickly adjusted via the dials on the top of the fork tubes. The red dial on the right alters rebound damping, while the white dial on the left is for compression damping.
Precision engineering by WP Performance Systems, quality materials and advanced production processes guarantee the highest performance levels.

• Revised WP 4CS setup → optimized damping characteristics
• Easy access clicker dials → simple and fast clicker settings

New CNC machined triple clamps
The black-anodized CNC machined triple clamps feature a new top clamp that integrates a rubber damping system that reduces vibrations, therefore increasing comfort. The triple clamps have been meticulously designed to evenly distribute the clamping force on the fork leg, maximizing contact area for optimal sensitivity and minimum friction. Handlebar position adjustability has been maintained for MY16.

• Rubber damping on top clamp → reduced vibrations, increased comfort
• Precise fork leg clamping → even distribution of clamping force on fork leg
• Adjustable handlebar position → adjustable ergonomics

New WP rear shock
A new, shorter and lighter shock by WP features a larger gas chamber designed to maintain consistent performance during use. New internal components, such as the piston and shock shaft increase setup options. A new clevis design contributes to shortening the overall length by 12 mm, while the stroke is increased by 3 mm. The shock is completely adjustable for high and low speed compression damping as well as rebound. The new rear shock is 500 grams lighter compared to the previous model.

• New WP shock → 12 mm shorter and 500 grams lighter with improved damping characteristics
• Redesigned reservoir with larger gas chamber → consistent damping

New rear link
The rear linkage has been completely redesigned to match the new rear shock. 148.2 mm pull rods replace the previous linkage’s 145 mm items and, combined with the redesigned bell crank, maintains a similar progressive rate as MY15.  Rear wheel travel is now 300 mm and, thanks to the updated rear suspension behavior, softer springs can be used.

• New rear link geometry → improved damping and balance

New footpeg mount
The new frame features an innovative footpeg mount that prevents mud and dirt build-up, allowing the footpeg to spring back into position even in the toughest conditions. The footpegs are larger for improved grip and stability.

• New footpeg mount → prevents mud and dirt build-up allowing footpeg to spring back into position
• New larger footpegs → improved grip and stability, lower weight

New Magura hydraulic clutch
The MY16 motocross range now features a new Magura hydraulic clutch system (except the TC 250 which features Brembo hydraulics). The high quality German-made clutch system guarantees even wear, almost maintenance-free operation and perfect modulation in every condition. This means that play is constantly compensated so that the pressure point and function of the clutch remain identical in cold or hot conditions, as well as over time.

• New Magura hydraulic clutch → perfect modulation in every condition
• High quality German craftsmanship → consistent clutch action and almost maintenance-free

Brakes
New brake discs from GSK feature increased braking power, combined with class-leading Brembo calipers and controls.

• New high performance discs and Brembo brake calipers → shorter stopping distance with greater control and confidence

New Pro Taper handlebar
The new Pro Taper handlebar is second to none for function and style. Manufactured to exacting standards, the Pro Taper handlebar features class-leading fatigue resistance while meeting stringent weight requirements. The Pro Taper logos are chemically applied and are scratch and peel resistant. The large Husqvarna bar pad has optimal impact resistance, while the standard handguards offer maximum roost protection.

• New Pro  Taper handlebar → class-leading function and style
• Oversized bar pad and standard handguards → optimal protection

New grips and throttle assembly
The new ODI lock-on grip on the left side does not require gluing, while on the right, the vulcanized grip features an innovative integrated throttle mechanism. The assembly has easy free-play adjustment and, by changing a cam, throttle characteristics can be altered.

• New throttle assembly and ODI grips → easily alter throttle progression; easy grip mounting without glue

Standard map switch and launch control
As in previous model years, the MY16 motocross range features a standard handlebar map switch. For MY16 the map switch now also activates launch control. With the engine at idle, launch control is engaged by switching once between the selected map and the alternative map, and then back again. When the fuel injection LED flashes, launch control is engaged. This function limits the amount of power to the rear wheel for approximately two seconds, improving traction and preventing loss of control under hard acceleration.

• Standard handlebar map switch → alter engine characteristics according to conditions and rider preference
• Launch control → maximum traction for perfect starts

New engine management system (EMS)
The new Keihin EMS is smaller, lighter and faster at processing data. It integrates launch control for perfect starts and selectable engine maps via the switch on the handlebar. Combined with the new gear sensor, power delivery can be tailored for each gear. Engine maps can be personalized according to rider preference with the optional Husky Power tool.

• New Keihin EMS → smaller, lighter and faster at processing engine data for more efficient engine management
• Gear sensor → specific engine maps for each gear

New 44 mm throttle body
The diameter of the throttle body remains the same at 44 mm; however, the injector has been repositioned in order to optimize flow into the combustion chamber. By eliminating the throttle linkage and directly mounting the throttle cables, overall throttle body weight has been reduced by 100 g while also providing more immediate throttle response and feeling.

• New throttle body → more compact and 100 g lighter; more immediate throttle response thanks to elimination of throttle linkage

New exhaust system
The exhaust system has been completely redesigned in an effort to improve mass-centralization and reduce noise. The new header pipes feature resonance chambers that improve performance, and on the 450 SOHC engine, the resonance chamber is integrated into the header pipe and resembles a 2-stroke expansion chamber. The silencer is much shorter than on the MY15 motocross 4-strokes; between 40 mm on the 250 and as much as 80 mm shorter on the 350 and 450. In conjunction with the new mounting points, the mass is moved approximately 60 mm closer to the center of gravity of the bikes, much improving handling and maneuverability. The TC 125 silencer has also been redesigned to match the new engine. Noise levels are kept under the FIM noise limits thanks to redesigned internals.

• New shorter exhausts → mass-centralization for improved maneuverability

New electric start and Li-Ion battery
The new electric starting system, standard on all 4-strokes, is more efficient and 150 g lighter and, combined with the new compact Samsung Li-Ion battery, saves over 1 kg in overall weight. The wiring harness has been optimized  so that the rear subframe can be removed without having to remove any wiring.

• New Samsung Li-Ion battery → compact and lightweight; 1 kg weight saving
• Repositioned battery and wiring harness → easy removal of subframe

Integrated cooling system and new radiators
New WP radiators maintain the integrated routing system as on previous model years. The cooling liquid is routed into the frame, dissipating heat more efficiently, guaranteeing optimal cooling and fitting thanks to reduced tubing.
The new radiators have been designed using the latest CFD (computational fluid dynamics) software, enabling a 10% increase in cooling while maintaining the same capacity and surface area. They are made of a new aluminum alloy that is stronger and feature a new filler cap and neck for easier filling. Optimized radiator louvers protect the radiators and simultaneously increase airflow.

• Integrated cooling → maximum efficiency in minimum space
• New WP radiators → stronger and more efficient for optimal cooling

New fuel tank
The new 7-liter polythene fuel tanks have a redesigned threaded filler cap and an integrated fuel pump on the 4-strokes.

• 7-liter polythene fuel tanks → large capacity for extended running times

New airbox design and tool-less air filter access
The airbox has been completely redesigned and features a new inlet duct that reduces deformation, ensuring maximum airflow and maximum filter protection. The air filter is easily accessed, without tools, by removing the left side panel. Easy maintenance is guaranteed by the new Twin Air filter and new filter cage design that features a simplified mounting system for safe and accurate filter installation.

• Redesigned airbox → improved air flow
• New filter mounting system → safe and accurate protection against dirt
• Tool-less filter access → easy and fast maintenance

Wheels
Black high-strength alloy rims by DID are matched to CNC machined hubs and new lightweight spokes and silver anodized aluminum nipples.
• Lightweight but strong and reliable construction → minimum unsprung weight

Tires
Dunlop MX52 Motocross tires that feature the proven “block-within-a-block” design for more progressive cornering and superior grip are fitted as standard.

• Developed in top-level AMA Supercross and Motocross → enhanced handling, cornering and steering feel combined with increased durability

Completely redesigned bodywork
Distinctive and futuristic bodywork highlights the massive performance leap of the MY16 motocross range, while striking pearl blue and electric yellow colors  and graphics stylishly adorn the modern design. The ergonomics have been completely revised for improved control and comfort, enabling riders to perform at the highest level for extended periods of time. The seat has a new low-profile design with revised padding and a new high-grip cover for superior comfort and control in all conditions.

• Completely new bodywork → distinctive looks, modern colors  and graphics
• Revised ergonomics → confidence-inspiring riding position in all riding situations
• New seat → greater comfort and superior control

Weight reduction on chassis
Component  Weight saving
Frame  380 g
Subframe  1 kg
Swingarm and link  250 g
Battery  1 kg
Rear shock  500 g
Spokes  100 g
Sprockets  70 g
Throttle body  100 g
Others  100 g
Total weight saving  3.50 kg

Weight reduction on engines
Engine  Weight saving  Overall engine weight
125 cc 2-stroke (TC 125)  2.1 kg  19.3 kg
250 cc 4-stroke (FC 250)  1.1 kg  26.1 kg
350 cc 4-stroke (FC 350)  1 kg  27.2 kg
450 cc 4-stroke (FC 450)  1.8 kg  27.8 kg

Overall weight difference MY16 vs. MY15
Model  MY16 weight (without fuel)  MY15 weight (without fuel)
TC 125  89.1 kg  92.3 kg
FC 250  100.1 kg  104.1 kg
FC 350  101.7 kg  106.4 kg
FC 450  102.4 kg  107.6 kg

TECHNICAL INFORMATION BY MODEL

FC 250
A completely new 250cc DOHC engine has been designed to perfectly match the new generation chassis. All internal components have been revised and repackaged in order to reposition the engine within the new chromoly steel frame, shifting the mass closer to the center of gravity of the motorcycle. In combination with the shorter and lighter carbon fiber rear subframe, revised 4CS fork, new shock, new rear link and shorter exhaust, the new FC 250 has enormously improved handling, maneuverability and performance compared to the previous generation.

Engine
The crankshaft has been repositioned and is now 6 mm higher than on the previous engine and, together with a 6 mm shorter con-rod, repositioned internal components and redesigned crankcases, results in a shortened engine by 20 mm, bringing the mass closer to the center of gravity of the bike. The 250 cc engine is not only smaller, but also 1.1 kg lighter for an overall weight of just 26.1 kg. Overall power output is now rated at 46 hp at the output shaft. The multifunctional counter balance shaft reduces vibrations while also driving the water pump and timing chain.

• Completely redesigned engine → lighter and smaller for optimized  mass-centralization
• Improved performance → 46 horsepower peak power and 14,000 rpm rev-limit
• Multifunctional counter balance shaft → reduces vibrations, drives water pump and timing chain

New cylinder head
The new DOHC cylinder head has an optimized  combustion chamber, new camshafts with new timing, 30% harder DLC coating on the finger followers to reduce friction and new valve springs and retainers. The modifications are aimed at boosting low- and mid-range torque as well as peak power.

• New combustion chamber and camshafts → increased low- and mid-range torque and peak power
• Large titanium valves (32.5 mm intake, 26.5 mm exhaust) → optimal gas flow
• New finger followers with harder DLC coating → reduced friction, better performance

New cylinder and piston
The large 78mm bore cylinder is lower and weighs 130 g less, while the forged bridged-box-type piston made by CP is 10 g lighter than in the previous generation DOHC engine. The compression ratio is 14.4:1.

• Large 78mm bore and large diameter valves → high-revving, quick response
• Forged box-type → high performance and reliability

New crankshaft
The crankshaft has been redesigned and is now stiffer. The plain big end bearing and two force-fitted bearing shells ensure maximum reliability and durability, guaranteeing long service intervals of 100 hours.

• Plain big end bearing and force-fitted bearing shells → increased durability and service intervals

New crankcases
The new generation motocross models feature completely redesigned engines with mass-centralization and weight reduction as the main goals. All the major components have been repositioned; the crankshaft has been raised by 6 mm while the clutch shaft is 11.1 mm further back and 26.9 mm higher up. These modifications required a complete redesign of the crankcases, which are now significantly more compact and lighter.
High-pressure die cast production processes keep the overall weight to a minimum, resulting in thin wall thickness. The historical Husqvarna logo adorns the bronze finished crankcase covers.

• Redesigned crankcases → lighter and more compact; optimized mass-centralization 
• High-pressure die cast production process → thin walls for reduced weight, while maintaining strength

New gearbox
The gearbox has been redesigned and is now lighter and more durable. The gear ratios are the same as in the previous generation, but the cogs are wider and the second, third and fourth-gear cogs are surface-treated for increased reliability. The shifting fork has a new low-friction coating for smoother shifting, while the gear lever is designed to prevent dirt build-up. An advanced gear sensor allows for specific engine maps in each gear.

• New lighter 5-speed gearbox → increased durability and improved shifting
• Integrated gear sensor → specific engine maps for each gear

New CSS clutch
The 250 cc and 350 cc engines feature CSS (coil spring steel) clutches with Magura hydraulics and lever. The CSS clutch has six coil springs and 7 clutch plates in place of the previous 8-plates, and a new, lighter one-piece CNC machined steel clutch basket. The inner hub and pressure plate have been redesigned to improve oil flow and separation, while the new coil springs give a more consistent feel.

• New CSS clutch → lighter with more consistent clutch action
• Magura hydraulic system → German-made precision and quality

Benefits
• Improved engine performance for better acceleration and increased speed
• Redefined weight distribution for top-level handling and maneuverability
• Advanced electronics for maximum performance
• Hydraulic clutch and new compact gearbox for precise and smooth shifting
• Reliable and dependable electric start

FC 350
The FC 350 shares much of its engine architecture with the smaller FC 250, therefore combining compact dimensions, light weight and 450-rivalling power. All the packaging benefits of the new DOHC engine are matched to the most advanced electronics. Standard launch control, switchable engine maps and a faster, more powerful engine management system, guarantee that all the 58 horsepower is put to the ground in total control.

Engine
The repositioning of the crankshaft and clutch shaft, together with the complete redesign of all the internal components as well as the crankcases, results in a 20 mm shorter engine. Weighing only 27.2 kg, the 58 horsepower 350 cc engine is 1 kg lighter than the previous generation engine and is mounted closer to the center of gravity of the bike. The multifunctional counter balance shaft reduces vibrations while also driving the water pump and timing chain.

• Improved packaging and better mounting within the frame → Optimized  mass-centralization for exceptional handling and agility
• 58 hp and only 27.2 kg → 450-rivalling power, 250 size and weight
• New engine stays → improved handling and lower vibrations

New cylinder head
The cylinder head retains the DOHC architecture but features a completely redesigned combustion chamber, new ports, new camshafts and new valve springs. The DLC (Diamond Like Carbon) coating on the finger followers is 30% harder, therefore reducing friction. Large, lightweight 36.3 mm diameter, 22.4 g titanium intake and 29.1 mm, 22.7 g titanium exhaust valves allow the engine to rev freely to the 13,400 rpm ceiling.

• New ports and redesigned combustion chamber → significant increase in peak power
• Large titanium valves → only 22.4g each on the intake and 22.7g each on the exhaust
• New finger followers with harder DLC coating → reduced friction, better performance

New cylinder and piston
The lighter and lower 88mm bore and 57.5mm stroke cylinder features a large diameter and lightweight forged bridged-box-type piston by CP and relatively low oscillating masses, giving the engine strong power, high revs and a very wide power band. The compression ratio is 14:1.

• Lightweight 88mm diameter piston → reduces oscillating masses
• Forged bridged-box-type piston → high performance and reliability

New crankshaft
A new stiffer crankshaft is at the heart of the high power output, high-revving FC 350 engine. The plain big end bearing and two force-fitted bearing shells ensure maximum reliability and durability, guaranteeing long service intervals of 100 hours.

• Plain big end bearing and force-fitted bearing shells → increased durability and service intervals

New crankcases
The new generation motocross models feature completely redesigned engines with mass-centralization and weight reduction as the main goals. All the major components have been repositioned; the crankshaft has been raised by 6 mm while the clutch shaft is 11.1 mm further back and 26.9 mm higher. These modifications required a complete redesign of the crankcases, which are now significantly more compact and lighter.
High-pressure die cast production processes keep the overall weight to a minimum, resulting in thin wall thickness. The historical Husqvarna logo adorns the bronze finished crankcase covers.

• Redesigned crankcases → lighter and more compact; optimized  mass-centralization 
• High pressure die cast production process → thin walls for reduced weight, while maintaining strength

Updated gearbox
A new surface treatment on 2nd, 3rd and 4th gear combined with a new low-friction coating on the shifting fork, guarantee smooth and precise shifting. The gear ratios are unchanged while the gear lever features a new tip design that prevents dirt build-up. An advanced gear sensor allows for specific engine maps in each gear.

• Updated 5-speed gearbox → improved reliability and shifting
• integrated gear sensor → specific engine maps for each gear

New CSS clutch
The 250 cc and 350 cc engines feature CSS (coil spring steel) clutches with Magura hydraulics and lever. The CSS clutch has six coil springs and 7 clutch plates in place of the previous 8-plates, and a new, lighter one-piece CNC machined steel clutch basket. The inner hub and pressure plate have been redesigned to improve oil flow and separation, while the new coil springs give a more consistent feel.

• New CSS clutch → lighter with more consistent clutch action
• Magura hydraulic system → German-made precision and quality

Benefits
• 450-class performance with less effort
• 250-class maneuverability and agility
• Standard map switch and launch control
• Magura hydraulic clutch for consistent, maintenance-free operation
• Reliable and dependable electric start

FC 450

The groundbreaking new generation chassis is fitted with the most powerful Husqvarna motocross engine ever developed. The 63 horsepower single-overhead-cam 450 cc power plant has been completely redesigned; it is now smaller and lighter and has been completely reconfigured for optimal mass-centralization within the new chromoly steel frame. The new bodywork elevates the riding experience thanks to accurately developed ergonomics that focus on instilling rider confidence, complete control and reduced fatigue.

Engine
The new SOHC engine is 23 mm shorter, 23 mm narrower and 9 mm lower than the previous generation. Every internal component was revised and repositioned, lowering weight by an astonishing 1.8 kg for an overall weight of 27.8kg, increasing power to 63 hp and improving torque along the entire rev-range. Mass-centralization was a key development factor, enabling chassis engineers to position the engine closer to the center of gravity for greatly improved handling and maneuverability. Vibrations are kept to a minimum thanks to a multifunctional counter balance shaft that also drives the water pump and timing chain.

• Completely redesigned 450 cc engine → lower, narrower, shorter and 1.8 kg lighter
• Increased performance → 63 hp and higher torque along entire rev-range
• New engine stays → improved handling and lower vibrations

New cylinder head
Every aspect of the SOHC cylinder head has been redesigned. It is 350 g lighter and features a new optimized  combustion chamber and ports. The camshaft is also new and actuates four lightweight titanium valves that weigh only 32 g on the intake side and 28 g on the exhaust. The diameter of the intake valves is 40 mm, while on the exhaust it is 33 mm. Low-friction DLC coating on the rocker arm, new shorter timing chain and low-friction chain guides contribute in reaching an 11,500 rev limit.

• SOHC → compact engine design
• Titanium valves → low weight, only 32 g on intake and 28 g on exhaust

New cylinder and piston
The new 95mm bore cylinder is 6 mm lower and features a revised water jacket. The new CP bridge-box-type piston weighs 320 g and the compression ratio is 12.6:1 for an amazing peak output of 63 hp.

• Redesigned cylinder → 6 mm lower with revised water jacket
• Lightweight CP forged bridged-box-type piston → high performance, reduced oscillating masses

New crankshaft
The new crankshaft features 10% more inertia and has been repositioned 9 mm backwards and 7 mm higher. The higher inertia increases traction and rideability while the new position within the engine contributes to mass-centralization  . A plain big end bearing and two force-fitted bearing shells ensure maximum reliability and durability, guaranteeing long service intervals of 100 hours.

• Repositioned crankshaft → improved mass-centralization 
• Plain big end bearing and force-fitted bearing shells → increased durability and service intervals

New crankcases
The new generation motocross models feature completely redesigned engines with mass-centralization and weight reduction as the main goals. All the major components have been repositioned; the crankshaft has been raised by 7 mm and moved backwards by 9 mm. These modifications required a complete redesign of the crankcases, which are now significantly more compact and lighter.
High-pressure die cast production processes keep the overall weight to a minimum, resulting in thin wall thickness. The historical Husqvarna logo adorns the bronze finished crankcase covers.

• Redesigned crankcases → lighter and more compact; optimized  mass-centralization 
• High pressure die cast production process → thin walls for reduced weight, while maintaining strength

New gearbox
A lighter and more compact 5-speed gearbox is 8 mm narrower and 350 g lighter than the previous generation. The new surface treatment on 1st and 5th gears improves reliability, and combined with a new low-friction coating on the shifting fork and a redesigned shift drum, guarantee smooth and precise shifting. The gear lever features a new tip design that prevents dirt build-up. An advanced gear sensor allows for specific engine maps in each gear.

• Redesigned 5-speed gearbox → improved reliability and shifting; lower weight and more compact
• Integrated gear sensor → specific engine maps for each gear

New DDS clutch
A new DDS (damped diaphragm steel) clutch system with a lighter clutch basket is fitted to the new FC 450. The inner hub and pressure plate have also been redesigned to improve oil flow and cooling, while the Magura hydraulics and lever offer perfect modulation and control.
The exclusive characteristics of this system include a single diaphragm steel pressure plate instead of traditional coil springs. It integrates a damping system for better traction and durability. The clutch basket is a single-piece CNC machined steel component that allows the use of thin steel liners and contributes to the narrowness of the engine.

• New DDS clutch → lighter with better modulation and improved durability
• Magura hydraulic system → perfect clutch modulation

Benefits
• Most powerful Husqvarna motocross engine ever developed
• Intuitive and confidence-inspiring riding experience
• Advanced electronics include launch control and adjustable engine maps
• Exclusive DDS clutch with Magura hydraulics for smooth and light clutch action
• Electric starter and compact Li-Ion battery

TC 125
The new generation motocross range marks the introduction of the first new two-stroke engine in years. The 125 cc engine is significantly smaller and lighter and features completely redesigned and repackaged internal components, a new power valve and a new exhaust for 40 hp and greatly improved overall performance. The lightweight TC 125 inspires confidence and total control thanks to the stronger brakes, Pro Taper handlebar and ODI lock-on grips.

Engine
With an increase in power output from 38 hp to 40 hp, and a reduction in overall weight from 19.3 kg to 17.2 kg, the new 125 cc engine marks a significant generational step in 2-stroke technology. Kick-start is standard but an electric starter is available as a Husky Power upgrade.

• New generation 2-stroke → increased power and torque, more compact and lighter
• Improved mass-centralization → significant benefits in handling and maneuverability

New cylinder and piston
The new cylinder features a 54 mm bore, revised ports and a new innovative power valve that improves power delivery along the entire rev range. Along with increased performance, the new cylinder has a redesigned water jacket that improves cooling, ensuring greater reliability and durability. The piston has been redesigned to match the new cylinder characteristics.

• Redesigned cylinder and power valve → 360 g lighter, improved performance and cooling

New crankshaft
The new crankshaft is lighter and balanced differently to the previous generation in order to reduce vibrations. It is now positioned 37 mm higher within the engine in an effort to improve mass-centralization  .

• Repositioned crankshaft → improved mass-centralization 

New crankcases
The new generation motocross models feature completely redesigned engines with mass-centralization and weight reduction as the main goals. All the major components have been repositioned; the crankshaft is now 37 mm higher while the clutch shaft has been raised by 27 mm. These modifications required a complete redesign of the crankcases which are now significantly more compact and lighter. The TC 125 crankcases can be fitted with an optional electric starter.
High-pressure die cast production processes keeps the overall weight to a minimum, resulting in thin wall thickness. The historical Husqvarna logo adorns the bronze finished crankcase covers.

• Redesigned crankcases → lighter and more compact; optimized  mass-centralization 
• High pressure die cast production process → thin walls for reduced weight, while maintaining strength

New gearbox
200 g lighter and 6 mm narrower, the all-new 6-speed gearbox features the same gear ratios as the outgoing model. The gear lever features a new tip design that prevents dirt build-up.

• Redesigned 6-speed gearbox → 200 g lighter and 6 mm narrower

Magura clutch
The hydraulic Magura clutch guarantees excellent modulation and clutch action.

• Magura hydraulic clutch → excellent modulation

New exhaust
The exhaust has been completely redesigned in order to match the new engine’s characteristics and the new chassis’ packaging.
• Completely redesigned exhaust → increased performance

Benefits
• New generation 2-stroke for maximum performance and low running costs
• Low weight and agile handling for easy access to competition-level motocross
• Hydraulic clutch
• High quality standard components

Previous generation motocross platform

TC 85
New stylish colors  and graphics adorn the MY16 TC 85. The agile and powerful little 2-stroke is equipped with the most advanced technology available in small-size motocross. The TC 85 is the ideal entry into motocross for the champions of tomorrow.

Engine
The high performance 2-stroke engine on the TC 85 features a power valve to maximize the power band and is mated to a 6-speed gearbox and a formula hydraulic clutch for smooth and precise shifting. The high performance cylinder has flow-optimized  ports.

• High performance 2-stroke → maximum performance, minimum running costs
• 6-speed gearbox and hydraulic clutch → precise shifting and smooth clutch operation

Frame
The chromoly steel frame and lightweight aluminum rear subframe combine to offer unrivalled precision and rider confidence.

• Steel frame and aluminum subframe → maximum stability and rider confidence

WP suspension
The TC 85 features completely adjustable WP suspension front and back for maximum performance on any track. The 43 mm upside down fork with 270 mm of travel is completely adjustable for rebound and compression damping. The PDS rear suspension offers stability and precision. The shock features complete adjustability and can be setup to perfectly match rider preference and track conditions.

• WP suspension → completely adjustable for precise setup on any track

Wheels and tires
Black Excel rims and CNC machined hubs are shod with Maxxis tires that deliver outstanding performance on a variety of terrain. The pattern design and rubber compound deliver exceptional straight-line stability and excellent traction and predictability.

• Black Excel wheels and CNC machined hubs → low unsprung weight and great stability
• Maxxis tires → exceptional straight-line stability and excellent traction and predictability

Brakes
A Formula four-piston brake caliper and 220mm wave disc at the front, and a two-piston caliper and 210mm wave disc at the rear, offer superior stopping power and feeling.

• Formula brake calipers and wave discs → superior stopping power and feeling

Benefits
• Full-size performance
• Light, agile and stable for complete rider confidence
• Fast starts thanks to smooth hydraulic clutch action
• High quality components

TC 250
Detail changes to the MY16 TC 250 are aimed at refining the riding experience thanks to a new CNC triple clamp with rubber damping and a new seat cover that greatly improves grip and durability. Stronger braking performance is guaranteed by new disc brakes and the 100 g lighter spokes reduce unsprung weight for improved agility. The standard handlebar map switch, polyamide rear subframe, hydraulic clutch and Brembo brakes make the TC 250 a formidable competitor to the more complex 4-strokes.

Engine
The powerful 250 cc 2-stroke engine features an exhaust power valve to boost power and torque along the entire rev range. A precise 5-speed gearbox and smooth hydraulic clutch ensure accurate gear changes and perfect clutch modulation with almost no maintenance.

• 250 cc 2-stroke → strong yet tractable power combines with low running costs
• Hydraulic clutch → smooth clutch action

Handlebar map switch
The standard handlebar map switch allows riders to alter ignition and modify power delivery according to track layout and conditions.

• Handlebar map switch → ignition can be modified according to track layout and conditions

DDS Clutch
A DDS (damped diaphragm steel) clutch system is fitted to the TC 250 to achieve smooth action and easy control. The exclusive characteristics of this system include a diaphragm spring instead of coil springs, an integrated damping system for better traction and durability, and a strong inner hub for increased stability.

• DDS clutch → integrated damping system for better traction and durability

Benefits
• Engine performance tuned for tractability, guarantees exceptional power delivery
• Cutting-edge chassis technology results in low weight and agility
• Maximum performance and enjoyment with 2-stroke affordability
• Light, precision engineered gearbox mated to a hydraulic clutch for smooth and confident starts and gear selection
• Performance upgrade available with 300 cc Husky Power kit