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Husqvarna TC 250 2009 User Manual

Husqvarna TC 250 2009
420 pages
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Workshop Manual
TC 250 / 2009
TC 250 / 2010
TE 250 / 2010
TXC 250 / 2010 (USA only)
Part. N. 8000 H1489 (10-2009)

Table of Contents

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Husqvarna TC 250 2009 Specifications

General IconGeneral
BrandHusqvarna
ModelTC 250 2009
CategoryMotorcycle
LanguageEnglish

Summary

General Information

Engine

Details on the engine specifications including bore, stroke, displacement, and compression ratio.

Suspension

Information regarding the front and rear suspension components and their specifications.

Brakes

Details on the front and rear brake systems, including disc specifications and caliper types.

Maintenance

Scheduled Maintenance Chart

Chart detailing scheduled maintenance tasks for TC-TE-TXC racing motorcycles based on hours or mileage.

Troubleshooting

Engine Troubleshooting

Lists common engine problems, their causes, and suggested remedies for starting and running issues.

Chassis Troubleshooting

Addresses chassis-related issues like handlebar handling, vibrations, damping, wheel shake, and braking.

Electrical System Troubleshooting

Covers troubleshooting for electrical systems including spark plugs, generators, batteries, and starter motors.

Settings and Adjustments

Valve clearance adjustment

Procedure for checking and adjusting valve clearances using feeler gauges and shims.

Clutch plate replacement

Step-by-step guide for removing, replacing, and reassembling clutch plates.

Compression adjustment

Instructions for adjusting the compression damping on the front suspension forks.

General Procedures

Exhaust system removal

Detailed steps for removing the exhaust silencer and pipe from the motorcycle.

Fuel tank, scoop and spoiler removal (TC)

Procedure for removing the fuel tank, scoops, and spoilers from the TC model.

Fuel pump removal (TE – TXC)

Instructions on how to remove the electric fuel pump from the fuel tank.

Engine Disassembly

Cylinder head cover removal

Steps to remove the cylinder head cover, including loosening retaining screws.

Valve removal

Procedure for removing valve buckets, shims, seals, springs, and valves.

Crankcase disassembly

Instructions for separating the crankcase halves, including using a puller tool.

Engine Overhaul

Cylinder head

Inspection of the cylinder head, including checking for warpage and cleaning deposits.

Piston rings

Details on inspecting piston rings for signs of forcing or scoring and their replacement.

Clutch

Inspection of clutch components, including plates and springs, for wear or distortion.

Engine Reassembly

Crankshaft assembly

Steps for assembling the crankshaft, including fitting bearings, connecting rod, and flywheel halves.

Input shaft (5 SPEED)

Instructions for fitting gears, washers, and retaining rings onto the 5-speed input shaft.

Clutch assembly

Procedure for installing clutch components like washer, hub, lock washer, nut, and plates.

Front Suspension

Front fork removal

Steps to remove the front wheel and fork legs, including measuring height 'A'.

Front fork disassembly (TC - TXC)

Detailed procedure for disassembling the TC-TXC front fork, including draining oil and removing components.

Rider sag adjustment

Guide to adjusting rider sag by measuring suspension settlement under rider weight.

Rear Suspension

Rear shock absorber removal

Steps to remove the rear shock absorber, including loosening front clamp and mounting bolts.

Disassembling, servicing and assembling the rear shock absorber

Procedure for cleaning, servicing, and reassembling the rear shock absorber.

Shock absorber damping adjustment

Instructions for adjusting compression and rebound damping on the shock absorber.

Brakes

Brake disc

Information on checking brake disc diameter, thickness, wear limits, and warpage.

Checking brake pads for wear / replacing the pads

Guide on checking brake pad wear and procedure for replacing worn pads.

Bleeding the front braking system

Procedure for bleeding air from the front braking system to restore lever feel.

Electrical System

Wiring diagram (TC)

Wiring diagram for the TC model, including key and colour coding.

Ignition system (TC)

Explanation of the Capacitor Discharge Ignition (CDI) system components and factors affecting timing.

BATTERY (TE - TXC)

Information on the TE-TXC battery, including maintenance and charging procedures.

Engine Cooling

Coolant level check

Procedure for checking the coolant level at regular intervals to ensure proper operation of the cooling system.

Cooling circuit (TC)

Diagram and list of components for the TC model's forced circulation cooling system.

Engine cooling system overhaul (TE-TXC)

Instructions for overhauling the TE-TXC engine cooling system, focusing on radiator checks.

"KIT" Installation Instructions

Carburettor KIT (TC)

Instructions for installing the Carburettor KIT on TC models, including fuel system adjustments.

Turning indicators KIT (TE)

Steps for installing front and rear turning indicators on TE models.

Hydraulically Controlled Clutch

Hydraulic clutch system

Description of the hydraulic clutch system components and their function.

Bleeding the clutch system

Procedure for bleeding air from the clutch hydraulic system to restore lever feel.

Optional Components

OPTIONAL COMPONENTS (TC)

List of optional components available for the TC model, including sprockets.

Fuel Injection System

INJECTION FUEL FEEDING SYSTEM (TE-TXC)

Overview of the TE-TXC injection fuel feeding system components and operating parameters.

Operation Manual for "DIAGNOSTIC TOOL SOFTWARE KIT" for injection fuel feeding system (TE-TXC)

Guide on using the diagnostic tool software kit for checking injection system malfunctions.

Special Tools

SPECIAL TOOLS

List of special tools required for maintenance and repair, with part numbers.

Tightening Torque Figures

TIGHTENING TORQUE FIGURES (+/- 5%) ENGINE (8000 A7028)

Table of specified torque values for engine components during assembly.

TIGHTENING TORQUE FIGURES (+/- 5%) CHASSIS (99669)

Table of specified torque values for chassis components during assembly.

TIGHTENING TORQUE FIGURES (+/- 5%) WHEELS AND BRAKES (99669)

Table of specified torque values for wheels and brakes components during assembly.

Chassis and Wheels

Front wheel

Details on front wheel construction, rims, tyre types, and cold tyre pressure.

Removing the front wheel

Step-by-step instructions for safely removing the front wheel.

Rear wheel

Specifications for rear wheel rims, tyre types, and cold tyre pressure.

Wheel servicing

Procedure for checking and servicing wheel hub bearings and balancing wheels.

Checking chain and sprockets for wear

Guide on how to check chain wear and sprocket condition.

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