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Husqvarna TC 250 2010 User Manual

Husqvarna TC 250 2010
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 2010 Specifications

General IconGeneral
Engine Stroke2-stroke
Displacement249 cc
StarterKickstarter
Transmission5-speed
Final DriveChain
Front Tire80/100-21
Rear Tire100/90-19
Seat Height985 mm
Fuel Capacity7.5 liters
Dry Weight96 kg
Bore x Stroke66.4 mm x 72 mm
IgnitionCDI ignition
FrameChromium molybdenum steel
Front BrakeBrembo hydraulic disc brake
Rear BrakeBrembo hydraulic disc brake
Engine TypeSingle cylinder, 2-stroke

Summary

Important Notices

Vehicle Configuration and Warranty

Details on required vehicle configurations for warranty validity and conditions.

General Information

Engine Specifications

Detailed technical specifications for the engine, including bore, stroke, displacement, and ratios.

Chassis and Suspension Details

Information on frame construction, front and rear suspension types, and brake system components.

Tyres and Capacities

Specifications for tyres, including cold tyre pressures, and fluid capacities for various systems.

Scheduled Maintenance

TC-TE-TXC Scheduled Maintenance Chart

Maintenance schedule for racing motorcycles (full power rating) with tasks and service intervals.

TE Standard Motorcycle Scheduled Maintenance

Maintenance schedule for standard TE models (derated for road use) based on mileage intervals.

Troubleshooting Guide

Engine Troubleshooting

Identifies common engine problems, their causes, and suggested remedies for starting, stalling, and noise issues.

Chassis Troubleshooting

Addresses issues related to handlebar, damping, wheel shakes, suspension noise, and braking.

Electrical System Troubleshooting

Diagnoses problems with spark plugs, generators, batteries, and starter motors.

Settings and Adjustments

Valve Clearance Adjustment

Procedure for checking and adjusting valve clearances to ensure proper engine operation.

Throttle Cable Adjustment

Instructions for adjusting throttle cable free play for TC and TE-TXC models.

Suspension Setup and Adjustment

Guidelines for setting front and rear suspension based on terrain and rider weight, including sag adjustment.

General Procedures

Saddle and Panel Removal

Step-by-step instructions for removing the motorcycle saddle and side panels.

Rear Chassis Removal Procedures

Detailed steps for removing the complete rear chassis with mudguard and air box for TC and TE-TXC models.

Fuel Tank and Exhaust System Removal

Instructions for removing the fuel tank, scoops, spoilers, and exhaust system components.

Engine Disassembly

Cylinder Head and Valve Removal

Steps for removing the cylinder head, valves, valve buckets, and related timing components.

Crankshaft Disassembly

Procedures for removing the crankshaft, including using pullers and separating flywheel halves.

Engine Overhaul

Cylinder Head and Piston Inspection

Procedures for cleaning, checking for warpage, and inspecting cylinder head and piston components.

Valve and Camshaft Checks

Instructions for checking valve seats, guides, springs, and camshaft condition for wear or damage.

Crankshaft and Clutch Component Checks

Procedures for measuring crankshaft and clutch component clearances and checking for wear.

Engine Reassembly

Crankcase and Gearbox Assembly

Procedures for assembling crankcase halves, bearings, shafts, and gearbox components.

Piston and Cylinder Installation

Instructions for installing piston rings, piston, cylinder, and related timing components.

Cylinder Head and Camshaft Reassembly

Steps for installing the cylinder head, timing chain tensioner, camshafts, and related parts.

Front Suspension

Front Fork Disassembly (TC - TXC)

Detailed steps for disassembling the TC-TXC front fork, including draining oil and removing internal parts.

Front Suspension (TE) Service

Instructions for servicing the KAYABA upside-down telescopic hydraulic fork for TE models.

Front Suspension (TC /2009) Service

Instructions for servicing the MARZOCCHI USD telescopic upside-down hydraulic fork for TC 2009 models.

Rear Suspension

Rear Shock Absorber Removal and Disassembly

Steps for removing and disassembling the rear shock absorber, including spring servicing and inspection.

Shock Absorber Damping Adjustment

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

Swinging Arm and Linkage Servicing

Procedures for disassembling, servicing, and checking the swinging arm and rear suspension linkage for wear.

Brakes

Brake Disc and Pad Checks

Instructions for checking brake disc condition, wear limits, and replacing brake pads.

Braking System Bleeding Procedures

Step-by-step guide for bleeding air from the front and rear braking systems.

Changing Brake Fluid

Instructions for safely changing the brake fluid, including precautions and replacement procedures.

Electrical System

Wiring Diagrams and Component Locations

Wiring diagrams, key, colour coding, and locations of electrical components for TC, TE, and TXC models.

Charging System Inspections

Procedures for checking battery charge, regulated voltage, and voltage regulator/rectifier for TE-TXC models.

Starting System and Ignition System

Details on starting system components and troubleshooting, plus ignition system operation for TC and TE-TXC models.

Engine Cooling

Coolant Level Check

Instructions for checking coolant level, including safety precautions and specific notes for TE-TXC models.

Cooling Circuit (TE-TXC) and Overhaul

Diagram and overhaul instructions for the TE-TXC models' cooling circuit, radiators, thermostat, and cooling fan.

"Kit" Installation Instructions

Carburettor Kit (TC) Installation

Steps for installing the carburettor kit, including fuel tank and component removal and replacement.

Turning Indicators KIT (TE) Installation

Instructions for installing front and rear turning indicators, flasher, and related components for TE models.

Rear-view Mirrors (TE) Installation

Procedure for fitting rear-view mirrors to the handlebar brake and clutch lever clamps.

Hydraulically Controlled Clutch

Draining and Servicing Clutch Master Cylinder

Steps for draining clutch fluid and servicing the clutch master cylinder.

Bleeding the Clutch System

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

Optional Components

Optional Components (TC)

Part numbers and descriptions for optional chain and transmission sprockets for TC models.

Optional Components (TE)

Part numbers and descriptions for optional chain and transmission sprockets for TE models.

Optional Components (TXC)

Part numbers and descriptions for optional chain and transmission sprockets for TXC models.

Fuel Injection System

Injection Fuel Feeding System (TE-TXC)

Overview of the fuel system components, operating parameters, and diagnostic tool usage for malfunctions.

Fuel Pump and Relay Inspection

Procedures for testing the fuel pump operation and relay functionality for TE-TXC models.

Tightening Torque Figures

Engine Torque Figures

Specific tightening torque values for engine components like cylinder head, crankcase, and transmission.

Chassis and Suspension Torque Figures

Torque specifications for chassis, handlebar controls, and front/rear suspension components.

Brake and Wheel Torque Figures

Torque values for rear suspension, wheels, brakes, and fairings.

Chassis and Wheels

Chassis Dimensions and Alignment

Detailed dimensional data for the chassis and rake angle, used for alignment checks.

Front Wheel Service

Procedures for removing and installing the front wheel, including axle and brake caliper steps.

Rear Wheel Service and Chain Maintenance

Steps for removing and installing the rear wheel, and checking chain/sprocket wear.

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