Husqvarna TXC 250 2009 Offroad Motorbike Manuals

Manuals and User Guides for Husqvarna TXC 250 2009 Offroad Motorbike. We have 1 Husqvarna TXC 250 2009 Offroad Motorbike manual available for free PDF download: Workshop Manual

Husqvarna TXC 250 2009 Workshop Manual

Husqvarna TXC 250 2009 Workshop Manual (412 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 62.52 MB

Table of Contents

Table of Contents

5
- Workshop Manual
  3
- Important Notices
  7
- General
  11
Table of Contents

12
- Cooling
  13
- Fuel Feeding
  13
- Ignition
  13
- Lubrication
  13
- Timing System
  13
- Transmission
  14
- Brakes
  16
- Frame
  16
- Suspensions
  16
- Tires
  16
- Wheels
  16
- Capacities
  19
- Maintenance
  21
- Troubles and Remedies
  29
- Settings and Adjustments
  35
Table of Contents

36
General Operations

70
Table of Contents

96
- Camshaft Disassembly
  98
- Cylinder Head Cover Disassembly
  98
- Water Pump Body Disassembly
  100
- Cylinder Head Disassembly
  101
- Valve Disassembly
  102
- Cylinder Disassembly
  104
- Piston Disassembly
  104
- Flywheel Disassembly
  105
- Kick Start Pedal Disassembly (TC-TE-TXC)
  106
- Transmission Cover Disassembly
  107
- Kick Start Components Disassembly (TC-TE-TXC)
  109
- Electric Starting System Disassembly (TE, TXC; SMR 450-510)
  110
- Oil Pump Disassembly
  111
- Gear Control Pedal and Gear Shifter Disassembly
  112
- Primary Transmission Driving Gear Disassembly
  114
- Crankcase Disassembly
  115
- Gearbox Disassembly
  116
- Crankshaft and Counter Balancing Shaft Disassembly (SMR 450-510)
  118
Engine Overhauling

121
- Assemblies
  122
- Cleaning of Components
  122
- Cylinder Head
  122
- Recutting the Valve Seats
  123
- Replacement of Valve Guides
  125
- Valve Guides
  125
- Valve
  126
- Valve Spring
  126
- Installation of Valves
  127
- Inspection of Rocker Arm
  128
- Starter Decompressor
  128
- Camshaft
  129
- Camchain Tensioner
  130
- Camshaft Chain and Gearing
  130
- Cylinder
  131
- Piston
  131
- Cylinder-Piston Fitting
  132
- Gudgeon Pin
  133
- Piston Rings
  134
- Piston Rings/Cylinder Clearance
  134
- Piston Ring/Piston Rings Groove Clearance
  135
- Connecting Rod Big End Side Clearance
  136
- Crankshaft
  136
- Connecting Rod Small End Bush Replacement
  137
- Clutch Housing-Friction Disc Clearance
  138
- Clutch Spring
  138
- Clutch Unit
  138
- Gear Selector Fork and Gearing
  140
- Oil Pump
  140
- Selector Drum
  141
- Engine Reassembly
  147
Engine Reassembly

148
Table of Contents

192
- Front Suspension (TE-SMR)
  194
- Components of the Fork
  196
- General Rules for a Proper Overhauling
  197
- Instructions for Clamping in the Vice
  197
- General Maintenance Operations
  198
- Problems - Possible Causes - Solutions
  198
- Bleeding the Air
  199
- Draining the Oil
  200
- Braking down the Pumping Element and the Bottom Valve
  201
- Braking down the Fork Leg - Slider and Removing the Oil Seals
  203
- Cartridge Overhauling (Rebound Braking)
  204
- Overhauling and Modifying the Cartridge and Bottom Valve Setting
  204
- Bottom Valve Overhauling (Compression Braking)
  205
- Re- Assembling the Fork Leg - Slider and Oil Seals
  206
- Re- Assembling the Pumping Element Unit and the Bottom Valve
  208
- Filling with Oil
  211
- Fitting the Fork Back on Themotorcycle
  212
- Adjustments
  213
- Compression Adjustment
  213
- Rebound Adjustment
  213
- Removing the Front Fork
  214
- Front Suspension (TC-TXC)
  216
- Components of the Fork
  218
- General Rules for a Proper Overhauling
  219
- Instructions for Clamping in the Vice
  219
- Cleaning the Fork Legs
  221
- Bleeding the Air
  222
- Draining the Oil
  223
- Valve Setting
  224
- Checking the Rebound Adjusting Unit
  226
- Compression Valve Overhauling
  227
- Re-Assembling the Cartridge Unit
  228
- Breaking down the Fork Leg - Slider and Removing the Sealing Rings
  231
- Re-Assembling the Fork Leg - Slider and Sealing Rings
  232
- Re-Assembling the Cartridge
  233
- Filling with Oil
  234
- Fitting the Fork Back on Themotorcycle
  234
- Adjustments
  235
- Initial Suspension Bottoming Adjustment
  235
- Rebound Adjustment
  236
- Spring Preload Adjustment
  236
- Compression Adjustment
  237
- Removing the Front Fork
  238
Rear Suspension

241
Brakes

271
- Cable Colour Coding (TE-SMR)
  273
- Cable Colour Coding (TXC 250)
  274
- Cable Colour Coding (TC, TXC 450-510)
  275
- Electrical Components Location (Te-Smr)
  276
- Electrical Components Location (Tc-Txc)
  278
- Charging System (Tc-Txc)
  280
- Charging System (Te-Smr)
  280
- Battery Current Leakage
  282
- Charging System Checks
  282
- Generator Stator Coil Resistance Check
  282
- Regulated Voltage
  282
- Voltage Regulator-Rectifier Check (TE-SMR-TXC)
  285
- Electric Starting System (Te-Smr)
  286
- Electric Starting System (Txc)
  286
- Starter Motor Check
  287
- Starter Motor Disassembly
  287
- Starter System Checks
  287
- Electric Start Remote Control Switch Check (TE-SMR-TXC)
  288
- Starter Motor Maintenance
  288
- Starter Motor Test Diagram
  288
- Electronic Ignition System (Tc-Txc)
  289
- Electronic Ignition System (Te-Smr)
  290
- Electronic Power Unit (ECU)
  290
- Electronic Power Unit Wiring Diagram (Ecu) (Te-Smr)
  294
- Voltage Regulator (TE-SMR-TXC)
  295
- Voltage Regulator-Rectifier Wiring Diagram
  295
- Spark Plug
  296
- Gear Shift Position Sensor Check (GPS)
  297
- Battery Recharge
  299
- Headlamp Adjustment
  300
- Headlamp, Tail Lamp (Te-Smr)
  300
- Rear Tail Light Bulb Replacement
  301
- Replacing the Licence Plate Light Lamp
  302
- Handlebar Commutators
  303
- Connectors
  305
- Couplings
  305
- Notes
  305
- Battery
  306
- Fuses
  306
- Semiconductors Parts
  306
- Digital Instrument, Warning Lights (Te-Smr)
  307
- Instrument Replacement
  310
- Locating Operating Troubles
  310
- Wire Harness TC-TXC
  311
- Wire Harness TE-SMR
  311
- Cable Runway and Assembling Instructions for the 'Te/Smr' Electric Parts
  312
- Important Recommendation
  325
- Engine Cooling System
  327
Table of Contents

333
- Assembling Instructions for Full Power Version on TE-SMR Models
  334
- Blinkers Kit (SMR)
  334
- Blinkers Kit (TE)
  334
- Central Engine Guard
  334
- Hand Guards Kit (TE)
  334
- Hook Kit for Race Starting Phase (TC-TXC)
  334
- Kick Starter Kit (SMR)
  334
- Passenger Footrest Kit (SMR)
  334
Hydraulic Control Clutch

369
- Hydraulic Clutch System
  371
- Discharge of Hydraulic System Fluid
  372
- Overhaul of the Control Pump for Clutch Release
  372
- Bleeding of the Hydraulic System
  373
- Optional Parts List
  375
- Fuel Injection System
  379
- Lubrication System
  385
- Specific Tools
  389
- Torque Wrench Settings
  391
  - Frame
    398
  - Front Wheel
    401
  - Rear Wheel
    406
  - Wheels Overhauling
    408
  - Wheel Spokes
    409
  - Rims Warpage
    409

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