Husqvarna TC 250 Owner's Manual
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Husqvarna TC 250 Owner's Manual

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OWNER'S MANUAL 2018
TC 250
TX 300
Art. no. 3402165en

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Summary of Contents for Husqvarna TC 250

  • Page 1 OWNER'S MANUAL 2018 TC 250 TX 300 Art. no. 3402165en...
  • Page 3 DEAR HUSQVARNA MOTORCYCLES CUSTOMER Congratulations on your decision to purchase a Husqvarna motorcycle. You are now the owner of a state-of- DEAR HUSQVARNA MOTORCYCLES CUSTOMER the-art sports motorcycle that will give you enormous pleasure if you service and maintain it properly.

  • Page 4: Table Of Contents

    Measuring the rear wheel dimension 6.12 Shift lever ..........21 unloaded ..........44 6.13 Kick starter.......... 21 10.8 Checking the static sag of the 6.14 Foot brake lever ........22 shock absorber ........45 6.15 Plug-in stand (TC 250) ......22...
  • Page 5 TABLE OF CONTENTS 10.9 Checking the riding sag of the 11.30 Changing the glass fiber yarn filling shock absorber ........46 in the main silencer ......72 10.10 Adjusting the spring pretension of 11.31 Removing the right side cover .... 73 the shock absorber ......
  • Page 6 TC 250.......... 144 14.4 Changing the main fuse (TX 300)..113 21.3.2 Carburetor - basic setting for COOLING SYSTEM........115 sandy surfaces (TC 250)....144 21.3.3 Carburetor tuning (TC 250)... 145 15.1 Cooling system ......... 115 21.3.4 TX 300 .......... 146 15.2...

  • Page 7: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interests of your own safety, have these jobs performed by an authorized Husqvarna Motorcycles workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use (TC 250) This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the currently valid regulations and categories of the top international motorsport organizations.

  • Page 9: Degrees Of Risk And Symbols

    2 SAFETY ADVICE Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

  • Page 10: Protective Clothing

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, Husqvarna Motorcycles recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks.

  • Page 11: Owner's Manual

    If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized Husqvarna Motorcycles dealer. The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if...

  • Page 12: Important Notes

    The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles workshop only and confirmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motor- cycles Dealer.net; otherwise, all warranty claims will be void. Damage or secondary damage caused by tam- pering with and/or conversions on the vehicle are not covered by the warranty.

  • Page 13: Customer Service

    3 IMPORTANT NOTES Customer service Your authorized Husqvarna Motorcycles dealer will be happy to answer any questions you may have regarding your vehicle and Husqvarna Motorcycles. A list of authorized Husqvarna Motorcycles dealers can be found on the Husqvarna Motorcycles website.

  • Page 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) H02378-10 Filler cap Air filter box cover Plug-in stand ( p. 22) (TC 250) Shift lever ( p. 21) Engine number ( p. 14) Choke ( p. 20) Fuel tap...

  • Page 15: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) H02379-10 Kill switch ( p. 17) Clutch lever ( p. 16) Fork air pressure adjustment Fork compression adjustment Throttle grip ( p. 16) Hand brake lever ( p. 16) Kick starter ( p.

  • Page 16: Serial Numbers

    5 SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steer- ing head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number The engine number is embossed on the left side of the engine above the engine sprocket.

  • Page 17: Shock Absorber Article Number

    5 SERIAL NUMBERS Shock absorber article number The shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 0 0 1 401948-10...

  • Page 18: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. F00223-10 Hand brake lever (Option: Brembo) The hand brake lever is fitted on the right side of the han- dlebar.

  • Page 19: Kill Switch

    6 CONTROLS Kill switch The kill switch is fitted on the left side of the handlebar. Possible states in basic position – In this position, the ignition • Kill switch circuit is closed, and the engine can be started. pressed – In this position, the ignition circuit •...

  • Page 20: Closing The Filler Cap

    Keep fuels correctly in a suitable canister, and out of the reach of children. Warning 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. (TC 250) – Turn filler cap counterclockwise and lift it off. K00902-10 (TX 300) –...

  • Page 21: Fuel Tap (Tc 250)

    Route fuel tank breather hose without kinks. F00229-10 Fuel tap (TC 250) The fuel tap is on the left side of the fuel tank. Open or close the supply of fuel to the carburetor using tap han- on the fuel tap.

  • Page 22: Fuel Tap (Tx 300)

    Fuel reserve supply open RES – Fuel can flow from the fuel • tank to the carburetor. The fuel tank empties completely. F00231-10 6.11 Choke (TC 250) Choke is fitted on the left side of the carburetor. F00233-10 (TX 300) Choke is fitted on the left side of the carburetor.

  • Page 23: Shift Lever

    The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears. 401950-11 (TC 250) The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears.

  • Page 24: Foot Brake Lever

    The foot brake lever is used to activate the rear brake. 401956-10 6.15 Plug-in stand (TC 250) Support for plug-in stand is the left side of the wheel spindle. The plug-in stand is used to park the motorcycle.

  • Page 25: Service Hour Counter

    6 CONTROLS 6.17 Service hour counter The service hour counter is fitted in front of the handlebar. It shows the total number of service hours of the engine. The service hour counter begins counting when the engine is started and stops when the engine is switched off. Info The value indicated by the service hour counter cannot be cleared or adjusted.

  • Page 26: Preparing For Use

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized Husqvarna Motorcy- cles workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.

  • Page 27: Running In The Engine

    7 PREPARING FOR USE Info The delivery certificate and the Service and Warranty Booklet are regarded as evidence of warranty services. – Before your first trip, read the entire Owner's Manual carefully. – Get to know the controls. – Adjust the basic position of the clutch lever. ( p.

  • Page 28: Preparing The Vehicle For Difficult Riding Conditions

    7 PREPARING FOR USE Preparing the vehicle for difficult riding conditions Info Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to considerably more rapid wear of components such as the drive train, brake system, or suspension components.
  • Page 29 7 PREPARING FOR USE – Fit a dust cover on the air filter. Dust cover for air filter (79006920000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01272-01 – Fit a sand cover on the air filter. Sand cover for air filter (79006922000)

  • Page 30: Preparing Vehicle For Rides On Wet Sand

    – Change the radiator cap. – Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01274-01 – Adjust the carburetor jetting and setting. Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop.

  • Page 31: Preparing Vehicle For Rides On Wet And Muddy Circuits

    Preparing vehicle for rides on wet and muddy circuits – Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01274-01 – Adjust the carburetor jetting and setting.

  • Page 32: Preparing Vehicle For High Temperatures Or Slow Riding

    Check the coolant level. ( p. 116) Preparing vehicle for low temperatures or snow – Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info Observe the fitting instructions for Husqvarna Motor- cycles accessories. M01274-01...
  • Page 33 7 PREPARING FOR USE – Adjust the carburetor jetting and setting. Info The recommended carburetor tuning is available from your authorized Husqvarna Motorcycles workshop. M01107-01...

  • Page 34: Riding Instructions

    8 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info 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 when it is being operated. –...

  • Page 35: Starting Off

    The motorcycle has been out of use for more than 1 week – Empty the carburetor float chamber. p. 125) (TC 250) – Turn the tap handle of the fuel tap to the ON position. Fuel can flow from the fuel tank to the carburetor.

  • Page 36: Shifting, Riding

    Danger of accidents 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. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 37: Stopping, Parking

    Shift gear to neutral. – Press and hold the kill switch while the engine is idling until the engine stops. (TC 250) – Turn the tap handle of the fuel tap to the OFF position. – Rest the vehicle on the plug-in stand.

  • Page 38: Refueling

    8 RIDING INSTRUCTIONS Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. –...
  • Page 39 Fill the fuel tank with fuel up to level Guideline 35 mm (1.38 in) Level Total fuel tank Super unleaded capacity, approx. (1.8 US gal) (95 octane) mixed (TC 250) with 2-stroke engine oil (1:60) p. 154) 401522-10 Total fuel tank 10 l Super unleaded capacity, approx.

  • Page 40: Service Schedule

    9 SERVICE SCHEDULE Additional information Any further work that results from the required work or from the recommended work must be ordered sepa- rately and can be invoiced separately. Different service intervals may apply in your country, depending on the local operating conditions. Required work after every race Every 40 operating hours...

  • Page 41: Recommended Work

    Final check: Check the vehicle for operating safety and take a test ride. ○ ○ ● ● ● ● Make the service entry in the Husqvarna Motorcycles Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval Recommended work...
  • Page 42 ● Perform minor engine service. (Check the reed valve housing, reed valve, and intake flange. Check the clutch. Under difficult operating conditions: Change the piston and check the cylinder and Z dimension.) (TC 250) ● ● ● Perform the intermediate engine service. (Change the piston and check the cylin- der and Z dimension.

  • Page 43: Tuning The Chassis

    – In the delivered condition, Husqvarna motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 75 …...

  • Page 44: Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 45: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber.

  • Page 46: Adjusting The Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor- rectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 47: Checking The Static Sag Of The Shock Absorber

    Info The static sag is the difference between measure- ments – Check the static sag. Static sag (TC 250) 35 mm (1.38 in) Static sag (TX 300) 35 mm (1.38 in) » If the static sag is less or more than the specified value: –...

  • Page 48: Checking The Riding Sag Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info Before changing the spring pretension, make a note of the present setting, e.g., by measuring the length of the spring.

  • Page 49: Adjusting The Riding Sag

    – Tighten the spring by turning adjusting ring to measure- ment Guideline Spring preload (TC 250) 5 mm (0.2 in) Spring preload (TX 300) 8 mm (0.31 in) Info Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring pretension.

  • Page 50: Checking The Basic Setting Of The Fork

    10 TUNING THE CHASSIS Guideline Spring rate (TC 250) Weight of rider: 65 … 39 N/mm (223 lb/in) 75 kg (143 … 165 lb.) Weight of rider: 75 … 42 N/mm (240 lb/in) 85 kg (165 … 187 lb.) Weight of rider: 85 …...

  • Page 51: Adjusting The Fork Air Pressure

    Read the accompanying instructions for Husqvarna Motorcycles accessories. – Adjust the air pressure as specified. Guideline Air pressure (TC 250) 10.5 bar (152 psi) Air pressure (TX 300) 9.4 bar (136 psi) Changing of the air pressure 0.2 bar (3 psi)

  • Page 52: Adjusting The Compression Damping Of The Fork

    – Turn counterclockwise by the number of clicks correspond- ing to the fork type. Guideline H01178-13 Compression damping (TC 250) Comfort 17 clicks Standard 12 clicks Sport 7 clicks...

  • Page 53: Handlebar Position

    – Turn counterclockwise by the number of clicks correspond- ing to the fork type. M01100-10 Guideline Rebound damping (TC 250) Comfort 17 clicks Standard 12 clicks Sport 7 clicks...
  • Page 54 10 TUNING THE CHASSIS Main work – Remove screws . Take off the handlebar clamp. Remove the handlebar and lay it to one side. Info Cover the components to protect them against dam- age. Do not kink the cables and lines. –...

  • Page 55: Service Work On The Chassis

    – Park the vehicle on a firm and level surface. – Ensure that nobody sits on the vehicle when the vehicle is parked on a stand. (TC 250) – Remove the motorcycle from the lift stand. – Remove the lift stand.

  • Page 56: Bleeding The Fork Legs

    11 SERVICE WORK ON THE CHASSIS 11.3 Bleeding the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 53) Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. –...

  • Page 57: Removing The Fork Legs

    11 SERVICE WORK ON THE CHASSIS 11.5 Removing the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 53) – Remove the front wheel. p. 103) Main work – Remove screws and take off the clamp. –...

  • Page 58: Removing The Fork Protector

    11 SERVICE WORK ON THE CHASSIS – Position the brake caliper. Mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) ® Loctite 243™ brake caliper – Position the brake line and clamp. Mount and tighten screws S01903-11 Finishing work –...

  • Page 59: Installing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS Main work – Take off cable holder in front of the left radiator. – Remove screw – Remove screw – Take off the upper triple clamp with the handlebar and set it aside. Info Protect the components against damage by covering V00887-10 them.
  • Page 60 11 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the handlebar. – Mount screw but do not tighten yet. V00888-10 – Position the fork legs. The air release screw of the right fork leg is posi- tioned to the front.

  • Page 61: Checking The Play Of The Steering Head Bearing

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

  • Page 62: Adjusting The Steering Head Bearing Play

    11 SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bear- ing. » If there is detectable play: –...

  • Page 63: Lubricating The Steering Head Bearing

    11 SERVICE WORK ON THE CHASSIS 11.13 Lubricating the steering head bearing – Remove the lower triple clamp. p. 56) – Install the lower triple clamp. p. 57) Info The steering head bearing is cleaned and lubricated in the course of removal and installation. H02387-01 11.14 Removing the start number plate...

  • Page 64: Installing Front Fender

    11 SERVICE WORK ON THE CHASSIS Main work – Remove screws . Remove front fender. H01535-10 11.17 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis H01535-10 Finishing work –...

  • Page 65: Removing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS 11.18 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 53) Main work – Remove the cable ties. – Remove screws – Remove screws with the washers. –...

  • Page 66: Installing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS – Remove the connecting link of the chain. – Take off the chain. H01540-01 – Remove nut and pull out the swingarm pivot. – Push the swingarm back and secure it against falling over. H01541-10 –...
  • Page 67 11 SERVICE WORK ON THE CHASSIS – Mount the chain. – Connect the chain with the connecting link. Guideline The closed side of the chain joint lock must face in the direction of travel. K00949-10 (Option: Brembo) – Position the foot brake cylinder. Push rod engages in the foot brake cylinder.

  • Page 68: Removing The Seat

    Remove the motorcycle from the lift stand. ( p. 53) 11.20 Removing the seat Preparatory work – Remove the air filter box cover. ( p. 68) Main work (TC 250) – Remove screw – Pull seat back and lift it off. F00237-10...

  • Page 69: Mounting The Seat

    Pull seat back and lift it off. F00107-10 11.21 Mounting the seat Main work (TC 250) – Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket. – Push the seat forward.

  • Page 70: Removing The Air Filter Box Cover

    Finishing work – Install the air filter box cover. ( p. 69) 11.22 Removing the air filter box cover (TC 250) – Pull off the air filter box cover sideways in areas , and remove toward the front. K00901-10 (TX 300) –...

  • Page 71: Installing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS 11.23 Installing the air filter box cover (TC 250) – Position air filter box cover on collar bushings and push toward the rear. – Engage the air filter box cover in areas K00900-10 (TX 300) –...

  • Page 72: Cleaning The Air Filter And Air Filter Box

    11 SERVICE WORK ON THE CHASSIS Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Preparatory work – Remove the air filter box cover. ( p.

  • Page 73: Installing The Air Filter

    11 SERVICE WORK ON THE CHASSIS 11.26 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 155) 102178-10 – Insert the air filter and position the top retaining pin bushing The air filter is correctly positioned.

  • Page 74: Removing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS 11.28 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. Preparatory work –...

  • Page 75: Removing The Right Side Cover

    Install the main silencer. ( p. 72) – Install the right side cover. ( p. 74) 11.31 Removing the right side cover (TC 250) – Remove screw – Pull off the side cover sideways in areas , and remove toward the front.

  • Page 76: Installing The Right Side Cover

    11 SERVICE WORK ON THE CHASSIS 11.32 Installing the right side cover (TC 250) – Position the side cover on collar bushings and push toward the rear. – Engage the side cover in areas – Mount and tighten screw Guideline Remaining screws, 5 Nm (3.7 lbf ft)

  • Page 77: Removing The Fuel Tank

    Change your clothing in case of fuel spills on them. – Keep fuels correctly in a suitable canister, and out of the reach of children. Preparatory work (TC 250) – Turn the tap handle of the fuel tap to the OFF position. (TX 300) –...

  • Page 78: Installing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS (TX 300) – Remove screw with the rubber bushing. – Pull the fuel tank breather hose off the tank lid. F00113-12 – Pull both spoilers off the sides of the radiator bracket and lift off the fuel tank.

  • Page 79: Checking The Chain For Dirt

    11 SERVICE WORK ON THE CHASSIS (TC 250) – Mount the fuel tank breather hose. – Mount and tighten screw with the rubber bushing. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis H01414-11 (TX 300) – Mount the fuel tank breather hose.

  • Page 80: Cleaning The Chain

    11 SERVICE WORK ON THE CHASSIS 11.36 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. – Remove the lubricant from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...

  • Page 81: Adjusting The Chain Tension

    11 SERVICE WORK ON THE CHASSIS Main work – Pull the chain at the end of the chain sliding component upwards to measure chain tension Info The bottom chain section must be taut. Chain wear is not always even; repeat this measure- ment at different chain positions.

  • Page 82: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    11 SERVICE WORK ON THE CHASSIS Guideline Nut, rear wheel spin- M25x1.5 80 Nm (59 lbf ft) Info The wide adjustment range of the chain adjusters (32 mm (1.26 in)) enables different secondary ratios with the same chain length. Chain adjusters can be turned by 180°.
  • Page 83 11 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with, or below, the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.

  • Page 84: Checking The Frame

    – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by Husqvarna M01314-01 Motorcycles. 11.41 Checking the swingarm – Check the swingarm for damage, cracking, and deformation.

  • Page 85: Checking The Rubber Grip

    11 SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. The throttle cable must be routed along the back of the handlebar, to the right of the frame, above the fuel tank bracket, and to the carburetor. The throttle cable must be fixed on the fuel tank bracket with a rubber band.

  • Page 86: Adjusting The Basic Position Of The Clutch Lever

    11 SERVICE WORK ON THE CHASSIS 11.44 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info When the adjusting screw is turned counterclockwise, the clutch lever moves away from the handlebar.

  • Page 87: Changing The Hydraulic Clutch Fluid

    11 SERVICE WORK ON THE CHASSIS Info Clean up overflowed or spilled brake fluid immediately with water. 11.46 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. –...
  • Page 88 11 SERVICE WORK ON THE CHASSIS – Now press the fluid into the system until it emerges from the hole of the master cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. –...

  • Page 89: Brake System

    12 BRAKE SYSTEM 12.1 Checking the free travel of the hand brake lever (Option: Brembo) Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. –...

  • Page 90: Checking The Brake Discs

    Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple...

  • Page 91: Adding Front Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 92 12 BRAKE SYSTEM Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.

  • Page 93: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) (Option: Brembo) – Check the brake linings for minimum thickness ≥...
  • Page 94 12 BRAKE SYSTEM Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Warning Environmental hazard Hazardous substances cause environmental damage. –...
  • Page 95 12 BRAKE SYSTEM – Insert the new brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

  • Page 96: Checking The Free Travel Of Foot Brake Lever

    12 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. H02377-10 – Insert the new brake linings. – Mount pin Leaf spring engages in the groove on the pin. Info Always change the brake linings in pairs.

  • Page 97: Adjusting The Basic Position Of The Foot Brake Lever

    12 BRAKE SYSTEM – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake 3 … 5 mm (0.12 … 0.2 in) lever »...

  • Page 98: Checking The Rear Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Preparatory work –...

  • Page 99: Adding Rear Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 100: Checking The Brake Linings Of The Rear Brake

    Mount new cable ties on the frame protector. 12.12 Checking the brake linings of the rear brake Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.)

  • Page 101: Changing The Rear Brake Linings

    Changing the rear brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation.
  • Page 102 12 BRAKE SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
  • Page 103 12 BRAKE SYSTEM – Insert the new brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs. Make sure that decoupling plate is mounted on the piston side brake lining. – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a M01329-10 pressure point.
  • Page 104 12 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. H02369-10 – Insert the new brake linings. – Mount pin Leaf spring engages in the groove on the pin. Info Always change the brake linings in pairs.

  • Page 105: Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 53) Main work (Option: Brembo) – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake...

  • Page 106: Installing The Front Wheel

    13 WHEELS, TIRES – Remove spacers H00934-10 13.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 107: Removing The Rear Wheel

    13 WHEELS, TIRES 13.3 Removing the rear wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 53) Main work (Option: Brembo) – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the...

  • Page 108: Installing The Rear Wheel

    13 WHEELS, TIRES (Option: Magura) – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.
  • Page 109 13 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p.

  • Page 110: Checking The Tire Condition

    Checking the tire condition Info Only mount tires approved and/or recommended by Husqvarna Motorcycles. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcy- cle.

  • Page 111: Checking Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) –...

  • Page 112: Electrical System

    14 ELECTRICAL SYSTEM 14.1 Removing the battery (TX 300) Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. – Only charge batteries in well-ventilated rooms. –...

  • Page 113: Installing The Battery (Tx 300)

    Dispose of batteries with less than the minimum voltage correctly. Warning Environmental hazard Batteries contain environmentally-hazardous materials. – Do not dispose of batteries as household waste. – Return batteries to your authorized Husqvarna Motorcycles dealer or dispose of them at a collection point for used batteries.
  • Page 114 14 ELECTRICAL SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Even when there is no load on the battery, it discharges steadily. The charging level and the method of charging are very important for the service life of the battery.

  • Page 115: Changing The Main Fuse (Tx 300)

    14 ELECTRICAL SYSTEM Finishing work – Install the battery. p. 111) – Mount the seat. ( p. 67) – Install the air filter box cover. ( p. 69) 14.4 Changing the main fuse (TX 300) Warning Fire hazard Incorrect fuses overload the electrical system. –...
  • Page 116 14 ELECTRICAL SYSTEM – Take off protection caps – Remove faulty main fuse Info You can recognize a faulty fuse by a burned-out fuse wire A spare fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109110) ( p.

  • Page 117: Cooling System

    15 COOLING SYSTEM 15.1 Cooling system (TC 250) Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling sys- tem is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant tempera- ture will not result in a risk of malfunctions.

  • Page 118: Checking The Coolant Level

    15 COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...

  • Page 119: Draining The Coolant

    Change clothing if coolant spills onto your clothing. Condition The engine is cold. – Position the motorcycle upright. – Place a suitable container under the water pump cover. (TC 250) – Remove screw . Take off radiator cap – Completely drain the coolant. –...

  • Page 120: Refilling With Coolant

    Rinse the affected area immediately with plenty of water in the event of contact with the skin. – Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes. – Change clothing if coolant spills onto your clothing. (TC 250) – Make sure that screw is tightened. –...
  • Page 121 15 COOLING SYSTEM (TX 300) – Make sure that screw is tightened. – Position the motorcycle upright. – Completely fill the radiator with coolant. Coolant ( p. 153) S01288-10 – Loosen screw until coolant escapes without bubbles. – Mount and tighten screw Guideline Bleeder screw, 10 Nm (7.4 lbf ft)

  • Page 122: Tuning The Engine

    Adjust the play in the throttle cable. p. 120) 16.2 Adjusting the play in the throttle cable Preparatory work (TC 250) – Turn the tap handle of the fuel tap to the OFF position. (TX 300) – Turn the tap handle of the fuel tap to the OFF position.

  • Page 123: Carburetor Setting

    16 TUNING THE ENGINE – Turn adjusting screw in such a way there is throttle cable play in the throttle grip. Guideline Play in throttle cable 2 … 3 mm (0.08 … 0.12 in) – Tighten nut – Slide on sleeve 400192-11 Finishing work –...
  • Page 124 16 TUNING THE ENGINE If the engine stutters when accelerating with a partially open throttle slide, the jet needle must be lowered. If the engine knocks when accelerating at the full power rpm range, the jet needle must be raised. Cylindrical part of the needle CYL The cylindrical part of the needle has the greatest influence when the throttle slide is almost closed.

  • Page 125: Carburetor - Idle

    Wear can result in malfunctioning. 402799-10 The factory setting for the carburetor is set for the following val- ues. (TC 250) Height above sea 301 … 750 m (988 … 2,461 ft) level Ambient tempera- 6 …...

  • Page 126: Carburetor - Adjusting The Idle Speed

    16 TUNING THE ENGINE (TX 300) Height above sea 301 … 750 m (988 … 2,461 ft) level Ambient tempera- 16 … 24 °C (61 … 75 °F) ture Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60) ( p.

  • Page 127: Emptying The Carburetor Float Chamber

    Carry out this work with a cold engine. Water in the float chamber results in malfunctioning. Preparatory work (TC 250) – Turn the tap handle of the fuel tap to the OFF position. Fuel no longer flows from the fuel tank to the carbu-...

  • Page 128: Checking The Basic Position Of The Shift Lever

    16 TUNING THE ENGINE (TX 300) – Turn the tap handle of the fuel tap to the OFF position. Fuel no longer flows from the fuel tank to the carbu- retor. Main work – Place a cloth under the carburetor to capture the draining fuel.

  • Page 129: Engine Characteristic - Auxiliary Spring

    16 TUNING THE ENGINE – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.
  • Page 130 16 TUNING THE ENGINE Main work (TC 250) – Remove screws K00896-10 – Remove cap , adjusting spring , auxiliary spring , and spring insert from the clutch cover. – Pull both springs off of the spring insert. B00056-11 –...
  • Page 131 16 TUNING THE ENGINE – Remove cap , adjusting spring , auxiliary spring , and spring insert from the clutch cover. – Pull both springs off of the spring insert. B00056-11 – Mount the required auxiliary spring ( p. 127) adjusting spring and position them together in the clutch cover.

  • Page 132: Service Work On The Engine

    – Mount and tighten the gear oil monitoring screw. Guideline K00898-10 Screw, gear oil level 10 Nm (7.4 lbf ft) check (TC 250) Screw, gear oil level 10 Nm (7.4 lbf ft) check (TX 300) 17.2 Changing the gear oil Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.

  • Page 133: Adding Gear Oil

    Guideline Gear oil drain M12x1.5 20 Nm (14.8 lbf ft) plug with magnet (TC 250) Gear oil drain plug M12x1.5 20 Nm (14.8 lbf ft) with magnet (TX 300) – Fill in gear oil.
  • Page 134 153) – Mount and tighten the gear oil monitoring screw. Guideline Screw, gear oil level 10 Nm (7.4 lbf ft) check (TC 250) 401955-11 Screw, gear oil level 10 Nm (7.4 lbf ft) check (TX 300) – Mount and tighten filler plug...

  • Page 135: Cleaning, Care

    18 CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 136 18 CLEANING, CARE – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 155) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 137: Storage

    108) 401058-01 – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info Husqvarna Motorcycles recommends raising the motorcycle. – Raise the motorcycle with a lift stand. ( p. 53) – Cover the vehicle with a tarp or similar cover that is perme- able to air.

  • Page 138: Preparing For Use After Storage

    19 STORAGE 19.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 53) – Perform checks and maintenance measures when preparing for use. ( p. 32) – Make a test ride. 401059-01...

  • Page 139: Troubleshooting

    – Electrode distance (plug gap) Adjust the plug gap. of spark plug too wide Guideline (TC 250) Spark plug electrode gap 0.60 mm (0.0236 in) (TX 300) Spark plug electrode gap 0.60 mm (0.0236 in) –...
  • Page 140 Diaphragm or reed valve hous- Check the diaphragm and reed valve ing damaged housing. Engine stalls or is popping into Lack of fuel (TC 250) – Turn the tap handle of the fuel tap the carburetor to the ON position. (TX 300) –...

  • Page 141: Technical Data

    21 TECHNICAL DATA 21.1 Engine 21.1.1 TC 250 Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 249 cm³ (15.19 cu in) Stroke 72 mm (2.83 in) Hole 66.4 mm (2.614 in) Exhaust valve, beginning of adjustment...

  • Page 142: Engine Tightening Torques

    Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kick starter and electric starter 21.2 Engine tightening torques 21.2.1 TC 250 ® Screw, inner membrane sheets EJOTDELTA PT 35x25 1 Nm (0.7 lbf ft) ® Screw, membrane support plate...

  • Page 143: Tx 300

    21 TECHNICAL DATA Screw, control flap, exhaust con- 10 Nm (7.4 lbf ft) ® Loctite 243™ trol Screw, engine case 10 Nm (7.4 lbf ft) Screw, exhaust flange 8 Nm (5.9 lbf ft) Screw, gear oil level check 10 Nm (7.4 lbf ft) Screw, intake flange/reed valve 6 Nm (4.4 lbf ft) housing...
  • Page 144 21 TECHNICAL DATA Screw, exhaust control cover 4 Nm (3 lbf ft) ® Loctite 222™ Screw, locking lever 6 Nm (4.4 lbf ft) ® Loctite 243™ Screw, retaining bracket of 7 Nm (5.2 lbf ft) ® Loctite 2701™ exhaust control Screw, water pump impeller 6 Nm (4.4 lbf ft) ®...
  • Page 145 21 TECHNICAL DATA Nut, primary gear M18LHx1.5 150 Nm (110.6 lbf ft) ® Loctite 648™...

  • Page 146: Carburetor

    42.5 (37.5 / 40 / 45 / 47.5) Starting jet Needle jet S‑1 Idle air adjusting screw Open 1.5 turns 21.3.2 Carburetor - basic setting for sandy surfaces (TC 250) Idle air adjusting screw Open 1.5 turns Idling jet Jet needle 6BFY44‑73 Needle position...

  • Page 147: Carburetor Tuning (Tc 250)

    21 TECHNICAL DATA 21.3.3 Carburetor tuning (TC 250) 402893-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from top Main jet Info Do not use on sandy terrain.

  • Page 148: Carburetor Tuning (Tx 300)

    21 TECHNICAL DATA 21.3.4 TX 300 Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 80 Needle position 2nd position from top Jet needle 6BFY43-75 (6BFY42-75) Main jet 450 (430, 440, 460) Idling jet 25 (22.5/27.5) Starting jet Needle jet S‑4 Idle air adjusting screw Open...

  • Page 149: Capacities

    21.4.3 Fuel Total fuel tank capacity, approx. 7 l (1.8 US gal) Super unleaded (95 octane) mixed (TC 250) with 2-stroke engine oil (1:60) p. 154) Total fuel tank capacity, approx. 10 l (2.6 US gal) Super unleaded (95 octane) mixed...

  • Page 150: Electrical System

    Ground clearance unloaded (TC 250) 375 mm (14.76 in) Ground clearance unloaded (TX 300) 370 mm (14.57 in) Weight without fuel, approx. (TC 250) 95.8 kg (211.2 lb.) Weight without fuel, approx. (TX 300) 98.4 kg (216.9 lb.) Maximum permissible front axle load 145 kg (320 lb.)

  • Page 151: Shock Absorber

    Oil capacity, right cartridge 380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1) p. 154) 21.9 Shock absorber 21.9.1 TC 250 Shock absorber article number 18.18.7R.53 Shock absorber WP Performance Systems 5018 DCC Link Compression damping, low-speed Comfort 17 clicks...
  • Page 152 21 TECHNICAL DATA Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 5 mm (0.2 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 39 N/mm (223 lb/in) Weight of rider: 75 …...

  • Page 153: Chassis Tightening Torques

    21 TECHNICAL DATA 21.10 Chassis tightening torques Screw, fixed grip 5 Nm (3.7 lbf ft) ® Loctite 243™ Screw, service hour counter 1 Nm (0.7 lbf ft) Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) Remaining nuts, chassis...
  • Page 154 21 TECHNICAL DATA Screw, top triple clamp 17 Nm (12.5 lbf ft) Engine bracket screw 60 Nm (44.3 lbf ft) Remaining nuts, chassis 45 Nm (33.2 lbf ft) Remaining screws, chassis 45 Nm (33.2 lbf ft) Screw, bottom shock absorber 60 Nm (44.3 lbf ft) ®...

  • Page 155: Substances

    22 SUBSTANCES Brake fluid DOT 4 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties. Recommended supplier Bel‑Ray ® – Super DOT 4 Brake Fluid Coolant Guideline –...
  • Page 156 22 SUBSTANCES Recommended supplier ® Bel‑Ray – Si‑7 Synthetic 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 156) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 157: Auxiliary Substances

    23 AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel‑Ray – Foam Filter Cleaner & Degreaser High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier ® Bel‑Ray – Waterproof Grease Multi-purpose grease (00062010051) Recommended supplier ®...

  • Page 158: Standards

    24 STANDARDS JASO T903 MA Different technical development directions required a separate specification for motorcycles – the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 159: List Of Abbreviations

    25 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 160: Index

    INDEX INDEX Chain checking ......80 Accessories ......10 cleaning .
  • Page 161 INDEX Figures ......10 Implied warranty ..... . 10 Intended use .
  • Page 162 INDEX Refueling chassis ......147 fuel ......36 chassis tightening torques .
  • Page 163 *3402165en* 3402165en 06/2017 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer, www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...

This manual is also suitable for:

Tx 300Tc 125

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