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Owner's Manual
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Table of Contents
Troubleshooting
Related Manuals for Husqvarna TC 250 2009
Summarization of Contents
Important Notices
Model Type Classification and Warranty
Classifies TC/TXC as racing, TE as road use, detailing warranty implications for each configuration.
General Information
General Information - Engine and Fuel Systems
Details engine specifications, fuel system type, air cleaning, lubrication, and cooling system.
General Information - Chassis, Suspension, and Brakes
Describes chassis construction, suspension types, brake specifications, and wheel details.
General Information - Tyres, Capacities, and Electrical Components
Lists tyre specifications, fluid capacities, and electrical component locations for various models.
Maintenance
Scheduled Maintenance Chart - TC-TE-TXC (Racing Use)
Outlines regular maintenance tasks for racing motorcycles at specific intervals.
Scheduled Maintenance Chart - TE (Standard Road Use)
Details maintenance schedule for standard TE models for road use at mileage intervals.
Troubleshooting
Troubleshooting - Engine and Transmission Issues
Lists common engine problems like no start, stalling, noise, and transmission issues, with causes and remedies.
Troubleshooting - Chassis and Electrical Issues
Addresses chassis problems like steering, damping, and braking, plus electrical faults like spark plug and battery issues.
Settings and Adjustments
Settings and Adjustments - Fuel and Carburettor Systems
Covers tank removal, valve clearance, throttle cable, carburettor, and idle adjustments.
Settings and Adjustments - Clutch, Brakes, and Suspension
Details clutch plate replacement, brake lever/pedal adjustments, fluid checks, and suspension setup.
Settings and Adjustments - Steering and Handlebar Configuration
Guides on adjusting steering bearing clearance, steering angle, and changing handlebar position and height.
General Procedures
General Procedures - Chassis and Fuel System Removal
Details rear chassis, exhaust system, and fuel tank removal procedures for TC and TE-TXC models.
General Procedures - Engine Component Removal
Covers removal of starter motor, ignition components, clutch hose, horn, and electric cooling fan.
General Procedures - Engine Removal Steps
Outlines the process for removing the engine, including chain, exhaust, and coolant system disconnection.
Engine Disassembly
Engine Disassembly - Cylinder Head and Valve Train
Details removal of cylinder head cover, camshafts, spark plug, head lubrication pipe, and valves.
Engine Disassembly - Piston, Cylinder, and Crankshaft
Covers removal of cylinder, piston, flywheel, crankshaft, and related components.
Engine Disassembly - Clutch, Oil Pump, and Gearbox
Details removal of oil filter, clutch cover, clutch components, oil pump, and gearbox parts.
Engine Disassembly - Starting System and Chassis Components
Covers removal of starter motor, starter drive, and related components.
Engine Overhaul
Engine Overhaul - Cylinder Head and Valve Train Inspection
Covers cleaning, clearances, cylinder head warpage, valve seat refacing, and valve guide servicing.
Engine Overhaul - Piston, Rings, and Crankshaft Checks
Details cylinder, piston, ring clearances, pin, and crankshaft measurements and checks.
Engine Overhaul - Clutch and Oil Pump Servicing
Covers clutch component inspection, friction plate clearance, clutch spring, and oil pump overhaul.
Engine Overhaul - Carburettor (TC) Procedures
Provides instructions for overhauling, setting, and inspecting the Keihin carburettor on TC models.
Engine Reassembly
Engine Reassembly - Crankcase and Gearbox Assembly
Details assembly and lubrication for crankcase, alternator, and gearbox components for 5-speed and 6-speed transmissions.
Engine Reassembly - Clutch and Starting System Assembly
Covers assembly and lubrication for clutch, kick start, and right crankcase half, including torque figures.
Engine Reassembly - Cylinder Head and Timing System Assembly
Details assembly of cylinder head, piston, timing system, water pump, and spark plug, including torque specifications.
Engine Reassembly - Crankshaft and Piston Assembly
Guides on crankshaft assembly, including oil galleries, bearings, connecting rod, and flywheel alignment.
Engine Reassembly - Final Motorcycle Integration
Covers engine installation, drive chain, clutch control, sprocket installation, and overall motorcycle assembly procedures.
Front Suspension
Front Suspension - TC-TXC /2010 Model Service
Provides service instructions for the Kayaba Ø48 USD forks used on TC-TXC 2010 models.
Front Suspension - TE /2010 Model Service
Details service instructions for the Kayaba Ø48 USD forks used on TE 2010 models.
Front Suspension - TC /2009 Model Service
Covers service instructions for the Marzocchi USD telescopic forks on TC 2009 models.
Front Suspension - Overhaul and Adjustments
Outlines general overhaul, troubleshooting, maintenance, and adjustment procedures for front forks.
Rear Suspension
Rear Suspension - Shock Absorber Servicing
Covers spring servicing, shock absorber inspection, reservoir cap removal, piston assembly, and seal replacement.
Rear Suspension - Swinging Arm and Linkage Servicing
Details disassembling and servicing the swinging arm, shaft, and rear suspension drop/drag links.
Rear Suspension - Chain Components Check
Guides on checking wear for chain roller, chain guide, and chain slider, and alignment.
Brakes
Brakes - System Overview and Disc Checks
Describes braking system components and procedures for checking brake discs for wear and warpage.
Brakes - Pad Replacement and Bleeding Procedures
Explains how to check/replace brake pads and bleed both front and rear braking systems.
Electrical System
Electrical System - Wiring Diagrams and Component Locations
Provides wiring diagrams for TC, TE, TXC models, and lists electrical component locations.
Electrical System - Charging, Starting, and Ignition Systems
Details charging system, starting system, and ignition system operations and inspections for TE-TXC and TC models.
Electrical System - Sensors, Dashboard, and Switches
Covers gear position sensor, TPS, battery, dashboard functions, and handlebar switches for various models.
Electrical System - Component Installation and Routing
Provides instructions for routing and installing electrical components and wiring harnesses for TE-TXC models.
Engine Cooling
Engine Cooling - Coolant Level and Circuit Checks
Explains how to check coolant level, safety precautions, and the cooling circuit for TC and TE-TXC models.
Engine Cooling - System Overhaul Procedures
Guides on overhauling the engine cooling system, focusing on radiators and connecting hoses for TC and TE-TXC models.
"KIT" Installation Instructions
"Kit" Installation - Carburettor Kit (TC)
Provides step-by-step instructions for installing the carburettor kit on TC models, including jet replacements.
"Kit" Installation - Guards, Indicators, and Mirrors
Guides on installing engine guards, start hooks, turning indicators, and rear-view mirrors for various models.
Hydraulically Controlled Clutch
Hydraulic Clutch System - Overview and Fluid Management
Explains clutch system components and procedures for draining clutch fluid and servicing the master cylinder.
Hydraulic Clutch System - Bleeding Procedure
Details the step-by-step process for bleeding the hydraulic clutch system to remove air and ensure proper operation.
Fuel Injection System
Fuel Injection System - TE-TXC Operation and Diagnosis
Describes the fuel injection system components, operating parameters, and the use of the diagnostic tool software kit.
Fuel Injection System - Fuel Pump and Relay Testing
Provides procedures for testing the fuel pump and relays on TE-TXC models.
Special Tools
Special Tools Required for Maintenance
Lists essential special tools required for various maintenance and repair tasks, including part numbers.
Tightening Torque Figures
Tightening Torque Figures - Engine Components
Details critical torque specifications for engine components like cylinder head, crankcase, and gearbox.
Tightening Torque Figures - Chassis and Suspension Components
Provides torque values for suspension, chassis, handlebars, controls, fairings, and mudguards.
Tightening Torque Figures - Wheels, Brakes, and Exhaust
Lists torque specifications for wheel, brake, and exhaust system fasteners.
Chassis and Wheels
Chassis and Wheels - Frame and Lubrication Points
Describes chassis construction, dimensions, and key lubrication points for the frame and steering bearings.
Chassis and Wheels - Front and Rear Wheel Service
Covers wheel specifications, removal, installation, tyre pressure, and rear wheel components.
Chassis and Wheels - Wheel Trueness and Chain Maintenance
Guides on servicing wheel bearings, checking axle warpage, wheel balancing, and chain/sprocket wear.
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