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Husqvarna Manuals
Motorcycle
2009 TC 250
Workshop manual
Husqvarna TC 250 2010 Workshop Manual
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Also See for TC 250 2010
:
Owner's manual
(338 pages)
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Foreword, Table of Contents
Workshop Manual
Table of Contents
Important Notices
General Information
Table of Contents
Cooling
Drive and Transmission
Engine
Fuel System
Ignition System
Lubrication
Starter
Timing System
Brakes
Chassis
Suspension
Wheels
Electrical Components Location
Tyres
Overall Dimensions - Weight
Capacities
Maintenance
Troubleshooting
Settings and Adjustments
Settings and Adjustments
Saddle Removal
Tank Removal (TC)
Tank Removal (te - TXC)
Valve Clearance Adjustment
Throttle Cable Adjustment (TC)
Enrichener Lever Play Adjustment (te - TXC)
Throttle Cable Adjustment (te - TXC)
Carburettor Adjustment (TC)
Idle Adjustment (TC)
Idle Adjustment (te - TXC)
Clutch Plate Replacement
Hydraulic Clutch Lever Adjustment and Fluid Level Check
Front Brake Lever Adjustment and Fluid Level Check
Rear Brake Pedal Adjustment
Rear Brake Fluid Level Check
Rear Brake Pedal Free Play Adjustment
Engine Oil Level Check
Engine Oil Replacement and Mesh Filters-Filter Cartridge Cleaning or Replacement
Coolant Level Check
Coolant Replacement
Air Filter Check (TC)
Air Filter Check (te - TXC)
Air Filter Cleaning
Secondary Drive Chain Adjustment
Chain Lubrication
Lubricating a Chain Without O-Rings
Lubricating an O-Ring Chain
Washing a Chain Without O-Rings
Suspension Setup According to Track Condition
Shock Absorber Spring Preload Adjustment
Shock Absorber Compression and Rebound Damping Adjustment
Shock Absorber Springs
MARZOCCHI Front Fork Adjustment (TC 2009)
KAYBA Front Fork Adjustment (TC - te - TXC / 2010)
KAYBA Front Fork Springs
MARZOCCHI Front Fork Springs
Steering Angle Adjustment
Steering Bearing Clearance Adjustment
Changing Handlebar Position and Height
Supply Hose Check (TC)
Supply Hose Check (te - TXC)
Silencer Sound Deadening Material Replacement
Exhaust System Check
General Procedures
General Procedures
Foreword
Saddle Removal
Side Panel Removal
Removing the Rear Chassis Complete with Mudguard and Air Box (TC)
Removing the Rear Chassis Complete with Mudguard and Air Box (TE-TXC)
Exhaust System Removal
Fuel Tank, Scoop and Spoiler Removal (TC)
Fuel Tank, Scoop and Spoiler Removal (TE-TXC)
Fuel Pump Removal (TE-TXC)
Solenoid Starter Removal (TE-TXC)
CDI Electronic Control Unit Removal
Voltage Regulator Removal (TE-TXC)
Ignition Coil Removal
Clutch Hose Removal
Horn Removal (TE)
Electric Cooling Fan Removal (TE-TXC)
Engine Removal
Secondary Drive Chain Removal
Radiator Removal
Thermostat Removal (TE-TXC)
Engine Disassembly
Engine Disassembly
Layout of Engine Components
Camshaft Removal
Cylinder Head Cover Removal
Water Pump Body Removal
Water Pump Disassembly
Cylinder Head Removal
Valve Removal
Cylinder Removal
Piston Removal
Flywheel Removal
Kick Start Pedal Removal
Sprocket Removal
Oil Filter Removal
Clutch Cover Removal
Clutch Disassembly
Kick Start Disassembly
Slider Removal
Starter Motor Removal (TE-TXC)
Starter Drive Disassembly (te - TXC)
Starter Motor Disassembly (TE-TXC)
Gear Shift Pedal and Selector Assembly Removal
Oil Pump Disassembly
Primary Drive Gear Removal
Crankcase Disassembly
Gearbox Disassembly
Crankshaft Disassembly
Engine Overhaul
Table of Contents
Cleaning Parts
Clearances
Cylinder Head
Valve Guide
Valve Seat Refacing
Valve Guide Replacement
Valve
Valve Spring
Valve Bucket Inspection
Valve Installation
Valve Leak Check
Camshaft
Timing Chain and Gears
Timing Chain Tensioners
Cylinder
Piston
Cylinder to Piston Clearance
Piston Pin
Piston Ring to Cylinder Clearance
Piston Rings
Big End Axial Clearance
Piston Ring to Groove Clearance
Crankshaft
Crankshaft Straightness
Clutch
Clutch Spring
Friction Plate to Clutch Housing Clearance
Oil Pump
Drive Bushing Roundness
Selector Drum
Shifter Forks and Gears
Carburettor Overhaul (TC)
Keihin" Carburettor Setting (TC)
Keihin" Carburettor Adjustment (TC)
Carburettor Inspection (TC)
Needle Assembly (TC)
Taper Needle (TC)
Throttle Valve (TC)
Accelerator Pump (TC)
Floater (TC)
Floater Height (TC)
Draining the Fuel (TC)
Engine Reassembly
Table of Contents
General
Assembly and Lubrication Instructions (CRANK- ALTERNATOR- LUBRICATION- LEFT CRANKCASE HALF)
Tightening Torque Figures
Assembly and Lubrication Instructions (GEARBOX - GEAR SHIFT CONTROL)
Tightening Torque Figures
Assembly and Lubrication Instructions (CLUTCH - KICK START- LUBRICATION- RIGHT CRANKCASE HALF)
Tightening Torque Figures
Assembly and Lubrication Instructions (RIGHT CRANKCASE HALF COVER)
Tightening Torque Figures
Assembly and Lubrication Instructions (HEAD - CYLINDER - PISTON - TIMING SYSTEM - WATER PUMP - SPARK PLUG)
Tightening Torque Figures
Crankshaft Assembly
Input Shaft (5 SPEED)
Output Shaft (5 SPEED)
Input Shaft (6 SPEED)
Crankcase Assembly
Gear Shift Control Assembly
Kick Start Assembly
Timing Chain and Primary Drive Assembly
Clutch Assembly
Sprocket Installation
Flywheel Installation (TC)
Flywheel and Starter Motor Installation (TE-TXC)
Assemble the Starter Motor (7)
Flywheel Installation (TC)
Piston and Cylinder Installation
Piston Ring Installation
Cylinder Head Gasket Selection Table
Cylinder Head Installation
Timing Chain Tensioner Installation
Camshaft Installation
Flywheel Cover Installation (TC)
Neutral Sensor Installation
Cylinder Head Cover, Spark Plug, Oil Feed Hose Installation
Starter Motor Seat Cover Installation (TC)
Right Crankcase Assembly
Filter and Drain Plug
Oil Feed Hose Installation
Gear Shift and Kick Start Pedal Installation
Installing the Engine and Assembling the Motorcycle
Front Suspension
Table of Contents
Front Fork Removal
Front Suspension Mod. TC-TXC /2010
Service Instructions for Ø48USD Kayba Fork - TC-TXC 250/2010
Front Suspension (TC - TXC)
Front Fork Disassembly (TC - TXC)
Front Suspension (TE)
Front Suspension Mod. te /2010
Front Suspension
Front Suspension Mod. TC /2009
Service Instructions for Ø50USD Fork
Fork Components
General Overhaul Instructions
Placing the Fork in a Vice
General Maintenance
Troubleshooting
Assembly
Cleaning the Fork Legs
Disassembly
Bleeding
Draining Oil
Cartridge Removal
Checking and Changing Cartridge and Compression Valve Setting
Assembly
Disassembly
Rebound Adjuster Servicing
Assembly
Compression Valve Servicing
Disassembly
Cartridge Assembly
Separating Inner and Outer Tube - Sealing Ring Removal
Assembling Inner and Outer Tube - Sealing Ring Installation
Cartridge Assembly
Installing the Fork on the Motorcycle
Oil Filling
How to Measure Sag
Rider Sag Adjustment
Settings
Rebound Adjustment
Spring Preload Adjustment
Compression Adjustment
Rear Suspension
Rear Suspension
Lubrication Points (Grease)
Rear Shock Absorber
Rear Suspension
Rear Shock Absorber Removal
Disassembling, Servicing and Assembling the Rear Shock Absorber
Shock Absorber Inspection
Spring Servicing
Piston Assembly Inspections
Seal Replacement
Checking the Setting
Reservoir Replacement
Floating Piston Removal
Shock Absorber Assembly
Shock Absorber Damping Adjustment
Disassembling and Servicing the Swinging Arm
Servicing the Swinging Arm Shaft
Chain Roller, Chain Guide, Chain Slider
Brakes
Brakes
Braking System
Brake Disc
Checking Brake Pads for Wear / Replacing the Pads
Bleeding the Front Braking System
Bleeding the Rear Braking System
Changing the Fluid
Electrical System
Table of Contents
Colour Coding Key
Key to Wiring Diagram
Wiring Diagram (TC)
Colour Coding Key
Key to Wiring Diagram
Wiring Diagram (TE)
Colour Coding Key
Key to Wiring Diagram
Wiring Diagram (TXC)
Electrical Components Location (TC)
Electrical Components Location (TE)
Electrical Components Location (TXC)
Checking Generator Stator Windings Resistance
Generator No-Load Performance (TC)
Ignition System (TC)
Ignition System (te - TXC)
Key
Key to Wiring Diagram
Charging System (te - Txc)
Charging System Wiring Diagram
Charging System Inspections
Current Loss at the Battery (te - TXC)
Regulated Voltage (te - TXC)
Voltage Regulator (te - TXC)
Voltage Regulator/Rectifier Inspection (te - TXC)
Voltage Regulator/Rectifier Wiring Diagram
Electrical Starting System (te - Txc)
Solenoid Starter Inspection (te - TXC)
Starter Motor Inspection (te - TXC)
Starter Motor Test Curves (te - TXC)
Starting System Inspection
Checking Coil Windings Resistance
Electronic Control Unit (ECU)
Spark Plug
Gear Position Sensor Inspection (GPS: Gear Position Sensor)
(TPS: Throttle Position Sensor) (TC)
Battery (te - Txc)
Battery Charger
Headlamp Adjustment
Headlamp Bulbs Replacement
Headlamp, Tail Light (Te)
Number Plate Bulb Replacement
Tail Light Replacement
Handlebar Switches
Left-Hand Switch (TC)
Left-Hand Switch (TE)
Colour Coding Key
Right-Hand Switch (te - TXC)
Fuses
Semiconductor Parts
Digital Dashboard, Warning Lights (Te)
SPEED / NUMBER of RPM
Warning Lights Panel (TXC)
Charging System (te - Txc)
Dashboard Replacement (TE)
Electronic Ignition System
Starting System (te - Txc)
Troubleshooting
Cable Routing and Electrical Parts Installation Instructions (TC)
Fuel Injection Control Unit Position (TC)
HT Coil Position (TC)
Securing Engine Stop Button Ground Cable to Chassis (TC)
Control Unit Connection (TC)
Gear Sensor Cable Connection (TC)
Ignition Coil Connection (TC)
Securing the Engine Stop Button Cable (TC)
Wiring (te - TXC)
Cable Routing and Electrical Parts Installation Instructions "Te - Txc
Coil Position te -TXC
Turning Indicators Flasher (TE) and Solenoid Starter Position
(Te - Txc)
Electronic Control Unit and Voltage Regulator Position
Securing the Starter Motor/Solenoid Starter Cable (te - TXC)
Battery Negative Cable Routing (te - TXC)
Securing the Voltage Regulator Ground Cable (te - TXC)
Securing the Engine Ground / Chassis Ground Cables
Electrical System Ground
Wiring Connection to Voltage Regulator (te - TXC)
Electric Fan Connection (te - TXC)
Ignition Coil Connection (te - TXC)
Fuel Pump Connector Position (te -TXC)
MAQS Connector (te - TXC)
• Engine Water Temperature Connector
(Te - Txc)
• Lambda Sensor Position And Connector
Air Box Cable Routing
Clip Installation on Fuse Holders
Ignition and Gear Sensor Cable Connection
Dashboard Bracket Connectors (TE)
Headlamp, Front Turning Indicators, STOP Connection (TE)
Rear Stop Connection
Routing of Steering Head Tube Wiring
Double Map Connector Cap (TE)
Horn Connector (TE)
Speed Sensor and Ignition Switch Connectors (TE)
Securing the Wiring Harness
Securing the Wiring Harness to Rear Chassis Left Side
Securing the Wiring Harness to Rear Chassis Right Side
Securing the Wiring Harness to the Chassis
Securing the Wiring Harness
Engine Cooling
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See also:
Owner's Manual
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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Chapters
Table of Contents
5
Table of Contents
10
Settings and Adjustments
32
General Procedures
68
Engine Disassembly
100
Table of Contents
138
Table of Contents
164
Table of Contents
222
Rear Suspension
272
Brakes
290
Table of Contents
301
Engine Cooling
354
"Kit" Installation Instructions
362
Table of Contents
Troubleshooting
Troubleshooting
25
Troubleshooting
252
Dashboard replacement (TE)
336
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This manual is also suitable for:
Tc 250 2009
Txc 250 2010
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