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2009 TC 250
User Manuals: Husqvarna 2009 TC 250 Motorbike
Manuals and User Guides for Husqvarna 2009 TC 250 Motorbike. We have
2
Husqvarna 2009 TC 250 Motorbike manuals available for free PDF download: Workshop Manual, Owner's Manual
Husqvarna 2009 TC 250 Workshop Manual (420 pages)
Brand:
Husqvarna
| Category:
Motorcycle
| Size: 27.75 MB
Table of Contents
Table of Contents
5
Foreword, Table of Contents
3
Workshop Manual
3
Table of Contents
5
Important Notices
7
General Information
9
Table of Contents
10
Cooling
11
Drive and Transmission
11
Engine
11
Fuel System
11
Ignition System
11
Lubrication
11
Starter
11
Timing System
11
Brakes
12
Chassis
12
Suspension
12
Wheels
12
Electrical Components Location
13
Tyres
13
Overall Dimensions - Weight
14
Capacities
15
Maintenance
17
Troubleshooting
25
Settings and Adjustments
31
Settings and Adjustments
32
Saddle Removal
34
Tank Removal (TC)
34
Tank Removal (te - TXC)
35
Valve Clearance Adjustment
36
Throttle Cable Adjustment (TC)
37
Enrichener Lever Play Adjustment (te - TXC)
38
Throttle Cable Adjustment (te - TXC)
38
Carburettor Adjustment (TC)
39
Idle Adjustment (TC)
39
Idle Adjustment (te - TXC)
39
Clutch Plate Replacement
40
Hydraulic Clutch Lever Adjustment and Fluid Level Check
41
Front Brake Lever Adjustment and Fluid Level Check
42
Rear Brake Pedal Adjustment
43
Rear Brake Fluid Level Check
44
Rear Brake Pedal Free Play Adjustment
44
Engine Oil Level Check
45
Engine Oil Replacement and Mesh Filters-Filter Cartridge Cleaning or Replacement
46
Coolant Level Check
47
Coolant Replacement
47
Air Filter Check (TC)
48
Air Filter Check (te - TXC)
49
Air Filter Cleaning
49
Secondary Drive Chain Adjustment
51
Chain Lubrication
52
Lubricating a Chain Without O-Rings
52
Lubricating an O-Ring Chain
52
Washing a Chain Without O-Rings
52
Suspension Setup According to Track Condition
53
Shock Absorber Spring Preload Adjustment
55
Shock Absorber Compression and Rebound Damping Adjustment
56
Shock Absorber Springs
56
MARZOCCHI Front Fork Adjustment (TC 2009)
57
KAYBA Front Fork Adjustment (TC - te - TXC / 2010)
58
KAYBA Front Fork Springs
59
MARZOCCHI Front Fork Springs
60
Steering Angle Adjustment
61
Steering Bearing Clearance Adjustment
61
Changing Handlebar Position and Height
62
Supply Hose Check (TC)
63
Supply Hose Check (te - TXC)
63
Silencer Sound Deadening Material Replacement
64
Exhaust System Check
65
General Procedures
67
General Procedures
68
Foreword
69
Saddle Removal
70
Side Panel Removal
70
Removing the Rear Chassis Complete with Mudguard and Air Box (TC)
71
Removing the Rear Chassis Complete with Mudguard and Air Box (TE-TXC)
71
Exhaust System Removal
74
Fuel Tank, Scoop and Spoiler Removal (TC)
76
Fuel Tank, Scoop and Spoiler Removal (TE-TXC)
79
Fuel Pump Removal (TE-TXC)
82
Solenoid Starter Removal (TE-TXC)
83
CDI Electronic Control Unit Removal
84
Voltage Regulator Removal (TE-TXC)
84
Ignition Coil Removal
85
Clutch Hose Removal
86
Horn Removal (TE)
86
Electric Cooling Fan Removal (TE-TXC)
87
Engine Removal
88
Secondary Drive Chain Removal
88
Radiator Removal
96
Thermostat Removal (TE-TXC)
97
Engine Disassembly
99
Engine Disassembly
100
Layout of Engine Components
101
Camshaft Removal
102
Cylinder Head Cover Removal
102
Water Pump Body Removal
106
Water Pump Disassembly
106
Cylinder Head Removal
108
Valve Removal
110
Cylinder Removal
112
Piston Removal
112
Flywheel Removal
113
Kick Start Pedal Removal
114
Sprocket Removal
114
Oil Filter Removal
116
Clutch Cover Removal
117
Clutch Disassembly
118
Kick Start Disassembly
121
Slider Removal
121
Starter Motor Removal (TE-TXC)
123
Starter Drive Disassembly (te - TXC)
125
Starter Motor Disassembly (TE-TXC)
125
Gear Shift Pedal and Selector Assembly Removal
128
Oil Pump Disassembly
128
Primary Drive Gear Removal
131
Crankcase Disassembly
132
Gearbox Disassembly
133
Crankshaft Disassembly
135
Engine Overhaul
137
Table of Contents
138
Cleaning Parts
139
Clearances
139
Cylinder Head
139
Valve Guide
140
Valve Seat Refacing
140
Valve Guide Replacement
141
Valve
142
Valve Spring
143
Valve Bucket Inspection
144
Valve Installation
144
Valve Leak Check
145
Camshaft
146
Timing Chain and Gears
146
Timing Chain Tensioners
146
Cylinder
147
Piston
147
Cylinder to Piston Clearance
148
Piston Pin
148
Piston Ring to Cylinder Clearance
149
Piston Rings
149
Big End Axial Clearance
150
Piston Ring to Groove Clearance
150
Crankshaft
151
Crankshaft Straightness
151
Clutch
152
Clutch Spring
153
Friction Plate to Clutch Housing Clearance
153
Oil Pump
155
Drive Bushing Roundness
156
Selector Drum
156
Shifter Forks and Gears
156
Carburettor Overhaul (TC)
157
Keihin" Carburettor Setting (TC)
157
Keihin" Carburettor Adjustment (TC)
158
Carburettor Inspection (TC)
159
Needle Assembly (TC)
160
Taper Needle (TC)
160
Throttle Valve (TC)
160
Accelerator Pump (TC)
161
Floater (TC)
161
Floater Height (TC)
161
Draining the Fuel (TC)
162
Engine Reassembly
163
Table of Contents
164
General
165
Assembly and Lubrication Instructions (CRANK- ALTERNATOR- LUBRICATION- LEFT CRANKCASE HALF)
166
Tightening Torque Figures
167
Assembly and Lubrication Instructions (GEARBOX - GEAR SHIFT CONTROL)
168
Tightening Torque Figures
169
Assembly and Lubrication Instructions (CLUTCH - KICK START- LUBRICATION- RIGHT CRANKCASE HALF)
170
Tightening Torque Figures
171
Assembly and Lubrication Instructions (RIGHT CRANKCASE HALF COVER)
172
Tightening Torque Figures
173
Assembly and Lubrication Instructions (HEAD - CYLINDER - PISTON - TIMING SYSTEM - WATER PUMP - SPARK PLUG)
174
Tightening Torque Figures
177
Crankshaft Assembly
178
Input Shaft (5 SPEED)
181
Output Shaft (5 SPEED)
182
Input Shaft (6 SPEED)
184
Crankcase Assembly
186
Gear Shift Control Assembly
191
Kick Start Assembly
195
Timing Chain and Primary Drive Assembly
196
Clutch Assembly
199
Sprocket Installation
201
Flywheel Installation (TC)
202
Flywheel and Starter Motor Installation (TE-TXC)
203
Assemble the Starter Motor (7)
204
Flywheel Installation (TC)
204
Piston and Cylinder Installation
205
Piston Ring Installation
205
Cylinder Head Gasket Selection Table
207
Cylinder Head Installation
208
Timing Chain Tensioner Installation
210
Camshaft Installation
211
Flywheel Cover Installation (TC)
213
Neutral Sensor Installation
214
Cylinder Head Cover, Spark Plug, Oil Feed Hose Installation
215
Starter Motor Seat Cover Installation (TC)
215
Right Crankcase Assembly
216
Filter and Drain Plug
218
Oil Feed Hose Installation
218
Gear Shift and Kick Start Pedal Installation
219
Installing the Engine and Assembling the Motorcycle
220
Front Suspension
221
Table of Contents
222
Front Fork Removal
224
Front Suspension Mod. TC-TXC /2010
226
Service Instructions for Ø48USD Kayba Fork - TC-TXC 250/2010
226
Front Suspension (TC - TXC)
227
Front Fork Disassembly (TC - TXC)
228
Front Suspension (TE)
238
Front Suspension Mod. te /2010
238
Front Suspension
248
Front Suspension Mod. TC /2009
248
Service Instructions for Ø50USD Fork
249
Fork Components
250
General Overhaul Instructions
251
Placing the Fork in a Vice
251
General Maintenance
252
Troubleshooting
252
Assembly
253
Cleaning the Fork Legs
253
Disassembly
253
Bleeding
254
Draining Oil
255
Cartridge Removal
256
Checking and Changing Cartridge and Compression Valve Setting
256
Assembly
258
Disassembly
258
Rebound Adjuster Servicing
258
Assembly
259
Compression Valve Servicing
259
Disassembly
259
Cartridge Assembly
260
Separating Inner and Outer Tube - Sealing Ring Removal
263
Assembling Inner and Outer Tube - Sealing Ring Installation
264
Cartridge Assembly
265
Installing the Fork on the Motorcycle
266
Oil Filling
266
How to Measure Sag
267
Rider Sag Adjustment
267
Settings
267
Rebound Adjustment
268
Spring Preload Adjustment
268
Compression Adjustment
269
Rear Suspension
271
Rear Suspension
272
Lubrication Points (Grease)
273
Rear Shock Absorber
273
Rear Suspension
273
Rear Shock Absorber Removal
275
Disassembling, Servicing and Assembling the Rear Shock Absorber
276
Shock Absorber Inspection
276
Spring Servicing
276
Piston Assembly Inspections
279
Seal Replacement
279
Checking the Setting
280
Reservoir Replacement
281
Floating Piston Removal
282
Shock Absorber Assembly
282
Shock Absorber Damping Adjustment
285
Disassembling and Servicing the Swinging Arm
286
Servicing the Swinging Arm Shaft
287
Chain Roller, Chain Guide, Chain Slider
288
Brakes
289
Brakes
290
Braking System
291
Brake Disc
292
Checking Brake Pads for Wear / Replacing the Pads
293
Bleeding the Front Braking System
294
Bleeding the Rear Braking System
295
Changing the Fluid
296
Electrical System
299
Table of Contents
301
Colour Coding Key
303
Key to Wiring Diagram
303
Wiring Diagram (TC)
303
Colour Coding Key
304
Key to Wiring Diagram
304
Wiring Diagram (TE)
304
Colour Coding Key
305
Key to Wiring Diagram
305
Wiring Diagram (TXC)
305
Electrical Components Location (TC)
306
Electrical Components Location (TE)
307
Electrical Components Location (TXC)
311
Checking Generator Stator Windings Resistance
314
Generator No-Load Performance (TC)
315
Ignition System (TC)
316
Ignition System (te - TXC)
317
Key
317
Key to Wiring Diagram
318
Charging System (te - Txc)
319
Charging System Wiring Diagram
319
Charging System Inspections
320
Current Loss at the Battery (te - TXC)
320
Regulated Voltage (te - TXC)
320
Voltage Regulator (te - TXC)
320
Voltage Regulator/Rectifier Inspection (te - TXC)
320
Voltage Regulator/Rectifier Wiring Diagram
320
Electrical Starting System (te - Txc)
321
Solenoid Starter Inspection (te - TXC)
322
Starter Motor Inspection (te - TXC)
322
Starter Motor Test Curves (te - TXC)
322
Starting System Inspection
322
Checking Coil Windings Resistance
323
Electronic Control Unit (ECU)
324
Spark Plug
324
Gear Position Sensor Inspection (GPS: Gear Position Sensor)
325
(TPS: Throttle Position Sensor) (TC)
326
Battery (te - Txc)
327
Battery Charger
327
Headlamp Adjustment
328
Headlamp Bulbs Replacement
328
Headlamp, Tail Light (Te)
328
Number Plate Bulb Replacement
329
Tail Light Replacement
329
Handlebar Switches
330
Left-Hand Switch (TC)
330
Left-Hand Switch (TE)
330
Colour Coding Key
331
Right-Hand Switch (te - TXC)
331
Fuses
332
Semiconductor Parts
332
Digital Dashboard, Warning Lights (Te)
333
SPEED / NUMBER of RPM
335
Warning Lights Panel (TXC)
335
Charging System (te - Txc)
336
Dashboard Replacement (TE)
336
Electronic Ignition System
336
Starting System (te - Txc)
336
Troubleshooting
336
Cable Routing and Electrical Parts Installation Instructions (TC)
338
Fuel Injection Control Unit Position (TC)
338
HT Coil Position (TC)
338
Securing Engine Stop Button Ground Cable to Chassis (TC)
338
Control Unit Connection (TC)
339
Gear Sensor Cable Connection (TC)
339
Ignition Coil Connection (TC)
339
Securing the Engine Stop Button Cable (TC)
340
Wiring (te - TXC)
341
Cable Routing and Electrical Parts Installation Instructions "Te - Txc
342
Coil Position te -TXC
342
Turning Indicators Flasher (TE) and Solenoid Starter Position
342
(Te - Txc)
343
Electronic Control Unit and Voltage Regulator Position
343
Securing the Starter Motor/Solenoid Starter Cable (te - TXC)
343
Battery Negative Cable Routing (te - TXC)
343
Securing the Voltage Regulator Ground Cable (te - TXC)
344
Securing the Engine Ground / Chassis Ground Cables
344
Electrical System Ground
344
Wiring Connection to Voltage Regulator (te - TXC)
344
Electric Fan Connection (te - TXC)
345
Ignition Coil Connection (te - TXC)
345
Fuel Pump Connector Position (te -TXC)
346
MAQS Connector (te - TXC)
346
• Engine Water Temperature Connector
346
(Te - Txc)
346
• Lambda Sensor Position And Connector
346
Air Box Cable Routing
347
Clip Installation on Fuse Holders
347
Ignition and Gear Sensor Cable Connection
347
Dashboard Bracket Connectors (TE)
348
Headlamp, Front Turning Indicators, STOP Connection (TE)
348
Rear Stop Connection
348
Routing of Steering Head Tube Wiring
348
Double Map Connector Cap (TE)
349
Horn Connector (TE)
349
Speed Sensor and Ignition Switch Connectors (TE)
349
Securing the Wiring Harness
350
Securing the Wiring Harness to Rear Chassis Left Side
350
Securing the Wiring Harness to Rear Chassis Right Side
350
Securing the Wiring Harness to the Chassis
350
Securing the Wiring Harness
351
Engine Cooling
353
Engine Cooling
354
Coolant Level Check
355
Cooling Circuit (TC)
356
Engine Cooling System Overhaul (TC)
357
Cooling Circuit (TE-TXC)
358
Engine Cooling System Overhaul (TE-TXC)
359
KIT" Installation Instructions
361
"Kit" Installation Instructions
362
Carburettor KIT (TC)
363
Central Engine Guard (TE-TC-TXC)
366
Left Muffler Guard (TE)
369
Battery Bracket and Battery (TE-TXC)
370
Turning Indicators KIT (TE)
371
Rear Turning Indicators
372
Rear-View Mirrors (TE)
376
Hydraulically Controlled Clutch
377
Hydraulic Clutch System
379
Draining Clutch Fluid
380
Clutch Master Cylinder Servicing
381
Bleeding the Clutch System
382
Optional Components
383
Fuel Injection System
387
Special Tools
395
Tightening Torque Figures
397
Chassis and Wheels
407
Lubrication Points (Lubricant)
410
Rear Wheel
414
Tightening Torque Figures
415
Wheel Servicing
416
Wheel Axle Warpage
416
Axle Runout over 100 MM
416
Wheel Spokes
417
Wheel Rim Warpage
417
Rear Chain Sprocket, Secondary Drive Sprocket and Chain
418
Tightening Torque Figures
418
Checking Chain and Sprockets for Wear
419
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Husqvarna 2009 TC 250 Owner's Manual (338 pages)
Brand:
Husqvarna
| Category:
Motorcycle
| Size: 3.94 MB
Table of Contents
Italiano
6
Pagina
3
Avvertenze Importanti
4
Presentazione
4
Table of Contents
6
Dati Per L'identificazione
7
Dati Tecnici
9
Tabella DI Lubrificazione, Rifornimenti
11
Comandi
12
Istruzioni Per L'uso del Motociclo
16
Gamba
19
Ubicazione Componenti Elettrici/Impianto Elettrico
57
Dotazione
60
Parti Optional
62
Appendice
63
Operazioni DI Preconsegna
65
Indice Alfabetico
66
English
70
Identification Data
71
Technical Data
73
Agip Racing 4T (10W
75
Controls
76
Riding
80
Equipment
124
Optional Parts List
126
Appendix
127
Pre-Delivery Inspection
129
Tampering Warning
133
Français
138
Avis Important
136
Presentation
136
Elements D'identification
139
Donnees Techniques
141
Tableau de Graissage, Ravitaillements
143
Commandes
144
Mode D'emploi de la Moto
148
Systeme Electrique
190
Fournitures
192
Elements en Option
194
Appendice
195
Operations de Pré Livraison
197
Index Alphabetique
198
Deutsch
202
Daten zur Identifizierung
203
Technische Daten
205
Schmierungstabelle, Tanken
207
Steuerungen
208
Ausrüstung
256
Extra-Teile
258
Voränge zur AUSLIEFERUNG
261
Español
266
Datos para la Identificacion
267
Ficha Tecnica
269
Controles
276
Istrucciones para el Uso de la Motocicleta
276
Partes Opcionales
322
Apendice
323
Operaciones de Pre-Entrega
325
Indice Alfabetico
326
Accensione
330
Carburante
332
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