Husqvarna TC 250 2009 Manuals

Manuals and User Guides for Husqvarna TC 250 2009. We have 2 Husqvarna TC 250 2009 manuals available for free PDF download: Workshop Manual

Husqvarna TC 250 2009 Workshop Manual

Husqvarna TC 250 2009 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
General Procedures

68
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
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
- 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 TC 250 2009 Workshop Manual

Husqvarna TC 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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