User Manuals: Husqvarna TC 250 2012 I.E. USA Workshop

Manuals and User Guides for Husqvarna TC 250 2012 I.E. USA Workshop. We have 1 Husqvarna TC 250 2012 I.E. USA Workshop manual available for free PDF download: Workshop Manual

Husqvarna TC 250 2012 I.E. USA Workshop Manual

Husqvarna TC 250 2012 I.E. USA Workshop Manual (376 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 69 MB

Table of Contents

Table of Contents

10
- St Edition (12-2011) -
  2
- Workshop Manual
  3
  - Table of Contents
    10
- Engine
  11
- Transmission
  12
- Rear Brake
  13
  - Electrical Components Location (TE)
    14
- Overall Dimensions
  15
- Weight
  16
Table of Contents

34
Table of Contents

66
- Foreword
  67
- Battery Removal (TE-TCX)
  68
- Saddle Removal
  68
- Side Panel Removal
  68
- Rear Chassis with Mudguard and Air Box Removal (TC)
  69
- Rear Chassis with Mudguard and Air Box Removal (TE-TXC)
  69
- Exhaust System Removal
  72
- Fuel Tank, Scoops and Spoiler Removal
  76
- Fuel Pump Removal (TC)
  80
- Fuel Pump Removal (te - TXC)
  81
- Condenser (TC)
  82
- Start-Up Relay Removal (TE-TXC)
  82
- Voltage Regulator Removal (TC)
  84
- Voltage Regulator Removal (TE-TXC)
  84
- Coil / Stick-Coil Removal (TC)
  85
- Ignition Coil Removal (TE-TXC)
  85
- Clutch Hose Removal
  86
- Horn Removal (TE)
  86
- Electric Cooling Fan Removal (TE-TXC)
  87
- Secondary Drive Chain Removal
  87
- Removal of Engine from Motorcycle
  88
- Radiator Removal
  95
- Thermostat Removal (TE-XC)
  96
Table of Contents

98
- Layout of Engine Components (te - TXC)
  99
- Layout of Engine Components (TC)
  100
- Camshaft Removal (te - TXC)
  102
- Camshaft Removal (TC)
  104
- Water Pump Disassembly
  107
- Valve Removal (TE-TXC)
  115
- Valve Removal (TC)
  117
  - Engine Disassembly
    118
- Cylinder Removal
  119
- Piston Removal
  119
- Flywheel Removal
  120
- Kick Start Pedal Removal
  121
- Sprocket Removal
  121
- Oil Filter Removal
  123
- Clutch Cover Removal
  124
- Clutch Disassembly
  125
- Kick Start Disassembly
  128
- Slider Removal
  128
- Starter Motor Removal (TE-TXC)
  130
- Starter Drive Disassembly (TE-TXC)
  132
- Starter Motor Disassembly (TE-TXC)
  132
- Oil Pump Disassembly
  135
- Gear Shift Pedal and Selector Assembly Removal
  136
- Primary Drive Gear Removal
  138
- Crankcase Disassembly
  139
- Gearbox Disassembly
  140
- Crankshaft Disassembly
  142
Table of Contents

144
- Clearances
  145
- Cylinder Head
  145
- Valve Seat Refacing
  146
- Valve
  147
- Valve Spring (TE-TXC)
  147
- Rocker Arm Check (TC)
  148
- Valve Bucket Inspection (TE-TXC)
  148
- Valve Leak Check
  150
- Camshaft
  151
- Timing Chain and Gears
  151
- Timing Chain Tensioners
  151
- Cylinder
  152
- Piston
  152
- Cylinder to Piston Clearance (TE-TXC)
  153
- Piston Diameter
  153
- Piston Pin
  153
- Piston Ring to Cylinder Clearance
  154
- Piston Rings (TE-TXC)
  154
- Big End Axial Clearance
  155
- Piston Pin to Small End Clearance (A)
  155
- Piston Ring to Groove Clearance
  155
- Crankshaft
  156
- Crankshaft Straightness
  156
- Clutch
  157
- Clutch Spring
  158
- Friction Plate to Clutch Housing Clearance
  158
- Oil Pump
  160
- Drive Bushing Roundness
  161
- Shifter Forks and Gears
  161
Table of Contents

164
- General
  165
- Assembly and Lubrication Instructions
  166
- Crank- Alternator- Lubrication- Left Crankcase Half
  166
- Tightening Torque Figures
  167
- Assembly and Lubrication Instructions
  168
- Gearbox - Gear Shift Control (5 Speed)
  168
- Tightening Torque Figures
  169
- Assembly and Lubrication Instructions
  170
- Gearbox - Gear Shift Control (6 Speed)
  170
- Tightening Torque Figures
  171
- Assembly and Lubrication Instructions
  172
- Clutch- Kick Start- Lubrication- Right Crankcase Half
  172
- Tightening Torque Figures
  173
- Assembly and Lubrication Instructions
  174
- Right Crankcase Cover
  174
- Tightening Torque Figures
  175
- Assembly and Lubrication Instructions
  176
- Head - Cylinder - Piston - Timing System - Water Pump - Spark Plug
  176
- Te-Txc
  176
- Assembly and Lubrication Instructions
  177
- Head - Cylinder - Piston - Timing System - Water Pump - Spark Plug (TC)
  177
- Tightening Torque Figures
  178
- Input Shaft (5 Speed)
  180
- Output Shaft (5 Speed)
  181
- Input Shaft (6 Speed)
  183
- Output Shaft (6 Speed)
  184
- Crankcase Assembly
  185
- Gear Shift Control Assembly
  190
- Kick Start Assembly
  194
- Timing Chain and Primary Drive Assembly
  195
- Clutch Assembly
  198
- Sprocket Installation
  200
- Flywheel and Starter Motor Installation (TE-TXC)
  201
- Flywheel Installation (TC)
  203
- Piston and Cylinder Installation
  204
- Piston Ring Installation
  204
- Cylinder Head Gasket Selection Table
  206
- Water Pump Installation
  210
- Camshaft Installation (TE-TXC)
  211
- Camshaft Installation (TC)
  213
- Flywheel Cover Installation
  215
- Neutral Sensor Installation (TE-TXC)
  216
- Plug Refitting (TC)
  217
- Cylinder Head Cover, Spark Plug (TE-TXC)
  218
- Starter Motor Seat Cover Installation (TC)
  218
- Refitting of the Head Cylinder Cover, Spark Plug, Coil (TC)
  219
- Right Crankcase Assembly
  220
- Blow-By Tube Fitting/Filter (310)
  222
- Filter and Drain Plug (250)
  222
- Oil Feed Hose Installation
  222
- Gear Shift and Kick Start Pedal Installation
  223
- Installing the Engine and Assembling the Motorcycle
  224
Table of Contents

226
- Front Fork Removal
  228
- Front Suspension
  228
- Front Suspension (TC - TXC)
  230
- Service Instructions for Ø48USD Kayaba Fork
  230
- Front Suspension (TE)
  242
Table of Contents

254
Table of Contents

262
- Brake Disc
  263
- Braking System
  263
- Checking Brake Pads for Wear / Replacing the Pads
  265
- Bleeding the Front Braking System
  266
- Bleeding the Rear Braking System
  267
- Changing the Fluid
  268
Table of Contents

272
- Wiring Diagram (TC)
  275
- Wiring Diagram (TE)
  276
- Wiring Diagram (TXC)
  277
- Condenser (TC)
  279
- Electrical Components Location (TXC)
  283
- Checking Generator Stator Windings Resistance
  286
- Generator No-Load Performance
  287
- Ignition and Starter System (TC)
  288
- Ignition and Starter System (TE-TXC)
  289
- Charging System (TE-TXC)
  291
- Charging System Wiring Diagram
  291
- Charging System Inspections
  292
- Current Loss at the Battery (TE-TXC)
  292
- Regulated Voltage (TE-TXC)
  292
- Voltage Regulator
  292
- Voltage Regulator/Rectifier Inspection (TE-TXC)
  292
- Voltage Regulator/Rectifier Wiring Diagram
  292
- Electrical Starting System (TE-TXC)
  293
- Cranking Test
  294
- No-Load Test
  294
- Solenoid Starter Inspection (TE-TXC)
  294
- Starter Motor
  294
- Starter Motor Inspection (TE-TXC)
  294
- Starter Motor Test Curves (TE-TXC)
  294
- Starting System Inspection
  294
- Checking Coil Windings Resistance (TE-TXC)
  295
- Coil Windings Resistance Inspection (TC)
  296
- Electronic Control Unit (ECU)
  297
- Spark Plug
  297
- Gear Position Sensor Inspection (GPS: Gear Position Sensor) (TE-TXC)
  298
- Battery (TE-TXC)
  299
- Battery Charger
  299
- Headlamp Adjustment
  300
- Headlamp Bulbs Replacement
  300
- Headlamp, Tail Light (TE)
  300
- Number Plate Bulb Replacement
  301
- Tail Light Replacement
  301
- Handlebar Switches
  302
- Right-Hand Switch (TE-TXC)
  303
- Fuses (TE-TXC)
  304
- Semiconductor Parts
  304
- Relay Test (te - TXC)
  305
- Digital Dashboard, Warning Lights (TE)
  306
- Warning Lights Panel (TXC)
  308
- Charging System (TE-TXC)
  309
- Dashboard Replacement (TE)
  309
- Electronic Ignition System
  309
- Starting System (TE-TXC)
  309
- Troubleshooting
  309
- Wiring (TC)
  310
- Cable Routing and Electrical Parts Installation Instructions (TC)
  311
- Fuel Injection Control Unit Position (2) (TC)
  311
- Position of the Coil / Stick-Coil
  311
- Position of the Connectors Front Side
  311
- Position of the Voltage Regulator (3) (TC)
  311
- Air Temperature Sensor Connection (TC)
  312
- Connection of the Injector Sensor (7), Throttle Position Sensor (9), and MAP Sensor (8)
  312
  - Fuel Pump Connector Position (TC)
    313
- Control Unit Connection (TC)
  312
  - Ignition Coil / Stick-Coil Connection (TC)
    312
- Securing the Engine Stop Button Cable (TC)
  313
- Securing the Wiring (TC)
  313
- Condenser Connection (TC)
  314
- Voltage Regulator Connection (TC)
  314
  - Connection of Alternator (TC)
    314
- Wiring (TE-TXC)
  315
- Cable Routing and Electrical Parts Installation Instructions "TE-TXC
  316
- Coil Position TE-TXC
  316
- Relay (1) and Fuses (2) Position (TE-TXC)
  316
- Turning Indicators Flasher (3) (TE) and Solenoid Starter
  316
- Battery Negative Cable Routing (TE-TXC)
  317
- Securing the Engine Ground to Chassis and Engine Ground to Battery Cables (8) (TE-TXC)
  317
- Securing the Starter Motor/Solenoid Starter Cable (TE-TXC)
  317
- Securing the Engine Ground / Chassis Ground Cables (10)
  318
- Securing the Voltage Regulator Ground Cable (9) (TE-TXC)
  318
- Clip Installation on Fuse Holders
  321
- Ignition and Gear Sensor Cable Connection
  321
- Routing of Rear Chassis Cables, Tail Light Connection, Flasher Contactor
  321
- Dashboard Bracket Connectors (TE)
  322
- Headlamp, Front Turning Indicators, STOP Connection (TE)
  322
- Rear Stop Connection
  322
- Routing of Steering Head Tube Wiring
  322
- Double Map Connector (TE)
  323
- Horn Connector (TE)
  323
- Speed Sensor and Ignition Switch Connectors (TE)
  323
- Securing the Wiring Harness to Rear Chassis Left Side
  324
- Securing the Wiring Harness to Rear Chassis Right Side
  324
- Securing the Wiring Harness to the Chassis
  324
- Important
  326
Table of Contents

328
- Coolant Level Check
  329
- Cooling Circuit (TC)
  330
- Engine Cooling System Overhaul (TC)
  331
- Cooling Circuit (TE-TXC)
  332
- Engine Cooling System Overhaul (TE-TXC)
  333
Table of Contents

336
- Hydraulic Clutch System
  337
- Draining Clutch Fluid
  338
- Clutch Master Cylinder Servicing
  339
- Bleeding the Clutch System
  340
  - Injection Fuel Feeding System (TE-TXC)
    343
  - Injection Fuel Feeding System (TC)
    344
  - Operation Manual for "HUSQVARNA SERVICE TOOL" for Injection Fuel Feeding System (TE-TXC)
    345
  - Operation Manual for "HUSQVARNA SERVICE TOOL" for Injection Fuel Feeding System (TC)
    347
  - Fuel Pump Test (TE-TXC)
    348
  - Fuel Pump Test (TC)
    349
  - Chassis
    365
  - Lubrication Points (Lubricant)
    366
  - Front Wheel
    367
  - Removing the Front Wheel
    368
  - Reassembling the Front Wheel
    369
  - Speed Sensor (TE)
    369
  - Rear Wheel
    370
  - Removing the Rear Wheel
    371
  - Wheel Servicing
    372
  - Wheel Axle Warpage
    372
  - Axle Runout over 100 MM
    372
  - Wheel Spokes
    373
  - Wheel Rim Warpage
    373
  - Rear Chain Sprocket, Secondary Drive Sprocket and Chain
    374
  - Checking Pinion and Sprockets for Wear
    375

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