Husqvarna 2009 TC 250 Gebrauchsanweisung

Workshop Manual

TC 250 / 2009

TC 250 / 2010

TE 250 / 2010

TXC 250 / 2010 (USA only)

Part. N. 8000 H1489 (10-2009)

HUSQVARNA MOTORCYCLES S.R.L. - Varese disclaims all liabilities

for any errors or omissions in this manual and reserves the right to make

changes to reect on-going product development. Illustrations in the ma-

nual may differ from actual components. No reproduction in full or in part

without written authorisation.

1st edition (10-2009)

a.1Part. N. 8000 H1489 (10-2009)

FOREWORD, TABLE OF CONTENTS

1st edition (10-2009)

Printed in Italy

Print no. 8000 H1489

MODELS COVERED (from serial number onwards)

HUSQVARNA MOTORCYCLES S.R.L.

BMW Group

Technical Service

Via Nino Bixio, 8

21024

(Varese) - Italy

tel. ++39 0332 75.61.11

tel. ++39 0332 756 558

www.husqvarna-motorcycles.com

Workshop Manual

TC 250: ZKHA300AAAV050001

TC 250 (USA): ZKHTC250#AV000001

TE 250: ZKHA300AAAV050001

TE 250 (USA): ZKHTE250#AV000001

TXC 250: ZKHTX250#AV000001

1. Chassis serial number

TC 250 / 2009

TC 250 / 2010

250:2010;

TXC 250 / 2010 (USA only)

a.2 Part. N. 8000 H1489 (10-2009)

FOREWORD, TABLE OF CONTENTS

Foreword

This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance

and repair of the models covered in this manual. The technical information provided in this manual is a critical comple-

ment to operator training and operators should become thoroughly familiar with it.

For ease of understanding, diagrams and photographs are provided next to the text.

Notes with special signicance are identied as follows throughout the manual:

Accident-prevention rules for operator and persons working nearby.

Damage to vehicle and/or its components may result from incompliance with relevant instructions.

Additional information concerning the operation covered in the text.

Useful tips

To prevent problems and ensure effective service work, observe the following HUSQVARNA recommendations:

– before repair, evaluate the customer's description of the problem and ask the appropriate questions to clearly identify

problem symptoms;

– diagnose the problem and identify the causes clearly. This manual provides basic background information that must

be supplemented with the operator's expertise and specic training available through HUSQVARNA held at regular

periods;

– plan ahead before starting work: gather any spare parts and tools to avoid unnecessary delays;

– avoid unnecessary disassembly work to get to the part that needs repairing.

Always read the relevant instructions and follow the disassembly sequence outlined in this manual.

Recommended shop practices

1 Always replace gaskets, sealing rings and split pins with new ones.

2 When loosening or tightening nuts or bolts, always begin with the bigger ones or from the centre. Tighten to the speci-

ed torque and follow a cross pattern.

3 Always mark any parts or positions that might be confused upon assembly.

4 Use genuine HUSQVARNA parts and the recommended lubricant brands.

5 Use special tools where specied.

6 Technical Bulletins might contain more up-to-date setting data and procedures than this manual. Be sure to read

them.

a.3Part. N. 8000 H1489 (10-2009)

FOREWORD, TABLE OF CONTENTS

Table of Contents

Title Section

Foreword, Table of Contents ...............................................................................a

Important Notices ................................................................................................b

General Information.............................................................................................A

Maintenance........................................................................................................B

Troubleshooting.................................................................................................. C

Settings and Adjustments................................................................................... D

General Procedures ............................................................................................E

Engine Disassembly............................................................................................F

Engine Overhaul.................................................................................................G

Engine Reassembly............................................................................................ H

Front Suspension .................................................................................................I

Rear Suspension.................................................................................................J

Brakes .................................................................................................................L

Electrical System................................................................................................M

Engine Cooling................................................................................................... N

“KIT” Installation Instructions..............................................................................O

Hydraulically Controlled Clutch............................................................................P

Optional Components......................................................................................... Q

Fuel Injection System..........................................................................................S

Special Tools ......................................................................................................W

Tightening Torque Figures...................................................................................X

Chassis and Wheels............................................................................................Y

NOTES

Unless otherwise specied, data and specications apply to all models.

b.1

Part. N. 8000 H1489 (10-2009)

IMPORTANT NOTICES

Section

b.2 Part. N. 8000 H1489 (10-2009)

IMPORTANT NOTICES

1) TC and TXC models are RACING motorcycles and are warranted to be free

fromoperatingdefects;ascheduledmaintenancechartforracinguseisprovided

in Section B.

2) The TE model is for ROAD USE (DERATED); it is warranted to free from

defects and covered by legal warranty, provided that the STANDARD CON-

FIGURATION IS MAINTAINED and the maintenance chart provided in Section

B is observed. For TE models modied to RACING SPECIFICATIONS (FULL

POWER RATING), observe the scheduled maintenance chart for racing use

provided in Section B.

* This motorcycle has not been designed to travel over long distances with the

engineattoprpm,as inlong-distanceroadorhighwaytravel.Ridingoverlong

distances at full throttle may result in severe engine damage.

* The geometry and setup of this motorcycle have been designed for racing

and to provide top performance when riding solo. We advise against riding

two-up, whether off-road or on the track.

* ALWAYS remember that these motorcycles are specically designed for

racing, i.e. for usage conditions signicantly different from those experienced

in regular road use.

IMPORTANT

VEHICLE CONFIGURATION as outlined below is a prerequisite for the war-

ranty to remain valid:

A) STANDARD MOTORCYCLE, FOR ROAD USE: DERATED;

B) RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING.

* In order to maintain the vehicle’s “Guarantee of Functionality”, the client must

follow the maintenance programme indicated in Section B by having the required

maintenance inspections carried out at authorised HUSQVARNA dealers. The

cost for changing parts and for the labour necessary in order to comply with

the maintenance plan is charged to the Client. The warranty becomes NULL

AND VOID if the motorcycle is rented.

Notes

Left and right side is determined when seated on motorcycle.

Z: number of teeth

A: Austria

AUS: Australia

B: Belgium

BR: Brazil

CDN: Canada

CH: Switzerland

D: Germany

E: Spain

F: France

FIN: Finland

GB: Great Britain

I: Italy

J: Japan

USA: United States of America

Unless otherwise specied, data and instructions apply to all market variants.

A.1

Part. N. 8000 H1489 (10-2009)

GENERAL INFORMATION

Section

A.2 Part. N. 8000 H1489 (10-2009)

GENERAL INFORMATION

Engine ..........................................................................................................A.3

Timing system ..............................................................................................A.3

Fuel system..................................................................................................A.3

Lubrication....................................................................................................A.3

Cooling .........................................................................................................A.3

Ignition system..............................................................................................A.3

Starter ..........................................................................................................A.3

Drive and Transmission................................................................................A.3

Chassis.........................................................................................................A.4

Suspension...................................................................................................A.4

Brakes ..........................................................................................................A.4

Wheels..........................................................................................................A.4

Tyres.............................................................................................................A.5

Electrical components location.....................................................................A.5

Overall dimensions - Weight.........................................................................A.6

Capacities.....................................................................................................A.7

Andere Handbücher für 2009 TC 250

Dieses Handbuch passt für folgende Modelle

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