Husqvarna 2009 TC 250 Instruction manual

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)
Copyright by
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
b
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
A
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