Husqvarna TE 250 - 310 2011 I.E. Instruction manual

Workshop Manual
TE 250 - 310 2011 I.E.
TEi 250 2011 I.E. USA
TC 250 2011 - TC 250i 2011 I.E. USA
TXCi 250 2011 I.E. USA
Ed. 07-2010

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 (07-2010)

a.1
H02175
FOREWORD, TABLE OF CONTENTS
Ed. 07-2010
1st edition (07-2010)
Printed in Italy
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
1. Chassis serial number
TE 250 - 310 2011 I.E.
TEi 250 2011 I.E. USA
TC 250 2011 - TC 250i 2011 I.E. USA
TXCi 250 2011 I.E. USA
TE 250: ZKHA300AABV000001
TE 250 USA: ZKHKCECF#BV000001
TE 310: ZKHA301AABV000001
TE 310 USA: ZKHKCEDG#BV000001
TC 250: ZKHA300AABV050001
TC 250 USA: ZKHTC253#BV000001
TXCi 250 USA: ZKHTX250#BV000001

a.2
FOREWORD, TABLE OF CONTENTS
Ed. 07-2010
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.3
FOREWORD, TABLE OF CONTENTS
Ed. 07-2010
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
Hydraulically Controlled Clutch............................................................................P
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
IMPORTANT NOTICES
Ed. 07-2010
Section

b.2
H02176
TC
H02177
TE
H02178
TXCi
IMPORTANT NOTICES
Ed. 07-2010
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,asinlong-distanceroadorhighwaytravel.Riding overlong
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
GENERAL INFORMATION
Ed. 07-2010
Section

A.2
GENERAL INFORMATION
Ed. 07-2010
ENGINE........................................................................................................A.3
Cooling .........................................................................................................A.3
Starting.........................................................................................................A.3
TIMING SYSTEM.........................................................................................A.3
LUBRICATION..............................................................................................A.3
IGNITION......................................................................................................A.3
FUEL SYSTEM.............................................................................................A.3
PRIMARY DRIVE.........................................................................................A.3
CLUTCH.......................................................................................................A.3
TRANSMISSION..........................................................................................A.3
Transmission ratio (TE-TXCi).......................................................................A.3
Transmission ratio (TC)................................................................................A.4
SECONDARY DRIVE...................................................................................A.4
FINAL RATIOS (TE-TXCi)............................................................................A.4
FINAL RATIOS (TC).....................................................................................A.4
FRAME.........................................................................................................A.4
FRONT SUSPENSION.................................................................................A.4
REAR SUSPENSION...................................................................................A.4
FRONT BRAKE............................................................................................A.4
REAR BRAKE ..............................................................................................A.4
RIMS.............................................................................................................A.4
TIRES...........................................................................................................A.5
Cold tire pressure ........................................................................................A.5
Electrical components location (TC).............................................................A.5
Electrical components location (TXCi)..........................................................A.5
Electrical components location (TE).............................................................A.5
Overall dimensions.......................................................................................A.6
Weight ..........................................................................................................A.7
Capacities.....................................................................................................A.7

A.3
GENERAL INFORMATION
Ed. 07-2010
ENGINE
Type..............................................................................single cylinder, 4 stroke
COOLING
Type................................................liquid, with electric fan on TE-TXCi models
(TC-TE-TXCi 250)
Bore..........................................................................................mm 79 (3,11 in.)
Stroke................................................................................... mm 50,9 (2.00 in.)
Displacement.............................................................. cm3249,5 (15,22 cu. in.)
Compression ratio ....................................................................................13,6:1
(TE 310)
Bore......................................................................................... mm 82 (3,23 in.)
Stroke................................................................................... mm 57,3 (2,26 in.)
Displacement............................................................ cm3302,44 (18,46 cu. in.)
Compression ratio ....................................................................................12,5:1
STARTING
(TC) .................................................. kick start (with automatic decompressor)
(TE-TXCi) ...............................................................................................electric
TIMING SYSTEM
Type.................................................4 titanium valves, in a radial arrangement,
operatedthrough bowlsbytwooverheadcamshafts drivenbyacombinedchain/
gears system
Valve clearance (with engine cold)
Intake................................................................................. 0,15 mm (0,006 in.)
Exhaust............................................................................... 0,20 mm (0,008 in.)
LUBRICATION
Type......................... wet crankcase, lobe pump and cartridge and mesh lters
IGNITION
Type ...........Electronic, inductive discharge, with adjustable advance (digital control)
Spark plug type..............................................................................NGK CR9EB
Spark plug gap ....................................................0,7÷0,8 mm (0.027÷0,031 in.)
FUEL SYSTEM
Type..............................................................................Electronic injection feed
PRIMARY DRIVE
Drive pinion gear- Clutch ring gear ...................................................Z 17- Z 54
Transmission ratio .....................................................................................3,176
CLUTCH
Type.............................................oil bath multiple disc clutch, hydraulic control
TRANSMISSION
Type............................................................................constant mesh gear type
Transmission ratio (TE-TXCi)
1st gear...................................................................................... 2,142 (z 30/14)
2nd gear .................................................................................... 1,750 (z 28/16)
3rd gear .................................................................................... 1,450 (z 29/26)
4th gear...................................................................................... 1,227 (z 27/22)
5 th gear..................................................................................... 1,041 (z 25/24)
6 th gear .................................................................................... 0,884 (z 22/27)

A.4
GENERAL INFORMATION
Ed. 07-2010
Transmission ratio (TC)
1st gear...................................................................................... 2,142 (z 30/14)
2nd gear .................................................................................... 1,750 (z 28/16)
3rd gear .................................................................................... 1,450 (z 29/26)
4th gear...................................................................................... 1,227 (z 27/22)
5 th gear..................................................................................... 1,041 (z 25/24)
SECONDARY DRIVE
Transmission sprocket- Rear wheel sprocket
(TC) ...................................................................................................Z 13- Z 50
(TE-TXCi) ..........................................................................................Z 13- Z 40
Transmission ratio
(TC) ...........................................................................................................3,846
(TE-TXCi). .................................................................................................3,076
FINAL RATIOS (TE-TXCi)
1st gear....................................................................................................20,944
2nd gear ..................................................................................................17,104
3rd gear...................................................................................................14,172
4th gear ...................................................................................................11,995
5th gear ...................................................................................................10,181
6th gear .....................................................................................................7,964
FINAL RATIOS (TC)
1st gear....................................................................................................26,180
2nd gear ..................................................................................................21,380
3rd gear...................................................................................................17,715
4th gear ...................................................................................................14,994
5th gear ...................................................................................................12,726
FRAME
Type................................. Steel single tube cradle (roud, rectangular, ellipsoidal tubes); light alloy rear frame
FRONT SUSPENSION
Type................................................ ”Upside-down”telescopic hydraulicfront forkwith advanced
axle (adjustable in compression and rebound stroke); stanchions tubes Ø 1.89 in. / ø 48 mm
Legs axis stroke......................................................................300 mm (11.8 in.)
REAR SUSPENSION
Type......................................progressive with hydraulic single shock absorber
Wheel stroke ......................................................................... 296 mm (11.6 in.)
FRONT BRAKE
Type xed disc Ø 10.23 mm “Wave” type with hydraulic control and oating caliper
REAR BRAKE
Type.... oating disc, ø 9.45 in. “Wave” type with hydraulic control and oating caliper
RIMS
Front..................................................................................in light alloy: 1,6x21”
Rear (TE, TXCi)...............................................................in light alloy: 2,15x18”
Rear (TC).........................................................................in light alloy: 1,85x19”

A.5
GENERAL INFORMATION
Ed. 07-2010
TIRES
Front
(TE -TXCi) ..........................................................................................90/90x21”
(TC) ................................................................................................80/100 x 21”
Rear
(TE-TXCi...........................................................................................120/90x18”
(TC) ..................................................................................................100/90x19”
Cold tire pressure
(front TC)..........................................................0,9÷1,0 Kg/cm2 (12,8÷14,2 Psi)
(front TE-TXCi) (*) ...........................................0,9÷1,0 Kg/cm2 (12,8÷14,2 Psi)
(front TE) (%)....................................................................1,1 Kg/cm2 (15,6 Psi)
(rear TC)...........................................................0,8÷0,9 Kg/cm2 (11,4÷12,8 Psi)
(rear TE-TXCi) (*) ............................................0,8÷0,9 Kg/cm2 (11,4÷12,8 Psi)
(rear TE) (%).....................................................................1,0 Kg/cm2 (14,2 Psi)
(*) In case of racing use - (%) Road use
Electrical components location (TC)
The ignition system includes the following elements:
- Generator on the inner side of L.H. crankcase half cover;
- Electronic ignition coil under the fuel tank;
- Electronic control unit under the fuel tank;
- Spark plug on cylinder head;
- M.A.Q.S. sensor
- Condenser on the left of rear chassis.
Electrical components location (TXCi)
The ignition system includes the following elements:
- Generator on the inner side of L.H. crankcase half cover;
- Electronic ignition coil under the fuel tank;
- Electronic control unit under the fuel tank;
- Voltage regulator under the fuel tank;
- Spark plug on cylinder head;
- 12V-450W starter motor behind the engine cylinder;
- Solenoid starter on the left of rear chassis;
- M.A.Q.S. sensor (pressure, throttle position, air temperature) on throttle body.
The electrical system includes the following elements:
- 12V-6Ah battery under the saddle;
- Electric fan relay on right side of chassis:
- Electric fan;
- Two 15A and 20Afuses on right side of rear chassis;
- Coolant temperature sensor;
- Lambda sensor;
- Fuel pump inside the fuel tank.
- Fuel and reserve indicator.
Electrical components location (TE)
The ignition system includes the following elements:
- Generator on the inner side of L.H. crankcase half cover;
- Electronic ignition coil under the fuel tank;
- Electronic control unit under the fuel tank;
- Voltage regulator under the fuel tank;
- Spark plug on cylinder head;
- 12V-450W starter motor behind the engine cylinder;
- Solenoid starter on the left of rear chassis;
- M.A.Q.S. sensor (pressure, throttle position, air temperature) on throttle body.

A.6
H02179
GENERAL INFORMATION
Ed. 07-2010
The electrical system includes the following elements:
- 12V-6Ah battery under the saddle;
- Turning indicator asher on left side of rear chassis;
- Relay for electric fan, fuel injection system and lights on right side of chassis:
- Electric fan;
- Two 15A fuses and one 20Afuse on right side of rear chassis;
- Coolant temperature sensor;
- Lambda sensor;
- Headlamp with 12V-35W twin halogen bulb and 12V-3W parking light bulb;
- LED tail light with stop light bulb;
- 12V-10W turning indicator bulbs;
- Fuel pump inside the fuel tank.
- Odometer.
Overall dimensions
Wheelbase A
(TE-TXCi) .......................................................................... mm 1460 (57.47 in.)
(TC) ................................................................................... mm 1470 (57.87 in.)
Overall length B
(TC) ................................................................................... mm 2215 (87.20 in.)
(TE).................................................................................... mm 2260 (88.97 in.)
(TXCi)................................................................................ mm 2176 (85.66 in.)
Overall width C.................................................................... mm 820 (32.28 in.)
Overall height D
(TE-TXCi) .......................................................................... mm 1290 (50.78 in.)
(TC) ................................................................................... mm 1305 (51.37 in.)

A.7
GENERAL INFORMATION
Ed. 07-2010
Saddle height E
(TC) ..................................................................................... mm 985 (38.77 in.)
(TE-TXCi) ............................................................................ mm 950 (37.40 in.)
Minimum ground clearance F
(TE-TXCi) .............................................................................mm 290 (11.41 in.)
(TC) ..................................................................................... mm 325 (12.79 in.)
Weight
Kerb weight, without fuel (TC):..................................................97 Kg (213,8 lb)
Kerb weight, without fuel (TE): .............................................102,5 Kg (225,9 lb)
Kerb weight, without fuel (TXCi):............................................99,7 Kg (219,7 lb)
Capacities Type Quantity
Fuel tank (TC) Imp. Gall. 1.43, U.S. Gall. 1.72
Fuel tank (TE-TXCi) Imp. Gall. 1.87, U.S. Gall. 2.25
(0.51 Imp. Qt./0.61 U.S. Qt. reserve included)
Gearbox/engine oil CASTROL POWER 1 RACING (SAE 10W50) 900 cc
(oil change and oil lter
replacement)
850 cc
(oil change)
Front fork oil KAYABA KHL15-11 (SAE 7,5; SAE 5 for extremely cold weather)
TC: 325 cu cm
TXC: 325 cu cm
TE: 100 mm
Rear shock absorber oil CASTROL SYNTHETIC FORK OIL (5W)
Coolant CASTROL MOTORCYCLE COOLANT 0.9 litres
Front brake uid CASTROL RESPONSE SUPER (DOT 4)
Rear brake uid CASTROL RESPONSE SUPER (DOT 4)
Clutch uid CASTROL RESPONSE SUPER (DOT 4)
Drive chain lubrication CASTROL CHAIN LUBE RACING
Grease lubrication CASTROL PASTE TA GREASE
Electric contact protection CASTROL METAL PARTS CLEANER
Fillers for radiator AREXONS LIQUID FILLER
Air lter oil AGIP FORMULA FILTER "Foam air lter protection oil"
Air lter detergent AGIP "Filter clean foam air detergent uid"
IMPORTANT - Do not add any additives to fuel or lubricants.

B.1
B
MAINTENANCE
Ed. 07-2010
Section

B.2
MAINTENANCE
Ed. 07-2010
SCHEDULED MAINTENANCE CHART
(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
TC - TE - TXCi
RACING MOTORCYCLE, FOR
RACING USE: FULL POWER RATING
SERVICE SERVICE SERVICE SERVICE SERVICE
COUPON COUPON COUPON COUPON COUPON
PART AFTER FIRST EVERY EVERY EVERY EVERY EVERY REPLACE
3 HOURS 4h MX/8h EN 8h MX/16h EN 16h MX/32h EN 32h MX/64h EN 40h MX/80h EN AS REQUIRED
VALVES C (•) C (•) S (#)
VALVE SPRINGS C X
VALVE SPRING RETAINERS, VALVE COLLETS C X
VALVE BUCKETS C X
CAMSHAFT C
TIMING CHAIN C S
TIMING CHAIN SLIDER C/S
TIMING DRIVEN GEAR C X
TIMING DRIVE GEAR C X
TIMING CHAIN TENSIONER C
INTAKE MANIFOLD AND CLAMPS C S
COMPLETE CYLINDER C S C X
COMPLETE PISTON S C S
COMPLETE CONNECTING ROD S
CRANKCASE BEARINGS S
ENGINE OIL S C S
OIL PUMP C
OIL FILTER/MESH FILTER S, P S, P
OIL PUMP TO CRANKCASE OIL LUBRICATION
PIPE C
PRIMARY DRIVE GEAR PAIR C
CLUTCH HUB C X
CLUTCH PLATES C S X
CLUTCH PRESSURE PLATE C
CLUTCH SPRINGS C X
CLUTCH HOUSING C
CLUTCH PUSHROD C
TRANSMISSION SPROCKET C S X
STARTER GEARS C X

B.3
MAINTENANCE
Ed. 07-2010
SCHEDULED MAINTENANCE CHART
(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
TC - TE - TXCi
RACING MOTORCYCLE, FOR
RACING USE: FULL POWER RATING
SERVICE SERVICE SERVICE SERVICE SERVICE
COUPON COUPON COUPON COUPON COUPON
PART AFTER FIRST EVERY EVERY EVERY EVERY EVERY REPLACE
3 HOURS 4h MX/8h EN 8h MX/16h EN 16h MX/32h EN 32h MX/64h EN 40h MX/80h EN AS REQUIRED
KICK START PEDAL L
GEAR SHIFT PEDAL C
SPARK PLUG P S
SPARK PLUG CAP C
AIR FILTER P, L
RADIATORS C
WATER HOSES AND CLAMPS C
RADIATORS TO WATER PUMP HOSE C
COOLANT C X
FOOTPEGS, PINS, SPRINGS C X
REAR CHASSIS MNTG BOLTS, ENGINE MNTG BOLTS C C
SIDE STAND C
CHAIN GUIDE ROLLER, BEARINGS C
STEERING HEAD, BOTTOM YOKE WITH STEM L
FRONT FORK R
HANDLEBAR MOUNTS AND FASTENERS C C
REAR SWINGING ARM BUSHING C
REAR CHAIN SLIDER C X
REAR SUSPENSION LINKAGE BUSHINGS C
CHAIN GUIDE/CHAIN GUARD C X
SWINGING ARMAXLE ROLLER CAGES L
REAR SHOCK ABSORBER R
ROLLER CAGES, LINKAGE PINS OF REAR SUSP. L
COMPLETE THROTTLE CONTROL C, L
COMPLETE CLUTCH CONTROL C (•) R (#)

B.4
MAINTENANCE
Ed. 07-2010
SCHEDULED MAINTENANCE CHART
(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
LEGEND
h: HOURS
S: REPLACE
C: CHECK
C (•): CHECK CLEARANCE
P: CLEAN
R: OVERHAUL
L: GREASE/LUBRICATE
MX: MOTOCROSS
EN: ENDURO
(#) SEE WORKSHOP MANUAL
NOTES:
- REPLACE GASKETS AND SEALSAFTER EACH REMOVAL;
- REPLACE SCREWS AND BOLTS IF DAMAGED;
- PERFORM AGENERAL INSPECTIONAFTER RIDING ON MUDDY OR SANDY TERRAIN.
TC - TE - TXCi
RACING MOTORCYCLE, FOR
RACING USE: FULL POWER RATING
SERVICE SERVICE SERVICE SERVICE SERVICE
COUPON COUPON COUPON COUPON COUPON
PART AFTER FIRST EVERY EVERY EVERY EVERY EVERY REPLACE
3 HOURS 4h MX/8h EN 8h MX/16h EN 16h MX/32h EN 32h MX/64h EN 40h MX/80h EN AS REQUIRED
THROTTLE CABLES C L X
FRONT BRAKE DISC C X
FRONT BRAKING SYSTEM FLUID C S
REAR BRAKE DISC C X
REAR BRAKING SYSTEM FLUID C S
BRAKE PADS C X
MASTER CYLINDER TO BRAKE CALLIPER HOSES C
FUEL PIPES C S X
SILENCER SOUND DEADENING MATERIAL S X
EXHAUST PIPE AND SILENCER C X
WHEEL SPOKE TENSION C C
WHEEL HUB BEARINGS S X
REAR CHAIN SPROCKET S X
SPROCKET BOLT TIGHTENING C C
SECONDARY DRIVE CHAIN C, L S X
TORQUE OF NUTSAND BOLTS C C