Husqvarna TC 250 2009 2010 Workshop Service Manual

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Stichworte: 2009 2010 Husqvarna Motorcycle Motorcycles TC 250 TC Models

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Beschreibung

The TC 250, produced for the 2009 and 2010 model years, is a performance-oriented motocross motorcycle renowned for its lightweight chassis, potent liquid-cooled 2-stroke engine, and agile handling. Engineered for competitive use, this model represents a dedication to the motocross discipline, offering a thrilling experience for enthusiasts and semi-professional riders. Its design prioritizes power and maneuverability on the track, making it a capable machine in its class, competing with other prominent motocross bikes of its era. This workshop service manual provides comprehensive guidance for the repair and overhaul of the TC 250. It covers all essential systems, including detailed procedures for engine and transmission disassembly and reassembly, fuel and ignition system maintenance, lubrication, exhaust, electrical, and bodywork components. The manual also details routine maintenance, troubleshooting, and specialized procedures, offering step-by-step instructions and identifying necessary special tools. Its purpose is to empower owners and technicians to maintain, diagnose, and repair the motorcycle effectively, ensuring its optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

TC 250

Year:

2009-2010

Codes

Vehicle Type:

Motocross Motorcycle

👋 Introduction

Market Position

Positioning:

Performance-oriented motocross motorcycle, aimed at enthusiasts and semi-professional riders.

Competitive Analysis

Competitors:

KTM 250 SX, Yamaha YZ250, Honda CRF250X, Suzuki RM-Z250.

Key Features

Vehicle Highlights:

Lightweight chassis, potent 2-stroke engine, agile handling, designed for competitive motocross use.

Manual Purpose

Objective:

To enable technicians and owners to perform accurate repairs, maintenance, and overhauls, ensuring optimal performance and longevity of the Husqvarna TC 250.

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair and Overhaul

Page Count

Estimated Pages:

Comprehensive (Exact page count not specified, but described as a 'complete Service Manual')

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete disassembly and reassembly, troubleshooting, performance tuning

Transmission:

Complete disassembly and reassembly, troubleshooting

Fuel System:

Carburetor (jetting, maintenance, overhaul), fuel pump, fuel lines, fuel tank

Ignition System:

Ignition timing, spark plug specifications, coil testing, CDI unit troubleshooting

Lubrication System:

Oil pump, oil filter, oil passages, oil type and capacity specifications

Exhaust System:

Exhaust pipe, muffler inspection and maintenance

Electrical System:

Wiring diagrams, component testing (lights, horn, battery, stator, rectifier/regulator)

Bodywork:

Fairings, seat, handlebars, footpegs, plastics removal and installation

Suspension:

Front forks (rebuild, adjustments, oil levels), rear shock absorber (rebuild, adjustments, spring preload).

Wheels And Tires:

Wheel bearing service, spoke tension, tire pressure, tire replacement.

Brakes:

Front and rear brake caliper service, master cylinder overhaul, brake line replacement, pad replacement, bleeding procedure.

Cooling System:

Radiator inspection, coolant hose replacement, water pump service.

Frame And Body:

Includes procedures for removing and reinstalling body panels, seat, fuel tank, and chassis components.

Procedures Included

Routine Maintenance:

Tune-ups, fluid changes, filter replacement, chain adjustment, brake pad inspection

Removal Installation:

Component removal and reinstallation procedures for all major systems

Assembly Disassembly:

Detailed step-by-step instructions for major component disassembly and assembly

Troubleshooting:

Diagnostic procedures for common and complex issues across all systems

Engine Tuning:

Carburetor tuning, ignition timing checks, exhaust system optimization.

Chassis Maintenance:

Steering head bearing service, swingarm pivot bearing service, linkage bearing service.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including special tool identification.

Special Tools:

Identifies and illustrates recommended or required special tools for specific adjustments and repairs (e.g., flywheel puller, clutch holding tool).

📊 Manual Specifications

File Format

File Format:

Searchability:

PDF format typically allows for text searching, enhancing usability.

Print Quality

Printability:

Yes, printable

Binding Type

Binding Type:

Not Applicable (Digital PDF)

Paper Type

Paper Type:

Not Applicable (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Type:

2-stroke, single-cylinder

Displacement:

Approx. 250cc (Specific bore/stroke not provided in product description, but standard for the class)

Cooling:

Liquid-cooled

Bore X Stroke:

Specific dimensions would be detailed in the manual, typically around 66.4 mm x 72 mm for a 250cc 2-stroke.

Performance

Horsepower:

Estimated 45-50 HP (typical for this class and era, specific figure not in product data)

Torque:

Estimated 25-30 lb-ft (typical for this class and era, specific figure not in product data)

Fuel System

Carburetor Type:

Mikuni VM34 or similar (common for this model, specific type not in product data)

Fuel Type:

Unleaded gasoline with 2-stroke oil premix (specific ratio in manual)

🔧 Transmission

Standard

Type:

6-speed manual

Optional

Type:

N/A (Motocross bikes typically have fixed transmissions)

Features

Clutch:

Hydraulic operated, multi-plate wet clutch

📐 Dimensions

Exterior

Wheelbase:

Approx. 1460-1470 mm (typical for this model, specific figure not in product data)

Weights

Dry Weight:

Approx. 102-105 kg (typical for this model, specific figure not in product data)

🛡️ Safety Features

Ratings

Crash Test Results:

Not Applicable (Motorcycle, not typically subjected to automotive crash testing standards).

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Passive Features

Frame Construction:

Chromium-molybdenum steel frame (standard for Husqvarna motocross bikes of this era).

💡 Technology Features

Infotainment

Features:

Not Applicable (Pure motocross competition bike, no infotainment systems).

Driver Assistance

Features:

Not Applicable (No electronic driver assistance features).

Connectivity

Features:

Not Applicable.

🔧 Maintenance

Service Intervals

Oil Change:

Recommended every 10-15 hours of operation or as per manual (specifics in manual).

Air Filter Cleaning:

Frequent cleaning, often after every few rides, depending on conditions (detailed in manual).

Top End Rebuild:

Recommended based on hours of use, typically between 40-80 hours for piston/rings (detailed in manual).

Fluid Specifications

Engine Oil:

Specific 2-stroke premix oil and transmission oil type/grade (detailed in manual, e.g., Motorex or equivalent).

Coolant:

Ethylene glycol-based coolant with anti-corrosion additives (specific mix ratio and type in manual).

Transmission Oil Capacity:

Approximately 0.7 - 0.8 liters (specific grade like SAE 75W/90 or 10W-40, as per manual).

Known Issues

Common Wear Items:

Clutch plates, piston rings, spark plug, air filter, chain and sprockets, wheel bearings.

Carburetor Tuning:

May require re-jetting depending on altitude and environmental conditions.

Suspension Maintenance:

Fork seal and shock absorber maintenance/rebuild required periodically.

Electrical Connector Corrosion:

Can be an issue in off-road environments; manual provides inspection and cleaning procedures.

📚 Vehicle History

Brand Heritage

Brand Origin:

Swedish, with a long history dating back to 1903, known for motorcycles and outdoor power products.

Model Evolution

Tc Series Evolution:

The TC series represents Husqvarna's commitment to motocross, with continuous development in engine performance, suspension, and chassis dynamics.

Production

Manufacturing Location:

Likely Italy (Husqvarna motorcycles were manufactured in Italy under the Cagiva Group ownership during this period).

🏆 Awards & Recognition

Recognitions

Motocross Reviews:

Generally well-regarded for its performance and handling in its class during its production years. Specific awards not detailed in product data.