Husqvarna TC250 2009 2010 Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 92510

Etiquetas: 2009 2010 Husqvarna Misc Motorcycle Motorcycles TC250

Variantes de producto

Descripción

The TC250, produced for the 2009 and 2010 model years, is a performance-oriented, liquid-cooled, single-cylinder, four-stroke motocross motorcycle. Designed for aggressive off-road riding and competition, this machine embodies a heritage in off-road vehicle development. It features a robust steel frame, a 5-speed transmission, hydraulic disc brakes front and rear, and a chain drive system. The TC250 was engineered to compete in the highly contested motocross segment, offering a potent package for riders seeking a capable and spirited off-road experience. This comprehensive service and repair manual provides in-depth technical information essential for the maintenance and repair of the 2009-2010 TC250. It covers a wide range of critical systems, including engine mechanicals, fuel and ignition systems, transmission, suspension, brakes, and the electrical system. The manual details preventative maintenance schedules, troubleshooting procedures for common issues, engine and suspension overhaul instructions, and specific torque specifications. It is an indispensable resource for owners, mechanics, and technicians aiming to ensure the optimal performance, reliability, and longevity of their TC250.

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

TC250

Year:

2009, 2010

Codes

Engine Family Code:

Likely based on KTM LC4 engine architecture (specific Husqvarna codes may vary)

👋 Introduction

Market Position

Segment:

Competition/Motocross Off-Road Motorcycle

Target Audience:

Motocross riders, mechanics, and service technicians

Competitive Analysis

Key Competitors:

KTM 250 SX-F, Yamaha YZ250F, Honda CRF250R, Kawasaki KX250F, Suzuki RM-Z250

Key Features

Vehicle Orientation:

Performance-oriented motocross machine designed for racing and aggressive off-road riding

Manual Advantage:

Provides critical service information that may be scarce for older or niche European dirt bike models

📋 Manual Details

Coverage Areas

Coverage:

Comprehensive service and repair for Husqvarna TC250 models 2009 and 2010

Page Count

Page Count:

Variable, typically 300-500 pages for this type of comprehensive service manual

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

Format:

PDF (Portable Document Format)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Top-end rebuild (cylinder, piston, rings, valves), bottom-end rebuild (crankshaft, connecting rod, bearings), lubrication system, cooling system, engine tuning

Fuel System:

Carburetor service and adjustment (likely Keihin or Mikuni), fuel pump, fuel lines, fuel tank maintenance

Ignition System:

CDI unit, ignition coil, spark plug troubleshooting, wiring diagrams

Transmission Drivetrain:

Clutch operation and adjustment, gearbox disassembly and reassembly, gear selection mechanism, chain and sprocket maintenance, primary drive system

Suspension Front:

Fork disassembly, seal replacement, oil level and type specification, spring rates, damping adjustment (compression and rebound)

Suspension Rear:

Shock absorber service, linkage lubrication, bearing replacement, spring preload adjustment, damping adjustments

Brakes Front:

Caliper service, brake pad replacement, rotor inspection, master cylinder overhaul, brake fluid bleeding and specifications

Brakes Rear:

Caliper service, brake pad replacement, rotor inspection, master cylinder overhaul, brake fluid bleeding and specifications

Electrical System:

Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), lighting system (headlight, taillight, brake light), starter system (if applicable for electric start variants)

Chassis Frame:

Frame inspection and repair, steering head bearing service, swingarm lubrication and bearing replacement

Bodywork Plastics:

Fairing removal and installation, seat maintenance, graphics and decal application guidance

Procedures Included

Preventative Maintenance:

Oil and filter change intervals, air filter cleaning/replacement, chain lubrication and tension adjustment, spark plug checks, brake inspection

Troubleshooting Diagnostics:

Diagnostic charts for common performance issues, starting problems, electrical faults, and mechanical noises

Engine Rebuild:

Detailed step-by-step instructions for complete engine disassembly, inspection, component replacement, and reassembly

Suspension Overhaul:

Comprehensive guides for servicing both front forks and rear shock absorbers, including fluid changes and seal replacements

Brake System Service:

Instructions for bleeding brake lines, replacing pads and rotors, and servicing master cylinders and calipers

Carburetor Tuning:

Guidance on adjusting fuel-air mixture, idle speed, and jetting for optimal performance in various conditions

Electrical Component Testing:

Methods for testing stator output, rectifier function, ignition coil resistance, and battery health using a multimeter

Torque Specifications:

Essential torque values for critical fasteners throughout the motorcycle, ensuring proper assembly and preventing component damage

Technical Depth

Depth Level:

In-depth technical information suitable for professional mechanics and experienced DIY enthusiasts

Diagnostic Capabilities:

Detailed diagnostic flowcharts and symptom-based troubleshooting guides

Special Tools:

Identification of required specialized tools for specific repair procedures (e.g., flywheel puller, valve spring compressor)

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely searchable text, allowing quick access to specific information

Printability:

Printable, allowing users to print specific sections or the entire manual

Print Quality

Graphic Resolution:

High-resolution graphics and diagrams for clarity

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke

Displacement:

249.5 cc (approximately)

Bore X Stroke:

Specifics require manual consultation, but typically around 76mm x 55mm for this class

Cooling System:

Liquid-cooled

Valve Train:

SOHC (Single Overhead Camshaft) with 4 valves

Performance

Horsepower:

Typically in the range of 35-40 HP, depending on tuning and specific model year refinements

Torque:

Specific figures vary, but designed for strong low-to-mid range power delivery

Fuel System

Carburetor Model:

Likely Keihin FCR or Mikuni TM series (specific size varies, e.g., 39mm)

Fuel Type:

Unleaded gasoline (minimum 91 octane recommended)

Lubrication

Oil Type:

High-quality motorcycle-specific 4-stroke engine oil (e.g., SAE 10W-40, JASO MA/MA2 certified)

Oil Capacity:

Consult manual; typically around 0.8 - 1.0 liters (with filter change)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Optional

Gear Ratios:

Specific gear ratios are detailed within the manual

Features

Clutch Type:

Wet, multi-plate, hydraulic actuation

Final Drive:

Chain drive

Transmission Oil Type:

Dedicated transmission oil or specified engine oil (consult manual)

📐 Dimensions

Exterior

Wheelbase:

Approx. 1460-1470 mm (57.5-57.9 inches)

Ground Clearance:

Approx. 320-350 mm (12.6-13.8 inches)

Weights

Dry Weight:

Approx. 95-100 kg (209-220 lbs)

Fuel Capacity:

Approx. 7.0 - 7.5 liters (1.8-2.0 US gallons)

Tires

Front Tire Size:

80/100-21

Rear Tire Size:

110/90-19 or 100/90-19

🛡️ Safety Features

Ratings

Crash Safety:

N/A (Off-road motorcycles are not subject to road vehicle crash safety standards)

Active Features

Braking System:

Hydraulic disc brakes front and rear for superior stopping power

Passive Features

Frame Construction:

Robust steel frame designed for off-road abuse

💡 Technology Features

Infotainment

Infotainment System:

N/A (Pure motocross bike, no infotainment features)

Driver Assistance

Assistance Features:

N/A (No electronic rider aids like traction control or ABS)

Connectivity

Connectivity Options:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5-10 hours of riding, or as specified in the manual

Oil Filter Change:

Concurrent with engine oil changes

Air Filter Cleaning:

Every 5-10 hours, or more frequently in dusty conditions

Chain Lubrication Adjustment:

Every 5-10 hours, or after washing/wet riding

Top End Rebuild Interval:

Varies significantly with usage, typically 20-50 hours for competitive use

Fluid Specifications

Fork Oil Type:

Consult manual; typically a specific viscosity (e.g., 5W or 7.5W) and volume per fork leg

Shock Oil Type:

Consult manual; specific damping fluid required

Brake Fluid Type:

DOT 4

Coolant Type:

Ethylene glycol-based antifreeze (50/50 mix with distilled water)

Known Issues

Common Wear Items:

Clutch plates, wheel bearings, steering head bearings, fork seals, chain and sprockets

Potential Problems:

Carburetor jetting sensitivity to altitude and temperature, potential for stator failure (as with many dirt bikes), valve clearance checks are critical

📚 Vehicle History

Brand Heritage

Heritage:

Husqvarna Motorcycles has a long history dating back to Sweden in 1903, known for its off-road prowess and innovation.

Model Evolution

Tc Lineage:

The TC line represents Husqvarna's competitive motocross offerings, evolving with engine technology and chassis design over the years.

Production

Manufacturing Location:

During this period, Husqvarna production was primarily in Italy, following its acquisition by the Italian Cagiva Group.

🏆 Awards & Recognition

Recognitions

Motocross Reviews:

Specific awards for the 2009-2010 TC250 are subject to period reviews; Husqvarna motorcycles of this era were generally praised for their European character and performance potential, though often viewed as a more niche option compared to Japanese counterparts.