Husqvarna TE250 2007 2008 Service Repair Manual

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Taper: Motorcycle

Distributeur:

UGS: 100349

Mots clés: 2007 2008 Husqvarna Misc Motorcycle Motorcycles TE250

Variantes de produits

Description

This manual covers the TE250, a high-performance Italian dual-sport and enduro motorcycle produced for the 2007 and 2008 model years. Renowned for its off-road prowess and sporty character, the TE250 represents Italian engineering excellence within its segment, competing with other 250cc enduro models. Its design prioritizes performance and handling, making it a capable machine for varied terrain and a compelling choice for riders seeking a spirited riding experience. This comprehensive service repair manual, presented in English, provides detailed guidance for the maintenance and repair of your TE250. It covers all major systems, including the engine, fuel, ignition, cooling, transmission, drivetrain, suspension, brakes, and electrical systems. The manual includes step-by-step procedures for disassembly, assembly, rebuilding, and adjustment, along with troubleshooting guides and technical specifications. Owners, mechanics, and technicians will find this resource invaluable for ensuring the optimal performance, reliability, and longevity of their motorcycle.

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

TE250

Year:

2007, 2008

Vehicle Type:

Dual-Sport / Enduro Motorcycle

👋 Introduction

Market Position

Vehicle Segment:

High-performance Italian dual-sport/enduro motorcycle known for its off-road prowess and sporty character.

Competitive Analysis

Competitors:

Competes with other European and Japanese 250cc enduro and dual-sport models of the era, such as KTM EXC 250, Yamaha WR250R/F, Honda CRF250X/L, Suzuki DR-Z250, and Kawasaki KLX250S.

Key Features

Italian Engineering:

Represents a segment of the market that appreciates Italian design and engineering for a more exotic feel.

Off Road Focus:

Primarily designed for off-road riding, but street-legal variants or conversions make it a capable dual-sport machine.

Performance Oriented:

Emphasizes performance and handling characteristics over comfort and long-distance touring.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Manual

Language:

English

Format:

Page Count

Estimated Page Count:

Comprehensive (Exact count not provided, but typical for full service manuals is 300-600+ pages)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, inspection, assembly, tuning, troubleshooting, and specifications for the TE250's 250cc 4-stroke engine.

Fuel System:

Carburetor system (Mikuni likely), fuel pump, fuel lines, fuel tank, and troubleshooting of fuel delivery issues.

Ignition System:

CDI ignition, spark plug, ignition coil, timing, troubleshooting ignition faults.

Cooling System:

Radiator, coolant, coolant hoses, fan (if equipped), water pump, and bleeding procedures.

Transmission:

Gearbox internals, clutch operation, clutch components, lubrication, shifting mechanisms, and troubleshooting.

Drivetrain:

Chain and sprockets, rear drive unit (if applicable to the TE250 model), lubrication, and adjustment.

Suspension Front:

Upside-down fork (likely Marzocchi or WP), oil types, oil levels, seal replacement, damping adjustments, spring rates, and troubleshooting.

Suspension Rear:

Monoshock rear suspension (likely WP or Öhlins), linkage system, shock absorber service, spring replacement, damping adjustments, and troubleshooting.

Brakes Front:

Hydraulic disc brake system, caliper overhaul, master cylinder service, brake fluid specifications, bleeding procedures, pad replacement, rotor specifications.

Brakes Rear:

Hydraulic disc brake system, caliper overhaul, master cylinder service, brake fluid specifications, bleeding procedures, pad replacement, rotor specifications.

Electrical System:

Wiring diagrams, battery, charging system (stator, rectifier/regulator), lighting (headlight, taillight, signals), starter motor, switches, fuses, troubleshooting electrical faults.

Chassis Frame:

Frame inspection, weld integrity, steering head bearings, subframe, general chassis component maintenance.

Wheels Tires:

Wheel bearing maintenance, spoke tensioning, rim inspection, tire pressure recommendations, tire types, wheel removal/installation.

Bodywork Plastics:

Fairings, fenders, seat, tank cover removal and installation, fasteners.

Exhaust System:

Muffler, header pipe, exhaust gaskets, inspection and maintenance.

Procedures Included

Preventative Maintenance:

Regular service checks, lubrication points, filter replacements, fluid changes, bolt torquing.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon faults across all vehicle systems.

Disassembly Assembly:

Step-by-step instructions for taking apart and putting back together major components and systems.

Rebuild Procedures:

Detailed instructions for overhauling key components such as the engine, transmission, and suspension.

Adjustment Calibration:

Procedures for adjusting carburetor settings, suspension damping, chain slack, and other critical parameters.

Electrical Diagnostics:

Interpreting wiring diagrams, testing electrical components, and diagnosing electrical issues using multimeters.

Special Tool Usage:

Identification and usage of specific tools required for certain maintenance or repair tasks.

Technical Depth

Depth Level:

Comprehensive: Covers everything from basic rider maintenance to full engine and transmission rebuilds.

Diagnostic Capabilities:

Advanced diagnostic trees and troubleshooting guides for pinpointing complex mechanical and electrical problems.

📊 Manual Specifications

File Format

File Type:

Digital (PDF)

Searchability:

Likely text-searchable PDF for quick information retrieval.

Printability:

Designed for digital viewing and printing of specific sections or the entire manual.

Print Quality

Image Resolution:

High-quality scanned or digital-native images and diagrams for clarity.

Binding Type

Binding Format:

N/A (Digital PDF format)

Paper Type

Paper Quality:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-Stroke, Liquid-Cooled Single Cylinder

Displacement:

Approximately 249.5 cc

Bore X Stroke:

Typical values around 76 mm x 55 mm (specific figures may vary slightly)

Valve Train:

DOHC (Double Overhead Camshaft), 4 Valves per cylinder

Performance

Horsepower:

Estimated 30-35 HP (at crankshaft, depending on specific tuning and emissions controls for the year/market)

Torque:

Estimated 20-23 lb-ft (at crankshaft, depending on specific tuning)

Fuel System

Fuel Delivery:

Carburetor (Likely Mikuni TM series, e.g., TM36-6)

Fuel Type:

Unleaded Gasoline (91+ Octane Recommended)

Ignition System

Ignition:

Digital CDI

Lubrication

Oil Type:

High-quality Motorcycle Specific 4-Stroke Engine Oil (e.g., SAE 10W-40 or 15W-50, JASO MA/MA2 certified)

Cooling System

Cooling Method:

Liquid-Cooled

🔧 Transmission

Standard

Transmission Type:

6-Speed Manual

Features

Clutch Type:

Wet, Multi-Plate

Final Drive:

Chain Drive (520 pitch typically)

Fluid Specifications

Transmission Oil:

Dedicated Transmission Oil (refer to manual for specific type, often a separate lubricant from engine oil for optimal clutch function, e.g., SAE 75W-90 or specific motorcycle gear oil)

📐 Dimensions

Exterior

Length:

Approx. 2150-2250 mm (highly variable based on exact model configuration and any added accessories)

Width:

Approx. 800-900 mm (at handlebars)

Height:

Approx. 1250-1350 mm (at handlebars)

Wheelbase:

Approx. 1470-1490 mm

Ground Clearance:

Approx. 300-350 mm

Weights

Dry Weight:

Approx. 105-115 kg (specific weight varies by market and features)

Curb Weight:

Approx. 115-125 kg (with all fluids)

Capacities

Fuel Tank Capacity:

Approx. 7-9 Liters (typically around 7.5 L)

Engine Oil Capacity:

Approx. 1.0 - 1.2 Liters (refer to manual for exact fill levels)

🛡️ Safety Features

Ratings

Safety Certification:

Designed for off-road use, compliance with street-legal regulations varies by market and specific model configuration.

Active Features

Braking System:

Hydraulic disc brakes front and rear for effective stopping power.

Suspension Performance:

Advanced suspension provides stability and control over varied terrain.

Passive Features

Frame Strength:

Robust frame construction for rider safety and control during impacts.

💡 Technology Features

Infotainment

Infotainment System:

Minimal; typically features a basic digital or analog odometer and trip meter.

Driver Assistance

Driver Assistance Features:

None typical for this era and type of motorcycle (no electronic aids like ABS or traction control).

Connectivity

Connectivity Features:

None.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10-15 hours of off-road riding or annually, whichever comes first. Refer to manual for precise intervals.

Air Filter Cleaning:

Regularly, especially after dusty rides. Clean and re-oil foam filter as needed.

Spark Plug Inspection:

Every 20-30 hours of riding. Check gap and condition.

Valve Clearance Check:

As per manual, typically every 100-200 hours. Requires specific tools and knowledge.

Chain And Sprocket Maintenance:

Lubricate and adjust chain tension every few rides. Inspect sprockets for wear at regular intervals.

Suspension Service:

Fork seal and oil change recommended every 50-100 hours or annually. Rear shock service as needed.

Fluid Specifications

Brake Fluid Type:

DOT 4 recommended for hydraulic brake systems.

Coolant Type:

Ethylene Glycol based antifreeze mixture (50/50 with distilled water), motorcycle specific coolant is preferred.

Known Issues

Common Wear Items:

Clutch plates, brake pads and rotors, wheel bearings, steering head bearings, swingarm bearings, fork seals, and air filter are common wear items in off-road use.

Electrical Connections:

Vibration can sometimes lead to loose electrical connections, requiring periodic inspection and dielectric grease application.

Carburetor Tuning:

Mikuni carburetors can be sensitive to altitude and temperature changes, requiring periodic adjustment for optimal performance.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Husqvarna Motorcycles is one of the oldest motorcycle manufacturers in the world, founded in Sweden in 1903. Ownership has changed over the decades, with the brand being part of Cagiva Group (Italy) and later acquired by BMW Motorrad before being sold to Pierer Mobility AG (parent company of KTM).

Model Evolution

Te Series:

The TE series represents Husqvarna's dedicated line of enduro motorcycles, known for their off-road capability. The 250cc displacement is a popular choice for agility and manageable power delivery.

Production

Manufacturing Location:

During the 2007-2008 period, Husqvarna motorcycles were primarily manufactured in Italy under the Cagiva Group ownership.

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

Specific awards for the 2007-2008 TE250 are not widely documented in public consumer reviews. However, Husqvarna motorcycles in general have a strong reputation in off-road racing and enthusiast communities for their performance and build quality.