The TC250 is a competitive 250cc two-stroke motocross motorcycle, produced for the 2009 and 2010 model years. Known for its potent engine and agile handling, this machine is designed for the demands of motocross riding, offering riders an aggressive power delivery characteristic of its two-stroke design. Featuring premium suspension components and robust build quality, the TC250 provides a distinct European performance profile, competing in a segment alongside other major motocross manufacturers. Its engineering emphasizes lightweight construction and reliable performance for both amateur and professional riders.
This comprehensive Workshop Repair Service Manual in English covers all aspects of the TC250 for 2009 and 2010. It details essential maintenance procedures, troubleshooting common issues, and in-depth technical specifications for all systems, including the engine, transmission, clutch, fuel, ignition, cooling, exhaust, suspension, brakes, and electrical systems. The manual provides step-by-step instructions for disassembly and reassembly of major components, routine maintenance, tune-ups, and rebuilds, making it an indispensable resource for owners and technicians seeking to maintain, repair, and optimize their TC250.
Vehicle Type:
Motocross Motorcycle
Market Position:
The Husqvarna TC250 is a competitive 250cc two-stroke motocross bike, known for its potent engine and agile handling in its class, targeting amateur and professional motocross riders.
Competitive Analysis:
Competes directly with models like the KTM 250 SX, Yamaha YZ250, Suzuki RM250, and Honda CR250R (in earlier years), offering a distinct European character and performance profile.
Key Features:
Two-stroke engine for aggressive power delivery, lightweight chassis, premium suspension components, and robust build quality expected from Husqvarna.
Manual Type:
Workshop Repair Service Manual
Coverage Areas:
All Models, All Engines, All Trims, All Transmissions
Systems Covered:
Engine, Transmission, Clutch, Fuel System, Ignition System, Cooling System, Exhaust System, Suspension (Front & Rear), Brakes (Front & Rear), Electrical System, Chassis, Frame, Wheels & Tires, Bodywork, Troubleshooting, Maintenance
Procedures Included:
General Maintenance, Lubrication, Engine Tune-up, Carburetor Adjustment/Rebuild, Valve Clearance Adjustment, Cylinder Head Removal/Installation, Piston/Ring Replacement, Crankshaft/Connecting Rod Service, Transmission Disassembly/Assembly, Clutch Service/Replacement, Shock Absorber Service, Fork Service/Rebuild, Brake Bleeding/Pad Replacement, Wheel Bearing Service, Electrical System Diagnosis, Wiring Diagrams, Component Testing, Troubleshooting Common Issues, Routine Inspections, Disassembly and Reassembly of all major components
Technical Depth:
Comprehensive; covers basic maintenance to full engine and chassis rebuilds, including detailed diagnostic procedures and specifications.
Print Quality:
High-resolution scans, suitable for printing individual pages or the entire manual.
Searchability:
Searchable text within the PDF document for quick information retrieval.
Engine Type:
Liquid-cooled, 2-stroke, single cylinder
Displacement:
249 cc (approx.)
Bore X Stroke:
Refer to manual for exact specifications (typically around 66.4 mm x 72 mm)
Horsepower:
Estimated 45-50 HP (depending on tuning and specific model year variations)
Torque:
Refer to manual for exact specifications
Fuel Delivery:
Carburetor (e.g., Keihin PWK 38mm)
Fuel Type:
Unleaded gasoline (min. 91 octane recommended), mixed with appropriate 2-stroke oil
2 Stroke Oil Type:
High-quality 2-stroke motorcycle oil (specific grade recommended in manual)
Ignition System:
Digital CDI
Cooling System:
Liquid-cooled
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (specific mixture ratio recommended in manual)
Transmission Type:
6-speed constant mesh
Clutch Type:
Hydraulically operated, wet multi-plate
Transmission Oil Type:
Specific motorcycle transmission oil or engine oil as per manual (e.g., SAE 10W/40 or SAE 15W/50)
Transmission Oil Capacity:
Refer to manual for exact capacity (typically around 0.7 - 0.9 liters)
Length:
Refer to manual for exact specifications
Width:
Refer to manual for exact specifications
Height:
Refer to manual for exact specifications
Dry Weight:
Around 100-105 kg (dry, depending on configuration)
Wet Weight:
Refer to manual for exact specifications
Front Wheel Size:
21 inches
Rear Wheel Size:
19 inches
Front Tire Size:
80/100-21 (typical)
Rear Tire Size:
100/90-19 (typical)
Front Suspension Type:
Upside-down telescopic fork (e.g., Marzocchi Shiver or similar)
Front Suspension Travel:
Refer to manual for exact travel (typically 300mm+)
Rear Suspension Type:
Monoshock with linkage system (e.g., Sachs or similar)
Rear Suspension Travel:
Refer to manual for exact travel (typically 300mm+)
Front Brake Type:
Hydraulic disc brake
Front Brake Rotor Diameter:
Refer to manual for exact specifications (typically 260mm)
Rear Brake Type:
Hydraulic disc brake
Rear Brake Rotor Diameter:
Refer to manual for exact specifications (typically 240mm)
Safety Ratings:
As a competition off-road motorcycle, it does not undergo standard automotive safety ratings (e.g., NHTSA, Euro NCAP).
Engine Management System:
Basic digital CDI with mechanical power valve actuation.
Infotainment Features:
N/A (Competition motocross motorcycle)
Driver Assistance Features:
N/A (Competition motocross motorcycle)
Connectivity Features:
N/A (Competition motocross motorcycle)
Oil Change Interval:
Refer to manual; typically every 5-10 hours of riding or annually.
Air Filter Cleaning:
Inspect and clean after every few rides, or as per manual recommendations.
Spark Plug Replacement:
Refer to manual; typically every 20-40 hours of riding.
Top End Rebuild:
Refer to manual; recommended between 50-100 hours of riding, depending on riding style and maintenance.
Clutch Fluid Type:
DOT 4 (if hydraulic)
Known Issues:
Common issues may include carburetor tuning sensitivity, wear on clutch components due to hard use, occasional issues with power valve operation if not properly maintained, and standard wear and tear on suspension and bearings.
Tuning Tips:
Proper jetting for the carburetor is critical for optimal performance and engine longevity. Regular clutch and chain adjustments are essential.
Brand Heritage:
Husqvarna Motorcycles, a Swedish brand founded in 1689, has a long history in motorcycle production, particularly known for its off-road prowess and innovation since the mid-20th century.
Model Evolution:
The TC series represents Husqvarna's commitment to the competitive motocross segment. The 250cc two-stroke models have evolved through chassis updates, engine refinements, and suspension improvements over the years to maintain competitiveness.
Production Era:
Husqvarna motorcycles of this period were primarily manufactured in Italy under previous ownership structures before acquisition by KTM.
Awards And Recognitions:
Specific awards for the 2009-2010 TC250 are not widely publicized, but Husqvarna motocross models of this era were generally praised for their European chassis dynamics and strong two-stroke power in reviews.
