The TC250 is a performance motocross motorcycle designed for competitive racing, emphasizing a strong power-to-weight ratio and agile handling. Built upon an extensive heritage in off-road vehicle development, this model represents a dedicated motocross platform. For the 2009 and 2010 model years, the TC250 features a liquid-cooled, two-stroke, single-cylinder engine with a displacement of approximately 249.1 cc, delivering aggressive, top-end focused power. Its engineering prioritizes the demands of motocross competition, positioning it among leading models in its segment. This comprehensive workshop service repair manual provides detailed guidance for the maintenance and repair of the TC250, covering the 2009 and 2010 model years. It encompasses a wide array of essential procedures, including complete engine and transmission service, fuel and cooling system maintenance, ignition and electrical system diagnostics, and detailed suspension and braking system overhauls. The manual also includes troubleshooting guides, routine maintenance schedules, and technical specifications such as torque values and fluid recommendations, enabling owners and technicians to effectively preserve and restore the motorcycle's performance and reliability. 🏷️ Basic Information Identification Make: Husqvarna Model: TC250 Year: 2009, 2010 Vehicle Type: Motocross Motorcycle Codes Vin Code: Refer to individual motorcycle VIN 👋 Introduction Market Position Vehicle Segment: Performance Motocross Competition Motorcycle Competitive Analysis Key Competitors: KTM 250 SX, Yamaha YZ250, Suzuki RM-Z250, Kawasaki KX250, Honda CRF250R Key Features Performance Focus: Designed for competitive motocross racing, emphasizing power-to-weight ratio and handling Brand Legacy: Leverages Husqvarna's rich heritage in off-road motorcycle development 📋 Manual Details Coverage Areas Manual Scope: Complete Workshop Service Repair Manual Page Count Estimated Page Count: Hundreds of pages (specific count not provided, but implies comprehensive coverage) Manual Type Manual Classification: Official Factory Service Repair Manual Language Language: English (assumed, standard for most factory manuals) Format Download Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service: Complete engine disassembly, assembly, inspection, and repair procedures for the TC250 Transmission Service: Gearbox disassembly, inspection, repair, and adjustment Fuel System Service: Carburetor (likely Keihin or Mikuni), fuel lines, fuel tank inspection and maintenance Cooling System Service: Radiator, coolant, hoses, water pump maintenance and troubleshooting Ignition System Service: CDI unit, spark plug, stator, ignition timing checks Exhaust System Service: Exhaust pipe, muffler inspection and maintenance Suspension Service Front: Fork disassembly, seal replacement, oil change, spring inspection Suspension Service Rear: Shock absorber service, linkage maintenance, adjustment procedures Braking System Service: Hydraulic brake system, caliper maintenance, pad replacement, fluid bleeding, rotor inspection Clutch Service: Clutch assembly, plates, springs, cable adjustment Electrical System Service: Wiring diagrams, component testing, battery maintenance, lighting Wheel And Tire Service: Wheel bearing maintenance, spoke tensioning, tire replacement Frame And Bodywork Service: Frame inspection, plastic body panel removal and installation Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, lubrication schedules Troubleshooting Guides: Diagnostic procedures for common issues, symptom-based fault finding Engine Rebuild: Detailed steps for piston, cylinder, crankshaft, and valve train overhaul Suspension Rebuild: Fork seal replacement, damper rod service, rear shock rebuilding Brake System Overhaul: Caliper rebuild, master cylinder service, hydraulic line replacement Carburetor Tuning: Jetting recommendations, idle speed adjustment, mixture control Electrical Diagnostics: Wiring diagram interpretation, component continuity testing Specifications And Tolerances: Torque values, clearances, fluid capacities, wear limits Technical Depth Depth Level: Comprehensive Factory Level (covering basic maintenance to complete engine and chassis overhauls) 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Printability: Printable (allows printing in its entirety or selected pages) Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, two-stroke, liquid-cooled Displacement: 249.1 cc (approximate, based on typical TC250 models) Bore X Stroke: Typical: 66.4 mm x 72 mm (specific values to be confirmed in manual) Compression Ratio: Typically around 8.2:1 to 8.6:1 (specific value to be confirmed) Cylinder Design: Aluminum cylinder with Nikasil coating Power Delivery: Aggressive, top-end focused powerband typical of 2-stroke motocross bikes Performance Horsepower: Estimated 40-45 HP (specific dyno figures vary) Torque: Estimated 25-28 lb-ft (specific figures vary) Fuel System Carburetor Model: Likely Keihin PWK 38 Air Stripper or similar (specific model in manual) Fuel Type: Unleaded gasoline with appropriate 2-stroke oil mix (e.g., 40:1 or 50:1, check manual) Ignition System: Digital CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Transmission Type: 5-speed manual Clutch Type: Wet, multi-plate Features Gearbox Design: Constant mesh, forged gears for durability 📐 Dimensions Exterior Wheelbase: Approx. 1470 mm / 57.9 inches (specific to model year) Seat Height: Approx. 965 mm / 38 inches (specific to model year) Ground Clearance: Approx. 350 mm / 13.8 inches (specific to model year) Weights Dry Weight: Approx. 99 kg / 218 lbs (specific to model year) 🛡️ Safety Features Ratings Safety Certification: Not applicable for competition off-road motorcycles in terms of road safety ratings Active Features Braking System Type: Hydraulic disc brakes front and rear Suspension Travel Front: Typically 300-320 mm (Marzocchi or similar...