Husqvarna TC250 TE250 TXC250 2009 2010 Repair Service Manual
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🏷️ Basic Information Identification Make: Husqvarna Model: TC250, TE250, TXC250 Year: 2009, 2010 Codes Engine Code General: LC4 4-stroke (though specific internal codes vary by model variant) 👋 Introduction Market Position Vehicle Segment: Off-road competition motorcycles (Enduro and Motocross variants). Competitive Analysis Key Competitors Era: KTM EXC/SX, Yamaha WR/YZ, Honda CRF, Kawasaki KX, Suzuki RM-Z. Key Features Brand Focus: Husqvarna's reputation for high-performance, specialized off-road machinery with European engineering. Manual Purpose Manual Value Proposition: Essential tool for owners and technicians to maintain peak performance, diagnose issues, and perform repairs on the specific Husqvarna TC250, TE250, and TXC250 models. 📋 Manual Details Coverage Areas General Coverage: Comprehensive service, maintenance, and troubleshooting for the specified models and years. Page Count Estimated Page Count: Likely 300-500+ pages (typical for a full workshop manual) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English (presumed based on common industry practice for this type of manual) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine assembly/disassembly, top-end components (cylinder, piston, valves), bottom-end components (crankshaft, connecting rod, bearings), lubrication system, cooling system, fuel injection system, ignition system, exhaust system. Transmission Drivetrain: Gearbox, clutch assembly, gear shift mechanism, final drive (chain and sprockets). Chassis Suspension: Frame, front fork (internal components, seals, adjustments), rear shock absorber (internal components, seals, adjustments), swingarm, linkage systems (if applicable), steering system. Brakes: Hydraulic brake systems (front and rear calipers, master cylinders, brake lines), rotor specifications, pad replacement procedures, bleeding procedures. Electrical Electronics: Wiring diagrams, lighting system, battery, charging system (stator, regulator/rectifier), starter motor, EFI control unit, sensors, instrumentation. Fuel System: Fuel tank, fuel pump, fuel filter, fuel injectors, throttle body. Bodywork Cosmetics Bodywork: Fairings, seat, fuel tank covers, fender removal/installation. Procedures Included Maintenance Procedures: Routine checks, oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain adjustment and lubrication, valve clearance checks and adjustment, brake pad inspection and replacement, fluid level checks. Troubleshooting Diagnostics: Diagnostic charts for common problems, symptom-based troubleshooting guides, error code interpretation (if applicable), electrical system diagnostics. Repair Rebuild Procedures: Detailed step-by-step instructions for engine teardown and reassembly, gearbox overhaul, suspension fork rebuild, brake system overhaul, electrical component replacement. Technical Specifications Data: Torque specifications for all fasteners, engine compression test procedures, component measurements, tolerances, valve timing procedures. Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds. Suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality Reproducibility: Designed for digital viewing and printing. Image clarity and text readability are crucial for technical diagrams and procedures. Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) Searchability Text Searchability: Likely text-searchable PDF, enabling quick navigation to specific topics. ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, liquid-cooled Displacement: Approximately 250cc (e.g., 249.4cc for some variants) Bore X Stroke: Typically around 76mm x 55mm (exact figures may vary slightly by model variant). Valve Train: DOHC (Double Overhead Camshaft), 4 valves Performance Horsepower Est: Estimated 35-40 HP (at the crank), depending on model and tuning. Torque Est: Estimated 20-25 Nm, depending on model and tuning. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Keihin or Mikuni throttle body and injectors (specifics vary). Fuel Type: Unleaded gasoline, minimum 95 RON (Octane rating). Lubrication Oil Type: High-performance 4-stroke motorcycle oil, typically JASO MA/MA2 certified, SAE 10W/40 or 15W/50 depending on operating temperature. Oil Capacity Engine Only: Approximately 0.8 - 1.1 liters (check manual for exact figures for each model variant). Cooling System Type: Liquid-cooled Coolant Type: Ethylene glycol based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water. Ignition System Type: Digital CDI (Capacitor Discharge Ignition) with variable ignition timing. Spark Plug Type: NGK CR8E or equivalent (confirm specific plug for each model). 🔧 Transmission Standard Transmission Type: 6-speed manual transmission Clutch Type: Wet multi-plate clutch Features Gear Ratios: Specific gear ratios are detailed within the manual, crucial for performance tuning and replacement. Final Drive: Chain drive Final Drive Ratio: Typically around 13:52 or similar, subject to model variation and user preference. 📐 Dimensions Exterior Wheelbase: Approx. 1480-1510 mm (varies by model: TC, TE, TXC) Weights Dry Weight Est: Approx. 100-110 kg (dry, varies by model and specific equipment) Fuel Tank Capacity: Typically 7-9 Liters (varies by model: TE/TC/TXC variants have different tank sizes for range). Seat Height: Approx. 950-980 mm (high seat height typical for off-road bikes). Ground Clearance: Approx. 300-330 mm. 🛡️ Safety Features Ratings Safety Certification: Not typically safety rated in the same way as road vehicles; built for off-road use and durability. Active Features Braking System: Hydraulic disc brakes front and rear, with high-performance calipers and rotors for excellent stopping power. Suspension System: High-quality, adjustable upside-down front forks (e.g., Marzocchi or Sachs) and monoshock rear...
Husqvarna's reputation for high-performance, specialized off-road machinery with European engineering.
Manual Purpose
Manual Value Proposition:
Essential tool for owners and technicians to maintain peak performance, diagnose issues, and perform repairs on the specific Husqvarna TC250, TE250, and TXC250 models.
📋 Manual Details
Coverage Areas
General Coverage:
Comprehensive service, maintenance, and troubleshooting for the specified models and years.
Page Count
Estimated Page Count:
Likely 300-500+ pages (typical for a full workshop manual)
Manual Type
Manual Type:
Workshop Repair Service Manual
Language
Language:
English (presumed based on common industry practice for this type of manual)
Fairings, seat, fuel tank covers, fender removal/installation.
Procedures Included
Maintenance Procedures:
Routine checks, oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain adjustment and lubrication, valve clearance checks and adjustment, brake pad inspection and replacement, fluid level checks.
Troubleshooting Diagnostics:
Diagnostic charts for common problems, symptom-based troubleshooting guides, error code interpretation (if applicable), electrical system diagnostics.
Repair Rebuild Procedures:
Detailed step-by-step instructions for engine teardown and reassembly, gearbox overhaul, suspension fork rebuild, brake system overhaul, electrical component replacement.
Technical Specifications Data:
Torque specifications for all fasteners, engine compression test procedures, component measurements, tolerances, valve timing procedures.
Technical Depth
Depth Of Coverage:
Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds. Suitable for professional mechanics and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality Reproducibility:
Designed for digital viewing and printing. Image clarity and text readability are crucial for technical diagrams and procedures.
Binding Type
Binding Type:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
Searchability
Text Searchability:
Likely text-searchable PDF, enabling quick navigation to specific topics.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, 4-stroke, liquid-cooled
Displacement:
Approximately 250cc (e.g., 249.4cc for some variants)
Bore X Stroke:
Typically around 76mm x 55mm (exact figures may vary slightly by model variant).
Valve Train:
DOHC (Double Overhead Camshaft), 4 valves
Performance
Horsepower Est:
Estimated 35-40 HP (at the crank), depending on model and tuning.
Torque Est:
Estimated 20-25 Nm, depending on model and tuning.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Keihin or Mikuni throttle body and injectors (specifics vary).
Fuel Type:
Unleaded gasoline, minimum 95 RON (Octane rating).
Lubrication
Oil Type:
High-performance 4-stroke motorcycle oil, typically JASO MA/MA2 certified, SAE 10W/40 or 15W/50 depending on operating temperature.
Oil Capacity Engine Only:
Approximately 0.8 - 1.1 liters (check manual for exact figures for each model variant).
Cooling System
Type:
Liquid-cooled
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.
Ignition System
Type:
Digital CDI (Capacitor Discharge Ignition) with variable ignition timing.
Spark Plug Type:
NGK CR8E or equivalent (confirm specific plug for each model).
🔧 Transmission
Standard
Transmission Type:
6-speed manual transmission
Clutch Type:
Wet multi-plate clutch
Features
Gear Ratios:
Specific gear ratios are detailed within the manual, crucial for performance tuning and replacement.
Final Drive:
Chain drive
Final Drive Ratio:
Typically around 13:52 or similar, subject to model variation and user preference.
📐 Dimensions
Exterior
Wheelbase:
Approx. 1480-1510 mm (varies by model: TC, TE, TXC)
Weights
Dry Weight Est:
Approx. 100-110 kg (dry, varies by model and specific equipment)
Fuel Tank Capacity:
Typically 7-9 Liters (varies by model: TE/TC/TXC variants have different tank sizes for range).
Seat Height:
Approx. 950-980 mm (high seat height typical for off-road bikes).
Ground Clearance:
Approx. 300-330 mm.
🛡️ Safety Features
Ratings
Safety Certification:
Not typically safety rated in the same way as road vehicles; built for off-road use and durability.
Active Features
Braking System:
Hydraulic disc brakes front and rear, with high-performance calipers and rotors for excellent stopping power.
Suspension System:
High-quality, adjustable upside-down front forks (e.g., Marzocchi or Sachs) and monoshock rear suspension, providing precise control and impact absorption.
Passive Features
Frame Construction:
Robust steel or chromoly frame designed for strength and torsional rigidity.
💡 Technology Features
Infotainment
Infotainment System:
N/A - Motorcycle, minimal electronic features beyond EFI and ignition management.
Driver Assistance
Driver Assistance Features:
N/A - Motorcycle, focus is on mechanical feedback and rider skill.
Connectivity
Connectivity Features:
N/A - Motorcycle.
Instrumentation
Instrument Cluster:
Digital instrument cluster providing speed, RPM, odometer, trip meters, and basic warning lights (engine check, oil pressure, etc.).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10-15 hours of riding, or annually, whichever comes first.
Air Filter Cleaning:
Every 5-10 hours of riding, or after each dusty ride.
Valve Clearance Check:
Every 20-30 hours of riding.
Spark Plug Replacement:
Every 20-30 hours of riding or annually.
Chain Lubrication Adjustment:
Every 5-10 hours of riding, or after washing.
Fluid Specifications
Engine Oil Specification:
See engine_specs for details. Manual will provide exact API and JASO ratings.
Brake Fluid Specification:
DOT 4 Hydraulic Brake Fluid.
Coolant Specification:
See engine_specs for details. Manual will confirm specific anti-corrosion and anti-freeze properties required.
Known Issues
Common Wear Items:
Clutch wear, piston ring wear, valve seat wear, wheel bearings, steering head bearings, fork seals, swingarm pivot bearings.
Potential Electrical Gremlins:
While generally robust, wiring harness integrity and connector cleanliness are critical for EFI systems. Manual will offer diagnostic steps.
Suspension Maintenance:
Regular fork oil changes and seal replacements are vital for optimal performance and longevity.
📚 Vehicle History
Brand Heritage
Brand Origin:
Husqvarna Motorcycles, originating from Sweden, known for its long history in motorcycle manufacturing, particularly in off-road disciplines.
Model Evolution
Lineage:
These models represent Husqvarna's 250cc four-stroke offerings for the enduro (TE), motocross (TC), and cross-country (TXC) segments during this period, often sharing core components with variations in suspension, tuning, and features tailored to their specific disciplines.
Production
Manufacturing Location:
Typically manufactured in Italy during this ownership period (prior to KTM acquisition).
🏆 Awards & Recognition
Recognitions
Model Specific Awards:
Specific awards for these exact 2009-2010 models are not widely documented in general automotive press, but Husqvarna generally receives positive reviews in off-road magazines for their performance and handling in their respective categories.
Ratings
Brand Reputation:
Husqvarna has a strong heritage and reputation within the off-road motorcycle community for building capable and competitive machines.