The TC 250, produced for the 2009 and 2010 model years, is a performance-oriented motocross motorcycle renowned for its lightweight chassis, potent liquid-cooled 2-stroke engine, and agile handling. Engineered for competitive use, this model represents a dedication to the motocross discipline, offering a thrilling experience for enthusiasts and semi-professional riders. Its design prioritizes power and maneuverability on the track, making it a capable machine in its class, competing with other prominent motocross bikes of its era. This workshop service manual provides comprehensive guidance for the repair and overhaul of the TC 250. It covers all essential systems, including detailed procedures for engine and transmission disassembly and reassembly, fuel and ignition system maintenance, lubrication, exhaust, electrical, and bodywork components. The manual also details routine maintenance, troubleshooting, and specialized procedures, offering step-by-step instructions and identifying necessary special tools. Its purpose is to empower owners and technicians to maintain, diagnose, and repair the motorcycle effectively, ensuring its optimal performance and longevity. 🏷️ Basic Information Identification Make: Husqvarna Model: TC 250 Year: 2009-2010 Codes Vehicle Type: Motocross Motorcycle 👋 Introduction Market Position Positioning: Performance-oriented motocross motorcycle, aimed at enthusiasts and semi-professional riders. Competitive Analysis Competitors: KTM 250 SX, Yamaha YZ250, Honda CRF250X, Suzuki RM-Z250. Key Features Vehicle Highlights: Lightweight chassis, potent 2-stroke engine, agile handling, designed for competitive motocross use. Manual Purpose Objective: To enable technicians and owners to perform accurate repairs, maintenance, and overhauls, ensuring optimal performance and longevity of the Husqvarna TC 250. 📋 Manual Details Coverage Areas Primary Coverage: Repair and Overhaul Page Count Estimated Pages: Comprehensive (Exact page count not specified, but described as a 'complete Service Manual') Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete disassembly and reassembly, troubleshooting, performance tuning Transmission: Complete disassembly and reassembly, troubleshooting Fuel System: Carburetor (jetting, maintenance, overhaul), fuel pump, fuel lines, fuel tank Ignition System: Ignition timing, spark plug specifications, coil testing, CDI unit troubleshooting Lubrication System: Oil pump, oil filter, oil passages, oil type and capacity specifications Exhaust System: Exhaust pipe, muffler inspection and maintenance Electrical System: Wiring diagrams, component testing (lights, horn, battery, stator, rectifier/regulator) Bodywork: Fairings, seat, handlebars, footpegs, plastics removal and installation Suspension: Front forks (rebuild, adjustments, oil levels), rear shock absorber (rebuild, adjustments, spring preload). Wheels And Tires: Wheel bearing service, spoke tension, tire pressure, tire replacement. Brakes: Front and rear brake caliper service, master cylinder overhaul, brake line replacement, pad replacement, bleeding procedure. Cooling System: Radiator inspection, coolant hose replacement, water pump service. Frame And Body: Includes procedures for removing and reinstalling body panels, seat, fuel tank, and chassis components. Procedures Included Routine Maintenance: Tune-ups, fluid changes, filter replacement, chain adjustment, brake pad inspection Removal Installation: Component removal and reinstallation procedures for all major systems Assembly Disassembly: Detailed step-by-step instructions for major component disassembly and assembly Troubleshooting: Diagnostic procedures for common and complex issues across all systems Engine Tuning: Carburetor tuning, ignition timing checks, exhaust system optimization. Chassis Maintenance: Steering head bearing service, swingarm pivot bearing service, linkage bearing service. Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including special tool identification. Special Tools: Identifies and illustrates recommended or required special tools for specific adjustments and repairs (e.g., flywheel puller, clutch holding tool). 📊 Manual Specifications File Format File Format: PDF Searchability: PDF format typically allows for text searching, enhancing usability. Print Quality Printability: Yes, printable Binding Type Binding Type: Not Applicable (Digital PDF) Paper Type Paper Type: Not Applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Type: 2-stroke, single-cylinder Displacement: Approx. 250cc (Specific bore/stroke not provided in product description, but standard for the class) Cooling: Liquid-cooled Bore X Stroke: Specific dimensions would be detailed in the manual, typically around 66.4 mm x 72 mm for a 250cc 2-stroke. Performance Horsepower: Estimated 45-50 HP (typical for this class and era, specific figure not in product data) Torque: Estimated 25-30 lb-ft (typical for this class and era, specific figure not in product data) Fuel System Carburetor Type: Mikuni VM34 or similar (common for this model, specific type not in product data) Fuel Type: Unleaded gasoline with 2-stroke oil premix (specific ratio in manual) 🔧 Transmission Standard Type: 6-speed manual Optional Type: N/A (Motocross bikes typically have fixed transmissions) Features Clutch: Hydraulic operated, multi-plate wet clutch 📐 Dimensions Exterior Wheelbase: Approx. 1460-1470 mm (typical for this model, specific figure not in product data) Weights Dry Weight: Approx. 102-105 kg (typical for this model, specific figure not in product data) 🛡️ Safety Features Ratings Crash Test Results: Not Applicable (Motorcycle, not typically subjected to automotive crash testing standards). Active Features Braking System: Hydraulic disc brakes front and rear. Passive Features Frame Construction: Chromium-molybdenum steel frame (standard for Husqvarna motocross bikes of this era). 💡 Technology Features Infotainment Features: Not Applicable (Pure motocross competition...