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Husqvarna TC250 TE250 TXC250 2009 2010 Repair Service Manual

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The TC250, TE250, and TXC250 models from 2009 and 2010 represent a commitment to high-performance off-road motorcycles, drawing on a rich heritage in competitive riding. These machines are engineered for demanding off-road disciplines, offering a blend of power, agility, and durability characteristic of European off-road design. Built with robust chassis and advanced suspension systems, they are designed to tackle challenging terrains and provide riders with precise control and an exhilarating experience, competing directly with established brands in the enduro and motocross segments. This comprehensive Workshop Repair Service Manual is an essential resource for owners and technicians seeking to maintain and repair the TC250, TE250, and TXC250 models from the 2009 and 2010 production years. It covers a wide array of critical systems, including detailed procedures for engine assembly and disassembly, transmission and clutch service, chassis and suspension adjustments, brake system maintenance, and electrical system diagnostics. The manual provides in-depth guidance on routine maintenance, troubleshooting common issues, and performing complex rebuilds, ensuring the longevity and optimal performance of these specialized off-road motorcycles. 🏷️ 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...
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Husqvarna TC250 TE250 TXC250 2009 2010 Repair Service ManualHusqvarna TC250 TE250 TXC250 2009 2010 Repair Service ManualHusqvarna TC250 TE250 TXC250 2009 2010 Repair Service ManualHusqvarna TC250 TE250 TXC250 2009 2010 Repair Service Manual
The TC250, TE250, and TXC250 models from 2009 and 2010 represent a commitment to high-performance off-road motorcycles, drawing on a rich heritage in competitive riding. These machines are engineered for demanding off-road disciplines, offering a blend of power, agility, and durability characteristic of European off-road design. Built with robust chassis and advanced suspension systems, they are designed to tackle challenging terrains and provide riders with precise control and an exhilarating experience, competing directly with established brands in the enduro and motocross segments. This comprehensive Workshop Repair Service Manual is an essential resource for owners and technicians seeking to maintain and repair the TC250, TE250, and TXC250 models from the 2009 and 2010 production years. It covers a wide array of critical systems, including detailed procedures for engine assembly and disassembly, transmission and clutch service, chassis and suspension adjustments, brake system maintenance, and electrical system diagnostics. The manual provides in-depth guidance on routine maintenance, troubleshooting common issues, and performing complex rebuilds, ensuring the longevity and optimal performance of these specialized off-road motorcycles.
🏷️ 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 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.
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