Husqvarna TC250 2009 2010 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: Husqvarna Model: TC250 Year: 2009, 2010 Vehicle Type: Motocross Motorcycle 👋 Introduction Market Context 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 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 Key Features: Two-stroke engine for aggressive power delivery, lightweight chassis, premium suspension components, and robust build quality expected from Husqvarna. 📋 Manual Details Coverage Manual Type: Workshop Repair Service Manual Language: English Format: PDF Download Coverage Areas: All Models, All Engines, All Trims, All Transmissions 📖 Manual Coverage Systems 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 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 Depth Technical Depth: Comprehensive; covers basic maintenance to full engine and chassis rebuilds, including detailed diagnostic procedures and specifications. 📊 Manual Specifications File Attributes File Format: PDF 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 Specifications Primary Engine 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) Performance Horsepower: Estimated 45-50 HP (depending on tuning and specific model year variations) Torque: Refer to manual for exact specifications Fuel System Fuel Delivery: Carburetor (e.g., Keihin PWK 38mm) Fuel Type: Unleaded gasoline (min. 91 octane recommended), mixed with appropriate 2-stroke oil Lubrication 2 Stroke Oil Type: High-quality 2-stroke motorcycle oil (specific grade recommended in manual) Ignition Ignition System: Digital CDI Cooling Cooling System: Liquid-cooled Coolant Type: Ethylene glycol-based coolant with corrosion inhibitors (specific mixture ratio recommended in manual) 🔧 Transmission Gearbox Transmission Type: 6-speed constant mesh Clutch Clutch Type: Hydraulically operated, wet multi-plate Fluids 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) 📐 Dimensions Overall Length: Refer to manual for exact specifications Width: Refer to manual for exact specifications Height: Refer to manual for exact specifications Weights Dry Weight: Around 100-105 kg (dry, depending on configuration) Wet Weight: Refer to manual for exact specifications Wheels Tires Front Wheel Size: 21 inches Rear Wheel Size: 19 inches Front Tire Size: 80/100-21 (typical) Rear Tire Size: 100/90-19 (typical) Suspension 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+) 🛡️ Safety Features Braking System 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) Ratings Safety Ratings: As a competition off-road motorcycle, it does not undergo standard automotive safety ratings (e.g., NHTSA, Euro NCAP). 💡 Technology Features Engine Management Engine Management System: Basic digital CDI with mechanical power valve actuation. Infotainment Infotainment Features: N/A (Competition motocross motorcycle) Driver Assistance Driver Assistance Features: N/A (Competition motocross motorcycle) Connectivity Connectivity Features: N/A (Competition motocross motorcycle) 🔧 Maintenance Service Intervals 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. Fluid Specifications Brake Fluid Type: DOT 4 Clutch Fluid Type: DOT 4 (if hydraulic) Known Issues 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 Tuning Tips: Proper jetting for the carburetor is critical for optimal performance and engine longevity. Regular clutch and chain adjustments are essential. 📚 Vehicle History Brand Heritage Brand Heritage: Husqvarna Motorcycles, a Swedish brand founded in 1689, has a long history in motorcycle production, particularly known for...
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
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
Key Features:
Two-stroke engine for aggressive power delivery, lightweight chassis, premium suspension components, and robust build quality expected from Husqvarna.
📋 Manual Details
Coverage
Manual Type:
Workshop Repair Service Manual
Language:
English
Format:
PDF Download
Coverage Areas:
All Models, All Engines, All Trims, All Transmissions
High-quality 2-stroke motorcycle oil (specific grade recommended in manual)
Ignition
Ignition System:
Digital CDI
Cooling
Cooling System:
Liquid-cooled
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (specific mixture ratio recommended in manual)
🔧 Transmission
Gearbox
Transmission Type:
6-speed constant mesh
Clutch
Clutch Type:
Hydraulically operated, wet multi-plate
Fluids
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)
📐 Dimensions
Overall
Length:
Refer to manual for exact specifications
Width:
Refer to manual for exact specifications
Height:
Refer to manual for exact specifications
Weights
Dry Weight:
Around 100-105 kg (dry, depending on configuration)
Wet Weight:
Refer to manual for exact specifications
Wheels Tires
Front Wheel Size:
21 inches
Rear Wheel Size:
19 inches
Front Tire Size:
80/100-21 (typical)
Rear Tire Size:
100/90-19 (typical)
Suspension
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+)
🛡️ Safety Features
Braking System
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)
Ratings
Safety Ratings:
As a competition off-road motorcycle, it does not undergo standard automotive safety ratings (e.g., NHTSA, Euro NCAP).
💡 Technology Features
Engine Management
Engine Management System:
Basic digital CDI with mechanical power valve actuation.
Infotainment
Infotainment Features:
N/A (Competition motocross motorcycle)
Driver Assistance
Driver Assistance Features:
N/A (Competition motocross motorcycle)
Connectivity
Connectivity Features:
N/A (Competition motocross motorcycle)
🔧 Maintenance
Service Intervals
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.
Fluid Specifications
Brake Fluid Type:
DOT 4
Clutch Fluid Type:
DOT 4 (if hydraulic)
Known Issues
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
Tuning Tips:
Proper jetting for the carburetor is critical for optimal performance and engine longevity. Regular clutch and chain adjustments are essential.
📚 Vehicle History
Brand Heritage
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
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
Production Era:
Husqvarna motorcycles of this period were primarily manufactured in Italy under previous ownership structures before acquisition by KTM.
🏆 Awards & Recognition
Recognitions
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.
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