Husqvarna TE 250-310 2012 I.E. Workshop Manual
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Husqvarna TE 250-310 2012 I.E. Workshop Manual

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TE 250 - 310 2012 I.E.
TE 250 - 310 2012 I.E. USA
TC 250 2012 - TC 250 2012 I.E. USA
TXC 250 - 310 2012 I.E. USA
Workshop Manual
Ed. 12-2011
Rev 02

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Summary of Contents for Husqvarna TE 250-310 2012 I.E.

  • Page 1 TE 250 - 310 2012 I.E. TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Workshop Manual Ed. 12-2011 Rev 02...

  • Page 2: St Edition (12-2011) -

    Correct drawing from H11102 to H11259 HUSQVARNA MOTORCYCLES S.R.L. - Varese disclaims all liabilities for any errors or omissions in this manual and reserves the right to make changes to reflect on-going product development. Illustrations in the manual may differ from actual components.

  • Page 3: Workshop Manual

    TE 250 - 310 2012 I.E. TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Copyright by HUSQVARNA MOTORCYCLES S.R.L. BMW Group Technical Service Via Nino Bixio, 8 21024 (Varese) - Italy tel.
  • Page 4 TXC 250 - 310 2012 I.E. USA Foreword This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance and repair of the models covered in this manual. The technical information provided in this manual is a critical comple- ment to operator training and operators should become thoroughly familiar with it.
  • Page 5 FOREWORD, TABLE OF CONTENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Table of Contents Title Section Foreword, table of contents ................. a Important notices ....................
  • Page 6 ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Workshop Manual Ed. 12-2011...
  • Page 7 IMPORTANT NOTICES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...
  • Page 8 * In order to maintain the vehicle’s “Guarantee of Functionality”, the client must follow the maintenance programme indicated in Section B by having the required maintenance inspections carried out at authorised HUSQVARNA dealers. The cost for changing parts and for the labour necessary in order to comply with the maintenance plan is charged to the Client.
  • Page 9 GENERAL INFORMATION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...

  • Page 10: Table Of Contents

    GENERAL INFORMATION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Sommario Engine ......................A.3 Cooling ......................A.3 Starting ......................A.3 Timing system ....................A.3 Lubrication ....................A.3 Ignition ......................A.3 Fuel system ....................A.3...

  • Page 11: Engine

    GENERAL INFORMATION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Engine Type ................single cylinder, 4 stroke Cooling Type ..........

  • Page 12: Transmission

    GENERAL INFORMATION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Transmission Type ................constant mesh gear type Transmission ratio (TE-TXC) 1st gear.

  • Page 13: Rear Brake

    GENERAL INFORMATION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Rear brake Type ..............floating disc, ø 9.45 in. “Wave” type with hydraulic control and floating caliper Rims Front ..................in light alloy: 1,6x21”...

  • Page 14: Electrical Components Location (Te)

    GENERAL INFORMATION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Electrical components location (TE) The ignition system includes the following elements: Generator on the inner side of L.H.

  • Page 15: Overall Dimensions

    GENERAL INFORMATION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA The electrical system includes the following elements: 12V-6Ah battery under the saddle; Turning indicator flasher on left side of rear chassis;...

  • Page 16: Weight

    GENERAL INFORMATION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Saddle height E (TC) ..................mm 985 (38.77 in.) (TE-TXC) ................
  • Page 17 MAINTENANCE TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...
  • Page 18 TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA SCHEDULED MAINTENANCE CHART TXC - TE 250 / TXC - TE 310 (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING SERVICE...
  • Page 19 TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA SCHEDULED MAINTENANCE CHART TXC - TE 250 / TXC - TE 310 (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING SERVICE...
  • Page 20 TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA SCHEDULED MAINTENANCE CHART TXC - TE 250 / TXC - TE 310 (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING SERVICE...
  • Page 21 TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) TE 250 / TE 310 AFTER FIRST EVERY...
  • Page 22 TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) TE 250 / TE 310 AFTER FIRST EVERY...
  • Page 23 TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) TE 250 / TE 310 REPLACE EVERY...
  • Page 24 TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) TC 250 RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING...
  • Page 25 TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) TC 250 RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING...
  • Page 27 TROUBLESHOOTING TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...
  • Page 28 TROUBLESHOOTING TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA ENGINE Trouble Cause Remedy Engine does not start or Insufficient compression has starting trouble 1.
  • Page 29 TROUBLESHOOTING TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Trouble Cause Remedy Clutch slips 1. Weak clutch springs Replace 2.
  • Page 30 TROUBLESHOOTING TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA CHASSIS Trouble Cause Remedy Handlebar turns hard 1. Insufficient tyre pressure Inflate 2.
  • Page 31 TROUBLESHOOTING TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA ELECTRICAL SYSTEM (see also Section M) Trouble Cause Remedy Spark plug fouls 1.
  • Page 33 SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...
  • Page 34 SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Sommario Saddle removal.....................D.4 Tank removal ....................D.4 Valve clearance adjustment (TE - TXC) ............D.6 Valve clearance adjustment (TC) ..............D.7 Adjustment throttle cable ................D.10 Enrichener lever play adjustment ...............D.10...
  • Page 35 SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA H09056 H09058 H09057 Workshop Manual Ed. 12-2011...

  • Page 36: Saddle Removal

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Saddle removal Turn the rear fixing (1) counter clockwise, remove it and extract the saddle. Tank removal During the fuel tank removal operations, pay particular attention to the couplings of the fuel hose on the pump body and on the throt-...
  • Page 37 SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Lift the tank and disconnect the fuel pump connector (7) from the main wiring harness.

  • Page 38: Valve Clearance Adjustment (Te - Txc)

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Valve clearance adjustment (TE - TXC) Remove saddle and tank as outlined in the relevant paragraphs. Remove spark plug (1), both head cover screws (2) and head cover (3).

  • Page 39: Valve Clearance Adjustment (Tc)

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Valve clearance adjustment (TC) Remove saddle and tank as outlined in the relevant paragraphs. Remove the connector (1) from the coil (2).
  • Page 40 SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Engage the 2 gear and push and pull the motorcycle back and forth to bring the piston to Top Dead Centre.
  • Page 41 SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Use a thickness gauge to make sure that the clearance is equal to 0.15 mm for the INTAKE side (Figure “A”) and 0.20 mm for the OUTLET side (Figure “B”).

  • Page 42: Enrichener Lever Play Adjustment

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Adjustment throttle cable To check the correct adjustment of the throttle operate as follows: Remove rubber caps (1);...
  • Page 43 SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Idle adjustment TE - TXC Adjust the carburetor with warm engine and with the throttle control in closed position.

  • Page 44: Clutch Plate Replacement

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Clutch plate replacement This procedure can be performed with the motorcycle leaning to the left - there is no need to drain engine oil.

  • Page 45: Hydraulic Clutch Lever Adjustment And Fluid Level Check

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the plates (8), lubricate the new plates with engine oil and install them (always start with a friction plate).

  • Page 46: Front Brake Lever Adjustment And Fluid Level Check

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Front brake lever adjustment and fluid level check The adjuster (1) located on the control lever, allows adjusting of the free play (a).

  • Page 47: Rear Brake Pedal Position Adjustment

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Rear brake pedal position adjustment The position of the rear brake pedal with respect to the footrest may be adjusted according to individual needs.

  • Page 48: Rear Brake Pedal Free Play Adjustment

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Rear brake pedal free play adjustment The rear brake pedal should have 5 mm free play (B) before the brake begins to bite.

  • Page 49: Engine Oil Level Check

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Engine oil level check Keeping the motorcycle level and upright, check the oil level through the inspec- tion window (1) on the right crankcase.

  • Page 50: Engine Oil Replacement And Mesh Filters-Filter Cartridge Cleaning Or Replacement

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Engine oil replacement and mesh filters-filter cartridge cleaning or replace- ment Drain the oil with WARM ENGINE;...

  • Page 51: Coolant Level Check

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Coolant level check Check level (1) in right-hand radiator when engine is cold (place the motorcycle so that it is perpendicular to the ground).

  • Page 52: Air Filter Check (Tc)

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Air filter check (TC) Turn the rear fixing (1) counter clockwise, remove it and extract the saddle re- leasing it from the front retaining screw.
  • Page 53 SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Air filter check (TE - TXC) Turn the rear fixing (1) counter clockwise, remove it and extract the saddle re- leasing it from the front retaining screw.
  • Page 54 SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Assembly Grease the edge (C) of the filter face that goes into the housing to ensure proper sealing.

  • Page 55: Secondary Drive Chain Adjustment

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Secondary drive chain adjustment Chain should be checked, adjusted and lubricated as per the "Maintenance Chart"...

  • Page 56: Chain Lubrication

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Chain lubrication Lubricate the chain following these instructions. Never use grease to lubricate the chain.

  • Page 57: Suspension Setup According To Track Condition

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Suspension setup according to track condition Following are a few guidelines to find the right suspension setup for different types of terrain.

  • Page 58: Shock Absorber Adjustment

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Shock absorber adjustment The rear shock absorber must be adjusted to suit rider weight and terrain condi- tions.

  • Page 59: Shock Absorber Spring Preload Adjustment

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Shock absorber spring preload adjustment Proceed as follows: 1.

  • Page 60: Shock Absorber Compression And Rebound Damping Adjustment

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Shock absorber compression and rebound damping adjustment Adjustment of the compression stroke is independent from the rebound stroke.

  • Page 61: Kayaba Front Fork Adjustment

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA KAYABA front fork adjustment COMPRESSION (Fig. a) (TC - TXC: TOP ADJUSTER;...

  • Page 62: Steering Bearing Clearance Adjustment

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Steering bearing clearance adjustment For safety reasons, the steering should always be adjusted so that the handlebar turns freely and without play.

  • Page 63: Supply Hose Check

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Supply hose check During the fuel tank removal operations, pay particular attention to the couplings of the fuel hose on the pump body and on the throt- tle body in order to prevent possible breakage / damages to the parts.

  • Page 64: Exhaust System Check

    SETTINGS AND ADJUSTMENTS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Exhaust system check Perform a visual inspection of the exhaust system first, in order to identify pos- sible gas leaks from the sealing elements (gaskets), and to ensure that the Silent-Blocks are not damaged.
  • Page 65 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...
  • Page 66 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Sommario Foreword ......................E.3 Saddle removal.....................E.4 Side panel removal ..................E.4 Battery removal (TE-TCX) ................E.4 Rear chassis with mudguard and air box removal (TC) .......E.5 Rear chassis with mudguard and air box removal (TE-TXC) .......E.5...

  • Page 67: Foreword

    GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Foreword This section describes the operations preliminary to engine removal. Please note that, in order to gain access to certain motorcycle components (rear shock absorber, electrical parts, wiring, etc.), it may be necessary to partially remove some parts.

  • Page 68: Saddle Removal

    GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Saddle removal Turn the rear fixing (1) counter clockwise and remove the saddle. H10001 Side panel removal Remove the saddle as described in the relevant paragraph.

  • Page 69: Rear Chassis With Mudguard And Air Box Removal (Tc)

    GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Rear chassis with mudguard and air box removal (TC) Remove the saddle as described in the relevant paragraph.
  • Page 70 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Disconnect the connector (4) of the tail light unit (TE). Detach relays (5) and fuses (6) on the right-hand side of the motorcycle.
  • Page 71 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Unscrew the clamp (9) connecting air filter (8) to throttle body (10). Remove the four screws (11) of the rear chassis (12) using a 10 mm ring wrench.

  • Page 72: Exhaust System Removal

    GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Exhaust system removal H10966 Key: 1) Silencer 2) Spring 3) Exhaust manifold 4) Flange 5) Nozzle...
  • Page 73 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA TE-TXC H10007 Key: 1) Silencer 2) Spring 3) Exhaust manifold 4) Front protection 5) Rear protection Workshop Manual Ed.
  • Page 74 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the saddle as described in the relevant paragraph. Remove the left-hand side panel as described in the relevant paragraph.
  • Page 75 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA (TE-TXC) TE-TXC Loosen the two bolts (5) and remove the exhaust pipe (6). H10011 (TC) Detach springs (7) and remove exhaust pipe (6).

  • Page 76: Fuel Tank, Scoops And Spoiler Removal

    GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Fuel tank, scoops and spoiler removal H10013 Workshop Manual Ed. 12-2011 E.12...
  • Page 77 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA TE-TXC H00630 H10014 Remove the saddle as described in the relevant paragraph. Remove the side panels as described in the relevant paragraph.
  • Page 78 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the screws (3) retaining the scoops to the fuel tank. Remove the scoops (4) and the screws (5) retaining the spoilers (6) to the radiators and then remove the spoilers.
  • Page 79 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Carefully disconnect the fuel hoses from the throttle body or from the fuel pump to prevent damage to the quick coupling.

  • Page 80: Fuel Pump Removal (Tc)

    GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Fuel pump removal (TC) Remove the fuel tank as described in the relevant paragraph. Remove the tank filler cap and pour the fuel contained in the tank into a ves- sel of adequate capacity.

  • Page 81: Fuel Pump Removal (Te - Txc)

    GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Fuel pump removal (TE – TXC) Remove the fuel tank as described in the relevant paragraph. Remove the tank filler cap and pour the fuel contained in the tank into a ves- sel of adequate capacity.

  • Page 82: Start-Up Relay Removal (Te-Txc)

    GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Start-up relay removal (TE-TXC) Remove saddle and left-hand side panel (in this order) as outlined in the relevant paragraphs.
  • Page 83 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Electronic control unit removal CDI TE-TXC Remove: saddle and fuel tank as described in the relevant paragraphs. (TE-TXC) Detach the connector (1) from the CDI electronic control unit (2) and take the control unit together with its vibration mount out of the chassis.

  • Page 84: Voltage Regulator Removal (Te-Txc)

    GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Voltage regulator removal (TE-TXC) Remove the electronic control unit as described in the relevant paragraph. Disconnect the connector (1).

  • Page 85: Ignition Coil Removal (Te-Txc)

    GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Ignition coil removal (TE-TXC) Remove: saddle and fuel tank as described in the relevant paragraphs. Remove the spark plug cap (1).

  • Page 86: Clutch Hose Removal

    GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Clutch hose removal Loosen the fitting (1) of the clutch hose (2) on the left-hand of the engine. Drain any oil left in the hose.

  • Page 87: Electric Cooling Fan Removal (Te-Txc)

    GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Electric cooling fan removal (TE-TXC) Remove saddle, fuel tank and scoops (in this order) as outlined in the relevant paragraphs.

  • Page 88: Removal Of Engine From Motorcycle

    GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Removal of engine from motorcycle Remove the saddle as described in the relevant paragraph. Remove the side panels as described in the relevant paragraph.
  • Page 89 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Loosen the two screws (1) of the intake manifold (2) by removing the throttle body (3) from the head.
  • Page 90 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Place a vessel on the left-hand side of the cylinder, under the engine. Slacken the radiator cap (8).
  • Page 91 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the spark plug cap (17 (TE - TXC). TE - TXC Disconnect the connector (17a) from the coil / Stick-Coil.
  • Page 92 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Loosen the three screws (22) and remove the clutch actuator (23). H02231 Remove the clip (24) that holds clutch hose and wiring harness together.
  • Page 93 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the positive power supply cable (29) of the starter motor (TE- TE-TXC TXC).
  • Page 94 GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the guards (37) on both sides shearing the clips (38). H02348 Remove the engine mounting bolts (41) using a 12 mm wrench on the left- hand side and a 10 mm wrench on the right-hand side.

  • Page 95: Radiator Removal

    GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Radiator removal Remove the fuel tank together with scoops and spoilers as outlined in the relevant paragraphs.

  • Page 96: Thermostat Removal (Te-Xc)

    GENERAL PROCEDURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Loosen the screws (12) and remove the left-hand radiator (5). Loosen the screws (13) and remove the right-hand radiator (8).
  • Page 97 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...
  • Page 98 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Sommario Layout of engine components (TE - TXC) ............ F.3 Layout of engine components (TC) ..............

  • Page 99: Layout Of Engine Components (Te - Txc)

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Layout of engine components (TE - TXC) Throttle body Cylinder head cover Cylinder head Chain tensioner...

  • Page 100: Layout Of Engine Components (Tc)

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Layout of engine components (TC) Cylinder head cover Cylinder head Chain tensioner Cylinder...
  • Page 101 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Cylinder head cover removal TE-TXC TE - TXC: Remove the two retaining screws (1) (10 mm wrench) and remove the head cover (2) with its gasket.

  • Page 102: Camshaft Removal (Te - Txc)

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Camshaft removal (TE - TXC) Remove the six retaining screws (1) of the alternator cover (2) and remove the cover with its gasket.
  • Page 103 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the spark plug (7) (16 mm wrench) and the head lubrication pipe (8) unscrewing the drilled screw (9) (12 mm wrench).

  • Page 104: Camshaft Removal (Tc)

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Camshaft removal (TC) Remove the six retaining screws (1) of the alternator cover (2) (4 mm Allen wrench) and remove the cover with its gasket.
  • Page 105 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the spark plug (4) (16 mm wrench) and the head lubrication pipe (5) loosening the drilled screw (6) (12 mm wrench).
  • Page 106 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the intake camshaft (11) and the exhaust camshaft (12). H10987 Workshop Manual Ed.

  • Page 107: Water Pump Disassembly

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Water pump body removal TE-TXC Remove the four screws (1) securing pump body (2) to head (4 mm Allen wrench) and remove pump body.
  • Page 108 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Loosen the impeller (3) and remove it. TE-TXC H10997 TE - TXC H10998...
  • Page 109 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the oil seal (4), remove the seeger (7) and remove the gear (5). Remove the seeger (9) and remove the bearing (6).
  • Page 110 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Cylinder head removal TE-TXC Remove the head cover as described in the relevant paragraph. Remove the camshafts as described in the relevant paragraph.
  • Page 111 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA • Loosen the two screws (4) using an 8 mm wrench and remove the chain TE-TXC tensioner (1).
  • Page 112 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA With a 12-mm wrench, loosen the drilled bolt (B) and remove the tube (C). TE-TXC H11015 H11016...
  • Page 113 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Support the gear (8) using a screwdriver or a punch, unwrap the chain (9) and remove the gear.
  • Page 114 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA TE-TXC: TE-TXC Loosen the four head bolts (10) using a 12 mm socket wrench. Mark each bolt with its position to avoid confusing them on assembly (three bolts are 112.5 mm long, one (10A) is 104.5 mm long).

  • Page 115: Valve Removal (Te-Txc)

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Valve removal (TE-TXC) Remove the four valve buckets (1) and the shims (2). Mark them with their positions to ensure correct assembly in the original position.
  • Page 116 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Use a valve spring compressor to compress the valve springs. Be careful not too damage the mating surfaces that contact the gasket or those of the combustion chamber.

  • Page 117: Valve Removal (Tc)

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Valve removal (TC) Lift the rocker arms (1) and remove the pads (2) using a suitable tool. Position the pads (2) so that they cannot be reversed during the refit.

  • Page 118: Engine Disassembly

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the pins (5) and the rocker arms (1). Mark the position of the pins (5) and of the rocker arms (1) so that you can refit them exactly in the same position making sure that you centre correctly the dowel on the pin groove.

  • Page 119: Cylinder Removal

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Cylinder removal Remove the front slider (1) of the timing chain pulling it upwards. Remove the cylinder (2) with its gasket (3).

  • Page 120: Flywheel Removal

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Flywheel removal Loosen the rotor (2) nut (1) (17 mm wrench). H02350 Remove the rotor (2) using the puller (3A) (part no.

  • Page 121: Kick Start Pedal Removal

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the key (4) from the crankshaft. Kick start pedal removal Remove the pedal retaining bolt (1) (12 mm wrench), the washer and the pedal (2).
  • Page 122 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Loosen the nut (2) using a 22 mm wrench and remove sprocket (3) and spacer (4).

  • Page 123: Oil Filter Removal

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Oil filter removal Loosen the drilled nut (1) and disconnect the hose (2) from the oil pump cover (3).

  • Page 124: Clutch Cover Removal

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Clutch cover removal Remove the nine screws (1) and the screw (2) securing the cover (3) (8 mm wrench) and remove the cover (3).

  • Page 125: Clutch Disassembly

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Clutch disassembly Remove the six retaining screws (2) and the clutch cover (3). Using an 8 mm wrench, unscrew the six screws (4) securing the clutch springs.
  • Page 126 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the plates (8), lubricate the new plates with engine oil and install them (always start with a friction plate).
  • Page 127 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the nut (11) (22 mm wrench) using the clutch removal tool (A) (part no.

  • Page 128: Slider Removal

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Slider removal Use a 5 mm Allen wrench to loosen the screw (1) and remove the slider (2).
  • Page 129 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the snap ring (4), the washer (5) and the timing drive gear (6). Disassemble the shaft as shown in the diagram.

  • Page 130: Starter Motor Removal (Te-Txc)

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Starter motor removal (TE-TXC) Remove the exhaust pipe as described in the relevant paragraph. Disconnect the positive power supply cable (1) loosening the hexagonal-head screw (8 mm wrench).
  • Page 131 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Slide the starter motor (3) towards the rear end of the motorcycle to remove H00756 H00758 Upon assembly, check the gasket (4) for damage and replace it if...

  • Page 132: Starter Motor Disassembly (Te-Txc)

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Starter motor disassembly (TE-TXC) Separate the starter motor (1) from the starter drive (2). Starter drive disassembly (TE-TXC) Workshop Manual Ed.
  • Page 133 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove flywheel and starter motor as outlined in the relevant paragraph. Disassemble the starter motor as outlined in the relevant paragraph.
  • Page 134 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Place the wormshaft (4) assembly in a vice with aluminium jaws, loosen the nut (5) using a 10 mm T-wrench and slide out the wormshaft (4).

  • Page 135: Oil Pump Disassembly

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Oil pump disassembly Loosen the screws (1) using a 4 mm Allen wrench and remove pump body (2) and gasket.

  • Page 136: Gear Shift Pedal And Selector Assembly Removal

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Gear shift pedal and selector assembly removal To facilitate assembly, mark the position of the gear shift pedal (1) on the shaft. Remove the retaining screw (2) of the gear shift pedal (1) (8 mm wrench) and slide the pedal from the selector shaft.
  • Page 137 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the bolt (7) of the selector drum (8) (12 mm wrench). Release the ratchet (10) spring (9) and remove retaining ring (11), washer (12) and ratchet (10).

  • Page 138: Primary Drive Gear Removal

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Primary drive gear removal Loosen the central nut (1) using a 22 mm wrench. Remove primary gear (2) and water pump drive gear (3).

  • Page 139: Crankcase Disassembly

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Crankcase disassembly Remove the nine screws (1) from the left crankcase (2) (8 mm wrench). Important: the screws (1) are not all the same length.

  • Page 140: Gearbox Disassembly

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Install the crankcase puller (3) (part no. 8000 A7015) using the flywheel cover holes and remove the left crankcase half (4).
  • Page 141 ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the retaining ring (5) and then the shaft (6) of the input shaft shifter fork (7).

  • Page 142: Crankshaft Disassembly

    ENGINE DISASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Crankshaft disassembly Slide the puller (1) (part no. 8000 A7015) over the right end of the crank- shaft.
  • Page 143 ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...
  • Page 144 ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Sommario Cleaning parts ..................... G.3 Clearances ....................G.3 Cylinder head ....................

  • Page 145: Clearances

    ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Cleaning parts All parts must be cleaned with gasoline and dried with compressed air. Flammable vapours develop during this procedure and metal filings blown by compressed air may get into your eyes.

  • Page 146: Valve Seat Refacing

    ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Valve seat refacing Clean off any fouling deposits from the valve. Apply Prussian Blue to the valve and rotate it in its seat using a rubber hose or other similar tool.

  • Page 147: Valve

    ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Valve Inspect valve stem and valve seating face to make sure they are in good condi- tion.

  • Page 148: Valve Bucket Inspection (Te-Txc)

    ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Check the valve springs for proper squareness. Maximum acceptable deviation is 1.5 mm on each side. Valve bucket inspection (TE-TXC) Check that the valve buckets (1) slides freely in their seats.
  • Page 149 ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Valve installation TE-TXC Smear valve guides and stems with oil before installation. Install spring seat (1) and springs (2) - place spring (a) at head end - and finally the spring retainer (3).

  • Page 150: Valve Leak Check

    ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Tap valve stem lightly with a plastic hammer and an aluminium punch to help the valve collets become seated.

  • Page 151: Camshaft

    ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Camshaft Check the contact faces of the lobes for streaks, scoring, dents and waviness. Clamp the camshaft between centres and check deviation using two dial gauges.

  • Page 152: Cylinder

    ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Cylinder Check the walls for dents or scuffing. Measure cylinder bore diameter at three different positions.

  • Page 153: Cylinder To Piston Clearance (Te-Txc)

    ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Cylinder to piston clearance (TE-TXC) Cylinder diameter Measure inside diameter (Dc) with an internal bore micrometer 25 mm (0.9842 in.) below the edge (distance “A”).

  • Page 154: Piston Rings (Te-Txc)

    ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Piston rings (TE-TXC) They should show no signs of forcing or scoring. Replacement pistons come with piston rings and piston pin.

  • Page 155: Piston Ring To Groove Clearance

    ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Piston ring to groove clearance Use a feeler gauge to measure the axial clearance (H) of piston rings. If the piston ring is marked on one side, that side must be facing up.

  • Page 156: Crankshaft

    ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Crankshaft Main journals should show no scoring or scuffing. Threads, keyways and splines must be in good condition.

  • Page 157: Clutch

    ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Clutch Inspect all clutch components to make sure they are in the best conditions. Clutch plates should show no signs of bluing, scoring or distortion.

  • Page 158: Friction Plate To Clutch Housing Clearance

    ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Friction plate to clutch housing clearance Measure clearance "A" between clutch housing (2) and plate (1) with a feeler gauge and compare measured clearance with the table below.
  • Page 159 ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA 1- Pressure plate, 2- Clutch actuator plate, 3- Pushrod, 4- Piston assembly: Check these parts for signs of wear or failure. If any are found, replace the part.

  • Page 160: Oil Pump

    ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Oil pump Loosen the screws (1) using a 4 mm Allen wrench and remove pump body (2) and gasket.

  • Page 161: Shifter Forks And Gears

    ENGINE OVERHAUL TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Shifter forks and gears Visually inspect the shifter forks (1) and replace any bent forks. A bent fork will make gears hard to engage or let the transmission jump out of gear unexpect- edly under loading.
  • Page 163 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...
  • Page 164 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Sommario General ......................H.3 Assembly and lubrication instructions .............H.4 Crank- alternator- lubrication- left crankcase half .........H.4 Tightening torque figures ................H.5 Assembly and lubrication instructions...

  • Page 165: General

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA General To reassemble, reverse the disassembly procedure. Any special instructions concerning reassembly are expressly highlighted in the text.

  • Page 166: Assembly And Lubrication Instructions

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Assembly and lubrication instructions CRANK- ALTERNATOR- LUBRICATION- LEFT CRANKCASE HALF Workshop Manual Ed.

  • Page 167: Tightening Torque Figures

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Tightening torque figures M5 - L20 (Loctite 272) 6 Nm- 0,6 Kgm- 4.43 ft/lb M4 - L30 (Loctite 272) 4 Nm- 0,4 Kgm- 2.95 ft/lb...

  • Page 168: Assembly And Lubrication Instructions

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Assembly and lubrication instructions GEARBOX - GEAR SHIFT CONTROL (5 SPEED) Workshop Manual Ed.

  • Page 169: Tightening Torque Figures

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Tightening torque figures M8x1.25 (+LOCTITE Alt. 243) 25 Nm- 2.55 Kgm- 18.44 ft/lb M6 - L13 (+LOCTITE 243) 8 Nm- 0.8 Kgm- 5.9 ft/lb M6 - L14 (+LOCTITE 243)

  • Page 170: Assembly And Lubrication Instructions

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Assembly and lubrication instructions GEARBOX - GEAR SHIFT CONTROL (6 SPEED) H11099 Workshop Manual Ed.

  • Page 171: Tightening Torque Figures

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Tightening torque figures M8x1.25 (+LOCTITE Alt. 243) 25 Nm- 2.55 Kgm- 18.44 ft/lb M6 - L13 (+LOCTITE 243) 8 Nm- 0.8 Kgm- 5.9 ft/lb M6 - L14 (+LOCTITE 243)

  • Page 172: Assembly And Lubrication Instructions

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Assembly and lubrication instructions CLUTCH- KICK START- LUBRICATION- RIGHT CRANKCASE HALF Workshop Manual Ed.

  • Page 173: Tightening Torque Figures

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Tightening torque figures M5 - L12 (+LOCTITE 270 or 272) 6 Nm- 0.6 Kgm- 4.43 ft/lb M8 X 1.25 (Al) 8 Nm- 0.8 Kgm- 5.9 ft/lb...

  • Page 174: Assembly And Lubrication Instructions

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Assembly and lubrication instructions RIGHT CRANKCASE COVER Workshop Manual Ed. 12-2011 H.12...

  • Page 175: Tightening Torque Figures

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Tightening torque figures M5 - L16 6 Nm- 0.6 Kgm- 4.43 ft/lb M6 - L22 8 Nm- 0.8 Kgm- 5.9 ft/lb M6 x 1 - L50...

  • Page 176: Assembly And Lubrication Instructions

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Assembly and lubrication instructions HEAD - CYLINDER - PISTON - TIMING SYSTEM - WATER PUMP - SPARK PLUG TE-TXC H11047 Workshop Manual Ed.

  • Page 177: Assembly And Lubrication Instructions

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Assembly and lubrication instructions HEAD - CYLINDER - PISTON - TIMING SYSTEM - WATER PUMP - SPARK PLUG H11048 Workshop Manual Ed.

  • Page 178: Tightening Torque Figures

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Tightening torque figures Special flanged screw L.23.4 8 Nm - 0,8 Kgm - 5.9 ft/lb Special flanged screw L.31.3 8 Nm - 0,8 Kgm - 5.9 ft/lb M5 x 0.8 - L8 (+LOCTITE 243)
  • Page 179 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Input shaft Output shaft Workshop Manual Ed. 12-2011 H.17...

  • Page 180: Input Shaft (5 Speed)

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Input shaft (5 SPEED) Fit roller cage (1) and 5th gear (2) on the bushing and then install the washer (3) and the retaining ring (4).

  • Page 181: Output Shaft (5 Speed)

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Output shaft (5 SPEED) Fit the roller cage (1). Fit 2nd gear (2), washer (3) and retaining ring (4).
  • Page 182 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Input shaft Albero secondario Output shaft 6 SPEED H00602 Workshop Manual Ed.

  • Page 183: Input Shaft (6 Speed)

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Input shaft (6 SPEED) Fit roller cage (1) and 5th gear (2) on the bushing and then install the washer (3) and the retaining ring (4).

  • Page 184: Output Shaft (6 Speed)

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Output shaft (6 SPEED) Fit the roller cage (1). Fit 2nd gear (2), washer (3) and retaining ring (4).

  • Page 185: Crankcase Assembly

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Crankcase assembly Clean the crankcase half mating faces and place crankcase half on tool no. 8A00 90662.
  • Page 186 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Install the input and output shaft assembly making sure the output shaft (3) shim is in place.
  • Page 187 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Insert the selector drum (6) into its seat. Install the fork shafts (7) and (8) and make sure the forks move freely.
  • Page 188 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Heat up the crankshaft bearing (10) and install the crankshaft (11). Make sure both crankcase locating bushings (12) are in place.
  • Page 189 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Heat up the left crankcase bearing housings and install the crankcase. To join the crankcase halves, tap with a plastic hammer.

  • Page 190: Gear Shift Control Assembly

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Gear shift control assembly Refit the spring abutment pin (1) using a 12 mm wrench (apply Loctite 243 and tighten to 20 Nm, 2.0 Kgm, 14.5 ft/lb).
  • Page 191 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Operate shifter and transmission shaft to test gearbox for proper operation. Refit the ratchet assembly (10) together with the plate, making sure ratchets and springs are in the correct positions.
  • Page 192 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Turn the engine over. Make sure the spring (15) of the gear shift lever shaft is positioned correctly. Check the gear shift lever shaft (16) and the slot of the gear selector mechanism for signs of wear.
  • Page 193 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Install the gear shift lever (19) and operate the gearbox manually (8 mm wrench, 8 Nm, 0.8 Kgm, 5.8 ft/lb).

  • Page 194: Kick Start Assembly

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Kick start assembly Refit the starter ratchet release plate (1) (use a 4 mm wrench, 8 Nm, 0.8 Kgm, 5.8 ft/lb, Loctite 243).

  • Page 195: Timing Chain And Primary Drive Assembly

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Timing chain and primary drive assembly Install the timing chain slider (1), tighten the screw (2) using a 5 mm wrench (10 Nm, 0.1 Kgm, 7.3 ft/lb, Loctite 243) and make sure the slider moves freely.
  • Page 196 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Install the timing chain (5). Refit the bushing (6). Refit the clutch housing (7).
  • Page 197 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Place a dummy gear (8) or an aluminium shim between clutch housing (7) gear and double gear (4), and then tighten the primary drive shaft nut (9) (use a 22 mm wrench, 100 Nm, 10 Kgm, 72.50 ft/lb).

  • Page 198: Clutch Assembly

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Clutch assembly Install washer (1), hub (2), lock washer (3) and nut (4). Use the suitable tool (5) to prevent rotation and tighten to 60 Nm, 6 Kgm, 43.5 ft/lb (use a 22 mm wrench).
  • Page 199 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Refit the plates (6) (install a friction plate first and then a steel plate and keep alternating between friction and steel plates;...

  • Page 200: Sprocket Installation

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Sprocket installation Install the oil seal retaining plate (1) and tighten the screws (2) (use an 8 mm wrench , 5.5 Nm, 0.55 Kgm, 4 ft/lb).

  • Page 201: Flywheel And Starter Motor Installation (Te-Txc)

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Flywheel and starter motor installation (TE-TXC) Clean flywheel rotor to remove any debris suspended in swirling oil and captured by the magnets.
  • Page 202 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Refit the rotor (5). Hold the rotor (5) to prevent rotation and place an aluminium shim or dummy gear between the primary drives gears on the right side, again to prevent rotation.

  • Page 203: Flywheel Installation (Tc)

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Flywheel installation (TC) Clean flywheel rotor to remove any debris suspended in swirling oil and captured by the magnets.

  • Page 204: Piston Ring Installation

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Piston ring installation Fit the piston rings as shown in the diagram. If the piston ring is marked on one side, that side must be facing up.
  • Page 205 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Lubricate the cylinder liner (7) with engine oil and slide it over the piston rings. Make sure to collect the timing chain (8).

  • Page 206: Cylinder Head Gasket Selection Table

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Fit screws and spacers (10) to temporarily secure the cylinder liner (7). (3 spacers 10a, h= 44.2 mm;...
  • Page 207 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Cylinder head installation TE-TXC For valve installation instructions, please see Section "G". Always use a new head gasket on assembly: see the "Cylinder head gasket selection table".
  • Page 208 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA TE-TXC: TE-TXC Refit the four shim (5) on the valves and the valve buckets (6) as marked on removal.
  • Page 209 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Tighten the screws (10) with a Phillips screwdriver (4 Nm, 0.4Kgm, 2.9 ft/lb, TE-TXC Loctite 243).

  • Page 210: Water Pump Installation

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Timing chain tensioner installation Refit the chain tensioner (12) and its gasket. Tighten the two screws (13) using an 6 mm wrench (8 Nm, 0.8 Kgm, 5.9 ft/lb).

  • Page 211: Camshaft Installation (Te-Txc)

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Camshaft installation (TE-TXC) Secure a dial gauge (1) to the spark plug hole. Turn the crankshaft manually until bringing the piston to Top Dead Centre.
  • Page 212 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Clean and refit the camshaft mounts (6) and tighten the screws (7) in a cross pattern as diagram “B”...

  • Page 213: Camshaft Installation (Tc)

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Camshaft installation (TC) Secure a dial gauge (1) to the spark plug hole. Turn the crankshaft manually until bringing the piston to Top Dead Centre.
  • Page 214 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Clean the mount and tighten the screws (A) with a fitting sequence from 7 to 14 as the diagram “B”...

  • Page 215: Flywheel Cover Installation

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Flywheel cover installation TE-TXC Install the stator (1) with its mark lined up with the flywheel cover mark and tighten the retaining screws (2) (use a 4 mm Allen wrench, 6 Nm, 0.6 Kgm, 4.3 ft/lb + Loctite 272).

  • Page 216: Neutral Sensor Installation (Te-Txc)

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Neutral sensor installation (TE-TXC) Refit pin (1) and spring (2). Check the O-ring (3) of the sensor (4).

  • Page 217: Plug Refitting (Tc)

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Plug refitting (TC) Check the plug (2) O-ring gasket (1). Refit the plug (2) tightening the screws (3) with an 8-mm wrench (5.5 Nm, 0.55 Kgm, 4 ft/lb, Loctite 243).

  • Page 218: Starter Motor Seat Cover Installation (Tc)

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Starter motor seat cover installation (TC) Refit the cover (1) with its gasket making sure the arrow is pointing "UP". Tighten the screws (2) with the wire clip (3) placed on the upper screw.

  • Page 219: Refitting Of The Head Cylinder Cover, Spark Plug, Coil (Tc)

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Refitting of the head cylinder cover, spark plug, coil (TC) Fit the central retaining gasket (1).

  • Page 220: Right Crankcase Assembly

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Right crankcase assembly Refit the oil pump drive gear (1) and its shaft (2). Check the O-rings of the oil suction stub (3) and replace them if needed.
  • Page 221 ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Install the crankcase (8) and tighten the screws (9) following a cross pattern (use an 8 mm wrench , 8 Nm, 0.8 Kgm, 5.90 ft/lb).

  • Page 222: Filter And Drain Plug (250)

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Filter and drain plug (250) Fit the oil filter (1) and tighten the cap (2) into place with its gasket using a 12 mm wrench (25 Nm, 2.5 Kgm, 18.44 ft/lb).

  • Page 223: Gear Shift And Kick Start Pedal Installation

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Gear shift and kick start pedal installation Install the gear shift pedal (1) and tighten the screw (2) using an 8 mm wrench (8 Nm, 0.8 Kgm, 5.8 ft/lb).

  • Page 224: Installing The Engine And Assembling The Motorcycle

    ENGINE REASSEMBLY TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Installing the engine and assembling the motorcycle TE 250-310 Install the engine and any parts you had removed in the order given below.
  • Page 225 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...
  • Page 226 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Sommario Front fork removal ..................I.4 Front suspension ..................I.6 Service instructions for Ø48USD Kayaba fork..........
  • Page 227 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA H09056 H09058 H09057 Workshop Manual Ed. 12-2011...

  • Page 228: Front Fork Removal

    FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Front fork removal Measure height "A" (it will need to be restored to original value on assembly). Set a block under the engine and see that the front wheel is lifted from the ground and then proceed as follows: H10056...
  • Page 229 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA loosen the bolts (4) that secure the fork legs to steering head and bottom yoke;...

  • Page 230: Service Instructions For Ø48Usd Kayaba Fork

    FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Front suspension Service instructions for Ø48USD Kayaba fork GENERAL The fork uses a multi-valve damping system with rebound and compression adjustment and spring preload adjustment for static load.
  • Page 231 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA H11100 Front suspension (TC - TXC) Front suspension is handled by a KAYABA upside-down telescopic hydraulic fork with advanced axle and 48 mm legs. Wheel travel is 300 mm.
  • Page 232 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Loosen the cap nut at the top of each outer tube. (Note: it is good practice to moderately slacken the cap nuts before removing the fork legs from the motorcycle).
  • Page 233 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Take the cartridge out of the outer tube. H06821 Do not remove the nut at the bottom end of the cartridge.
  • Page 234 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA If outer tube and inner tube are still assembled together, place the fork leg upside down and allow at least 20 minutes for oil to drain.
  • Page 235 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the sealing rings and the metal rings mounted on the inner tube. Do not reuse any metal parts after removal.
  • Page 236 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Mount sealing rings and metal parts on the inner tube. See the figure below for the installation sequence.
  • Page 237 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Fit the dust seal to the outer tube. Make sure that there is not play between dust seal and outer tube.
  • Page 238 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Pull the piston rod until fully extended. Check oil level. It should be about 145 mm (5.7 in.). H06843 Push the piston rod all the way down and install the bottom valve assembly.
  • Page 239 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Drain excess oil from the cartridge pushing the damper unit all the way home. Be careful not to distort or damage the piston rod or any other parts.
  • Page 240 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Push down the inner tube. Slip the tool shown in the figure between wheel axle carrier and cartridge nut. Insert the rebound adjuster rod into the piston rod and tighten the adjuster screw.
  • Page 241 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Clamp the wheel axle carrier in a vice and tighten the adjuster screw onto the carrier to 55 Nm (40.5 ft/lb).

  • Page 242: Front Suspension (Te)

    FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA H10103 Front suspension (TE) Front suspension is handled by a KAYABA upside-down telescopic hydraulic fork with advanced axle and 48 mm legs. Wheel travel is 300 mm.
  • Page 243 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Loosen the cap nut at the top of each outer tube. (Note: it is good practice to moderately slacken the cap nuts before removing the fork legs from the motorcycle).
  • Page 244 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove nut, spring guide, O-ring and collar bushing. H10061 Hold the cartridge top end steady.
  • Page 245 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Take the cartridge out of the outer tube. H06868 Remove the dust seal using a flat head screwdriver.
  • Page 246 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the retaining ring using a flat head screwdriver. H06873 Pull the inner tube until separating it from the outer tube.
  • Page 247 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Check the spring. Replace it if: outside diameter is damaged or exceedingly worn. Free length is 457 mm (18 in.) or less.
  • Page 248 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Fit metal bushing and washer to outer tube using an appropriate installer. Fit the oil seal to the outer tube and push it home using an appropriate in- staller.
  • Page 249 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Insert the cartridge into the outer tube. H06868 Hold the cartridge top end into place.
  • Page 250 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Fit collar bushing, O-ring, spring guide and nut onto piston rod. Insert the rebound adjuster rod into the piston rod.
  • Page 251 FRONT SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Filling oil to specific level Fill the damper unit with oil up to the top edge of the outer tube. Slowly pump the outer tube up and down to help oil flow equally into both inner and outer tube.
  • Page 253 REAR SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...
  • Page 254 REAR SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Sommario Rear shock absorber ..................J.3 Lubrication points (grease) ................J.3 Rear suspension....................J.4 Rear shock absorber removal ...............J.4 Disassembling and servicing the swinging arm ..........J.5...

  • Page 255: Lubrication Points (Grease)

    REAR SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Rear shock absorber TIGHTENING TORQUE FIGURES 1, 2: 52.4 Nm/ 5.35 Kgm/ 38.6 ft/lb H10107 H10106 Lubrication points (grease)

  • Page 256: Rear Shock Absorber Removal

    REAR SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Rear suspension The rising-rate rear suspension is made up of a shock absorber, a linkage system and a swinging arm.

  • Page 257: Disassembling And Servicing The Swinging Arm

    REAR SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Disassembling and servicing the swinging arm Set a stand or a block under the engine and see that the rear wheel is lifted from the ground.

  • Page 258: Servicing The Swinging Arm Shaft

    REAR SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Servicing the swinging arm shaft Check shaft taper using a dial gauge. Place the shaft on two identical reference blocks.

  • Page 259: Chain Roller, Chain Guide, Chain Slider

    REAR SUSPENSION TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Chain roller, chain guide, chain slider Check the wear of the above-mentioned elements and replace them when necessary.
  • Page 261 BRAKES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed.12-2011...
  • Page 262 BRAKES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Sommario Braking system ..................... L.3 Brake disc ..................... L.4 Checking brake pads for wear / replacing the pads ........

  • Page 263: Braking System

    BRAKES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Braking system The braking system uses two independent circuits. Each system is equipped with a brake calliper connected to a master cylinder with a fluid reservoir.
  • Page 264 BRAKES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Brake disc Checking the brake disc is an important safety procedure; the disc must be spot- less, i.e.

  • Page 265: Checking Brake Pads For Wear / Replacing The Pads

    BRAKES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Checking brake pads for wear / replacing the pads Check brake pad wear.

  • Page 266: Bleeding The Front Braking System

    BRAKES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Bleeding the front braking system A long travel and mushy feel of the brake lever indicate that there is air in the system and the brake needs bleeding.

  • Page 267: Bleeding The Rear Braking System

    BRAKES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Bleeding the rear braking system A long travel and mushy feel of the brake pedal indicate that there is air in the system and the brake needs bleeding.

  • Page 268: Changing The Fluid

    BRAKES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Changing the fluid Brake fluid should be checked and changed as per the "Maintenance Chart" (see Section B), or earlier if contaminated with debris or water.
  • Page 269 BRAKES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Remove the reservoir cover (2) or (2A) and the rubber gaiter. Pull the lever (3) and hold it pulled, or press the pedal (3A) and hold it pressed so that the system is under pressure.
  • Page 270 BRAKES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Periodically check the connecting hoses (C) and (D) (see Scheduled Maintenance Chart, Section B): replace worn or cracked hoses.
  • Page 271 ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...
  • Page 272 ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Sommario Wiring diagram (TC) ..................M.5 Wiring diagram (TE) ..................M.6 Wiring diagram (TXC) ..................
  • Page 273 ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA • Position of the connectors front side ............M.41 •...
  • Page 274 ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Workshop Manual Ed. 12-2011...

  • Page 275: Wiring Diagram (Tc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Wiring diagram (TC) H10111 Key to wiring diagram Colour coding key 1.

  • Page 276: Wiring Diagram (Te)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Wiring diagram (TE) H10112 30. Turning indicators flasher Key to wiring diagram 31.

  • Page 277: Wiring Diagram (Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Wiring diagram (TXC) H10113 Key to wiring diagram Colour coding key 1.
  • Page 278 ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Electrical components location (TC) The ignition system includes the following elements: Generator (1), on the inner side of L.H.

  • Page 279: Condenser (Tc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Condenser (TC) Condenser (9) connected to a plate strapped to the throttle body. H10988 Electrical components location (TE) The ignition system includes the following elements:...
  • Page 280 ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA 12V-350W starter motor (6) behind the cylinder; H10119 Solenoid starter (7) on left side of rear chassis;...
  • Page 281 ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Power Relay (11): coil, injection system, fuel pump, on right side of rear chassis;...
  • Page 282 ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Headlamp (20) with 12V-35/35W twin halogen bulb and 12V-5W parking light bulb;...

  • Page 283: Electrical Components Location (Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Electrical components location (TXC) The ignition system includes the following elements: Generator (1), on the inner side of L.H.
  • Page 284 ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA 12V-350W starter motor (6) behind the cylinder; H10119 Solenoid starter (7) on left side of rear chassis;...
  • Page 285 ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA The electrical system includes the following elements: 12V-6Ah battery (9) under the saddle; Relay (10): coil, injection system, fuel pump, on right side of rear chassis;...

  • Page 286: Checking Generator Stator Windings Resistance

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Coolant temperature sensor (16); Lambda sensor (17); Fuel pump (18) inside the fuel tank. H11128 Checking generator stator windings resistance Disconnect the stator coil connector from the wiring and measure resistance...

  • Page 287: Generator No-Load Performance

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA 1) Measure across the terminals of the connector (1); correct value is about TE - TXC If resistance is outside the specified limits, replace the complete generator.

  • Page 288: Ignition And Starter System (Tc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Ignition and starter system (TC) The engine injection and starter system is controlled by the control unit (ECU); by means of a series of sensors, the ECU controls the status of the engine and of the surrounding environment at each given moment.

  • Page 289: Ignition And Starter System (Te-Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Ignition and starter system (TE-TXC) The engine injection and starter system is controlled by the control unit (ECU); by means of a series of sensors, the ECU controls the status of the engine and of the surrounding environment at each given moment.
  • Page 290 ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA H10113 Key to wiring diagram 1. Electronic control unit 2.

  • Page 291: Charging System (Te-Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Charging system (TE-TXC) The charging system is composed of: - Alternator (1);...

  • Page 292: Charging System Inspections

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Charging system inspections Current loss at the battery (TE-TXC) Remove the saddle (as described in the relevant paragraph) to gain access to the battery (1).

  • Page 293: Electrical Starting System (Te-Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Electrical starting system (TE-TXC) The starting system is composed of: - Battery (16);...

  • Page 294: Starting System Inspection

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Starting system inspection Starter motor inspection (TE-TXC) Remove the starter motor (1) as described in the relevant paragraph. Whenever a starter motor fault is detected, check the starter motor as follows: - connect a meter across ground and starter motor contact.

  • Page 295: Checking Coil Windings Resistance (Te-Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Checking coil windings resistance (TE-TXC) Remove saddle and fuel tank (see relevant paragraph) to gain access to the coil (1).

  • Page 296: Coil Windings Resistance Inspection (Tc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Coil windings resistance inspection (TC) Disconnect the connector (1) from the coil (2). Remove the coil (2) as described in the relevant paragraph.

  • Page 297: Electronic Control Unit (Ecu)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Electronic control unit (ECU) Remove saddle and fuel tank (see Section E) to gain access to the electronic control unit (1).

  • Page 298: Gear Position Sensor Inspection (Gps: Gear Position Sensor) (Te-Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Gear position sensor inspection (GPS: Gear Position Sensor) (TE-TXC) Set the meter to the “Ohm”...

  • Page 299: Battery (Te-Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Battery (TE-TXC) The battery (1) is a sealed-for-life, maintenance-free battery. If the vehicle remains unused for long periods, it is recommended to disconnect the battery from the electrical system and store it in a dry place.

  • Page 300: Headlamp, Tail Light (Te)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Headlamp, tail light (TE) Headlamp adjustment The headlamp features a twin bulb for low and high beam and a festoon bulb for the city or parking light.

  • Page 301: Tail Light Replacement

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Tail light replacement Remove the tail light as follows: - Loosen the two screws (1) under the rear mudguard.

  • Page 302: Handlebar Switches

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Handlebar switches Measure continuity on the different switches using a meter. Replace any part found to be faulty.

  • Page 303: Right-Hand Switch (Te-Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Right-hand switch (TE-TXC) 1. Engine start button 2. Engine start/stop switch H10131 H01040 Bk-Br...

  • Page 304: Fuses (Te-Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Fuses (TE-TXC) • When you find a blown fuse (1), always investigate and eliminate the cause before replacing it.

  • Page 305: Relay Test (Te - Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Relay test (TE - TXC) Remove saddle and fuel tank as described in "Section E". Remove the relays (1) located on the R.H.

  • Page 306: Digital Dashboard, Warning Lights (Te)

    IMPORTANT: In the event of a FUEL INJECTION SYSTEM MALFUNCTION, the word FAIL appears on the right side of the dashboard display (see page 14). When this is the case, contact your HUSQVARNA dealer. 1- SPEED (Km/h or mph) / ODO (figure 1) - SPEED: vehicle speed - maximum value: 299 Km/h or 299 mph;...
  • Page 307 ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA 2 - SPEED / CLOCK (figure 2) - SPEED: speed - maximum value: 299 Km/h or 299 mph; - CLOCK: clock - reading from 0:00 to 23:59:59.

  • Page 308: Warning Lights Panel (Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA 5 - SPEED / NUMBER of RPM (figure 5) - SPEED: speed - maximum value: 299 Km/h or 299 mph - NUMBER OF RPM: MIN.

  • Page 309: Dashboard Replacement (Te)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Dashboard replacement (TE) - Remove the upper retaining screw securing headlamp fairing to dashboard bracket (A);...

  • Page 310: Wiring (Tc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Wiring (TC) H10133 1 Engine stop button 2 Coil / Stick-coil 3 Control unit 4 Voltage regulator 5 Main wiring harness...

  • Page 311: Cable Routing And Electrical Parts Installation Instructions (Tc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Cable routing and electrical parts installation instructions (TC) •...

  • Page 312: Control Unit Connection (Tc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA • Control unit connection (TC) Connect the control unit connector (4) as shown. H10138 •...

  • Page 313: Fuel Pump Connector Position (Tc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA • Fuel pump connector position (TC) Position the fuel pump connector (21) as shown. H10143 •...

  • Page 314: Voltage Regulator Connection (Tc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA • Voltage regulator connection (TC) Connect the connector (10) as shown. •...

  • Page 315: Wiring (Te-Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Wiring (TE-TXC) H00973 H10150 Workshop Manual Ed. 12-2011 M.45...

  • Page 316: Cable Routing And Electrical Parts Installation Instructions "Te-Txc

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Cable routing and electrical parts installation instructions "TE-TXC" •...

  • Page 317: Securing The Starter Motor/Solenoid Starter Cable (Te-Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA • Position of control unit (5) and voltage regulator (6) (TE –...

  • Page 318: Securing The Voltage Regulator Ground Cable (9) (Te-Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA • Securing the voltage regulator ground cable (9) (TE-TXC) Secure the regulator ground cable to the right-hand screw of the injection coil.

  • Page 319: Connection Of Relays And Fuses (Te-Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA • Connection of relays and fuses (TE-TXC) RELAYS Connect the cable marked “POW”...

  • Page 320: Fuel Pump Connector Position (Te-Txc)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA • Fuel pump connector position (TE-TXC) Position the fuel pump connector (21) as shown. H02325 •...

  • Page 321: Ignition And Gear Sensor Cable Connection

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA • Ignition and gear sensor cable connection Connect the ignition (26) and gear sensor (27) connectors as shown. •...

  • Page 322: Rear Stop Connection

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA • Clip installation on fuse holders Secure the three fuses to the suitable perforated panel of the rear mudguard. •...

  • Page 323: Double Map Connector (Te)

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA • Double map connector (TE) Connect the connector (40). H02328 •...

  • Page 324: Securing The Wiring Harness To Rear Chassis Right Side

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA • Securing the wiring harness to rear chassis right side Strap wiring to rear chassis with clips as shown in the figure.
  • Page 325 ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Secure the generator connector as shown (26). Secure the ignition, gear sensor and Lambda sensor wiring loom to the clutch hose with two clips.

  • Page 326: Important

    ELECTRICAL SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Important Before washing the motorcycle, it is necessary to duly protect the following parts from water: a) Rear opening of the muffler;...
  • Page 327 ENGINE COOLING TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...
  • Page 328 ENGINE COOLING TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Sommario Coolant level check ..................N.3 Cooling circuit (TC) ..................N.4 Engine cooling system overhaul (TC)............N.5 Cooling circuit (TE-TXC) ................N.6 Engine cooling system overhaul (TE-TXC) ..........N.7...

  • Page 329: Coolant Level Check

    ENGINE COOLING TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Coolant level check Coolant takes the heat from the piston-cylinder-and-head assembly and transfers it to the radiator, where it is released to the atmosphere.

  • Page 330: Cooling Circuit (Tc)

    ENGINE COOLING TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Cooling circuit (TC) H10154 The forced circulation cooling system uses a centrifugal pump (located to the left of the head) and two down-draft radiators.

  • Page 331: Engine Cooling System Overhaul (Tc)

    ENGINE COOLING TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Engine cooling system overhaul (TC) If the coolant runs too hot, check the radiators. Any foreign matter trapped between the fins (such as leaves, bugs, mud, etc.) will obstruct air flow and must be removed carefully to avoid damage to radiator.

  • Page 332: Cooling Circuit (Te-Txc)

    ENGINE COOLING TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Cooling circuit (TE-TXC) TE-TXC H10158 The forced circulation cooling system uses a centrifugal pump (located to the left of the head) and two down-draft radiators.

  • Page 333: Engine Cooling System Overhaul (Te-Txc)

    ENGINE COOLING TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Engine cooling system overhaul (TE-TXC) If the coolant runs too hot, check the radiators. Any foreign matter trapped between the fins (such as leaves, bugs, mud, etc.) will obstruct air flow and must be removed carefully to avoid damage to radiator.
  • Page 335 HYDRAULICALLY CONTROLLED CLUTCH TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...
  • Page 336 HYDRAULICALLY CONTROLLED CLUTCH TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Sommario Hydraulic clutch system ................P.3 Draining clutch fluid ..................P.4 Clutch master cylinder servicing ..............

  • Page 337: Hydraulic Clutch System

    HYDRAULICALLY CONTROLLED CLUTCH TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Hydraulic clutch system The hydraulic circuit is composed of a master cylinder with its reservoir located on the left side of the handlebar, and a piston installed on the left crankcase half.

  • Page 338: Draining Clutch Fluid

    HYDRAULICALLY CONTROLLED CLUTCH TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Draining clutch fluid Connect a plastic hose to the bleed valve (1) and the loosen the valve turning it back 1 or 2 turns.

  • Page 339: Clutch Master Cylinder Servicing

    HYDRAULICALLY CONTROLLED CLUTCH TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Clutch master cylinder servicing Drain the circuit, detach the master cylinder from the left side of the handlebar and take it apart.

  • Page 340: Bleeding The Clutch System

    HYDRAULICALLY CONTROLLED CLUTCH TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Bleeding the clutch system A long travel and mushy feel of the clutch lever indicate that there is air in the system and the clutch hydraulic system needs bleeding.
  • Page 341 FUEL INJECTION SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...
  • Page 342 TXC 250 - 310 2012 I.E. USA Sommario Injection fuel feeding system (TE-TXC) ............S.3 Injection fuel feeding system (TC) ..............S.4 Operation Manual for "HUSQVARNA SERVICE TOOL" for injection fuel feeding system (TE-TXC) ..............S.5 Operation Manual for "HUSQVARNA SERVICE TOOL" for injection fuel feeding system (TC) .................S.7 Fuel pump test (TE-TXC) ................S.8...

  • Page 343: Injection Fuel Feeding System (Te-Txc)

    Lambda sensor heater; Lean or rich mixture (LAMBDA sensor). The "HUSQVARNA SERVICE TOOL" provides a tool to check these parameters in the event the fuel injection malfunctions. The electric fuel pump (2) is installed on the bottom of the tank (1) and is com- posed of rotor, magnet, impeller, brushes, pressure regulator.

  • Page 344: Injection Fuel Feeding System (Tc)

    Gear shift position; Fuel injection pulse width; The "HUSQVARNA SERVICE TOOL" provides a tool to check these parameters in the event the fuel injection malfunctions. The electric fuel pump (2) is installed on the bottom of the tank (1) and is com- posed of rotor, magnet, impeller, brushes, control valve and relief valve.

  • Page 345: Operation Manual For "Husqvarna Service Tool" For Injection Fuel Feeding System (Te-Txc)

    (TE-TXC) The injection fuel feeding system does not require scheduled maintenance. The "HUSQVARNA SERVICE TOOL" part no. 8000 H3898 lets you test system components in the event of a malfunction. TE = A malfunction is indicated by the word "FAIL" appearing in the right-hand portion of the dashboard display when the ignition key is set to ON and the right switch is set to RUN.
  • Page 346 FUEL INJECTION SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA In addition to identifying any current malfunction, the software stores past malfunctions that have been resolved: store malfunc- tions can be deleted following the instructions provided in the Operation Manual.

  • Page 347: Operation Manual For "Husqvarna Service Tool" For Injection Fuel Feeding System (Tc)

    Operation Manual for "HUSQVARNA SERVICE TOOL" for injection fuel feeding system (TC) The injection fuel feeding system does not require scheduled maintenance. The "HUSQVARNA SERVICE TOOL" part no. 8000 H3898 lets you test system components in the event of a malfunction. The "HUSQVARNA SERVICE TOOL" is composed of: 1) "Diagnostic Tool"...

  • Page 348: Fuel Pump Test (Te-Txc)

    FUEL INJECTION SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Fuel pump test (TE-TXC) Remove the pump as described in Section "E". pump operation Connect the RED (+) and BLACK (-) wires on the pump connector to a power supply unit with constant 12V output and make sure that the pump runs.

  • Page 349: Fuel Pump Test (Tc)

    FUEL INJECTION SYSTEM TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Fuel pump test (TC) Remove the pump as described in Section "E". A: fuel reserve sensor Make sure there is no fuel left in the sensor and then set the meter to the "Impedance"...
  • Page 351 SPECIAL TOOLS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...
  • Page 352 SPECIAL TOOLS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA SPECIAL TOOLS 1 (8000 A7015) Crankcase puller 2 (8000 A1580) T.D.C. timing tool 3 (8000 H2146) Flywheel puller 5 (8000 A7345) Jig (TC) (8000 H7345) Jig (TE-TXC)
  • Page 353 TIGHTENING TORQUE FIGURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Tighten all nuts and screws to the specified torque using a torque wrench. If not tightened securely, a nut or a screw might become damaged or work itself loose, causing damage to motorcycle and injury to rider.
  • Page 354 TIGHTENING TORQUE FIGURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA TIGHTENING TORQUE FIGURES (+/- 5%) ENGINE Cylinder head Special screw Fastening camshaft mount (TC) 1) 7 Nm...
  • Page 355 TIGHTENING TORQUE FIGURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Lubrication Screw TCEI M5x0.8 L20 Oil pump body 6 Nm 0.6 Kgm Oil drain plug M14x1.5...
  • Page 356 TIGHTENING TORQUE FIGURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA TIGHTENING TORQUE FIGURES (+/- 5%) CHASSIS (99669) 1 Nm = 0.73756 ft/lb NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows M5x0.8...
  • Page 357 TIGHTENING TORQUE FIGURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA TIGHTENING TORQUE FIGURES (+/- 5%) FRONT SUSPENSION (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) REAR SUSPENSION (99669) 1 Nm = 0.73756 ft/lb...
  • Page 358 TIGHTENING TORQUE FIGURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA TIGHTENING TORQUE FIGURES (+/- 5%) FAIRINGS AND MUDGUARDS (99669) 1 Nm = 0.73756 ft/lb Workshop Manual Ed.
  • Page 359 TIGHTENING TORQUE FIGURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA TIGHTENING TORQUE FIGURES (+/- 5%) ELECTRICAL SYSTEM (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) FUEL SYSTEM (99669) 1 Nm = 0.73756 ft/lb...
  • Page 360 TIGHTENING TORQUE FIGURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA TIGHTENING TORQUE FIGURES (+/- 5%) WHEELS AND BRAKES (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) EXHAUST (99669) 1 Nm = 0.73756 ft/lb...
  • Page 361 TIGHTENING TORQUE FIGURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA TIGHTENING TORQUE FIGURES (+/- 5%) INSTRUMENTS (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) COOLING SYSTEM (99669) 1 Nm = 0.73756 ft/lb...
  • Page 362 TIGHTENING TORQUE FIGURES TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows (+/- 5%) Steel screws on plastic, with metal spacers 2 Nm 0.2 Kgm...
  • Page 363 CHASSIS AND WHEELS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Section Workshop Manual Ed. 12-2011...
  • Page 364 CHASSIS AND WHEELS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Sommario Chassis ......................Y.3 Lubrication points (lubricant) ................ Y.4 Front wheel ....................

  • Page 365: Chassis

    CHASSIS AND WHEELS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Chassis The single frame branches off at the exhaust and is made of steel tubes with circular, rectangular and ellipsoidal section; the rear chassis is made from light alloy.

  • Page 366: Lubrication Points (Lubricant)

    CHASSIS AND WHEELS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Lubrication points (lubricant) 1 Steering bearings (grease) H02333 H02332 Check the assemblies shown in the figure...

  • Page 367: Front Wheel

    CHASSIS AND WHEELS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Front wheel 8 13 H06832 Legend 1) Tyre 2) Inner tube 3) Rim 4) Spoke...

  • Page 368: Removing The Front Wheel

    CHASSIS AND WHEELS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Removing the front wheel Set a stand or a block under the engine and see that the front wheel is lifted from the ground.

  • Page 369: Reassembling The Front Wheel

    CHASSIS AND WHEELS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Reassembling the front wheel Fit the L.H. spacer (1) on the wheel hub. Fit the wheel between the fork legs so as to set the brake disc into the calliper.

  • Page 370: Rear Wheel

    CHASSIS AND WHEELS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Rear wheel 9 10 H06860 1) Tyre 2) Inner tube 3) Rim 4) Spoke...

  • Page 371: Removing The Rear Wheel

    CHASSIS AND WHEELS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Removing the rear wheel Set a stand or a block under the engine and see that the rear wheel is lifted from the ground.

  • Page 372: Wheel Servicing

    CHASSIS AND WHEELS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Wheel servicing Check the wheel hub bearings for wear. If you find too much (radial or axial) clearance, replace the bearings as follows: place the hub on a flat surface with an appropriate hole (for when you knock out the bearing);...

  • Page 373: Wheel Spokes

    CHASSIS AND WHEELS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Wheel spokes Make sure all nipples are firmly tightened (4.4 Nm, 0.45 Kgm, 3.2 ft/lb). Re- tighten if needed.

  • Page 374: Rear Chain Sprocket, Secondary Drive Sprocket And Chain

    CHASSIS AND WHEELS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Rear chain sprocket, secondary drive sprocket and chain The figure at the side shows the profiles of a normally worn and an exceedingly worn sprocket.

  • Page 375: Checking Pinion And Sprockets For Wear

    CHASSIS AND WHEELS TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA TC 250 2012 - TC 250 2012 I.E. USA TXC 250 - 310 2012 I.E. USA Checking pinion and sprockets for wear Check the transmission sprocket for damage or wear. When worn down like the sprocket shown in the figure, it must be replaced.

This manual is also suitable for:

Tc 250 2012Tc 250 2012 i.e. usaTxc 250-310 2012 i.e. usa

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