Page 1 TE 250R - 310R 2013 I.E. TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Workshop Manual Ed. 07-2012 Rev 00...
Page 2 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. No reproduction in full or in part without written authorisation.
Page 3: Workshop Manual
TE 250R - 310R 2013 I.E. TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 250R - 310R 2013 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 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Table of Contents Title Section Foreword, table of contents ................. a Important notices ....................
Page 7 IMPORTANT NOTICES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
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 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 10: Table Of Contents
GENERAL INFORMATION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Sommario Engine ......................A.3 Starting ......................A.3 Timing system ....................A.3 Lubrication ....................A.3 Ignition ......................A.3 Fuel system ....................A.3 Primary drive ....................A.3...
Page 11: Starting
GENERAL INFORMATION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Engine Type ................single cylinder, 4 stroke TE-TXC 250R - 310R Cooling ............liquid, with electric fan on models TC 250R Cooling ......................
Page 12: Transmission
GENERAL INFORMATION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Transmission Type ................constant mesh gear type TE-TXC 250R - 310R Transmission ratio 1st gear..................
Page 13: Rear Suspension
GENERAL INFORMATION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Rear suspension Type ........progressive with hydraulic single shock absorber Wheel stroke................11.6 in.
Page 14: General Information
GENERAL INFORMATION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Electrical components location (TC) The ignition system includes the following elements: Generator on the inner side of L.H.
Page 15: Overall Dimensions
GENERAL INFORMATION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA H11272 Overall dimensions Wheelbase A (TE-TXC) ................mm 1460 (57.47 in.) (TC) ...................
Page 16: Weight
GENERAL INFORMATION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Weight (TC) Kerb weight, without fuel: .............101,2 Kg (213,8 lb) (TE) Kerb weight, without fuel: ..113 Kg (249,1 lb) 250 / 113,5 Kg (250,2 lb) 310 (TXC)
Page 17 MAINTENANCE TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 18 TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) TXC - TE 250R / TXC - TE 310R RACING MOTORCYCLE, FOR RAC-...
Page 19 TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) TXC - TE 250R / TXC - TE 310R RACING MOTORCYCLE, FOR RAC-...
Page 20 TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) TE 250R / TE 310R AFTER FIRST...
Page 21 TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) TE 250R / TE 310R AFTER FIRST...
Page 22 TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) TC 250R RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING...
Page 23 TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) TC 250R RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING...
Page 25 TROUBLESHOOTING TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 26 TROUBLESHOOTING TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA ENGINE Trouble Cause Remedy Engine does not start or Insufficient compression 1.
Page 27 TROUBLESHOOTING TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Trouble Cause Remedy 1. Weak clutch springs Replace Clutch slips 2. Worn clutch plates Replace 1.
Page 28 TROUBLESHOOTING TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA CHASSIS Trouble Cause Remedy 1. Insufficient tyre pressure Inflate Handlebar turns hard 2.
Page 29 TROUBLESHOOTING TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA ELECTRICAL SYSTEM (see also Section M) Trouble Cause Remedy 1. Dirty air filter Clean Spark plug fouls 2.
Page 31 SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 32 SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Sommario Saddle removal.....................D.4 Tank removal ....................D.4 Valve clearance adjustment .................D.6 Adjustment throttle cable ................D.9 Idle adjustment .....................D.9 Clutch plate replacement ................D.10...
Page 33 SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA H11269 H11270 H11271 Workshop Manual Ed. 07-2012...
Page 34: Saddle Removal
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 throttle...
Page 35 SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Lift the tank and disconnect the fuel pump connector (7) from the main wiring harness.
Page 36: Valve Clearance Adjustment
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Valve clearance adjustment Remove saddle and tank as outlined in the relevant paragraphs. Remove the connector (1) from the coil (2).
Page 37 SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA gear and push and pull the motorcycle back and forth to bring Engage the 2 the piston to Top Dead Centre.
Page 38 SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 39: Adjustment Throttle Cable
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Adjustment throttle cable To check the correct adjustment of the throttle operate as follows: Remove rubber caps (1);...
Page 40: Clutch Plate Replacement
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 41: Hydraulic Clutch Lever Adjustment And Fluid Level Check
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Remove the plates (8), lubricate the new plates with engine oil and install them (always start with a friction plate).
Page 42: Front Brake Lever Adjustment And Fluid Level Check
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 43: Rear Brake Pedal Position Adjustment
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 44: Rear Brake Pedal Free Play Adjustment
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 45: Engine Oil Level Check
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 46: Engine Oil Replacement And Mesh Filters-Filter Cartridge Cleaning Or Replacement
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Engine oil replacement and mesh filters-filter cartridge cleaning or replace- ment Drain the oil with WARM ENGINE;...
Page 47: Coolant Level Check
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 48: Air Filter Check (Tc)
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 49: Air Filter Check (Te - Txc)
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 50 SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Assembly Grease the edge (C) of the filter face that goes into the housing to ensure proper sealing.
Page 51: Secondary Drive Chain Adjustment
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Secondary drive chain adjustment Chain should be checked, adjusted and lubricated as per the "Maintenance Chart"...
Page 52: Chain Lubrication
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Chain lubrication Lubricate the chain following these instructions. Never use grease to lubricate the chain. Grease helps to accumulate dust and mud, which act as abrasive and help to rapidly wear out the chain, the front and rear sprockets.
Page 53: Suspension Setup According To Track Condition
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 54: Shock Absorber Adjustment
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Shock absorber adjustment The rear shock absorber must be adjusted to suit rider weight and terrain condi- tions.
Page 55: Shock Absorber Spring Preload Adjustment
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Shock absorber spring preload adjustment Proceed as follows: 1. Turn the rear fixing (1) counter clockwise and remove the saddle, unscrew the retaining screws (2) and remove the right-hand side panel (3).
Page 56: Shock Absorber Compression And Rebound Damping Adjustment
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Shock absorber compression and rebound damping adjustment Adjustment of the compression stroke is independent from the rebound stroke. A) COMPRESSION - Standard setting: 1) Low damping speed: - TE: 14 clicks;...
Page 57: Kayaba Front Fork Adjustment
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA KAYABA front fork adjustment COMPRESSION (Fig. a) (TC - TXC: TOP ADJUSTER; TE: LOWER ADJUSTER) KAYABA: -9 clicks (TC EU - TXC);...
Page 58: Steering Bearing Clearance Adjustment
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 59: Supply Hose Check
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 throttle body in order to prevent possible breakage / damages to the parts.
Page 60: Exhaust System Check
SETTINGS AND ADJUSTMENTS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 61 GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 62 GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 Exhaust system removal ................E.8...
Page 63: Foreword
GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 64: Saddle Removal
GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 65: Rear Chassis With Mudguard And Air Box Removal (Tc)
GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Rear chassis with mudguard and air box removal (TC) Remove the saddle as described in the relevant paragraph. Remove the side panels as described in the relevant paragraph.
Page 66 GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 67 GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Unscrew the clamp (9) connecting air filter (8) to throttle body (10). H11291 Remove the four screws (11) of the rear chassis (12) using a 10 mm ring wrench.
Page 68: Exhaust System Removal
GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Exhaust system removal H10966 Key: 1) Silencer 2) Spring 3) Exhaust manifold 4) Flange 5) Nozzle 6) Protection...
Page 69 GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA TE-TXC H11292 Key: 1) Silencer 2) Spring 3) Exhaust manifold 4) Front protection 5) Rear protection 6) Catalyst...
Page 70 GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Remove the saddle as described in the relevant paragraph. Remove the left-hand side panel as described in the relevant paragraph. Using an 8 mm T-wrench on the outside and a 10 mm T-wrench on the inside, remove the silencer (4) retaining screw (1).
Page 71 GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 72: Fuel Tank, Scoops And Spoiler Removal
GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Fuel tank, scoops and spoiler removal H10013 Workshop Manual Ed. 07-2012 E.12...
Page 73 GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 74 GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 75 GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 76: Fuel Pump Removal (Tc)
GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 77: Fuel Pump Removal (Te - Txc)
GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 78: Start-Up Relay Removal (Te-Txc)
GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 79: Electronic Control Unit Removal Cdi
GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Electronic control unit removal CDI Remove: saddle and fuel tank as described in the relevant paragraphs. Unhook the support elastic (1) then detach the connector (2) and remove the control unit (3).
Page 80: Voltage Regulator Removal (Tc)
GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Voltage regulator removal (TC) Remove the fuel tank as described in the relevant paragraph. Disconnect the connector (1).
Page 81: Clutch Hose Removal
GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 82: Electric Cooling Fan Removal (Te-Txc)
GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 83: Removal Of Engine From Motorcycle
GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 84 GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Place a vessel on the left-hand side of the cylinder, under the engine. Slacken the radiator cap (8).
Page 85 GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 86 GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Remove the positive power supply cable (27) of the starter motor (TE-TXC). TE-TXC H11311 To remove the brake lever (28), use an 8 mm wrench to loosen the master...
Page 87 GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Remove the guards (33) on both sides shearing the clips (34). H11314 Remove the engine mounting bolts (35) using a 12 mm wrench on the left- hand side and a 10 mm wrench on the right-hand side.
Page 88: Radiator Removal
GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Radiator removal Remove the fuel tank together with scoops and spoilers as outlined in the relevant paragraphs.
Page 89: Thermostat Removal (Te-Xc)
GENERAL PROCEDURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 91 ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 92 ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Sommario Layout of engine components (TE - TXC) ............ F.3 Layout of engine components ..............
Page 93: Layout Of Engine Components (Te - Txc)
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Layout of engine components (TE - TXC) Sprocket Cylinder head cover Cylinder head Chain tensioner Cylinder...
Page 94: Layout Of Engine Components
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Layout of engine components Cylinder head cover Cylinder head Chain tensioner Cylinder Head lubrication pipe Oil filter...
Page 95: Cylinder Head Cover Removal
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Cylinder head cover removal Remove the four retaining screws (1) and remove the head cover (2) with its gasket.
Page 96: Camshaft Removal
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Camshaft removal Remove the six retaining screws (1) of the alternator cover (2) (4 mm Allen wrench) and remove the cover with its gasket.
Page 97 ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 98: Water Pump Body Removal
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Remove the intake camshaft (11) and the exhaust camshaft (12). H10987 Water pump body removal Remove the four screws (1) securing pump body (2) to head (4 mm Allen...
Page 99: Water Pump Disassembly
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Water pump disassembly Loosen the screw (1) to disassemble the pump. H11324 Loosen the impeller (3) and remove it.
Page 100: Cylinder Head Removal
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Cylinder head removal Remove the head cover as described in the relevant paragraph. Remove the camshafts as described in the relevant paragraph.
Page 101 ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA With a 12-mm wrench, loosen the drilled bolt (B) and remove the tube (C). H11330 Loosen the two screws (6) using a Phillips screwdriver and remove the timing drive shaft (7) while holding the gear (8) with your hand.
Page 102 ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Support the gear (8) using a screwdriver or a punch, unwrap the chain (9) and remove the gear.
Page 103 ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA With a 12-mm socket wrench, loosen the four screws (10) and their washers. H11336 Remove the cylinder head (11) and its gasket (12).
Page 104: Valve Removal
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Valve removal 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 105 ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA 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 106: Cylinder Removal
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 107: Flywheel Removal
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 108: Kick Start Pedal Removal
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Kick start pedal removal Remove the pedal retaining bolt (1) (12 mm wrench), the washer and the pedal (2).
Page 109: Oil Filter Removal
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Oil filter removal Loosen the drilled nut (1) and disconnect the hose (2) from the oil pump cover (3).
Page 110: Clutch Cover Removal
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 111: Clutch Disassembly
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 112 ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Remove the plates (8), lubricate the new plates with engine oil and install them (always start with a friction plate).
Page 113 ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Remove the nut (11) (22 mm wrench) using the clutch removal tool (A) (part no.
Page 114: Slider Removal
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Slider removal Use a 5 mm Allen wrench to loosen the screw (1) and remove the slider (2). Kick start disassembly Release the spring (1) from the casing (2) and remove the complete shaft assembly (3).
Page 115 ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 116: Starter Motor Removal (Te-Txc)
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 117 ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 118: Starter Motor Disassembly (Te-Txc)
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 119 ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 120 ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 121: Oil Pump Disassembly
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Oil pump disassembly Loosen the screws (1) using a 4 mm Allen wrench and remove pump body (2) and gasket.
Page 122: Gear Shift Pedal And Selector Assembly Removal
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 123 ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 124: Primary Drive Gear Removal
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 125: Crankcase Disassembly
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 126: Gearbox Disassembly
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 127 ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Remove the retaining ring (5) and then the shaft (6) of the input shaft shifter fork (7).
Page 128: Crankshaft Disassembly
ENGINE DISASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Crankshaft disassembly Slide the puller (1) (part no. 8000 A7015) over the right end of the crankshaft. Secure the puller to the crankcase half and remove the crankshaft (2) from the opposite side.
Page 129 ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 130 ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Sommario Cleaning parts ..................... G.3 Clearances ....................G.3 Cylinder head ....................G.3 Valve seat refacing ..................
Page 131: Cleaning Parts
ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 132: Valve Seat Refacing
ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 133: Valve
ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Valve Inspect valve stem and valve seating face to make sure they are in good condi- tion.
Page 134: Rocker Arm Check
ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Check the valve springs for proper squareness. Maximum acceptable deviation is 1.5 mm on each side. Rocker arm check Make sure that the rocker arms (1) can oscillate freely.
Page 135: Valve Installation
ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Valve installation 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 136: Valve Leak Check
ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Valve leak check Check the valves for proper sealing before assembling the cylinder head to the engine.
Page 137: Camshaft
ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 138: Cylinder
ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Cylinder Check the walls for dents or scuffing. Measure cylinder bore diameter at three different positions.
Page 139: Cylinder To Piston Clearance
ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Cylinder to piston clearance Cylinder diameter Measure inside diameter (Dc) with an internal bore micrometer 25 mm (0.9842 in.) below the edge (distance “A”).
Page 140: Piston Rings
ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Piston rings They should show no signs of forcing or scoring. Replacement pistons come with piston rings and piston pin.
Page 141: Piston Ring To Groove Clearance
ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 142: Crankshaft
ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Crankshaft Main journals should show no scoring or scuffing. Threads, keyways and splines must be in good condition.
Page 143: Clutch
ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 144: Friction Plate To Clutch Housing Clearance
ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 145 ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 146: Oil Pump
ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Oil pump Loosen the screws (1) using a 4 mm Allen wrench and remove pump body (2) and gasket.
Page 147: Shifter Forks And Gears
ENGINE OVERHAUL TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 149 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 150 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Sommario General ......................H.3 Assembly And Lubrication Instructions Crank- Alternator- Lubrication- Left Crankcase Half .......H.4 Tightening Torque Figures .................H.5 Assembly And Lubrication Instructions Gearbox - Gear Shift Control (5 Speed) ..........H.6...
Page 151: General
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA General To reassemble, reverse the disassembly procedure. Any special instructions concerning reassembly are expressly highlighted in the text.
Page 152: Assembly And Lubrication Instructions
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Assembly and lubrication instructions CRANK- ALTERNATOR- LUBRICATION- LEFT CRANKCASE HALF H11343 Workshop Manual Ed.
Page 153: Tightening Torque Figures
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Tightening torque figures 6 Nm- 0,6 Kgm- 4.43 ft/lb M5 - L20 (Loctite 272) 4 Nm- 0,4 Kgm- 2.95 ft/lb M4 - L30 (Loctite 272) 6 Nm- 0,6 Kgm- 4.43 ft/lb...
Page 154: Assembly And Lubrication Instructions
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Assembly and lubrication instructions GEARBOX - GEAR SHIFT CONTROL (5 SPEED) H11344 Workshop Manual Ed.
Page 155: Tightening Torque Figures
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 156: Assembly And Lubrication Instructions
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Assembly and lubrication instructions GEARBOX - GEAR SHIFT CONTROL (6 SPEED) H11345 Workshop Manual Ed.
Page 157: Tightening Torque Figures
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 158: Assembly And Lubrication Instructions
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Assembly and lubrication instructions CLUTCH- KICK START- LUBRICATION- RIGHT CRANKCASE HALF Workshop Manual Ed.
Page 159: Tightening Torque Figures
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 160: Assembly And Lubrication Instructions
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Assembly and lubrication instructions RIGHT CRANKCASE COVER Workshop Manual Ed. 07-2012 H.12...
Page 161: Tightening Torque Figures
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 162: Assembly And Lubrication Instructions
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Assembly and lubrication instructions HEAD - CYLINDER - PISTON - TIMING SYSTEM - WATER PUMP - SPARK PLUG H11398 Workshop Manual Ed.
Page 163: Tightening Torque Figures
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Tightening torque figures M6 - L20 8 Nm - 0,8 Kgm - 5.9 ft/lb Special screw M6 x 1 8 Nm - 0,8 Kgm - 5.9 ft/lb Screw M5 x 0.8...
Page 164 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Input shaft Output shaft Workshop Manual Ed. 07-2012 H.16...
Page 165: Input Shaft (5 Speed)
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 166: Output Shaft (5 Speed)
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Output shaft (5 SPEED) Fit the roller cage (1). Fit 2nd gear (2), washer (3) and retaining ring (4). Fit 4th gear (5) and retaining ring (6).
Page 167 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Input shaft Albero secondario Output shaft 6 SPEED H00602 Workshop Manual Ed. 07-2012 H.19...
Page 168: Input Shaft (6 Speed)
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 169: Output Shaft (6 Speed)
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Output shaft (6 SPEED) Fit the roller cage (1). Fit 2nd gear (2), washer (3) and retaining ring (4). Fit 6th gear (5) and retaining ring (6).
Page 170: Crankcase Assembly
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Crankcase assembly Clean the crankcase half mating faces and place crankcase half on tool no. 8A00 90662.
Page 171 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Install the input and output shaft assembly making sure the output shaft (3) shim is in place.
Page 172 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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. Make sure the fork bushings (5) are correctly located in the drum grooves (6).
Page 173 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 174 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 175: Gear Shift Control Assembly
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 176 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 177 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA 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 178 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 179: Kick Start Assembly
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 180: Timing Chain And Primary Drive Assembly
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 181 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Install the timing chain (5). Refit the bushing (6). Refit the clutch housing (7). Workshop Manual Ed.
Page 182 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 183: Clutch Assembly
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 184 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 185: Sprocket Installation
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 186: Flywheel And Starter Motor Installation (Te-Txc)
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 187 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 188: Flywheel Installation (Tc)
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Flywheel installation (TC) Clean flywheel rotor to remove any debris suspended in swirling oil and captured by the magnets.
Page 189: Piston Ring Installation
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 190 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 191: Cylinder Head Gasket Selection Table
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Fit screws and spacers (10) to temporarily secure the cylinder liner (7). (3 spacers 10a, h= 44.2 mm;...
Page 192: Cylinder Head Installation
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Cylinder head installation Tighten the screws (3) gradually and in a cross pattern, starting with a 20 Nm - 2.0 Kgm - 14.75 lb/ft pre-tightening torque, then with a 40 Nm - 4.0 Kgm - 29.50 lb/ft torque (12 mm wrench) .
Page 193 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Check the bearings of the timing drive upper gear (7) and replace them if needed. The gear (7) requires no timing.
Page 194: Timing Chain Tensioner Installation
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 195: Camshaft Installation
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Camshaft installation Secure a dial gauge (1) to the spark plug hole. Turn the crankshaft manually until bringing the piston to Top Dead Centre.
Page 196 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Clean the mount and tighten the screws (A) with a fitting sequence from 7 to 14 as the diagram “B”...
Page 197: Flywheel Cover Installation
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 an Allen wrench;...
Page 198: Plug Refitting
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Plug refitting 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 199: Refitting Of The Head Cylinder Cover, Spark Plug, Coil
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Refitting of the head cylinder cover, spark plug, coil Fit the central retaining gasket (1). H11086 Fir the cover (3) on the head (2) with the respective gasket.
Page 200: Right Crankcase Assembly
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 201 ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 202: Filter And Drain Plug (250)
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 203: Gear Shift And Kick Start Pedal Installation
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 204: Installing The Engine And Assembling The Motorcycle
ENGINE REASSEMBLY TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Installing the engine and assembling the motorcycle Install the engine and any parts you had removed in the order given below. Place the engine in the chassis.
Page 205 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 206 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Sommario Front fork removal ..................I.4 Service instructions for Ø48USD Kayaba fork..........I.6 Front suspension (TC - TXC) ...............
Page 207 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA H11269 H11270 H11271 Workshop Manual Ed. 07-2012...
Page 208: Front Fork Removal
FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 209 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA loosen the bolts (4) that secure the fork legs to steering head and bottom yoke;...
Page 210: Service Instructions For Ø48Usd Kayaba Fork
FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 211 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 212 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 213 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Take the cartridge out of the outer tube. H06821 Do not remove the nut at the bottom end of the cartridge. H06822 Remove the bottom valve assembly from the cartridge.
Page 214 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 215 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 216 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Mount sealing rings and metal parts on the inner tube. See the figure below for the installation sequence.
Page 217 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Fit the dust seal to the outer tube. Make sure that there is not play between dust seal and outer tube. H06839 Refit the cartridge.
Page 218 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA 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 219 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 220 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 221 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 222: Front Suspension (Te)
FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 223 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 224 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Remove nut, spring guide, O-ring and collar bushing. H10061 Hold the cartridge top end steady. Loosen and remove the bottom valve assembly.
Page 225 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Take the cartridge out of the outer tube. H06868 Remove the dust seal using a flat head screwdriver. H06869 Workshop Manual Ed.
Page 226 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 227 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 228 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 installer.
Page 229 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Insert the cartridge into the outer tube. H06868 Hold the cartridge top end into place. Tighten the bottom valve assembly to 55 Nm (40.5 ft/lb).
Page 230 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 231 FRONT SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA 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 233 REAR SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 234 REAR SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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.4 Servicing the swinging arm shaft ..............J.5...
Page 235: Rear Shock Absorber
REAR SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 236: Rear Shock Absorber Removal
REAR SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 237: Disassembling And Servicing The Swinging Arm
REAR SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 238: Servicing The Swinging Arm Shaft
REAR SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Servicing the swinging arm shaft Check shaft taper using a dial gauge. Place the shaft on two identical reference blocks.
Page 239: Chain Roller, Chain Guide, Chain Slider
REAR SUSPENSION TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Chain roller, chain guide, chain slider Check the wear of the above-mentioned elements and replace them when necessary.
Page 241 BRAKES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 242 BRAKES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Sommario Braking system ..................... L.3 Brake disc ..................... L.4 Checking brake pads for wear / replacing the pads ........L.5 Bleeding the front braking system ..............
Page 243: Braking System
BRAKES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 244: Brake Disc
BRAKES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Brake disc Checking the brake disc is an important safety procedure; the disc must be spot- less, i.e.
Page 245: Checking Brake Pads For Wear / Replacing The Pads
BRAKES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Checking brake pads for wear / replacing the pads Check brake pad wear. Service limit ”A”...
Page 246: Bleeding The Front Braking System
BRAKES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 247: Bleeding The Rear Braking System
BRAKES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 248: Changing The Fluid
BRAKES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 249 BRAKES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 250 BRAKES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Periodically check the connecting hoses (C) and (D) (see Scheduled Maintenance Chart, Section B): replace worn or cracked hoses.
Page 251 ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 252 ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Sommario Wiring diagram (TC) ..................M.5 Wiring diagram (TE) ..................M.6 Wiring diagram (TXC) ..................
Page 253 ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA • Control unit connection (TC) ..............M.42 • Ignition coil / stick-coil connection (TC) ........... M.42 •...
Page 254 ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Workshop Manual Ed. 07-2012...
Page 255: Wiring Diagram (Tc)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Wiring diagram (TC) H10111 Key to wiring diagram Colour coding key 1.
Page 256: Wiring Diagram (Te)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Wiring diagram (TE) H11466 30. Turning indicators flasher Key to wiring diagram 31.
Page 257: Wiring Diagram (Txc)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Wiring diagram (TXC) H11481 Key to wiring diagram 14. Injector Colour coding key 15.
Page 258 ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Electrical components location (TC) The ignition system includes the following elements: Generator (1), on the inner side of L.H.
Page 259 ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Condenser (10) connected to a plate strapped to the throttle body. H11377 Electrical components location (TE) The ignition system includes the following elements:...
Page 260 ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA 12V-350W starter motor (5) behind the cylinder; H11380 Electric solenoid starter (6) on left of rear chassis, with 20A fuse. H11381 Throttle position sensor (7) on the LH of the throttle body.
Page 261 ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA POW (12): 15A (cable sheath with “POW” written on it): ECU, coil, Lambda probe heater, injector.
Page 262 ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Headlamp (20) with 12V-35/35W twin halogen bulb and 12V-5W parking light bulb;...
Page 263 ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA DC Relay (25): light system, turning indicators, horn, on right side of rear chassis.
Page 264 ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Electrical components location (TXC) The ignition system includes the following elements: Generator (1), on the inner side of L.H.
Page 265 ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Solenoid starter (6) on left side of rear chassis; H11389 Throttle position sensor (7) on the LH of the throttle body.
Page 266 ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA The electrical system includes the following elements: 12V-6Ah battery (10) under the saddle; H11390 GEN (11): starter relay fuse (general).
Page 267 ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Coolant temperature sensor (16). H11394 Lambda sensor (17). H11395 Fuel pump (18) inside the fuel tank. TE - TXC H11128 Condenser (19) connected to a plate strapped to the throttle body.
Page 268: Checking Generator Stator Windings Resistance
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Relay (20): coil, injection system, fuel pump, on right side of rear chassis. H11468 TE - TXC Checking generator stator windings resistance...
Page 269: Generator No-Load Performance
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 270: Ignition And Starter System (Tc)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 271: Ignition And Starter System (Te-Txc)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 272 ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA H11482 1. Electronic control unit 2. Throttle position sensor 3. Coolant temperature sensor 4.
Page 273: Charging System (Te-Txc)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Charging system (TE-TXC) The charging system is composed of: - Alternator (1); - Voltage regulator/rectifier (2);...
Page 274: Charging System Inspections
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Charging system inspections Battery (TE-TXC) Remove the saddle (as described in the relevant paragraph) to gain access to the battery (1).
Page 275: Voltage Regulator/Rectifier Wiring Diagram
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Voltage regulator/rectifier wiring diagram TE-TXC H11002 H10123 TE - TXC Electrical starting system (TE-TXC) The starting system is composed of: - Battery (5);...
Page 276: Starting System Inspection
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 277: Coil Windings Resistance Inspection
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Coil windings resistance inspection Disconnect the connector (1) from the coil (2). Remove the coil (2) as described in the relevant paragraph.
Page 278: Electronic Control Unit (Ecu)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 279: Battery (Te-Txc)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 280: Headlamp, Tail Light (Te)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 281: Headlamp Bulbs Replacement (Te)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Headlamp Bulbs Replacement (TE) To gain access to the healamp bulbs, proceede as follows: - remove the upper fastening screw of the the headlamp carrier to the instrument panuel support (A);...
Page 282: Tail Light Replacement
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Tail light replacement Remove the tail light as follows: - Loosen the two screws (1) under the rear mudguard. - Extract the tail light (2) and disconnect the connector (3).
Page 283: Handlebar Switches
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Handlebar switches Measure continuity on the different switches using a meter. Replace any part found to be faulty.
Page 284: Fuses (Te-Txc)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Fuses (TE-TXC) • When you find a blown fuse (1), always investigate and eliminate the cause before replacing it.
Page 285: Relay Test (Te - Txc)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 286: Digital Instrument, Warning Lights (Te)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Digital instrument, warning lights (TE) The motorcycle is equipped with a digital instrument; on the instrument are located 3 warning lights too: high beam, blinkers and fuel reserve.
Page 287 ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA 3- SPEED / TRIP - SPEED: motorcycle speedmaximum value: 299 Km/h o 299 mph - TRP: distance- maximum value: 999.9 km (the data will be lost after battery detachment).
Page 288: Fi Lamp - Operating Failures (Te-Txc)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA FI Lamp - Operating failures (TE-TXC) FI Lamp (1) is located on the side of the digital dashboard. H11422 TXC: The FI lamp (1) is positioned on panel (2).
Page 289: Dashboard Replacement (Te)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Dashboard replacement (TE) - Remove the upper retaining screw securing headlamp fairing to dashboard bracket (A);...
Page 290: Wiring (Tc)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Wiring (TC) H11427 1 Engine stop button 2 Coil / Stick-coil 3 Control unit 4 Voltage regulator 5 Main wiring harness...
Page 291: Cable Routing And Electrical Parts Installation Instructions (Tc)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Cable routing and electrical parts installation instructions (TC) • Position of the coil / stick-coil Connect the coil / stick-coil (1) as the figure shows.
Page 292: Control Unit Connection (Tc)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA • Control unit connection (TC) Connect the control unit connector (4) as shown. H10138 •...
Page 293: Fuel Pump Connector Position (Tc)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA • Fuel pump connector position (TC) Position the fuel pump connector (21) as shown. H10143 •...
Page 294: Voltage Regulator Connection (Tc)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA • Voltage regulator connection (TC) Connect the connector (10) as shown. •...
Page 295: Wiring (Te-Txc)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Wiring (TE-TXC) H11429 H11430 Workshop Manual Ed. 07-2012 M.45...
Page 296: Cable Routing And Electrical Parts Installation Instructions "Te-Txc
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Cable routing and electrical parts installation instructions "TE-TXC" • Position of the coil / stick-coil Connect the coil / stick-coil (X) as the figure shows.
Page 297: Electronic Control Unit Positioning
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA • Electronic control unit (5) positioning Control unit installed with flat side upwards. H11433 •...
Page 298: Battery Negative Cable Routing (A)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA • Battery negative cable routing (A) Routing of engine ground to battery negative cable (A). H11459 •...
Page 299: Electric Fan And Thermo Switch Connection
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA • Electric fan and Thermo switch connection Connect the electric fan connector (16). Connect the Thermo-switch connector (16a).
Page 300: Engine Water Temperature Connector
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA • Engine water temperature connector Connect the engine water temperature connector (20) to the thermostat. H11471 •...
Page 301: Clip Installation On Fuse Holders
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA • Clip installation on fuse holders Install the suitable clips (28) on the three fuse holders. H11448 •...
Page 302: Dashboard Bracket Connectors (Te)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA • Dashboard bracket connectors (TE) Fasten the instrument connector (30). Connect the diagnosis instrument to the connector (31).
Page 303: Left Side Steering Tube Cable Fastening (Te)
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA • Left side steering tube cable fastening (TE) Main harness transit front branch and left control cable under voltage regulator. H11476 •...
Page 304: Fastening The Lambda Probe Cables
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA • Fastening the Lambda probe cables H11479 • Fastening the electric fan cable H11480 Workshop Manual Ed.
Page 305: Important
ELECTRICAL SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 306 ENGINE COOLING TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 307 ENGINE COOLING TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Sommario Coolant level check ..................3 Cooling circuit (TC) ..................4 Engine cooling system overhaul (TC)..............
Page 308: Coolant Level Check
ENGINE COOLING TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 309: Cooling Circuit (Tc)
ENGINE COOLING TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 310: Engine Cooling System Overhaul (Tc)
ENGINE COOLING TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Engine cooling system overhaul (TC) If the coolant runs too hot, check the radiators. Any foreign matter trapped be- tween the fins (such as leaves, bugs, mud, etc.) will obstruct air flow and must be removed carefully to avoid damage to radiator.
Page 311: Cooling Circuit (Te-Txc)
ENGINE COOLING TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Cooling circuit (TE-TXC) TE-TXC H11359 The forced circulation cooling system uses a centrifugal pump (located to the left of the head) and two down-draft radiators.
Page 312: Engine Cooling System Overhaul (Te-Txc)
ENGINE COOLING TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Engine cooling system overhaul (TE-TXC) If the coolant runs too hot, check the radiators. Any foreign matter trapped be- tween the fins (such as leaves, bugs, mud, etc.) will obstruct air flow and must be removed carefully to avoid damage to radiator.
Page 314 HYDRAULICALLY CONTROLLED CLUTCH TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 315 HYDRAULICALLY CONTROLLED CLUTCH TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Sommario Hydraulic clutch system ................P.3 Draining clutch fluid ..................P.4 Clutch master cylinder servicing ..............
Page 316: Hydraulic Clutch System
HYDRAULICALLY CONTROLLED CLUTCH TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 317: Draining Clutch Fluid
HYDRAULICALLY CONTROLLED CLUTCH TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 318: Bleeding The Clutch System
HYDRAULICALLY CONTROLLED CLUTCH TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 320 FUEL INJECTION SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 321 TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Sommario Injection fuel feeding system ...............S.3 Operation Manual for "HUSQVARNA SERVICE TOOL" for injection fuel feeding system ................S.4 Fuel pump test (TE-TXC) ................S.5 Fuel pump test (TC)..................S.6...
Page 322: Injection Fuel Feeding System
Lambda sensor heater (only TE); Lean or rich mixture (LAMBDA sensor) (only TE). 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 323: Operation Manual For "Husqvarna Service Tool" For Injection Fuel Feeding System
Operation Manual for "HUSQVARNA SERVICE TOOL" for injection fuel feeding system 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 324: Fuel Pump Test (Te-Txc)
FUEL INJECTION SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 325: Fuel Pump Test (Tc)
FUEL INJECTION SYSTEM TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 326 SPECIAL TOOLS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 327 SPECIAL TOOLS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 328 TIGHTENING TORQUE FIGURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 329 TIGHTENING TORQUE FIGURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA TIGHTENING TORQUE FIGURES (+/- 5%) ENGINE Cylinder head Special screw Fastening camshaft mount 1) 7 Nm 0,7 kgm...
Page 330 TIGHTENING TORQUE FIGURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Electrical System Screw TCEI M5-L12 Stator (use LOCTITE 272) (TE - TXC) 6 Nm 0.6 Kgm...
Page 331 TIGHTENING TORQUE FIGURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 5.6-6.2 Nm...
Page 332 TIGHTENING TORQUE FIGURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA TIGHTENING TORQUE FIGURES (+/- 5%) HANDLEBAR AND CONTROLS (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) FRONT SUSPENSION (99669) 1 Nm = 0.73756 ft/lb...
Page 333 TIGHTENING TORQUE FIGURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA TIGHTENING TORQUE FIGURES (+/- 5%) REAR SUSPENSION (99669) 1 Nm = 0.73756 ft/lb Workshop Manual Ed.
Page 334 TIGHTENING TORQUE FIGURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA TIGHTENING TORQUE FIGURES (+/- 5%) FAIRINGS AND MUDGUARDS (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) ELECTRICAL SYSTEM (99669) 1 Nm = 0.73756 ft/lb...
Page 335 TIGHTENING TORQUE FIGURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA TIGHTENING TORQUE FIGURES (+/- 5%) FUEL SYSTEM (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) WHEELS AND BRAKES (99669) 1 Nm = 0.73756 ft/lb Workshop Manual Ed.
Page 336 TIGHTENING TORQUE FIGURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA TIGHTENING TORQUE FIGURES (+/- 5%) EXHAUST (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) INSTRUMENTS (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) COOLING SYSTEM (99669)
Page 337 TIGHTENING TORQUE FIGURES TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 338 CHASSIS AND WHEELS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Section Workshop Manual Ed. 07-2012...
Page 339 CHASSIS AND WHEELS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Sommario Chassis ......................Y.3 Lubrication points (lubricant) ................ Y.4 Front wheel ....................
Page 340: Chassis
CHASSIS AND WHEELS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 341: Lubrication Points (Lubricant)
CHASSIS AND WHEELS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Lubrication points (lubricant) 1 Steering bearings (grease) H02333 H02332 Check the assemblies shown in the figure for cracks or damage.
Page 342: Front Wheel
CHASSIS AND WHEELS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Front wheel 8 13 H06832 Legend 1) Tyre 2) Inner tube 3) Rim 4) Spoke 5) Nipple...
Page 343: Removing The Front Wheel
CHASSIS AND WHEELS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 344: Reassembling The Front Wheel
CHASSIS AND WHEELS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 345: Rear Wheel
CHASSIS AND WHEELS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 I.E. USA Rear wheel 9 10 H06860 1) Tyre 2) Inner tube 3) Rim 4) Spoke 5) Nipple...
Page 346: Removing The Rear Wheel
CHASSIS AND WHEELS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 347: Wheel Servicing
CHASSIS AND WHEELS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 348: Wheel Spokes
CHASSIS AND WHEELS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 349: Rear Chain Sprocket, Secondary Drive Sprocket And Chain
CHASSIS AND WHEELS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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 350: Checking Pinion And Sprockets For Wear
CHASSIS AND WHEELS TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA TC 250R 2013 - TC 250R 2013 I.E. USA TXC 250R - 310R 2013 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.

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Husqvarna 2013 TC 250R Workshop Manual

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