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TXC 310R USA (2013)
Operation And Maintenance
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Workshop Manual
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Husqvarna TC 250R (2013), TE 310R USA (2013), TXC 250R USA (2013), TE 310R (2013), TXC 310R USA (2013) Workshop Manual

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TE 250R - 310R 2013 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
reserves the right to make changes to reect on-going product development. Illustrations in the manual may differ from actual components. No reproduction in full or in part without written authorisation. 1st edition (07-2012) - Rev. 00
a.1
simbolo
TE 250R - 310R 2013 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 250R - 310R 2013 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 250R: ZKHA300AADV000001 TE 310R: ZKHA301AADV000001
TE 310R USA: ZKHKCEDG#DV000001
TC 250R: ZKHA300AADV050001
TC 250R USA: ZKHTC253#DV000001 TXC 250R USA: ZKHTX253#DV000001 TXC 310R USA: ZKHTX313#DV000001
H11268
1
Workshop Manual Ed. 07-2012
FOREWORD, TABLE OF CONTENTS
1st edition (07-2012) - Rev. 00 Printed in Italy
MODELS COVERED (from serial number onwards)
Copyright by
HUSQVARNA MOTORCYCLES S.R.L. BMW Group
Technical Service
Via Nino Bixio, 8
21024
(Varese) - Italy tel. ++39 0332 75.61.11 tel. ++39 0332 756 558 www.husqvarna-motorcycles.com
Workshop Manual
1. Chassis serial number
a.2
simbolo
TE 250R - 310R 2013 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, TABLE OF CONTENTS
Workshop Manual Ed. 07-2012
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 comple­ment to operator training and operators should become thoroughly familiar with it. For ease of understanding, diagrams and photographs are provided next to the text. Notes with special signicance are identied as follows throughout the manual:
Accident-prevention rules for operator and persons working nearby.
Damage to vehicle and/or its components may result from incompliance with relevant instructions.
Additional information concerning the operation covered in the text.
Useful tips
To prevent problems and ensure effective service work, observe the following HUSQVARNA recommendations: – before repair, evaluate the customer's description of the problem and ask the appropriate questions to clearly identify
problem symptoms;
– diagnose the problem and identify the causes clearly. This manual provides basic background information that must
be supplemented with the operator's expertise and specic training available through HUSQVARNA held at regular
periods; – plan ahead before starting work: gather any spare parts and tools to avoid unnecessary delays; – avoid unnecessary disassembly work to get to the part that needs repairing. Always read the relevant instructions and follow the disassembly sequence outlined in this manual.
Recommended shop practices
1 Always replace gaskets, sealing rings and split pins with new ones. 2 When loosening or tightening nuts or bolts, always begin with the bigger ones or from the centre. Tighten to the speci-
ed torque and follow a cross pattern. 3 Always mark any parts or positions that might be confused upon assembly. 4 Use genuine HUSQVARNA parts and the recommended lubricant brands. 5 Use special tools where specied. 6 Technical Bulletins might contain more up-to-date setting data and procedures than this manual. Be sure to read
them.
a.3
simbolo
TE 250R - 310R 2013 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
FOREWORD, TABLE OF CONTENTS
Table of Contents
Title Section
Foreword, table of contents .................................................................................a
Important notices .................................................................................................b
General information
.............................................................................................A
Maintenance ........................................................................................................B
Troubleshooting
.................................................................................................. C
Settings and adjustments ................................................................................... D
General procedures .............................................................................................E
Engine disassembly.............................................................................................F
Engine overhaul.................................................................................................. G
Engine reassembly ............................................................................................. H
Front suspension ..................................................................................................I
Rear suspension.................................................................................................. J
Brakes .................................................................................................................L
Electrical system.................................................................................................M
Engine cooling .................................................................................................... N
Hydraulically controlled clutch .............................................................................P
Fuel injection system ...........................................................................................S
Special tools .......................................................................................................W
Tightening torque gures .....................................................................................X
Chassis and wheels.............................................................................................Y
NOTES
Unless otherwise specied, data and specications apply to all models.
b.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
b
Workshop Manual Ed. 07-2012
IMPORTANT NOTICES
Section
b.2
TE 250R - 310R 2013 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
TE
H11270
TXC
H11271
TC
IMPORTANT NOTICES
Workshop Manual Ed. 07-2012
1) TC, TXC models are RACING motorcycles and are warranted to be free from operating defects; a scheduled maintenance chart for racing use is provided in Section B.
2) The TE model is for ROAD USE (DERATED); it is warranted to free from defects and covered by legal warranty, provided that the STANDARD CON­FIGURATION IS MAINTAINED and the maintenance chart provided in Section B is observed. For TE models modied to RACING SPECIFICATIONS (FULL POWER RATING), observe the scheduled maintenance chart for racing use provided in Section B.
* This motorcycle has not been designed to travel over long distances with the
engine at top rpm, as in long-distance road or highway travel. Riding over long distances at full throttle may result in severe engine damage.
* The geometry and setup of this motorcycle have been designed for racing
and to provide top performance when riding solo. We advise against riding two-up, whether off-road or on the track.
* ALWAYS remember that these motorcycles are specically designed for
racing, i.e. for usage conditions signicantly different from those experienced in regular road use.
IMPORTANT
VEHICLE CONFIGURATION as outlined below is a prerequisite for the war­ranty to remain valid:
A) STANDARD MOTORCYCLE, FOR ROAD USE: DERATED; B) RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING.
* 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. The warranty becomes NULL AND VOID if the motorcycle is rented.
Notes Left and right side is determined when seated on motorcycle.
Z: number of teeth A: Austria
AUS: Australia
B: Belgium BR: Brazil CDN: Canada CH: Switzerland
D: Germany
E: Spain
F: France
FIN: Finland GB: Great Britain I: Italy J: Japan
USA: United States of America
Unless otherwise specied, data and instructions apply to all market variants.
A.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
A
Workshop Manual Ed. 07-2012
GENERAL INFORMATION
Section
A.2
TE 250R - 310R 2013 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 INFORMATION
Workshop Manual Ed. 07-2012
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
Clutch ...........................................................................................................A.3
Transmission ................................................................................................A.4
Secondary drive............................................................................................A.4
Final ratios (TE) ............................................................................................A.4
Final ratios (TXC) .........................................................................................A.4
Final ratios (TC)
............................................................................................A.4
Frame ...........................................................................................................A.4
Front suspension ..........................................................................................A.4
Rear suspension...........................................................................................A.5
Front brake ...................................................................................................A.5
Rear brake
....................................................................................................A.5
Rims .............................................................................................................A.5
Tires ..............................................................................................................A.5
Cold tire pressure
.........................................................................................A.5
Electrical components location (TC)
.............................................................A.6
Electrical components location (TXC)
..........................................................A.6
Electrical components location (TE)
.............................................................A.6
Overall dimensions .......................................................................................A.7
Weight
..........................................................................................................A.8
Capacities
.....................................................................................................A.8
A.3
TE 250R - 310R 2013 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
GENERAL INFORMATION
Engine
Type .............................................................................. single cylinder, 4 stroke
TE-TXC 250R - 310R
Cooling ..........................................................liquid, with electric fan on models
TC 250R
Cooling ......................................................................................................liquid
TE-TXC 250R + TC 250R
Bore ..........................................................................................3,11 in. (79 mm)
Stroke .................................................................................. 2,00 in. (50,9 mm)
Displacement ...............................................................15,22 cu. in. (249,5 cm3)
Compression ratio
....................................................................................13,6:1
TE-TXC 310R
Bore
......................................................................................... 3,23 in. (82 mm)
Stroke ................................................................................... 2,26 in. (57,3 mm)
Displacement
.............................................................18,46 cu. in. (302,44 cm3)
Compression ratio ......................................................................................13:1
Starting
TE-TXC 250R - 310R ............................................................................ electric
TC 250R
............................................ kick start (with automatic decompressor)
Timing system
Type .......................................................................................4 titanium valves,
controlled by twin nger follower type camshafts, mixed chain/gear drive system
Valve clearance (with engine cold)
Intake .................................................................................. 0,006 in. (0,15 mm)
Exhaust............................................................................... 0,008 in. (0,20 mm)
Lubrication
Type ......................... wet crankcase, lobe pump and cartridge and mesh lters
Ignition
Type ..................................................................Electronic, inductive discharge,
with adjustable advance (digital control)
Spark plug type..........................................................................NGK CR9EIA-9
Spark plug gap
....................................................0.031÷0,035 in. (0,8÷0,9 mm)
Fuel system
Type .............................................................................Electronic injection feed
Primary drive
Drive pinion gear- Clutch ring gear
................................................... Z 17- Z 54
Transmission ratio
....................................................................................3,176
Clutch
Type
.............................................oil bath multiple disc clutch, hydraulic control
A.4
TE 250R - 310R 2013 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 INFORMATION
Workshop Manual Ed. 07-2012
Transmission
Type ............................................................................ constant mesh gear type
TE-TXC 250R - 310R Transmission ratio
1st gear...................................................................................... 2,142 (z 30/14)
2nd gear .................................................................................... 1,750 (z 28/16)
3rd gear ..................................................................................... 1,450 (z 29/26)
4th gear ..................................................................................... 1,227 (z 27/22)
5 th gear .................................................................................... 1,041 (z 25/24)
6 th gear .................................................................................... 0,884 (z 22/27)
TC 250R Transmission ratio
1st gear. ..................................................................................... 2,142 (z 30/14)
2nd gear .................................................................................... 1,750 (z 28/16)
3rd gear .................................................................................... 1,450 (z 29/26)
4th gear...................................................................................... 1,227 (z 27/22)
5 th gear..................................................................................... 1,041 (z 25/24)
Secondary drive
Transmission sprocket- Rear wheel sprocket
TXC + TC...........................................................................................Z 13- Z 50
TE ......................................................................................................Z 13- Z 40
Transmission ratio
TXC + TC..................................................................................................3,846
TE ..............................................................................................................3,076
Final ratios (TE)
1st gear ...................................................................................................20,926
2nd gear ..................................................................................................17,096
3rd gear ..................................................................................................14,165
4th gear ..................................................................................................11,987
5th gear ..................................................................................................10,169
6th gear ....................................................................................................8,636
Final ratios (TXC)
1st gear....................................................................................................26,164
2nd gear .................................................................................................21,376
3rd gear ..................................................................................................17,251
4th gear ...................................................................................................14,987
5th gear ...................................................................................................12,715
6th gear ...................................................................................................10,797
Final ratios (TC)
1st gear....................................................................................................26,180
2nd gear ..................................................................................................21,380
3rd gear ...................................................................................................17,715
4th gear ...................................................................................................14,994
5th gear ...................................................................................................12,726
Frame
Type ................... Steel single tube cradle (roud, rectangular, ellipsoidal tubes);
light alloy rear frame
Front suspension
Type ............."Upside-down" telescopic hydraulic front fork with advanced axle
(adjustable in compression and rebound stroke); stanchions tubes Ø 1.89 in. (Ø 48 mm)
Legs axis stroke......................................................................11.8 in. (300 mm)
A.5
TE 250R - 310R 2013 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
GENERAL INFORMATION
Rear suspension
Type ...................................... progressive with hydraulic single shock absorber
Wheel stroke...........................................................................11.6 in. (296 mm)
Front brake
Type ................................................. xed disc Ø 10.23 in. (Ø 260 mm) “Wave”
type with hydraulic control and oating caliper
Rear brake
Type .............................................. oating disc, Ø 9.45 in. (Ø 240 mm) “Wave”
type with hydraulic control and oating caliper
Rims
Front ..................................................................................in light alloy: 1,6x21”
TE-TXC 250R - 310R
Rear .................................................................................in light alloy: 2,15x18”
TC 250
Rear .................................................................................in light alloy: 1,85x19”
Tires
TE-TXC 250R- 310R
Front ...................................................................................................90/90x21”
TC 250R
Front ...............................................................................................80/100 x 21”
Rear TE - TXC ................................................................................. 120/90x18”
Rear TE USA ................................................................................... 140/90x18”
Rear TC ........................................................................................... 100/90x19”
Cold tire pressure
Front TE - TXC - TC (*) .............................................................. 0,9÷1,0 Kg/cm
2
Front TE - TXC (%) .......................................................................... 1,1 Kg/cm
2
Rear TE - TXC - TC (*) .............................................................. 0,8÷0,9 Kg/cm
2
Rear TE - TXC (%) .......................................................................... 1,0 Kg/cm
2
(*) In case of racing use - (%) Road use
A.6
TE 250R - 310R 2013 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 INFORMATION
Workshop Manual Ed. 07-2012
Electrical components location (TC)
The ignition system includes the following elements:
- Generator on the inner side of L.H. crankcase half cover;
- Integrated electronic ignition coil on the spark plug cap;
- Electronic control unit under the fuel tank;
- Spark plug on cylinder head;
- Throttle position sensor on the throttle body;
- MAP Sensor on the throttle body;
- Condenser on the left of rear chassis;
- Voltage regulator under the reservoir;
- Air temperature sensor on intake lter.
Electrical components location (TXC)
The ignition system includes the following elements:
- Generator on the inner side of L.H. crankcase half cover;
- Integrated electronic ignition coil on the spark plug cap;
- Electronic control unit under the fuel tank;
- Voltage regulator located to the left side of the motorcycle near the steering tube;
- Spark plug on cylinder head;
- 12V-450W starter motor behind the engine cylinder;
- Solenoid starter on the left of rear chassis;
- Throttle position sensor on the throttle body;
- MAP Sensor on the throttle body;
- Air temperature sensor on intake lter.
The electrical system includes the following elements:
- 12V-6Ah battery under the saddle;
- Electric fan;
- Two 15A and 20A fuses located to the right of the rear chassis, plus one 20A fuse on the starter relay;
- Coolant temperature sensor;
- Lambda sensor;
- Fuel pump inside the fuel tank.
- Fuel and reserve indicator.
Electrical components location (TE)
The ignition system includes the following elements:
- Generator on the inner side of L.H. crankcase half cover;
- Integrated electronic ignition coil on the spark plug cap;
- Electronic control unit under the fuel tank;
- Voltage regulator located to the left side of the motorcycle near the steering tube;
- Spark plug on cylinder head;
- 12V-450W starter motor behind the engine cylinder;
- Solenoid starter on the left of rear chassis;
- Throttle position sensor on the throttle body;
- MAP Sensor on the throttle body;
- Air temperature sensor on intake lter.
The electrical system includes the following elements:
- 12V-6Ah battery under the saddle;
- Turning indicator asher on left side of rear chassis;
- Injection and lighting system relay on the right side of the chassis;
- Electric fan;
- Three fuses (two 15A fuses and one 20A fuse), located to the right of the rear chassis, plus one 20A fuse on the starter relay;
- Coolant temperature sensor;
- Lambda sensor;
- Headlamp with 12V-35/35W twin halogen bulb and 12V-5W parking light bulb;
- LED tail light with stop light bulb;
- 12V-10W turning indicator bulbs;
- Fuel pump inside the fuel tank.
- Odometer.
A.7
TE 250R - 310R 2013 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
C
D
E
F
A
B
Workshop Manual Ed. 07-2012
GENERAL INFORMATION
Overall dimensions
Wheelbase A
(TE-TXC) ........................................................................... mm 1460 (57.47 in.)
(TC) ................................................................................... mm 1470 (57.87 in.)
Overall length B
(TC) ................................................................................... mm 2215 (87.20 in.)
(TE) .................................................................................... mm 2260 (88.97 in.)
(TXC) ................................................................................. mm 2176 (85.66 in.)
Overall width C .................................................................... mm 820 (32.28 in.)
Overall height D
(TE-TXC) ........................................................................... mm 1290 (50.78 in.)
(TC) ................................................................................... mm 1305 (51.37 in.)
Saddle height E
(TC) ..................................................................................... mm 985 (38.77 in.)
(TE-TXC) ............................................................................. mm 950 (37.40 in.)
Minimum ground clearance F
(TE-TXC) ..............................................................................mm 290 (11.41 in.)
(TC) ..................................................................................... mm 325 (12.79 in.)
A.8
TE 250R - 310R 2013 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 INFORMATION
Workshop Manual Ed. 07-2012
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)
Kerb weight, without fuel:
.....108,6 Kg (239,4 lb) 250 / 109,1 Kg (240,5 lb) 310
Capacities Type Quantity
Fuel tank (TC) Premium grade unleaded fuel (R.O.N. 98) 6,5 liters Imp. Gall. 1.43 U.S. Gall. 1.72
Fuel tank (TE-TXC) Premium grade unleaded fuel (R.O.N. 98) 8,5 liters (2,3 liters - 0.51 Imp. Gall. - 0.61 U.S. Gall. reserve included)
Imp. Gall. 1.87
U.S. Gall. 2.25
Gearbox/engine oil CASTROL POWER 1 RACING (SAE 10W50) 900 cc
(oil change and oil lter replacement) 850 cc
(oil change)
Front fork oil KAYABA KHL15-11 (SAE 7,5; SAE 5 for extremely cold weather)
Oil quantity in each fork leg (TC - TXC) 556 cm3 (33.93 in3) Cartridge: 196 cm3 (11.96 in3) Fork sleeve: 360 cm3 (21.97 in3)
Oil quantity in each fork leg (TE) 674 cm3 (41.13 in3)
Rear shock absorber oil CASTROL SYNTHETIC FORK OIL (5W) Coolant CASTROL MOTORCYCLE COOLANT 0.9 litres 0,24 U.S. Gall. 0,2 Imp. Gall. Front brake uid CASTROL RESPONSE SUPER (DOT 4) Rear brake uid CASTROL RESPONSE SUPER (DOT 4) Clutch uid CASTROL RESPONSE SUPER (DOT 4) Drive chain lubrication CASTROL CHAIN LUBE RACING
Grease lubrication CASTROL PASTE TA GREASE
Electric contact protection CASTROL METAL PARTS CLEANER
CASTROL MOTORCYCLE DWF
Fillers for radiator AREXONS LIQUID FILLER
Front fork oil: Kayaba KHL15-11
Air lter oil AGIP FORMULA FILTER "Foam air lter protection oil" Air lter detergent AGIP "Filter clean foam air detergent uid"
IMPORTANT - Do not add any additives to fuel or lubricants.
B.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
B
Workshop Manual Ed. 07-2012
MAINTENANCE
Section
B.2
TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA
TC 250R 2013 - TC 250R 2013 I.E. USA
TXC 250R - 310R 2013 I.E. USA
MAINTENANCE
Workshop Manual Ed. 07-2012
SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
TXC - TE 250R / TXC - TE 310R RACING MOTORCYCLE, FOR RAC­ING USE: FULL POWER RATING
AFTER THE
FIRST 2,5 h
EVERY 5 h
EVERY 10 h
EVERY 20 h
EVERY 30 h
EVERY 40 h
EVERY 50 h
EVERY 60 h
EVERY 70 h
EVERY 80 h
EVERY 90 h
EVERY
100 h
REPLACE
AS
REQUIRED
PARTICOLARE
CHECK
CHECK
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
AIR FILTER
P,L P,L
REAR CHASSIS MNTG BOLTS, EN­GINE MNTG BOLTS
C C
WHEEL SPOKE TENSION
C C
SPROCKET BOLT TIGHTENING
C C
TORQUE OF NUTS AND BOLTS
C C
COOLANT
C X,
*
BRAKE PADS
C X
REAR CHAIN SPROCKET
C X
HANDLEBAR MOUNTS AND FAS­TENERS
C
REAR SWINGING ARM BUSHING
L
REAR SUSPENSION LINKAGE BUSH­INGS
L
CHAIN GUIDE/CHAIN GUARD
C X
SWINGING ARM AXLE ROLLER
CAGES
L
ROLLER CAGES, LINKAGE PINS OF REAR SUSP.
L
COMPLETE THROTTLE CONTROL
C, L
EXHAUST PIPE AND SILENCER
C X
FUEL PIPES
C S X
SECONDARY DRIVE CHAIN
C, L C, L X
KICK START PEDAL
L
GEAR SHIFT PEDAL
C
RADIATORS
C
WATER HOSES AND CLAMPS
C
RADIATORS TO WATER PUMP HOSE
C
FOOTPEGS, PINS, SPRINGS
C X
STEERING HEAD, BOTTOM YOKE WITH STEM
L
REAR CHAIN SLIDER
C X
FRONT BRAKE DISC
C X
REAR BRAKE DISC
C X
CHAIN GUIDE ROLLER, BEARINGS
C
SIDESTAND
C
COMPLETE CLUTCH CONTROL
R
THROTTLE CABLES
C/L X
B.3
TE 250R - 310R 2013 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
MAINTENANCE
SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
TXC - TE 250R / TXC - TE 310R RACING MOTORCYCLE, FOR RAC­ING USE: FULL POWER RATING
AFTER THE
FIRST 2,5 h
EVERY 5 h
EVERY 10 h
EVERY 20 h
EVERY 30 h
EVERY 40 h
EVERY 50 h
EVERY 60 h
EVERY 70 h
EVERY 80 h
EVERY 90 h
EVERY
100 h
REPLACE
AS
REQUIRED
PARTICOLARE
CHECK
CHECK
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
FRONT BRAKING SYSTEM FLUID
C S
REAR BRAKING SYSTEM FLUID
C S
MASTER CYLINDER TO BRAKE CALLIPER HOSES
C X
WHEEL HUB BEARINGS
C X
ENGINE OIL AND FILTER
S
SPARK PLUG
S
VALVES
C (•) S
VALVE SPRINGS, ROCKER ARMS AND PLATES
C
TIMING CHAIN / TIMING CHAIN SLIDER
C
TIMING CHAIN GEARS
C
TIMING CHAIN TENSIONER
C
OIL PUMP
C X
CRANKSHAFT OIL SEALS
S
PISTON
S
CYLINDER
C S X
CLUTCH HUB
C X
CRANKCASE BEARINGS
C S
CRANKSHAFT
S
PRIMARY DRIVE GEAR PAIR
C X
LEGEND:
h: HOURS S: REPLACE C: CHECK
(•): CHECK CLEARANCE P: CLEAN
R: OVERHAUL
L: GREASE/LUBRICATE
*
: CHANGE AND/OR ADD IF NECESSARY
NOTES:
- REPLACE GASKETS AND SEALS AFTER EACH REMOVAL
- REPLACE SCREWS AND BOLTS IF DAMAGED
- PERFORM A GENERAL INSPECTION AFTER RIDING ON MUDDY OR SANDY TERRAIN
B.4
TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA
TC 250R 2013 - TC 250R 2013 I.E. USA
TXC 250R - 310R 2013 I.E. USA
MAINTENANCE
Workshop Manual Ed. 07-2012
SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
TE 250R / TE 310R
STANDARD MOTORCYCLE, FOR ROAD USE
(DERATED)
AFTER FIRST
1000 KM
EVERY 5000 KM EVERY 10000 KM
REPLACE AS
REQUIRED
PART
SERVICE COUPON SERVICE COUPON SERVICE COUPON
VALVES
C (•) C (•) S
VALVE SPRINGS C X TIMING CHAIN
S
TIMING CHAIN SLIDER C S TIMING DRIVEN GEAR C X TIMING DRIVE GEAR
C
TIMING CHAIN TENSIONER
C
INTAKE MANIFOLD AND CLAMPS C C S X COMPLETE CYLINDER
C X
COMPLETE PISTON
S
COMPLETE CRANKSHAFT
S
CRANKCASE BEARINGS
S
CRANKSHAFT OIL SEAL
C X
ENGINE OIL AND OIL FILTER S S S OIL PUMP
C
PRIMARY DRIVE GEAR PAIR
C X
CLUTCH HUB
C X CLUTCH PLATES C C X CLUTCH PRESSURE PLATE
C X
CLUTCH SPRINGS
C X
CLUTCH PUSHROD
C X TRANSMISSION SPROCKET C C X STARTER GEARS
C X
KICK START PEDAL
L
GEAR SHIFT PEDAL
C X
SPARK PLUG P S
AIR FILTER P, L P, L X RADIATORS
C
WATER HOSES AND CLAMPS C C RADIATORS TO WATER PUMP HOSE C C CRANKSHAFT OIL SEAL C C FOOTPEGS, PINS, SPRINGS
C X
REAR CHASSIS MNTG BOLTS, ENGINE MNTG BOLTS
C C
SIDE STAND
C
CHAIN GUIDE ROLLER, BEARING C C X STEERING HEAD, BOTTOM YOKE WITH STEM
L
FRONT FORK
R
HANDLEBAR MOUNTS WITH FASTENERS
C C
REAR SWINGING ARM BUSHING
C
B.5
TE 250R - 310R 2013 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
MAINTENANCE
SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
TE 250R / TE 310R
STANDARD MOTORCYCLE, FOR ROAD USE
(DERATED)
AFTER FIRST
1000 KM
EVERY 5000 KM EVERY 10000 KM
REPLACE AS
REQUIRED
PART
SERVICE COUPON SERVICE COUPON SERVICE COUPON
REAR CHAIN SLIDER
C C X
REAR SUSPENSION LINKAGE BUSHINGS
C X
CHAIN GUIDE/CHAIN GUARD
C C X
ROLLER CAGES, LINKAGE PINS OF REAR SUSP.
L
REAR SHOCK ABSORBER
C
COMPLETE THROTTLE CONTROL
C, L
COMPLETE CLUTCH CONTROL C R THROTTLE CABLES C L X FRONT BRAKE DISC C X FRONT BRAKING SYSTEM FLUID C S REAR BRAKE DISC
C X
REAR BRAKING SYSTEM FLUID C S BRAKE PADS C C C X MASTER CYLINDER TO BRAKE CALLIPER HOSES
C X
FUEL PIPES
C X
EXHAUST PIPE AND SILENCER
C X
WHEEL SPOKE TENSION
C C
WHEEL HUB BEARINGS
C X
REAR CHAIN SPROCKET C S SPROCKET BOLT TIGHTENING C C C SECONDARY DRIVE CHAIN C, L C, L C, L X TORQUE OF NUTS AND BOLTS
C C
LÉGENDE:
S: REMPLACEMENT C: CONTRÔLE (•): CONTRÔLE JEU P: NETTOYAGE R: CONTRÔLE TECHNIQUE L: GRAISSAGE/LUBRIFICATION
REMARQUES:
- REMPLACER LES JOINTS À CHAQUE DÉPOSE
- REMPLACER LA VISSERIE SI ENDOMMAGÉE
- APRÈS CHAQUE PARCOURS SUR TERRAIN BOUEUX OU SUR SABLE, FAIRE UN CONTRÔLE GÉNÉRAL
B.6
TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA
TC 250R 2013 - TC 250R 2013 I.E. USA
TXC 250R - 310R 2013 I.E. USA
MAINTENANCE
Workshop Manual Ed. 07-2012
SCHEDULED MAINTENANCE CHART
(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
TC 250R
RACING MOTORCYCLE, FOR RACING
USE: FULL POWER RATING
EVERY 2,5 h
EVERY 5 h
EVERY 10 h
EVERY 20 h
EVERY 30 h
EVERY 40 h
EVERY 50 h
EVERY 60 h
EVERY 70 h
EVERY 80 h
EVERY 90 h
EVERY 100 h
REPLACE AS
REQUIRED
PART
CHECK
CHECK
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
AIR FILTER
P,L
REAR CHASSIS MNTG BOLTS, ENGINE MNTG BOLTS
C
WHEEL SPOKE TENSION C SPROCKET BOLT TIGHTENING C TORQUE OF NUTS AND BOLTS C COOLANT C X,
*
BRAKE PADS C X REAR CHAIN SPROCKET C X HANDLEBAR MOUNTS AND FASTEN-
ERS
C
REAR SWINGING ARM BUSHING L REAR SUSPENSION LINKAGE BUSH-
INGS
L
CHAIN GUIDE/CHAIN GUARD C X SWINGING ARM AXLE ROLLER CAGES L ROLLER CAGES, LINKAGE PINS OF
REAR SUSP.
L
COMPLETE THROTTLE CONTROL C, L EXHAUST PIPE AND SILENCER C X FUEL PIPES C S X SECONDARY DRIVE CHAIN C, L X KICK START PEDAL L GEAR SHIFT PEDAL C RADIATORS C WATER HOSES AND CLAMPS C RADIATORS TO WATER PUMP HOSE C FOOTPEGS, PINS, SPRINGS C X STEERING HEAD, BOTTOM YOKE
WITH STEM
L
REAR CHAIN SLIDER C X FRONT BRAKE DISC C S X REAR BRAKE DISC C S X CHAIN GUIDE ROLLER, BEARINGS C COMPLETE CLUTCH CONTROL
R (#)
B.7
TE 250R - 310R 2013 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
MAINTENANCE
SCHEDULED MAINTENANCE CHART
(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
TC 250R
RACING MOTORCYCLE, FOR RACING
USE: FULL POWER RATING
EVERY 2,5 h
EVERY 5 h
EVERY 10 h
EVERY 20 h
EVERY 30 h
EVERY 40 h
EVERY 50 h
EVERY 60 h
EVERY 70 h
EVERY 80 h
EVERY 90 h
EVERY 100 h
REPLACE AS
REQUIRED
PART
CHECK
CHECK
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
SERVICE
COUPON
THROTTLE CABLES C X FRONT BRAKING SYSTEM FLUID S REAR BRAKING SYSTEM FLUID S MASTER CYLINDER TO BRAKE CALLI-
PER HOSES
C X
WHEEL HUB BEARINGS C ENGINE OIL AND FILTER S
PLUG S VALVES C (•) S
VALVE SPRINGS, ROCKER ARMS AND
PLATES
C
TIMING CHAIN / TIMING CHAIN SLIDER C TIMING CHAIN GEARS C TIMING CHAIN TENSIONER C OIL PUMP C X CRANKSHAFT OIL SEALS S PISTON S CYLINDER S CLUTCH HUB C X CRANKCASE BEARINGS S CRANKSHAFT S PRIMARY DRIVE GEAR PAIR C X
LEGEND:
h: HOURS
P: CLEAN L: GREASE/LUBRICATE
C: CHECK R: OVERHAUL S: REPLACE
(•): CHECK CLEARANCE
*
: CHANGE AND/OR ADD IF NECESSARY
NOTES:
- REPLACE GASKETS AND SEALS AFTER EACH REMOVAL
- REPLACE SCREWS AND BOLTS IF DAMAGED
- PERFORM A GENERAL INSPECTION AFTER RIDING ON MUDDY OR SANDY TERRAIN
C.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
C
Workshop Manual Ed. 07-2012
TROUBLESHOOTING
Section
C.2
TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA
TC 250R 2013 - TC 250R 2013 I.E. USA
TXC 250R - 310R 2013 I.E. USA
TROUBLESHOOTING
Workshop Manual Ed. 07-2012
ENGINE
Trouble Cause Remedy
Engine does not start or Insufcient compression
has starting trouble 1. Piston seized Replace
2. Connecting rod small or big end seized Replace
3. Worn piston rings Replace
4. Worn cylinder Replace
5. Cylinder head loosely tightened Tighten
6. Head gasket leaking Replace
7. Spark plug loose Tighten
8. Incorrect valve clearances Adjust
9. Weak or seized valve springs Replace
10. Seized valves Replace
Weak or no spark
1. Spark plug faulty Replace
2. Fouled or wet spark plug Clean or dry
3. Spark plug electrode gap too wide Adjust
4. Ignition coil faulty Replace
5. High-tension cables open circuit or shorted Check
6. Electronic control unit faulty Replace
7. Right-hand switch faulty (TE - TXC) Replace
Engine stalls 1. Fouled spark plug Clean easily 2. Electronic control unit faulty Replace
3. Carburettor jets clogged Clean
4. Low idle Adjust
Engine is noisy Noise seems to come from piston
1. Too much piston-to-cylinder clearance Replace
2. Worn piston rings or piston grooves Replace
3. Too much carbon build-up in combustion chamber or on piston crown Clean
4. Valve clearances too large Adjust
5. Weak or seized valve springs Replace
6. Worn timing chain Replace
7. Incorrect timing chain tension Adjust
Noise seems to come from crankshaft
1. Worn main bearings Replace
2.
Connecting rod big end has too much side clearance or end oat
Replace
3. Crankshaft gear damaged Replace
4. Crankshaft locknut loose Tighten
Noise seems to come from the clutch
1. Worn plates Replace
2.
Too much clearance between clutch housing and friction plates
Replace
Noise seems to come from gearbox
1. Worn gears Replace
2. Worn gear grooves Replace
Noise seems to come 1. Chain stretched (worn) or improperly adjusted Replace or adjust from secondary drive 2. Worn transmission sprocket and rear chain sprocket Replace chain
C.3
TE 250R - 310R 2013 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
TROUBLESHOOTING
Trouble Cause Remedy
Clutch slips 1. Weak clutch springs Replace
2. Worn clutch plates Replace
Clutch is hard to operate 1. Uneven spring load Replace
2. Bent clutch plates Replace
Gears do not engage 1. Bent or seized shifter forks Replace
2. Worn gear ratchets Replace
3. Damaged shifter fork shafts Replace
Gear shift pedal does not return to original position
1. Weak or broken selector return spring Replace
2. Worn shifter forks Replace
Transmission jumps out of gear 1. Worn sliding gear dogs Replace
2. Worn gear grooves Replace
3. Worn dog slots in gears Replace
4. Worn selector shaft splines Replace
5. Damaged shifter fork shafts Replace
Engine has low power 1. Dirty air lter Clean
2. Poor fuel quality Replace
3. Intake coupling loose Tighten
4. Spark plug electrode gap too wide Adjust
5. Insufcient compression Identify cause
6. Incorrect valve clearances Adjust
7. Valve seats or guides faulty Replace
8. Weak or seized valve springs Replace
Engine overheats 1. Combustion chamber and/or piston crown fouled with carbon deposits Clean
2. Insufcient oil in engine or wrong oil Top up or change
3. Obstructions blocking air ow on radiator Clean
4. Cylinder head gasket leaking Replace
5. Clutch slips Adjust
6. Cooling fan faulty (TE-TXC) Replace the fan
7. Faulty thermostatic valve (TE-TXC) Replace the valve
8. Faulty fan thermal switch Replace
C.4
TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA
TC 250R 2013 - TC 250R 2013 I.E. USA
TXC 250R - 310R 2013 I.E. USA
TROUBLESHOOTING
Workshop Manual Ed. 07-2012
CHASSIS
Trouble Cause Remedy Handlebar turns hard 1. Insufcient tyre pressure Inate
2. Bearing adjuster ring nut or steering stem nut overtightened Adjust
3. Bent steering stem Replace bottom yoke
4. Worn or seized steering bearings Replace
Handlebar vibration 1. Bent fork legs Replace
2. Bent front wheel axle Replace
3. Warped chassis Replace
4. Bent front wheel rim Replace
5. Worn front wheel bearings Replace
Damping is 1. Too much oil in fork legs Remove excess oil too hard 2. Fork oil viscosity too high Change
3. Overinated tyres Deate
4. Improperly set rear shock absorber Adjust
Damping is 1. Insufcient oil in fork legs Top up too soft 2. Fork oil viscosity too low Change
3. Weak fork springs Replace
4. Weak rear shock absorber spring Replace
5. Improperly set rear shock absorber Adjust
(Front / rear) wheel 1. Bent wheel rim Replace shakes 2. Worn wheel hub bearings Replace
3. Incorrect spoke tension Adjust
4. Wheel axle nut loose Tighten
5. Worn rear swinging arm bearings Replace
6. Improperly adjusted chain tensioners Adjust
7. Improperly balanced wheel Balance
Rear suspension is 1. Worn link rod spacers or bearings Replace noisy 2. Worn shock absorber ball joints Replace
3. Shock absorber faulty Replace
Poor braking 1. Air in brake system Bleed (front and rear) 2. Insufcient uid in tank Top up
3. Worn brake pad and/or disc Replace
4. Damaged disc Replace
5. Improperly adjusted brake pedal Adjust
6. Water in brake system Change uid
C.5
TE 250R - 310R 2013 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
TROUBLESHOOTING
ELECTRICAL SYSTEM (see also Section M)
Trouble Cause Remedy
Spark plug fouls 1. Dirty air lter Clean easily 2. Worn piston rings Replace
3. Worn piston or cylinder liner Replace
Spark plug electrodes 1. Spark plug electrode gap too close Adjust overheat 2. Heat rating too high Replace with recommended
spark plug
Generator does not charge or 1.
Cables running to voltage regulator improperly connected or
Connect correctly or
is not providing enough charge shorted replace
2. Voltage regulator faulty Replace
3. Generator coil faulty Replace
Generator overcharges battery 1. Voltage regulator faulty Replace
Battery does not hold charge 1. Battery terminals dirty Clean (TE-TXC)
Starter motor 1. Battery is at Charge does not start or slips 2. Control on R.H. switch faulty Replace (TE-TXC) 3. Starter relay faulty Replace
4. Starter motor faulty Repair or replace
5. Worn starter gears Replace
6. Worn or damaged freewheel rollers Replace freewheel
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