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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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 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

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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

Workshop Manual Ed. 07-2012

FOREWORD, TABLE OF CONTENTS

1st edition (07-2012) - Rev. 00 Printed in Italy

MODELS COVERED (from serial number onwards)

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

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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.

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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

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.

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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

IMPORTANT NOTICES

Section

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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

H11269

H11270

TXC

H11271

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.

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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

GENERAL INFORMATION

Section

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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

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

Page 11

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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

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

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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

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)

Page 13

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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

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

Front TE - TXC (%) .......................................................................... 1,1 Kg/cm

Rear TE - TXC - TC (*) .............................................................. 0,8÷0,9 Kg/cm

Rear TE - TXC (%) .......................................................................... 1,0 Kg/cm

(*) In case of racing use - (%) Road use

Page 14

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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

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.

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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

H11272

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.)

Page 16

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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

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.

Page 17

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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

MAINTENANCE

Section

Page 18

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

REQUIRED

PARTICOLARE

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

REAR SWINGING ARM BUSHING

REAR SUSPENSION LINKAGE BUSHINGS

CHAIN GUIDE/CHAIN GUARD

C X

SWINGING ARM AXLE ROLLER

CAGES

ROLLER CAGES, LINKAGE PINS OF REAR SUSP.

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

GEAR SHIFT PEDAL

RADIATORS

WATER HOSES AND CLAMPS

RADIATORS TO WATER PUMP HOSE

FOOTPEGS, PINS, SPRINGS

C X

STEERING HEAD, BOTTOM YOKE WITH STEM

REAR CHAIN SLIDER

C X

FRONT BRAKE DISC

C X

REAR BRAKE DISC

C X

CHAIN GUIDE ROLLER, BEARINGS

SIDESTAND

COMPLETE CLUTCH CONTROL

THROTTLE CABLES

C/L X

Page 19

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

REQUIRED

PARTICOLARE

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

SPARK PLUG

VALVES

C (•) S

VALVE SPRINGS, ROCKER ARMS AND PLATES

TIMING CHAIN / TIMING CHAIN SLIDER

TIMING CHAIN GEARS

TIMING CHAIN TENSIONER

OIL PUMP

C X

CRANKSHAFT OIL SEALS

PISTON

CYLINDER

C S X

CLUTCH HUB

C X

CRANKCASE BEARINGS

C S

CRANKSHAFT

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

Page 20

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

TIMING CHAIN SLIDER C S TIMING DRIVEN GEAR C X TIMING DRIVE GEAR

TIMING CHAIN TENSIONER

INTAKE MANIFOLD AND CLAMPS C C S X COMPLETE CYLINDER

C X

COMPLETE PISTON

COMPLETE CRANKSHAFT

CRANKCASE BEARINGS

CRANKSHAFT OIL SEAL

C X

ENGINE OIL AND OIL FILTER S S S OIL PUMP

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

GEAR SHIFT PEDAL

C X

SPARK PLUG P S

AIR FILTER P, L P, L X RADIATORS

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

CHAIN GUIDE ROLLER, BEARING C C X STEERING HEAD, BOTTOM YOKE WITH STEM

FRONT FORK

HANDLEBAR MOUNTS WITH FASTENERS

C C

REAR SWINGING ARM BUSHING

Page 21

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.

REAR SHOCK ABSORBER

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

Page 22

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

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

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

REAR SWINGING ARM BUSHING L REAR SUSPENSION LINKAGE BUSH-

INGS

CHAIN GUIDE/CHAIN GUARD C X SWINGING ARM AXLE ROLLER CAGES L ROLLER CAGES, LINKAGE PINS OF

REAR SUSP.

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

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 (#)

Page 23

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

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

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

Page 24

Page 25

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

Workshop Manual Ed. 07-2012

TROUBLESHOOTING

Section

Page 26

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

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

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

Page 27

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

Page 28

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

Page 29

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

Page 30

Page 31

D.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

SETTINGS AND ADJUSTMENTS

Section

Page 32

D.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

SETTINGS AND ADJUSTMENTS

Workshop Manual Ed. 07-2012

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

Hydraulic clutch lever adjustment and uid level check ............................D.11

Front brake lever adjustment and uid level check ....................................D.12

Rear brake pedal position adjustment ........................................................D.13

Rear brake pedal free play adjustment.......................................................D.14

Rear brake uid level check .....................................................................D.14

Engine oil level check .................................................................................D.15

Engine oil replacement and mesh lters-lter cartridge cleaning or replacement

...D.16

Coolant level check ....................................................................................D.17

Coolant replacement ..................................................................................D.17

Air lter check (TC)

.....................................................................................D.18

Air lter cleaning .........................................................................................D.18

Air lter check (TE - TXC)

...........................................................................D.19

Air lter cleaning .........................................................................................D.19

Assembly ....................................................................................................D.20

Secondary drive chain adjustment

.............................................................D.21

Chain lubrication

.........................................................................................D.22

Disassembling and cleaning

.......................................................................D.22

Washing a chain without O-rings (TC)

........................................................D.22

Lubricating a chain without O-rings (TC) ...................................................D.22

Washing the chain with OR (TE - TXC)

......................................................D.22

Lubricating an O-ring chain

........................................................................D.22

Suspension setup according to track condition

..........................................D.23

Shock absorber adjustment

........................................................................D.24

Shock absorber spring preload adjustment ................................................D.25

Shock absorber compression and rebound damping adjustment

.............D.26

Shock absorber springs ....

........................................................................D.26

KAYABA front fork adjustment

....................................................................D.27

Steering bearing clearance adjustment

......................................................D.28

Steering angle adjustment .........................................................................D.28

Supply hose check

.....................................................................................D.29

Exhaust system check

................................................................................D.30

Page 33

D.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

H11269

H11270

TXC

H11271

Workshop Manual Ed. 07-2012

SETTINGS AND ADJUSTMENTS

Page 34

D.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

H02181

H02183

SETTINGS AND ADJUSTMENTS

Workshop Manual Ed. 07-2012

Saddle removal

Turn the rear xing (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 body in order to prevent possible breakage / damages to the parts.

Remove the screws (1) and the side panels.

Remove the tank retaining screw (2).

(TE-TXC)

Close the two taps (3) and (4) and connect the hose (5). Disconnect connector (6) of the reserve sensor.

Page 35

D.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

H09060

H09061

H11273

TE - TXC

H11274

Workshop Manual Ed. 07-2012

SETTINGS AND ADJUSTMENTS

Lift the tank and disconnect the fuel pump connector (7) from the main wiring harness.

Disconnect the supply hose (8) from the outlet tting (9) on the fuel pump, located in the rear bottom section of the tank.

Remove the tank (10) together with the scoops.

Page 36

D.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

H10948

H10949

H10950

SETTINGS AND ADJUSTMENTS

Workshop Manual Ed. 07-2012

Valve clearance adjustment

Remove saddle and tank as outlined in the relevant paragraphs.

- Remove the connector (1) from the coil (2).

- Loosen the two screws (3), remove coil (2) and retaining bracket (4), and then remove the spark plug.

NOTE: During retting, check that the gasket (5) is correctly positioned;

the reference lug (6) must correspond with the retaining bracket (4) gap (7).

Loosen the four screws (8) of the head cover and remove the head cover (9).

Page 37

D.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

H10951

H10952

Workshop Manual Ed. 07-2012

SETTINGS AND ADJUSTMENTS

Engage the 2nd gear and push and pull the motorcycle back and forth to bring

the piston to Top Dead Centre. In this condition, the engraved reference marks (10) on the gears of the camshafts are positioned on the same axle although they are diametrically opposed.

INTAKE OUTLET

Page 38

D.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

H10953

H10954

H10955

H10956

SETTINGS AND ADJUSTMENTS

Workshop Manual Ed. 07-2012

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”).

If not so, remove the shim from under the valve bucket and measure its thickness. Depending on what you nd, replace the shim with a new shim with the required thickness to achieve correct clearance (replacement shims are available in a

1.60 mm to 2.60 mm thickness range, in 0.05 mm increments).

Check valve clearances again. If clearances are correct, ret the parts you have removed reversing the disassembly procedure.

For camshaft disassembly and reassembly, see Section “F” Engine disassembly and Section “H” Engine assembly.

FIGURE A

INTAKE

FIGURE A

INTAKE

FIGURE B

OUTLET

FIGURE B

OUTLET

Page 39

D.9

TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA

TC 250R 2013 - TC 250R 2013 I.E. USA

TXC 250R - 310R 2013 I.E. USA

H11275

H11276

Workshop Manual Ed. 07-2012

SETTINGS AND ADJUSTMENTS

Adjustment throttle cable

To check the correct adjustment of the throttle operate as follows:

- Remove rubber caps (1);

- By moving the opening cable (2) back and forth, check that free play is 3 mm;

- By moving the closing cable (3) back and forth, check that free play is 1 mm;

- If it does not happen, loosen the nut (4) and appropriately turn the adjuster screw (5);

(loosen it to decrease clearance, tighten it to increase it);

- After adjustment block the nut (4).

Operation with damaged throttle cable could result in an unsafe

riding condition.

Exhaust gas contains poisonous carbon monoxide. Never run the

engine indoors.

To replace the cables, you will need to remove the fuel tank as described in the relevant paragraph.

Idle adjustment

Adjust the carburetor with warm engine and with the throttle control in closed position. Proceed as follows:

- turn the knob (1) on the right side of the throttle body of about 34 clicks from

the fully closed position, checking with the suitable device that revs are of about 1,950 RPM (turn clockwise to increase the speed and counter clockwise to reduce it).

Page 40

D.10

TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA

TC 250R 2013 - TC 250R 2013 I.E. USA

TXC 250R - 310R 2013 I.E. USA

H11101

SETTINGS AND ADJUSTMENTS

Workshop Manual Ed. 07-2012

Clutch plate replacement This procedure can be performed with the motorcycle leaning to the left - there is no need to drain engine oil.

- Remove the brake pedal (1).

- 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. Remove springs, pressure plate (5) with bearing (6) and clutch actuator plate (7).

Page 41

D.11

TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA

TC 250R 2013 - TC 250R 2013 I.E. USA

TXC 250R - 310R 2013 I.E. USA

H11277

H11278

4mm (0,16 in.)

Workshop Manual Ed. 07-2012

SETTINGS AND ADJUSTMENTS

- Remove the plates (8), lubricate the new plates with engine oil and install them (always start with a friction plate).

Ret clutch actuator plate, bearing and pressure plate. Tighten the spring screws gradually in a cross pattern (8 Nm - 0.8 Kgm - 5.8 ft/lb). When retting the clutch cover (8 Nm - 0.8 Kgm - 5.8 ft/lb), check gasket for wear and replace as required.

For additional information on assembly procedures, see Section

"H" Engine assembly.

Hydraulic clutch lever adjustment and uid level check

Free play (A) must be at least 0,39 in. (10 mm). The lever position can be adjusted to suit the rider hand size. To decrease the lever distance from the handgrip, rotate the adjuster (B) CLOCKWISE. To increase the lever distance from the handgrip, rotate the adjuster (B) COUNTER CLOCKWISE. Fluid level is checked as follows:

- Remove screws (1), cover (2) and rubber diaphragm from the control;

- Keep the control cylinder (3) in a horizontal position and make sure that uid level has not dropped lower than 4 mm (0.16 in.) below the upper edge (D) of master cylinder body;

- If needed, top up with the uid specied in the LUBRICANT CHART included in Section "A".

Ret any parts you have removed. Periodically check the connecting hose (see “Scheduled Maintenance Chart”); if hose (C) is worn or cracked, its replacement is advised.

Page 42

D.12

TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA

TC 250R 2013 - TC 250R 2013 I.E. USA

TXC 250R - 310R 2013 I.E. USA

H09070

H09071

H11279

SETTINGS AND ADJUSTMENTS

Workshop Manual Ed. 07-2012

A: to increase clearance

B: to decrease clearance

Front brake lever adjustment and uid level check

The adjuster (1) located on the control lever, allows adjusting of the free play (a). Free play (a) must be at least 0,39 in. (10 mm). The level of the uid in master cylinder reservoir must never be below the minimum value (2), which can be checked from the inspection window on the rear of the master cylinder body. A decrease of the uid level will let air into the system, hence an extension of the lever stroke.

If the brake lever feels mushy when pulled, there may be air in the

brake line or the brake may be defective: CHECK THE BRAKING SYSTEM (see Section "L").

Too much brake lever free play may reduce braking action: CHECK

BRAKE PAD THICKNESS (see Section "L").

Do not spill brake uid onto any painted surface or lens (for example

lights lens).

Do not mix two brands of uid. Completely change the brake uid

in the brake system if you wish to switch to another uid brand.

Brake uid may cause irritation. Avoid contact with skin or eyes.

In case of contact, ush thoroughly with water and call a doctor if

your eyes were exposed.

Page 43

D.13

TE 250R - 310R 2013 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

SETTINGS AND ADJUSTMENTS

Rear brake pedal position adjustment

The position of the rear brake pedal with respect to the footrest may be adjusted according to individual needs. For adjusting, proceed as follows:

- Loosen the screw (1).

- Turn the cam (2) in order to raise or lower the brake pedal within the range available (A).

- When nished, tighten the screw (1).

Once this operation is completed, it is necessary to check/adjust the free play of the pedal as well, according to the instructions below.

Page 44

D.14

TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA

TC 250R 2013 - TC 250R 2013 I.E. USA

TXC 250R - 310R 2013 I.E. USA

SETTINGS AND ADJUSTMENTS

Workshop Manual Ed. 07-2012

C: to increase clearance D: to decrease clearance

Rear brake pedal free play adjustment

The rear brake pedal should have 5 mm free play (B) before the brake begins to bite. Should this not happen, operate as follows:

- Loosen the nut (3);

- Operate the master cylinder linkage (4) to increase or decrease free play;

- Tighten the nut (3) at the end of the operation.

When the free play requirement is not met, the brake pads will be

subjected to an early wear that may lead to TOTAL BRAKE INEFFECTIVENESS.

If the brake pedal feels mushy when pulled, there may be air in the

brake line or the brake may be defective. CHECK THE BRAKING SYSTEM (see Section L).

Rear brake uid level check

Level (A) must be between the MIN and MAX notches visible on the master cylinder reservoir.

Page 45

D.15

TE 250R - 310R 2013 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

SETTINGS AND ADJUSTMENTS

Engine oil level check

Keeping the motorcycle level and upright, check the oil level through the inspection window (1) on the right crankcase. Make sure level is up to window midline (1). To top up, remove the ller cap (2).

Have this operation made with warmed-up engine.

Be careful not to touch hot engine oil.

Page 46

D.16

TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA

TC 250R 2013 - TC 250R 2013 I.E. USA

TXC 250R - 310R 2013 I.E. USA

H00977-1

H02335

H02336

310

250

SETTINGS AND ADJUSTMENTS

Workshop Manual Ed. 07-2012

Engine oil replacement and mesh lters-lter cartridge cleaning or replacement

Drain the oil with WARM ENGINE; proceed as follows:

- Remove the oil ller cap (2).

- The oil sump guard (A) may be left in place. However, the procedure will be easier with the guard removed.

- Place an oil drain pan under the engine.

(TE-TC-TXC 250)

- Remove oil drain plug (3) and lter (4), drain the oil and clean the plug magnet.

- Wash the lter (4) with petrol and ret it into its seat.

(TE 310)

- loosen tie (3a) without disconnecting tube (3b);

- unscrew hose tail (3c), remove mesh lter (4) and drain the used oil.

- Unscrew the screws (5) and remove cover (6) together with lter (7).

- Change the lter (7) and ret the assembly making sure to t the Belleville washer (8) in the correct position.

(TE-TC-TXC 250)

- Ret the drain plug (3) (25 Nm - 2.5 Kgm - 33.89 ft/lb) and the oil sump guard (A).

(TE 310)

- Reassemble tting (3c), screw clamp (3a), and ret the engine cover (A).

- Fill with the specied quantity of oil.

For recommended oil type and quantity, see "Capacities" table in Section

"A".

Be careful not to touch hot engine oil.

WARNING When assembling lter to cover, make sure to t the lter

oil seal (A) rst onto the cover (6).

Page 47

D.17

TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA

TC 250R 2013 - TC 250R 2013 I.E. USA

TXC 250R - 310R 2013 I.E. USA

H02187

H09072

H11280

H11281

Workshop Manual Ed. 07-2012

SETTINGS AND ADJUSTMENTS

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). The coolant should be approximately

0.39 in. above the cells. The radiator cap features two locking positions: the rst one is for prior discharge of pressure from the cooling system.

Avoid removing radiator cap when engine is hot, as coolant may

spout out and cause scalding.

Difculties may arise in eliminating coolant from painted surfaces.

If this occurs, wash off with water.

Coolant replacement

Place a vessel on the L.H. side of the cylinder, under the hose (1). Loosen the clamp (2) on the hose (1) and detach the hose from the engine. SLOWLY open the cap (3) of the right-hand radiator and lean the motorcycle to the left to let the coolant drain into the vessel. When nished, ret the hose (1) and secure it with the clamp (2). Pour the necessary quantity of coolant in the radiator then warm up the engine in order to eliminate any possible air bubbles. Periodically check the connecting hoses (see “Scheduled Maintenance Chart”): this will avoid coolant leakage and consequent engine seizure. If hoses (A) show cracks, swelling or hardening due to sheaths desiccation, their replacement shall be advisable. Check the correct tightening of the clamps (B).

Page 48

D.18

TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA

TC 250R 2013 - TC 250R 2013 I.E. USA

TXC 250R - 310R 2013 I.E. USA

SETTINGS AND ADJUSTMENTS

Workshop Manual Ed. 07-2012

Air lter check (TC)

Turn the rear xing (1) counter clockwise, remove it and extract the saddle releasing it from the front retaining screw. Remove the screw (3), remove the complete air lter (4) and separate lter (5) from rear chassis (6).

Air lter cleaning

Wash the lter with a specic detergent (see "Capacities" table in Section A) then dry it fully (wash lter with gasoline only in case of need). Plunge the lter in special oil for lters (see "Capacities" table in Section A), then wring it to drain superuous oil.

Do not use fuel or a low ash-point solvent to clean the ltering

element. A re or explosion could result.

Clean the ltering element in a well ventilated area and do not allow

sparks or ames anywhere near the working area.

Page 49

D.19

TE 250R - 310R 2013 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

SETTINGS AND ADJUSTMENTS

Air lter check (TE - TXC)

Turn the rear xing (1) counter clockwise, remove it and extract the saddle releasing it from the front retaining screw. Take out the battery (A) and leave it hanging on the side of the motorcycle. Remove the screw (3), remove the complete air lter (4) and separate lter (5) from intake silencer (6).

Air lter cleaning

Do not use fuel or a low ash-point solvent to clean the ltering

element. A re or explosion could result.

Clean the ltering element in a well ventilated area and do not allow

sparks or ames anywhere near the working area.

Page 50

D.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

H09073

TE - TXC

SETTINGS AND ADJUSTMENTS

Workshop Manual Ed. 07-2012

Assembly

Grease the edge (C) of the lter face that goes into the housing to ensure proper sealing. When retting the lter into its housing, make sure to position it with the tab (A) pointing upwards and edge (B) at the left bottom corner of the lter housing. Ret any parts you have removed.

An improperly positioned lter might let dirt or dust into the engine,

leading to early wear of piston rings and cylinder.

A = Upper side B = Left-hand side

Page 51

D.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

H09074

H09075

H09076

H09077

145

[mm]

REGOLAZIONE CATENA

Workshop Manual Ed. 07-2012

SETTINGS AND ADJUSTMENTS

Fig. A

Fig. B

Secondary drive chain adjustment

Chain should be checked, adjusted and lubricated as per the "Maintenance Chart" (see Section B) to ensure safety and prevent excessive wear. If the chain becomes badly worn or is poorly adjusted (i.e., if it is too loose or too taut), it could escape from sprocket or break. To adjust chain tension, you need to lower the rear end of the motorcycle so as to bring the axes of rotation of sprocket, swinging arm and rear wheel into alignment as shown in gure "A", and then turn the rear wheel three turns. In this condition, the chain should be neither taut nor slack. (Fig. A).

Quick adjustment (Fig. B) Insert, at a distance of 145 mm (5.7 in.) from the fork centre, a bushing (a) with a 35 mm (1.37 in.) diameter (as an alternative, insert a spacer of the same dimensions) and make sure that the lower arm (C) of the chain is slightly tight. If it is not, proceed as follows:

- Loosen the wheel axle nut (1) on the right-hand side using a 27 mm socket wrench;

- Loosen the check nuts (2) on both chain tensioners with a 12 mm wrench and work the screws (3) until achieving the correct tension;

- When the adjustment is completed, tighten the check nuts (2) and the wheel axle nut (1).

After any adjustment, always check wheel alignment and tighten wheel axle securely (142.1 Nm - 14.5 Kgm - 104.8 ft/lb).

Asse pignone = Sprocket axis Asse forcellone = Swinging arm axis Asse ruota = Wheel axis

* : Chain adjustment

Page 52

D.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

H09078

H11142

SETTINGS AND ADJUSTMENTS

Workshop Manual Ed. 07-2012

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.

Disassembling and cleaning

When particularly dirty, remove and clean the chain before lubrication. Proceed as follows:

- Set a stand or a block under the engine and see that the rear wheel is lifted from the ground.

- Remove: screws (1), sprocket guard (2), clip (3), master link (4) and chain (5). To reassemble, reverse the above procedure.

Make sure that the chain is neither worn out nor damaged. If the rollers or the links are damaged, replace the chain by following the instructions given in the Scheduled Maintenance Chart. Ensure that the sprockets are not damaged. Wash and clean the chain as described hereunder.

Washing a chain without O-rings (TC)

Wash using petroleum or naphtha. If you use fuel or especially trichloroethylene, dry and lubricate the chain to avoid oxidisation.

Lubricating a chain without O-rings (TC)

After drying, dip the chain in Molybdenum Disulphide chain lubricant, if possible, or in warm high-viscosity engine oil (if warmed up, oil will be more uid).

NOTE: As an alternative, you can use suitable spray lubricants.

Washing the chain with OR (TE - TXC)

Wash using oil, diesel oil, or parafn oil. Never use gasoline, tricloroetilene, or solvents, as the OR may suffer damages. Use instead special sprays for chains with OR.

Lubricating an O-ring chain

Lubricate all metallic and rubber (O-ring) elements using a brush and engine oil

with SAE 80-90 viscosity, inside and outside parts.

Assemble the master link clip (3) by setting the closed side facing the chain direction of rotation, as shown in the gure.

The master link is the most critical safety part in the drive chain. Even

if the master links are reusable when in good conditions, for safety

purposes we advise using a new master link when reassembling the chain.

Accurately adjust the chain as described on page D.18.

The chain lubricant shall NEVER get in contact with the tyres or the

rear brake disc.

Chain guide roller, chain guide roller, chain guide, chain slider

Check the wear of the above-mentioned elements and replace them

when necessary.

Check the chain guide alignment, and remember that a bent element

can cause chain early wear. In this case, chain might unwrap from

the sprocket.

Page 53

D.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

Workshop Manual Ed. 07-2012

SETTINGS AND ADJUSTMENTS

Suspension setup according to track condition

Following are a few guidelines to nd the right suspension setup for different types of terrain. Always start from the suspensions standard setting before making any change. Afterwards, increase or decrease the adjusting clicks, one at a time.

HARD GROUND

Front fork: softer compression setting. Shock absorber: softer compression setting. For fast tracks, a softer compression and rebound setting both front and rear will give more grip.

SANDY GROUND

Front fork: set compression harder, or replace the standard spring with a harder spring and set the compression softer and the rebound harder. Shock absorber: harder compression, and especially harder rebound settings. Work on the spring preload to lower the motorcycle riding height (rear end).

MUDDY GROUND

Front fork: set compression harder, or replace the standard spring with a harder spring. Shock absorber: harder compression and rebound settings or replace the standard spring with a harder spring. Work on the spring preload to lift the motorcycle riding height (rear end). Changing the springs front and rear is advised in order to compensate for increased motorcycle weight due to caked-on mud.

NOTES

If the fork remains too soft or too hard no matter what setting you choose, check oil level in the fork tubes, as it might be too low or too high. Remember that the more oil you add, the more frequently you will need to bleed the forks. If changes to suspension settings take no effect, check the adjuster assemblies, as they might be stuck. Standard settings, available replacement springs and adjusting procedures are outlined in the following pages.

Page 54

D.24

TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA

TC 250R 2013 - TC 250R 2013 I.E. USA

TXC 250R - 310R 2013 I.E. USA

H02180

SETTINGS AND ADJUSTMENTS

Workshop Manual Ed. 07-2012

B: panel retaining screw axis C: rear wheel axle height

Shock absorber adjustment

The rear shock absorber must be adjusted to suit rider weight and terrain conditions. Proceed as follows:

1. Place the motorcycle on the stand and measure distance (A).

2. Sit on the motorcycle in normal riding position with full riding gear on.

3. Have someone else measure distance (A) again.

4. The difference between these two measurements is the distance the rear end settles when the rider sits on the motorcycle (RIDER SAG). Recommended rider sag is 100 mm with a cold shock absorber and 95 mm with a warm shock absorber.

5. To achieve correct rider sag for your weight, adjust the spring preload of the shock absorber (see relevant paragraph).

Page 55

D.25

TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA

TC 250R 2013 - TC 250R 2013 I.E. USA

TXC 250R - 310R 2013 I.E. USA

H09079

H09080

H09081

H09082

Workshop Manual Ed. 07-2012

SETTINGS AND ADJUSTMENTS

The standard length of the preloaded spring is

as follows:

TC - TXC: A= 250 ± 0.5 mm (9.84 ± 0.02 in.)

TE: A= 247 ± 0.5 mm (9.72 ± 0.02 in.)

Shock absorber spring preload adjustment

Proceed as follows:

1. Turn the rear xing (1) counter clockwise and remove the saddle, unscrew the retaining screws (2) and remove the right-hand side panel (3).

2. Clean lock ring nut (4) and adjuster ring nut (5) of the spring (6).

3. Either with a hook wrench or an aluminium punch, loosen the lock ring nut.

4. Turn the adjuster ring nut as required.

5. Adjust preload to suit your weight or riding style and tighten the lock ring nut rmly (tightening torque 50 Nm - 5 Kgm - 67.8 ft/lb).

6. Reassemble the R.H. side panel and the saddle.

Be careful not to touch hot exhaust pipe while adjusting the shock

absorber.

Page 56

D.26

TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA

TC 250R 2013 - TC 250R 2013 I.E. USA

TXC 250R - 310R 2013 I.E. USA

H09083

H09084

H09085

H09086

SETTINGS AND ADJUSTMENTS

Workshop Manual Ed. 07-2012

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;

- TC - TXC: 12 clicks;

- TC 250 USA: 10 clicks.

(adjuster 1)

2) High damping speed:

- TE: 1+1/2 turns;

- TC - TXC: 1+1/4 turns.

(adjuster 3)

To reset the standard setting, turn upper adjusters (1) and (3) clockwise until reaching fully closed position. Then turn them back the number of clicks / turns specied above. In order to obtain a smooth braking efciency, turn the adjusters counter clockwise. Vice versa to obtain a harder braking action.

B) REBOUND - Standard setting:

- 10 clicks (+1 / -2 clicks) To reset the standard setting, turn lower adjuster (2) clockwise until reaching fully closed position. Then turn it back by the mentioned clicks. In order to obtain a smooth braking action, turn the adjuster counter clockwise. Vice versa to obtain a harder braking action.

Shock absorber springs (4)

STANDARD K=5,2 kg/mm (TC - TXC) K=5,2 - 5,8 kg/mm (TE)

Page 57

D.27

TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA

TC 250R 2013 - TC 250R 2013 I.E. USA

TXC 250R - 310R 2013 I.E. USA

H09087

TC - TXC

H11259

TC-TXC

Workshop Manual Ed. 07-2012

SETTINGS AND ADJUSTMENTS

KAYABA front fork adjustment

- COMPRESSION (Fig. a)

(TC - TXC: TOP ADJUSTER; TE: LOWER ADJUSTER)

KAYABA: -9 clicks (TC EU - TXC); KAYABA: -12 clicks (TE); KAYABA: -10 clicks (TC 250 USA).

To reset the standard setting, turn cap nut (A) clockwise to reach the fully closed position; then, turn it back by the mentioned clicks. In order to obtain a smooth braking action, turn the adjuster counter clockwise. Vice versa to obtain a harder braking action.

- REBOUND (Fig. b)

(TC - TXC: LOWER ADJUSTER; TE: TOP ADJUSTER)

KAYABA: -13 clicks (TC EU - TXC); KAYABA: -8 clicks (TE); KAYABA: -12 clicks (TC 250 USA).

To reset standard setting, turn adjuster (C) clockwise to reach the fully closed position; then, turn it back by the mentioned clicks. In order to obtain a smooth braking action, turn the adjuster counter clockwise. Vice versa to obtain a harder braking action.

- BLEEDING (Fig. a/b) (to carry out after each competition, or monthly).

Set the motorcycle on a central stand, release the fork fully extended and loosen the bleed valve (D). Once this operation is over, tighten the valve.

NOTE: Never force the adjuster screws beyond the maximum open and

closed positions.

Page 58

D.28

TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA

TC 250R 2013 - TC 250R 2013 I.E. USA

TXC 250R - 310R 2013 I.E. USA

H09090

H09091

H11282

SETTINGS AND ADJUSTMENTS

Workshop Manual Ed. 07-2012

Steering bearing clearance adjustment

For safety reasons, the steering should always be adjusted so that the handlebar turns freely and without play. To check steering adjustment, set a stand or a block under the engine and see that the front wheel is lifted from the ground. Press lightly on the handlebar grips to cause the front end to rotate; the handlebar should turn smoothly. Sit on the ground in front of the front wheel and hold the lower ends of the fork legs. Push and pull in a front to rear motion to feel for play. If any play is detected, adjust as follows:

- Loosen the steering head tube nut (1);

- Loosen the four bolts (3) that secure the fork legs to the steering head; Turn the steering head tube ring nut (2) clockwise using the special key until achieving correct play adjustment;

- Tighten the steering head tube nut (1) to 8÷9 Kgm. (78.4÷88.3 Nm);

- Tighten the four bolts (3) on the steering head to 22.5-26.5 Nm (2.3-2.7 Kgm).

Steering angle adjustment

Steering angle can be modied by means of the adjuster assemblies located on either side of the steering head tube as follows: loosen the check nut (1), turn the adjuster screw (2) until setting the desired steering angle and then re-tighten the check nut (1). Make the same changes on both sides.

Page 59

D.29

TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA

TC 250R 2013 - TC 250R 2013 I.E. USA

TXC 250R - 310R 2013 I.E. USA

H09093

TE-TXC

H09092

H11284

H11103

H11283

Workshop Manual Ed. 07-2012

SETTINGS AND ADJUSTMENTS

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.

Remove saddle and side panels as described in Section "E". Remove the tank (1) retaining screw (2). Lift the tank (2) and check the hose (3) running from the pump (4) to the throttle body (5). To replace the hose, squeeze the two retainer tabs (6) at one end of the hose and detach hose. Repeat at the other end of the hose.

Page 60

D.30

TE 250R - 310R 2013 I.E. / TE 310R 2013 I.E. USA

TC 250R 2013 - TC 250R 2013 I.E. USA

TXC 250R - 310R 2013 I.E. USA

H11148

H11147

TE-TXC

H11145

H11285

TE-TXC

H11143

H11287

TE-TXC

SETTINGS AND ADJUSTMENTS

Workshop Manual Ed. 07-2012

Exhaust system check

Perform a visual inspection of the exhaust system rst, in order to identify possible gas leaks from the sealing elements (gaskets), and to ensure that the Silent-Blocks are not damaged.

Subsequently, inspect the single components by disassembling the exhaust system.

In addition to this, check the tightening of the screws (1) of the anges and the tightening of the screws (2) that strap the silencer to the respective supports.

The damaged or broken parts must be replaced.

Page 61

E.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

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

Section

Page 62

E.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 PROCEDURES

Workshop Manual Ed. 07-2012

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

Fuel tank, scoops and spoiler removal .......................................................E.12

Fuel pump removal (TC).............................................................................E.16

Fuel pump removal (TE – TXC) ..................................................................E.17

Start-up relay removal (TE-TXC) ................................................................E.18

Condenser .................................................................................................E.18

Electronic control unit removal CDI ............................................................E.19

Voltage regulator removal (TE-TXC) ..........................................................E.19

Voltage regulator removal (TC) ..................................................................E.20

Coil / Stick-Coil removal ............................................................................E.20

Clutch hose removal ...................................................................................E.21

Horn removal (TE) ......................................................................................E.21

Electric cooling fan removal (TE-TXC) .......................................................E.22

Secondary drive chain removal ..................................................................E.22

Removal of engine from motorcycle ...........................................................E.23

Radiator removal ........................................................................................E.28

Thermostat removal (TE-XC) .....................................................................E.29

Page 63

E.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

H11288

H11289

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

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.

RIGHT-HAND SIDE LEFT-HAND SIDE

Page 64

E.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

H10001

H10002

2 3

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

Saddle removal

- Turn the rear xing (1) counter clockwise and remove the saddle.

Side panel removal

- Remove the saddle as described in the relevant paragraph.

- Loosen the retaining screws (1) and remove the side panels (2) and (3).

Battery removal (TE-TCX)

- Remove the saddle as described in the relevant paragraph.

- First remove the BLACK negative cable (8 mm Allen wrench), then the RED positive cable (when reassembling, rst connect the RED positive cable, then the BLACK negative cable); remove the battery (1) from its housing.

Page 65

E.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

H00633

H10003

H10004

H10005

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

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.

- Lift the tank at the rear end.

- Disconnect the air temperature sensor (1).

- Remove the exhaust silencer as described in the relevant para-

graph.

- Slacken clamp (2) that secures the rubber coupling of the air box (3) to the throttle body.

- Remove the upper xing (4) and lower xings (5) on both sides of the rear chassis using a 10 mm ring wrench.

- Pull the rear chassis (6) rearwards together with mudguard and air box, and detach it from the main chassis.

Rear chassis with mudguard and air box removal (TE-TXC)

- Remove the following parts in the order given: saddle, side panels, fuel tank, silencer and battery (see relevant paragraphs for instructions).

- Shear the plastic clips securing wiring to rear chassis.

- Disconnect the connector (1) of the turning indicator relay (2) (TE).

- Remove the solenoid starter (3) from its mount.

Page 66

E.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

H00621

H11290

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

- Disconnect the connector (4) of the tail light unit (TE).

- Detach relays (5) and fuses (6) on the right-hand side of the motorcycle.

- Detach the breather hose (7) from the air lter (8).

Page 67

E.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

H11291

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

- Unscrew the clamp (9) connecting air lter (8) to throttle body (10).

- Remove the four screws (11) of the rear chassis (12) using a 10 mm ring wrench.

- Pull the rear chassis (12) rearwards together with mudguard and air box , and detach it from the main chassis.

Page 68

E.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

H10966

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

Exhaust system removal

Key:

Silencer

2) Spring

3) Exhaust manifold

4) Flange

5) Nozzle

6) Protection

Page 69

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TXC 250R - 310R 2013 I.E. USA

H11292

TE-TXC

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

Key:

1) Silencer

2) Spring

3) Exhaust manifold

4) Front protection

5) Rear protection

6) Catalyst

Page 70

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TXC 250R - 310R 2013 I.E. USA

H10010

TE-TXC

H11464

H10008

H11293

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

- 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).

- Remove the spring (2) and the screw (3) using an 8 mm T-wrench; slide out the silencer (4).

- Disconnect the Lambda sensor connector (7) and shear the wiring clips (TETXC).

Page 71

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TXC 250R - 310R 2013 I.E. USA

H10011

TE-TXC

H10012

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

(TE-TXC)

- Loosen the two bolts (5) and remove the exhaust pipe (6).

(TC)

- Detach springs (7) and remove exhaust pipe (6).

Page 72

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H10013

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

Fuel tank, scoops and spoiler removal

Page 73

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H00630

H10014

TE-TXC

H10015

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

- Remove the saddle as described in the relevant paragraph.

- Remove the side panels as described in the relevant paragraph.

- Remove the breather hose (1).

- Loosen the fuel tank retaining screw (2).

Page 74

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H02212

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

- 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

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H10020

TE-TXC

H10018

TE-TXC

H10019

TE-TXC

H02216

H10016

H10017

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

Carefully disconnect the fuel hoses from the throttle body or from

the fuel pump to prevent damage to the quick coupling.

(TC)

- Disconnect the fuel hose (7) from the throttle body.

- Lift the tank and disconnect the fuel pump connector (8) from the main wiring harness.

(TE-TXC)

- Close the two taps (7) and (8) and connect the hose (9).

- Disconnect connector (6) of the reserve sensor.

- Lift the tank and disconnect the hose (10) from the fuel pump outlet tting (11) in the bottom section of the tank.

- Disconnect the fuel pump connector (12) from the main wiring harness.

- Slide out the tank (13).

Page 76

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H00648

H02339

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

Fuel pump removal (TC)

- Remove the fuel tank as described in the relevant paragraph.

- Remove the tank ller cap and pour the fuel contained in the tank into a ves-

sel of adequate capacity.

- Use an Allen wrench to loosen the 6 screws (1) and remove the pump (2).

On assembly, make sure that the pump O-ring (3) is correctly po-

sitioned in its seat.

Page 77

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H02340

H02341

H02342

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

Fuel pump removal (TE – TXC)

- Remove the fuel tank as described in the relevant paragraph.

- Remove the tank ller cap and pour the fuel contained in the tank into a vessel of adequate capacity.

- Make use of a 10 mm wrench to slacken the 4 screws (1) of the pump ange (2) and the four screws (3) of the tting ange (4).

- Slide the tting ange (4) out of the tank, then remove the delivery and return hoses by releasing the quick ttings (5) and (6).

- Disconnect the pump supply connector (7).

- Slide the pump (2) with relevant small hoses out of the tank.

NOTE: To ret the pump follow the removal reverse procedure and make

sure that the seals under the anges (2) and (4) are not worn.

Page 78

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H10021

H11106

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

Start-up relay removal (TE-TXC)

- Remove saddle and left-hand side panel (in this order) as outlined in the relevant paragraphs.

- Disconnect the negative and positive cables of the battery.

- Disconnect the starter motor positive cable (1) from the solenoid starter.

- Disconnect the connector (2) and remove the solenoid starter (3) from its

mount.

Condenser

This operation must be performed with a cool engine.

- Cut the clamp (1) and disconnect the connector (2).

- Pull outwards the condenser (3) so that it comes out of the supporting bracket (4).

Page 79

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H11294

H11295

H11296

H11297

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

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).

Voltage regulator removal (TE-TXC)

- Disconnect the connectors (1) and (2).

- Loosen the two retaining screws (3) and remove the regulator (4).

Page 80

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H11112

H11113

H11109

H11110

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

Voltage regulator removal (TC)

- Remove the fuel tank as described in the relevant paragraph.

- Disconnect the connector (1).

- Loosen the two screws (2) and remove the voltage regulator (3).

Coil / Stick-Coil removal

- With an 8-mm wrench loosen the screws (2), then remove the oater needle (1).

- Disconnect the connector (3) and remove the coil / Stick-Coil (4).

- During the reassembly, pay attention to the positioning of the gasket (5) with respect to the plate (1).

Page 81

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TXC 250R - 310R 2013 I.E. USA

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

Clutch hose removal

- Loosen the tting (1) of the clutch hose (2) on the left-hand of the engine.

- Drain any oil left in the hose. On assembly, bleed the clutch system as de-

scribed in Section "P".

Horn removal (TE)

- Remove saddle and fuel tank (in this order) as outlined in the relevant para-

graphs.

- Loosen the screw (1) securing the spoiler to the right-hand radiator.

- Disconnect the two connectors (2) and remove the horn (3) with its bracket.

Page 82

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TXC 250R - 310R 2013 I.E. USA

H11299

H02226

H11298

H11300

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

Electric cooling fan removal (TE-TXC)

- Remove saddle, fuel tank and scoops (in this order) as outlined in the relevant paragraphs.

- Disconnect the connector (1).

- Loosen the screw (2) and remove the electric fan (3).

Secondary drive chain removal

The following procedure applies to both O-ring chains and chains without O-rings:

- Remove: screws (1), sprocket guard (2), clip (3), master link (4) and chain (5).

Page 83

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TXC 250R - 310R 2013 I.E. USA

H11301

H11302

H11303

H11304

TE - TXC

H11305

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

Removal of engine from motorcycle

- Remove the saddle as described in the relevant paragraph.

- Remove the side panels as described in the relevant paragraph.

- Remove the fuel tank as described in the relevant paragraph.

- Remove the exhaust system as described in the relevant paragraph.

- Remove the engine guard as outlined in the respective section.

- Loosen the two screws (1) of the intake manifold (2) by removing the throttle body (3) from the head.

- Remove the connector (4) of the coil / Stick-Coil.

- Disconnect the connector (5) of the generator.

Page 84

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H10040

H02345

H11306

H11307

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

- Place a vessel on the left-hand side of the cylinder, under the engine.

- Slacken the radiator cap (8).

- Slacken the clamp (11) and disconnect the hose (12) connecting the radiators to the engine. Drain all uid.

- Slacken the clamp (13) and disconnect the hose (14) connecting the radiator to the water pump.

TE 310

- Due to the blow-by circuit structure, engine oil must be drained in the TE

310 version.

For the oil draining operation, follow the instructions outlined in the respec-

tive section.

- Disconnect the connector (17) from the coil / Stick-Coil.

- Open the clamp (18) and detach the small blow-by tube (19) from the cylinder head cover.

- Remove the chain as described in the relevant paragraph.

- Remove the chain guide plate (20) unscrewing the screw (21) with an 8 mm wrench.

Page 85

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TXC 250R - 310R 2013 I.E. USA

H02231

H11308

H11309

TE - TXC

H11310

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

- Loosen the three screws (22) and remove the clutch actuator (23).

- Remove the clip (24) that holds clutch hose and wiring harness together.

- Remove the water temperature sensor connector (25).

- Remove the ground cables (26) (TE-TXC).

Page 86

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TXC 250R - 310R 2013 I.E. USA

H11313

H11311

TE-TXC

H11312

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

- Remove the positive power supply cable (27) of the starter motor (TE-TXC).

- To remove the brake lever (28), use an 8 mm wrench to loosen the master cylinder linkage (29) and a 6 mm Allen wrench to loosen the central screw (34). Remove the lever.

- Loosen the upper retaining screw (31) of the shock absorber (32) with a 14 mm wrench.

Page 87

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TXC 250R - 310R 2013 I.E. USA

H11314

H11315

H11316

H11317

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

- Remove the guards (33) on both sides shearing the clips (34).

- Remove the engine mounting bolts (35) using a 12 mm wrench on the lefthand side and a 10 mm wrench on the right-hand side.

- Loosen the swinging arm axle nut (36) using a 22 mm wrench; pull out the axle (37) from the right-hand side of the engine and pull the swinging arm rearwards to facilitate engine removal.

- Lift the engine, tilt it to the left and remove it from the motorcycle.

- Place the engine on a rotating stand to perform the procedures described in Sections F-G-H.

Page 88

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H00685

H00687

H11318

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

Radiator removal

- Remove the fuel tank together with scoops and spoilers as outlined in the relevant paragraphs.

- Remove the electric cooling fan (TE – TXC) as described in the relevant

paragraph.

- Place a pan under the hose (1) to collect coolant, then loosen the clamp (2), detach the hose (1) and drain all coolant.

- Loosen the clamp (3) and disconnect the hose (4) from the left-hand radiator (5).

- Loosen the clamp (6) and disconnect the hose (7) from the right-hand radiator (8).

- Remove the plastic grids (9) from the radiators.

- Remove the clamp (10) and disconnect the radiator connecting hose (11).

Page 89

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H11319

GENERAL PROCEDURES

Workshop Manual Ed. 07-2012

- Loosen the screws (12) and remove the left-hand radiator (5).

- Loosen the screws (13) and remove the right-hand radiator (8).

Thermostat removal (TE-XC)

- Remove the fuel tank and the left-hand spoiler as outlined in the relevant paragraph.

- Loosen the three clamps (1) securing the thermostat (2).

- Disconnect the hoses (3) and remove the thermostat (2).

Page 90

Page 91

F.1

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TC 250R 2013 - TC 250R 2013 I.E. USA

TXC 250R - 310R 2013 I.E. USA

ENGINE DISASSEMBLY

Workshop Manual Ed. 07-2012

Section

Page 92

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TXC 250R - 310R 2013 I.E. USA

ENGINE DISASSEMBLY

Workshop Manual Ed. 07-2012

Sommario

Layout of engine components (TE - TXC) .................................................... F.3

Layout of engine components ...................................................................... F. 4

Cylinder head cover removal ........................................................................ F.5

Camshaft removal ....................................................................................... F. 6

Water pump body removal ........................................................................... F. 8

Water pump disassembly ............................................................................. F.9

Cylinder head removal................................................................................ F.10

Valve removal ............................................................................................ F.14

Cylinder removal......................................................................................... F.16

Piston removal ............................................................................................ F.16

Flywheel removal........................................................................................ F.17

Kick start pedal removal ............................................................................. F.18

Sprocket removal........................................................................................ F.18

Oil lter removal.......................................................................................... F.19

Clutch cover removal .................................................................................. F.20

Clutch disassembly..................................................................................... F.21

Slider removal............................................................................................. F.24

Kick start disassembly ................................................................................ F.24

Starter motor removal (TE-TXC) ................................................................ F.26

Starter motor disassembly (TE-TXC) ......................................................... F.28

Starter drive disassembly (TE-TXC) ........................................................... F.28

Oil pump disassembly ................................................................................ F.31

Gear shift pedal and selector assembly removal........................................ F.32

Primary drive gear removal ........................................................................ F.34

Crankcase disassembly.............................................................................. F.35

Gearbox disassembly ................................................................................. F.36

Crankshaft disassembly ............................................................................. F.38

Page 93

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TXC 250R - 310R 2013 I.E. USA

H11320

H11321

ENGINE DISASSEMBLY

Workshop Manual Ed. 07-2012

Layout of engine components (TE - TXC)

1 Sprocket

2 Cylinder head cover 3 Cylinder head 4 Chain tensioner 5 Cylinder

6 Starter motor 7 Head lubrication pipe 8 Oil lter 9 Clutch cover

10 Kick start lever

11 Water pump

12 Alternator cover

Page 94

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TXC 250R - 310R 2013 I.E. USA

H10973

H11114

ENGINE DISASSEMBLY

Workshop Manual Ed. 07-2012

Layout of engine components

1 Cylinder head cover 2 Cylinder head 3 Chain tensioner 4 Cylinder

5 Head lubrication pipe 6 Oil lter

7 Clutch cover

8 Kick start lever 9 Water pump

10 Alternator cover

11 Coolant temperature thermostat

Page 95

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TXC 250R - 310R 2013 I.E. USA

H11322

ENGINE DISASSEMBLY

Workshop Manual Ed. 07-2012

Cylinder head cover removal

- Remove the four retaining screws (1) and remove the head cover (2) with its gasket.

Page 96

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TXC 250R - 310R 2013 I.E. USA

H10980

H10981

H11149

H10989

H10990

ENGINE DISASSEMBLY

Workshop Manual Ed. 07-2012

Camshaft removal

- Remove the six retaining screws (1) of the alternator cover (2) (4 mm Allen wrench) and remove the cover with its gasket.

- With a 17mm wrench, position the piston on the TDC at the end of the compression phase. In this condition, the two engraved reference marks (3) on the gears of the camshafts are positioned on the same axle although they are diametrically opposed.

INTAKE OUTLET

Page 97

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TXC 250R - 310R 2013 I.E. USA

H10982

H10983

H10984

H10985

ENGINE DISASSEMBLY

Workshop Manual Ed. 07-2012

- Remove the spark plug (4) (16 mm wrench) and the head lubrication pipe (5) loosening the drilled screw (6) (12 mm wrench).

- Remove the bushing (7) from the spark plug recess.

When you ret the bushing (7) make sure not to damage the O-Ring

(8).

- Loosen the screws (9) with a 5-mm wrench, and remove the mount (10).

Page 98

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H10987

H11323

ENGINE DISASSEMBLY

Workshop Manual Ed. 07-2012

- Remove the intake camshaft (11) and the exhaust camshaft (12).

Water pump body removal

- Remove the four screws (1) securing pump body (2) to head (4 mm Allen wrench) and remove pump body.

Page 99

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H11325

H11326

H11324

ENGINE DISASSEMBLY

Workshop Manual Ed. 07-2012

Water pump disassembly

- Loosen the screw (1) to disassemble the pump.

- Loosen the impeller (3) and remove it.

- Remove the oil seal (4), remove the seeger (7) and remove the gear (5). Remove the seeger (9) and remove the bearing (6).

During the ret, make sure that the centring plugs (8) are correctly

positioned in their own seat. Make also sure the pump gear (5) and the camshaft gear are correctly timed.

Page 100

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TXC 250R - 310R 2013 I.E. USA

H11327

H11328

H11329

ENGINE DISASSEMBLY

Workshop Manual Ed. 07-2012

Cylinder head removal

- Remove the head cover as described in the relevant paragraph.

- Remove the camshafts as described in the relevant paragraph.

- Remove the chain tensioner (1) as follows:

• Loosen the screw (2) with an 8 mm wrench.

• Turn the screw (3) fully clockwise with a at head screwdriver until locking it so as to release the spring.

• Loosen the two screws (4) using an 8 mm wrench and remove the chain tensioner (1).