Husqvarna 2009 TC 250, Workshop Manual, Page: 156 / 420

G.20 Part. N. 8000 H1489 (10-2009)
ENGINE OVERHAUL
Shifter forks and gears
Visually inspect the shifter forks (1) and replace any bent forks. A bent fork will
make gears hard to engage or let the transmission jump out of gear unexpect-
edly under loading.
Check the clearance of the each shifter fork in its gear groove using a feeler
gauge. If any one of the three gears is outside the service limit, measure the
width of gear groove and fork thickness to determine which component needs
to be replaced. Shifter fork to groove clearance (new fork and gear): 0.22 - 0.37
mm (0.008661 - 0.014566 in.)
Service limit: 0.5 mm (0.019685 in.).
Selector drum
Check the grooves "A" for wear or dents and make sure the selector drum is not
bent, worn or damaged.
Drive bushing roundness
Check the drive bushings (1) of the shifter forks for out-of-round and make sure
they slide freely in the drum grooves and on the selector shaft.