Husqvarna 2009 TC 250, Workshop Manual, Page: 220 / 420

H.58 Part. N. 8000 H1489 (10-2009)
ENGINE REASSEMBLY
Installing the engine and assembling the motorcycle
Install the engine and any parts you had removed in the order given below.
Place the engine in the chassis.
Insert the swinging arm shaft from the right-hand side and tighten its nut using
a 22 mm wrench (122.5 Nm, 12.5 Kgm, 90.3 ft/lb).
Tighten the engine mounting bolts to the frame using a 12 mm wrench on the
left-hand side and a 10 mm wrench on the right-hand side (35.3 Nm, 3.6 Kgm,
26 ft/lb).
Install the drive chain (fit the master link clip by setting the closed side facing
the chain direction of rotation).
Install the clutch control on the engine and tighten the fitting with an 8 mm wrench
(8 Nm, 0.8 Kgm, 5.8 ft/lb). Add clutch fluid.
On the left-hand side, use an 8 mm wrench to install the chain guide plate (8 Nm,
0.8 Kgm, 5.8 ft/lb). Fit the transmission sprocket cover and tighten its screws
using a 6 mm wrench (10.4 Nm, 1 Kgm, 7.7 ft/lb).
Fit the spark plug cap to the spark plug. Install the rubber hose on the right-hand
side of the cylinder head cover.
Refit the oil sump guard if you had removed it (14.7 Nm, 1.5 Kgm, 10.8 ft/lb).
Refit the coolant hoses with their clamps.
Refit the rear brake pedal with its bolt (41.6 Nm, 4.2 Kgm, 30.7 ft/lb + Loctite
243).
Refit the side guards of the chassis.
Refit the carburettor.
Refit the exhaust system (pipe retaining screws: 10.4 Nm, 1Kgm, 7.7 ft/lb) (exhaust
pipe retaining screws: use an 8 mm wrench , 8.4 Nm, 0.8 Kgm, 5.8 ft/lb).
Refit the fuel tank together with the scoops.
Refit the fuel tank front retaining screw (10.4 Nm, 1Kgm, 7.7 ft/lb) and hook up
the scoops to the spoilers on the radiators.
Refit the breather hose of the fuel tank plug on the steering stem. Refit the hose
running from fuel tank to carburettor.
Refit the side panels with their retaining screws.
Refit the saddle and secure it with its rear fixing.
NOTES
1) Unless otherwise specified, standard torque values for the different thread
sizes are as follows
M5x0.8 (5.6-6.2 Nm; 0.57-0.63 Kgm; 4.1-4.5 ft/lb)
M6x1 (7.6-8.4 Nm; 0.80-0.85 Kgm; 5.8-6.1 ft/lb)
M8x1.25 (24-26 Nm; 2.4-2.6 Kgm; 17.3-18.8 ft/lb)
2) For electrical connections, see relevant diagram included in Section M.
3) Bleed the clutch (see Section P).
4) Add 0.9 l of CASTROL POWER 1 RACING oil (10W-50) to the crankcase.
5) Add 1.1-1.3 l of AGIP COOL fluid to the right radiator.
6) Check that the kick start pedal moves freely.
7) Perform the necessary adjustments as outlined in Section D "Settings and
adjustments".