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C.2
TROUBLESHOOTING
Ed. 07-2010
ENGINE
Trouble
Cause
Remedy
Engine does not start or
Insufficient 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 - TXCi)
Replace
Engine stalls
1. Fouled spark plug
Clean
easily
2. Electronic control unit faulty
Replace
3. Carburettor jets clogged
Clean
4. Low idle
Adjust
Engine is noisy
Noise seems to come from piston
1. Too much piston-to-cylinder clearance
Replace
2. Worn piston rings or piston grooves
Replace
3. Too much carbon build-up in
combustion chamber or on piston crown
Clean
4. Valve clearances too large
Adjust
5. Weak or seized valve springs
Replace
6. Worn timing chain
Replace
7. Incorrect timing chain tension
Adjust
Noise seems to come from crankshaft
1. Worn main bearings
Replace
2.
Connecting rod big end has too much side clearance or end float
Replace
3. Crankshaft gear damaged
Replace
4. Crankshaft locknut loose
Tighten
Noise seems to come from the clutch
1. Worn plates
Replace
2. Too much clearance between clutch housing and friction plates
Replace
Noise seems to come from gearbox
1. Worn gears
Replace
2. Worn gear grooves
Replace
Noise seems to come
1. Chain stretched (worn) or improperly adjusted
Replace or adjust
from secondary drive
2. Worn transmission sprocket and rear chain sprocket
Replace
chain
Summary of Contents for TC 250 2011
Page 6: ......
Page 7: ...b 1 b IMPORTANT NOTICES Ed 07 2010 Section ...
Page 9: ...A 1 A GENERAL INFORMATION Ed 07 2010 Section ...
Page 16: ......
Page 17: ...B 1 B MAINTENANCE Ed 07 2010 Section ...
Page 24: ......
Page 25: ...C 1 C TROUBLESHOOTING Ed 07 2010 Section ...
Page 30: ......
Page 31: ...D 1 D SETTINGS AND ADJUSTMENTS Ed 07 2010 Section ...
Page 33: ...D 3 H02176 TC H02177 TE H02178 TXCi SETTINGS AND ADJUSTMENTS Ed 07 2010 ...
Page 62: ......
Page 63: ...E 1 E GENERAL PROCEDURES Ed 07 2010 Section ...
Page 70: ...E 8 H02338 TE TXCi H02205 TC GENERAL PROCEDURES Ed 07 2010 Exhaust system removal ...
Page 93: ...F 1 F ENGINE DISASSEMBLY Ed 07 2010 Section ...
Page 130: ......
Page 131: ...G 1 G ENGINE OVERHAUL Ed 07 2010 Section ...
Page 151: ...H 1 H ENGINE REASSEMBLY Ed 07 2010 Section ...
Page 162: ...H 12 ENGINE REASSEMBLY Ed 07 2010 Assembly and lubrication instructions RIGHT CRANKCASE COVER ...
Page 166: ...H 16 ENGINE REASSEMBLY Ed 07 2010 Input shaft Output shaft ...
Page 169: ...H 19 ENGINE REASSEMBLY Ed 07 2010 Input shaft Output shaft ...
Page 206: ......
Page 207: ...I 1 I FRONT SUSPENSION Ed 07 2010 Section ...
Page 209: ...I 3 H02176 TC H02177 TE H02178 TXCi FRONT SUSPENSION Ed 07 2010 ...
Page 234: ......
Page 235: ...J 1 J REAR SUSPENSION Ed 07 2010 Section ...
Page 253: ...L 1 L BRAKES Ed 07 2010 Section ...
Page 263: ...M 1 M ELECTRICAL SYSTEM Ed 07 2010 Section ...
Page 305: ...M 43 TE H00973 H02324 TXCi ELECTRICAL SYSTEM Ed 07 2010 Wiring TE TXCi ...
Page 317: ...N 1 N ENGINE COOLING Ed 07 2010 Section ...
Page 324: ......
Page 325: ...P 1 P HYDRAULICALLY CONTROLLED CLUTCH Ed 07 2010 Section ...
Page 331: ...S 1 S FUEL INJECTION SYSTEM Ed 07 2010 Section ...
Page 340: ......
Page 341: ...W 1 W SPECIAL TOOLS Ed 07 2010 Section ...
Page 353: ...Y 1 Y CHASSIS AND WHEELS Ed 07 2010 Section ...
Page 366: ......