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Husqvarna TC 250 2012 I.E. USA, Workshop Manual

The Husqvarna TC 250 2012 I.E. USA is a powerful and reliable dirt bike designed for thrilling off-road adventures. To ensure its optimal maintenance and performance, a comprehensive Workshop Manual is available for download, absolutely free, from our website. Get the most out of your TC 250 with this essential manual.

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TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA

TC 250 2012 - TC 250 2012 I.E. USA

TXC 250 - 310 2012 I.E. USA

TROUBLESHOOTING

Workshop Manual  Ed. 12-2011

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 - TXC) 

Replace

Engine stalls 

1.  Fouled spark plug  

Clean

easily 

2.  Electronic control unit faulty 

Replace

 

3.  Carburettor jets clogged 

Clean

 

4.  Low idle 

Adjust

Engine is noisy 

Noise seems to come from piston

 

1.  Too much piston-to-cylinder clearance 

Replace

 

2.  Worn piston rings or piston grooves 

Replace

 

3.  Too much carbon build-up in 

 

  combustion chamber or on piston crown 

Clean

 

4.  Valve clearances too large 

Adjust

 

5.  Weak or seized valve springs 

Replace

 

6.  Worn timing chain 

Replace

 

7.  Incorrect timing chain tension 

Adjust

 

Noise seems to come from crankshaft

 

1.  Worn main bearings 

Replace

 

2.  Connecting rod big end has too much side clearance or end 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 2012 I.E. USA

Page 1: ...TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA Workshop Manual Ed 12 2011 Rev 02 ...

Page 2: ...05 2012 D 29 Correction values KAYABA front fork adjustment Compression and Re bound 02 03 05 2012 D 29 Correct drawing from H11102 to H11259 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 reflect on going product development Illustrations in the manual may differ from actual components No reproducti...

Page 3: ...00001 TE 310 USA ZKHKCEDG CV000001 TC 250 ZKHA300AACV050001 TC 250 USA ZKHTC253 CV000001 TXC 250 USA ZKHTX253 CV000001 TXC 310 USA ZKHTX313 CV000001 Workshop Manual Ed 12 2011 FOREWORD TABLE OF CONTENTS 1st edition 12 2011 Rev 02 Printed in Italy MODELS COVERED from serial number onwards Copyright by HUSQVARNA MOTORCYCLES S R L BMW Group Technical Service Via Nino Bixio 8 21024 Varese Italy tel 39...

Page 4: ...mmendations 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 specific training available through HUSQVARNA held at regular periods plan ahead before s...

Page 5: ...ces 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 figures X Chassis and wheels Y NOTES Unless otherwise spec...

Page 6: ...M 4 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ELECTRICAL SYSTEM Workshop Manual Ed 12 2011 ...

Page 7: ...b 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA b Workshop Manual Ed 12 2011 IMPORTANT NOTICES Section ...

Page 8: ... top performance when riding solo We advise against riding two up whether off road or on the track ALWAYS remember that these motorcycles are specifically designed for racing i e for usage conditions significantly different from those experienced in regular road use IMPORTANT VEHICLE CONFIGURATION as outlined below is a prerequisite for the war ranty to remain valid A STANDARD MOTORCYCLE FOR ROAD ...

Page 9: ...A 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA A Workshop Manual Ed 12 2011 GENERAL INFORMATION Section ...

Page 10: ...A 3 Primary drive A 3 Clutch A 3 Transmission A 4 Transmission ratio TE TXC A 4 Transmission ratio TC A 4 Secondary drive A 4 Final ratios TE TXC A 4 Final ratios TC A 4 Frame A 4 Front suspension A 4 Rear suspension A 4 Front brake A 4 Rear brake A 5 Rims A 5 Tires A 5 Cold tire pressure A 5 Electrical components location TC A 5 Electrical components location TXC A 5 Electrical components locatio...

Page 11: ... a radial arrangement operated through bowls by two overhead camshafts driven by a combined chain gears system TC Type 4 titanium valves controlled by twin finger follower type camshafts mixed chain gear drive sys tem Valve clearance with engine cold Intake 0 15 mm 0 006 in Exhaust 0 20 mm 0 008 in Lubrication Type wet crankcase lobe pump and cartridge and mesh filters Ignition Type Electronic ind...

Page 12: ...TXC Z 13 Z 50 TE Z 13 Z 40 Transmission ratio TC TXC 3 846 TE 3 076 Final ratios TE TXC 1st gear 20 944 2nd gear 17 104 3rd gear 14 172 4th gear 11 995 5th gear 10 181 6th gear 7 964 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 Upsid...

Page 13: ...s Generator on the inner side of L H crankcase half cover Electronic ignition coil under the fuel tank Electronic control unit under the fuel tank Spark plug on cylinder head M A Q S sensor Condenser on the left of rear chassis Electrical components location TXC The ignition system includes the following elements Generator on the inner side of L H crankcase half cover Electronic ignition coil unde...

Page 14: ...cludes the following elements Generator on the inner side of L H crankcase half cover Electronic ignition coil under the fuel tank Electronic control unit under the fuel tank Voltage regulator under the fuel tank Spark plug on cylinder head 12V 450W starter motor behind the engine cylinder Solenoid starter on the left of rear chassis M A Q S sensor pressure throttle position air temperature on thr...

Page 15: ...hts on right side of chassis Electric fan Two 15A fuses and one 20A fuse on right side of rear chassis Coolant temperature sensor Lambda sensor Headlamp with 12V 35W twin halogen bulb and 12V 3W parking light bulb LED tail light with stop light bulb 12V 10W turning indicator bulbs Fuel pump inside the fuel tank Odometer Overall dimensions Wheelbase A TE TXC mm 1460 57 47 in TC mm 1470 57 87 in Ove...

Page 16: ...00 cc 54 92 in3 oil change and oil filter replacement 850 cc 51 87 in3 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 C...

Page 17: ...B 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA B Workshop Manual Ed 12 2011 MAINTENANCE Section ...

Page 18: ...h 80 h AS REQUIRED VALVES C C S VALVE SPRINGS C X VALVE SPRING RETAINERS VALVE COLLETS C X VALVE BUCKETS C X CAMSHAFT C TIMING CHAIN C S TIMING CHAIN SLIDER C S TIMING DRIVEN GEAR C X TIMING DRIVE GEAR C X TIMING CHAIN TENSIONER C INTAKE MANIFOLD AND CLAMPS C S COMPLETE CYLINDER C S C X COMPLETE PISTON S C S COMPLETE CONNECTING ROD S CRANKCASE BEARINGS S ENGINE OIL S C S OIL PUMP C OIL FILTER MESH...

Page 19: ... h AS REQUIRED KICK START PEDAL L GEAR SHIFT PEDAL C SPARK PLUG P S SPARK PLUG CAP C AIR FILTER P L RADIATORS C WATER HOSES AND CLAMPS C RADIATORS TO WATER PUMP HOSE C COOLANT C X FOOTPEGS PINS SPRINGS C X REAR CHASSIS MNTG BOLTS ENGINE MNTG BOLTS C C SIDE STAND C CHAIN GUIDE ROLLER BEARINGS C STEERING HEAD BOTTOM YOKE WITH STEM L FRONT FORK R HANDLEBAR MOUNTS AND FASTENERS C C REAR SWINGING ARM B...

Page 20: ...250 TXC TE 310 RACING MOTORCYCLE FOR RACING USE FULL POWER RATING SERVICE SERVICE SERVICE SERVICE SERVICE COUPON COUPON COUPON COUPON COUPON PART AFTER FIRST EVERY EVERY EVERY EVERY EVERY REPLACE 3 HOURS 8 h 16 h 32 h 64 h 80 h AS REQUIRED 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 X MASTER CYLINDER TO BR...

Page 21: ...D CLAMPS C C S X COMPLETE CYLINDER C X COMPLETE PISTON S COMPLETE CONNECTING ROD S CRANKCASE BEARINGS S ENGINE OIL AND OIL FILTER S S S OIL PUMP C OIL FILTER MESH FILTER S P S P OIL PUMP TO CRANKCASE OIL FEED C PRIMARY DRIVE GEAR PAIR C X CLUTCH HUB C X CLUTCH PLATES C S X CLUTCH PRESSURE PLATE C CLUTCH SPRINGS C X CLUTCH PUSHROD C TRANSMISSION SPROCKET C S STARTER GEARS C X SCHEDULED MAINTENANCE ...

Page 22: ...NG HEAD BOTTOM YOKE WITH STEM L FRONT FORK R HANDLEBAR MOUNTS WITH FASTENERS C C REAR SWINGING ARM BUSHING C REAR CHAIN SLIDER C C X REAR SUSPENSION LINKAGE BUSHINGS C X CHAIN GUIDE CHAIN GUARD C C X ROLLER CAGES LINKAGE PINS OF REAR SUSP L REAR SHOCK ABSORBER C COMPLETE THROTTLE CONTROL C L COMPLETE CLUTCH CONTROL C R THROTTLE CABLES C L X FRONT BRAKE DISC C X FRONT BRAKING SYSTEM FLUID C S SCHED...

Page 23: ...DEADENING MATERIAL X EXHAUST PIPE AND SILENCER C X WHEEL SPOKE TENSION C C WHEEL HUB BEARINGS C X REAR CHAIN SPROCKET S SPROCKET BOLT TIGHTENING C C C SECONDARY DRIVE CHAIN C L C L S TORQUE OF NUTS AND BOLTS C C SCHEDULED MAINTENANCE CHART TO BE CARRIED OUT AT THE HUSQVARNA DEALER AFTER FIRST 1000 KM PART REPLACE AS REQUIRED EVERY 5000 KM EVERY 10000 KM LEGEND S REPLACE C CHECK CHECK CLEARANCE P C...

Page 24: ...PON SERVICE COUPON AIR FILTER P L REAR CHASSIS MNTG BOLTS ENGINE MNTG BOLTS C WHEEL SPOKE TENSION C SPROCKET BOLT TIGHTENING C TORQUE OF NUTS AND BOLTS C COOLANT C X BRAKE PADS C X REAR CHAIN SPROCKET C X HANDLEBAR MOUNTS AND FASTENERS C REAR SWINGING ARM BUSHING L REAR SUSPENSION LINKAGE BUSHINGS L CHAIN GUIDE CHAIN GUARD C X SWINGING ARM AXLE ROLLER CAGES L ROLLER CAGES LINKAGE PINS OF REAR SUSP...

Page 25: ...ERVICE COUPON SERVICE COUPON COMPLETE CLUTCH CONTROL R THROTTLE CABLES C X FRONT BRAKING SYSTEM FLUID S REAR BRAKING SYSTEM FLUID S MASTER CYLINDER TO BRAKE CALLIPER HOSES C X WHEEL HUB BEARINGS C ENGINE OIL AND FILTER S PLUG S VALVES C S Valve springs rocker arms and plates C TIMING CHAIN TIMING CHAIN SLIDER C Timing chain gears C TIMING CHAIN TENSIONER C OIL PUMP C X Crankshaft oil seals S PISTO...

Page 26: ......

Page 27: ...C 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA C Workshop Manual Ed 12 2011 TROUBLESHOOTING Section ...

Page 28: ...ls 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 val...

Page 29: ... 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 filter Clean 2 Poor fuel quality Replace 3 Intake coupling loose Tighten 4 Spark plug electrode gap too wide Adjust 5 Insufficient compression Identify cause 6 Incorrect valve clearan...

Page 30: ...Improperly set rear shock absorber Adjust Damping is 1 Insufficient 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 ...

Page 31: ...mended 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...

Page 32: ......

Page 33: ...D 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA D Workshop Manual Ed 12 2011 SETTINGS AND ADJUSTMENTS Section ...

Page 34: ... 17 Engine oil replacement and mesh filters filter cartridge cleaning or replacement D 18 Coolant level check D 19 Coolant replacement D 19 Air filter check TC D 20 Air filter check TE TXC D 21 Air filter cleaning D 21 Assembly D 22 Secondary drive chain adjustment D 23 Chain lubrication D 24 Disassembling and cleaning D 24 Washing a chain without O rings TC D 24 Lubricating a chain without O ring...

Page 35: ...D 3 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA H09056 TE H09057 TXC H09058 TC Workshop Manual Ed 12 2011 SETTINGS AND ADJUSTMENTS ...

Page 36: ...ockwise 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 throt tle 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 con...

Page 37: ... TE H09060 TC 7 H09061 TC 8 9 Workshop Manual Ed 12 2011 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 fitting 9 on the fuel pump located in the rear bottom section of the tank Remove the tank 10 together with the scoops ...

Page 38: ...the positions shown Cover parting line A is visible through the holes 4 Use a feeler gauge to make sure clearance is 0 15 mm on the INTAKE side and 0 20 mm on the EXHAUST side If not so remove the shim from under the valve bucket and measure its thick ness Depending on what you find replace the shim with a new shim with the required thickness to achieve correct clearance replacement shims are avai...

Page 39: ...justment TC 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 refitting 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...

Page 40: ... 10 SETTINGS AND ADJUSTMENTS Workshop Manual Ed 12 2011 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 41: ...from under the valve bucket and measure its thick ness Depending on what you find 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 refit the parts you have removed reversing the disassembly procedure For camsha...

Page 42: ...m 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 desc...

Page 43: ...on Proceed as follows TE TXC turn the idle speed adjuster screw 1 located on the throttle body on the right hand side of the vehicle until setting idle speed to 1 950 RPM turn clockwise to increase the speed and counterclockwise to reduce it TC turn the knob 2 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...

Page 44: ... 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 45: ...clutch lever adjustment and fluid 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 COUN TER CLOCKWISE Fluid level is checked as follows Remove screws 1 cover 2 and rubber diaphrag...

Page 46: ...dow on the rear of the master cylinder body A decrease of the fluid 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 b...

Page 47: ...ear 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 finished tighten the screw 1 Once this adjustment is completed adjust the free play of the pedal following the instructions provided in paragraph Rear brake pedal fr...

Page 48: ...rate 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 INEF FECTIVENESS If the brake pedal feels mushy when pulled there may be air in the brake line or the brake may be defective CHE...

Page 49: ...011 SETTINGS AND ADJUSTMENTS Engine oil level check Keeping the motorcycle level and upright check the oil level through the inspec tion window 1 on the right crankcase Make sure level is up to window midline 1 To top up remove the filler cap 2 Have this operation made with warmed up engine Be careful not to touch hot engine oil ...

Page 50: ...lean the plug mag net Wash the filter 4 with petrol and refit it into its seat TE 310 loosen tie 3a without disconnecting tube 3b unscrew hose tail 3c remove mesh filter 4 and drain the used oil Unscrew the screws 5 and remove cover 6 together with filter 7 Change the filter 7 and refit the assembly making sure to fit the Belleville washer 8 in the correct position TE TC TXC 250 Refit the drain pl...

Page 51: ...ing 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 finished refit the hose 1 and secure it with th...

Page 52: ... and separate filter 5 from rear chassis 6 Air filter cleaning Wash the filter with a specific detergent see Capacities table in Section A then dry it fully wash filter with gasoline only in case of need Plunge the filter in special oil for filters see Capacities table in Section A then wring it to drain superfluous oil Do not use fuel or a low flash point solvent to clean the filtering element A ...

Page 53: ...rew 3 remove the complete air filter 4 and separate filter 5 from intake silencer 6 Air filter cleaning Wash the filter with a specific detergent see Capacities table in Section A then dry it fully wash filter with gasoline only in case of need Plunge the filter in special oil for filters see Capacities table in Section A then wring it to drain superfluous oil Do not use fuel or a low flash point ...

Page 54: ... the filter face that goes into the housing to ensure proper sealing When refitting the filter into its housing make sure to position it with the tab A pointing upwards and edge B at the left bottom corner of the filter housing Refit any parts you have removed An improperly positioned filter might let dirt or dust into the engine leading to early wear of piston rings and cylinder A Upper side B Le...

Page 55: ...own in figure 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 dimen sions and make sure that the lower arm C of the chain is slightly tight If it is not proceed as foll...

Page 56: ...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 fluid Note As an alternative you can use suitable spray lubricants Washing the chain with OR TE TXC Wash using oil diesel oil or paraffin oil Never use gasoline tricloroetilene or solvents as the OR may...

Page 57: ...k 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 r...

Page 58: ...ceed 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 wit...

Page 59: ...s follows 1 Turn the rear fixing 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 r...

Page 60: ...clicks 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 speci fied above In order to obtain a smooth braking efficiency turn the adjusters counter clock wise Vice versa to obtain a harder braking action B REBOUND Standard setting 10 clicks 1 2 clicks To reset the standard setting turn lower...

Page 61: ...djuster 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 clock...

Page 62: ...el 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...

Page 63: ...uel tank removal operations pay particular attention to the couplings of the fuel hose on the pump body and on the throt tle 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...

Page 64: ...rform a visual inspection of the exhaust system first in order to identify pos sible 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 flanges and the tightening of the screws 2 that strap the silencer to the r...

Page 65: ...E 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA E GENERAL PROCEDURES Workshop Manual Ed 12 2011 Section ...

Page 66: ... 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 TC E 18 Electronic control unit removal CDI E 19 Voltage regulator removal TE TXC E 20 Voltage regulator removal TC E 20 Ignition coil removal TE TXC E 21 Coil Stick Coil removal TC E 21 Clutch hose removal E 22 Horn removal TE E 22 Elec...

Page 67: ...ENERAL PROCEDURES Workshop Manual Ed 12 2011 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 RIGHT HAND SIDE LEFT HAND SIDE ...

Page 68: ...ve 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 first connect the RED positive cable then the BLACK negative ca...

Page 69: ...n the relevant paragraph Slacken clamp 2 that secures the rubber coupling of the air box 3 to the throttle body Remove the upper fixing 4 and lower fixings 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 pa...

Page 70: ...0 2012 I E USA TXC 250 310 2012 I E USA H00621 8 7 GENERAL PROCEDURES Workshop Manual Ed 12 2011 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 filter 8 ...

Page 71: ...I E USA GENERAL PROCEDURES Workshop Manual Ed 12 2011 Unscrew the clamp 9 connecting air filter 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 72: ...2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA H10966 TC 1 2 3 2 5 6 4 GENERAL PROCEDURES Workshop Manual Ed 12 2011 Exhaust system removal Key 1 Silencer 2 Spring 3 Exhaust manifold 4 Flange 5 Nozzle 6 Protection ...

Page 73: ... 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA H10007 TE TXC 1 2 3 4 5 GENERAL PROCEDURES Workshop Manual Ed 12 2011 Key 1 Silencer 2 Spring 3 Exhaust manifold 4 Front protection 5 Rear protection ...

Page 74: ...move 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 TE TXC ...

Page 75: ...SA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA H10011 5 6 5 TE TXC H10012 7 6 TC 7 GENERAL PROCEDURES Workshop Manual Ed 12 2011 TE TXC Loosen the two bolts 5 and remove the exhaust pipe 6 TC Detach springs 7 and remove exhaust pipe 6 ...

Page 76: ...0 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA H10013 TC 1 2 3 4 3 5 6 3 4 3 6 10 11 12 GENERAL PROCEDURES Workshop Manual Ed 12 2011 Fuel tank scoops and spoiler removal ...

Page 77: ...E USA H00630 3 2 1 3 4 6 7 8 9 3 4 10 11 5 6 3 H10014 TE TXC H10015 2 1 GENERAL PROCEDURES Workshop Manual Ed 12 2011 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 78: ...250 2012 I E USA TXC 250 310 2012 I E USA H02212 4 3 3 GENERAL PROCEDURES Workshop Manual Ed 12 2011 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 79: ...y 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 fitting 11 in the bottom secti...

Page 80: ... Manual Ed 12 2011 Fuel pump removal TC Remove the fuel tank as described in the relevant paragraph Remove the tank filler 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 81: ...ntained in the tank into a ves sel of adequate capacity Make use of a 10 mm wrench to slacken the 4 screws 1 of the pump flange 2 and the four screws 3 of the fitting flange 4 Slide the fitting flange 4 out of the tank then remove the delivery and return hoses by releasing the quick fittings 5 and 6 Disconnect the pump supply connector 7 Slide the pump 2 with relevant small hoses out of the tank N...

Page 82: ...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 TC This operation must be performed with a cool engine Cut the clamp 1 and disconnect the connector 2 Pull outwards the condenser 3 s...

Page 83: ...ROCEDURES Workshop Manual Ed 12 2011 Electronic control unit removal CDI Remove saddle and fuel tank as described in the relevant paragraphs TE TXC Detach the connector 1 from the CDI electronic control unit 2 and take the control unit together with its vibration mount out of the chassis TC Unhook the support elastic 1 then detach the connector 2 and remove the control unit 3 ...

Page 84: ... Ed 12 2011 Voltage regulator removal TE TXC Remove the electronic control unit as described in the relevant paragraph Disconnect the connector 1 Loosen the two retaining screws 2 and remove the regulator 3 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 ...

Page 85: ...l TE TXC Remove saddle and fuel tank as described in the relevant paragraphs Remove the spark plug cap 1 Remove the retaining screws 2 and then the coil 3 Coil Stick Coil removal TC With an 8 mm wrench loosen the screws 2 then remove the floater 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 t...

Page 86: ...ting 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 87: ...lectric 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 88: ...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 TE TXC Disconnect connectors 1 and 2 and MAQS connector 3 from the throttle body 4 Unloose the clamps 5 and 6 Push the intake coupling 7 towards the rear end of the mo...

Page 89: ...0 2012 I E USA H10036 TC 2 3 1 H10037 TC 1 H10038 TC 4 H10039 TC 5 GENERAL PROCEDURES Workshop Manual Ed 12 2011 TC 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 ignition connector 5 ...

Page 90: ...der the engine Slacken the radiator cap 8 Slacken the clamp 11 and disconnect the hose 12 connecting the radiators to the engine Drain all fluid 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 r...

Page 91: ...C 17a GENERAL PROCEDURES Workshop Manual Ed 12 2011 Remove the spark plug cap 17 TE TXC Disconnect the connector 17a 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 92: ...0972 28 29 TE TXC GENERAL PROCEDURES Workshop Manual Ed 12 2011 Loosen the three screws 22 and remove the clutch actuator 23 Remove the clip 24 that holds clutch hose and wiring harness together TE TXC Disconnect connectors 25 and 26 that connect generator and gear sensor connector 27 Remove the water temperature sensor connector 28 Remove the ground cables 29 TE TXC ...

Page 93: ...OCEDURES Workshop Manual Ed 12 2011 Remove the positive power supply cable 29 of the starter motor TE TXC To remove the brake lever 32 use an 8 mm wrench to loosen the master cylinder linkage 33 and a 6 mm Allen wrench to loosen the central screw 34 Remove the lever Loosen the upper retaining screw 35 of the shock absorber 36 with a 14 mm wrench ...

Page 94: ...ove the engine mounting bolts 41 using a 12 mm wrench on the left hand side and a 10 mm wrench on the right hand side Loosen the swinging arm axle nut 42 using a 22 mm wrench pull out the axle 43 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...

Page 95: ...ned 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 f...

Page 96: ...hop Manual Ed 12 2011 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 97: ...F 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA F ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Section ...

Page 98: ...val F 14 Valve removal TE TXC F 19 Valve removal TC F 21 Cylinder removal F 23 Piston removal F 23 Flywheel removal F 24 Kick start pedal removal F 25 Sprocket removal F 25 Oil filter removal F 27 Clutch cover removal F 28 Clutch disassembly F 29 Slider removal F 32 Kick start disassembly F 32 Starter motor removal TE TXC F 34 Starter motor disassembly TE TXC F 36 Starter drive disassembly TE TXC ...

Page 99: ... 6 10 H02241 2 3 5 13 6 1 11 12 ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Layout of engine components TE TXC 1 Throttle body 2 Cylinder head cover 3 Cylinder head 4 Chain tensioner 5 Cylinder 6 Starter motor 7 Head lubrication pipe 8 Oil filter 9 Clutch cover 10 Kick start lever 11 Water pump 12 Alternator cover 13 Sprocket ...

Page 100: ...4 12 9 10 H11114 1 11 3 7 6 4 5 2 8 ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Layout of engine components TC 1 Cylinder head cover 2 Cylinder head 3 Chain tensioner 4 Cylinder 5 Head lubrication pipe 6 Oil filter 7 Clutch cover 8 Kick start lever 9 Water pump 10 Alternator cover 11 Coolant temperature thermostat ...

Page 101: ...012 I E USA TE TXC H10975 H10976 1 1 2 TC ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Cylinder head cover removal TE TXC Remove the two retaining screws 1 10 mm wrench and remove the head cover 2 with its gasket TC Remove the four retaining screws 1 and remove the head cover 2 with its gasket ...

Page 102: ...x retaining screws 1 of the alternator cover 2 and remove the cover with its gasket To remove the gear sensor 3 loosen the two screws 4 and its pushrod and spring Using a 17 mm wrench bring the piston to T D C at the end of the compres sion stroke in this condition the two holes 5 and the two marks 6 on the gears must be positioned as shown in the figure Cover parting line A is visible through the...

Page 103: ...ISASSEMBLY Workshop Manual Ed 12 2011 Remove the spark plug 7 16 mm wrench and the head lubrication pipe 8 unscrewing the drilled screw 9 12 mm wrench Remove the screws 10 4 mm wrench and the screws 11 5 mm wrench from both clamps 12 and 13 and remove them Remove the intake camshaft 14 and the exhaust camshaft 15 ...

Page 104: ...d 12 2011 Camshaft removal TC 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 com pression 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 105: ...5 9 9 10 ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 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 refit 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 106: ...0 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA H10987 11 12 ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Remove the intake camshaft 11 and the exhaust camshaft 12 ...

Page 107: ...2012 I E USA TE TXC H10992 TC H10993 1 1 2 TE TXC H10994 TC H10996 ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Water pump body removal Remove the four screws 1 securing pump body 2 to head 4 mm Allen wrench and remove pump body Water pump disassembly Loosen the screw 1 to disassemble the pump ...

Page 108: ...0 2012 I E USA TE TXC H10997 TC H10998 TE TXC H10999 1 8 3 4 5 6 7 ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Loosen the impeller 3 and remove it TE TXC Remove the oil seal 4 and slide off the gear 5 together with the bearing 6 Remove the circlip 7 and remove the bearing 6 from the gear 5 ...

Page 109: ...9 7 ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 TC 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 refit 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 110: ...E DISASSEMBLY Workshop Manual Ed 12 2011 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 flat head screwdriver until locking it so as to release the spring ...

Page 111: ...I E USA TXC 250 310 2012 I E USA TE TXC H11009 4 4 1 TC H11010 4 4 1 TE TXC H11014 5 ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Loosen the two screws 4 using an 8 mm wrench and remove the chain tensioner 1 TE TXC Remove the timing gear retaining clip 5 using a screwdriver ...

Page 112: ...5 B C TC H11016 B C TE TXC H11017 TE TXC H11018 TC H11019 6 6 7 TC H11020 7 8 ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 With a 12 mm wrench loosen the drilled bolt B and remove the tube C Loosen the two screws 6 using a Phillips screwdriver and remove the timing drive shaft 7 while holding the gear 8 with your hand ...

Page 113: ...0 2012 I E USA TE TXC H11021 TE TXC H11022 TC H11023 9 8 TC H11024 TC H11025 9 ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Support the gear 8 using a screwdriver or a punch unwrap the chain 9 and remove the gear Let the chain drop into the engine otherwise support the chain with an elastic ...

Page 114: ...Manual Ed 12 2011 TE TXC Loosen the four head bolts 10 using a 12 mm socket wrench Mark each bolt with its position to avoid confusing them on assembly three bolts are 112 5 mm long one 10A is 104 5 mm long TC With a 12 mm socket wrench loosen the four screws 10 and their wash ers Remove the cylinder head 11 and its gasket 12 Be careful not to lose the locating pins positioned between head and cyl...

Page 115: ... 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Valve removal TE TXC Remove the four valve buckets 1 and the shims 2 Mark them with their positions to ensure correct assembly in the original position ...

Page 116: ... bend the valve stem Do not compress the springs too much or they will weaken Mark all parts to ensure that they are refitted in their original positions on assembly If the valve collets have caused burrs on the valve stems remove them before removing the valves Remove the seals A from the valve guides Remember that seals must be replaced on assembly Compress the springs using the valve spring com...

Page 117: ...30 1 1 1 2 2 2 2 H11031 3 H11032 4 4a ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Valve removal TC Lift the rocker arms 1 and remove the pads 2 using a suitable tool Position the pads 2 so that they cannot be reversed during the refit Loosen the plugs 3 then loosen the dowels 4 and 4a with a 5 mm Allen wrench ...

Page 118: ...mage the mating surfaces that contact the gasket or those of the combustion chamber Make sure the valve spring compressor is aligned straight on the spring or you might bend the valve stem Do not compress the springs too much or they will weaken Mark all parts to ensure that they are refitted in their original positions on assembly If the valve collets have caused burrs on the valve stems remove t...

Page 119: ... 2012 I E USA H11115 ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Cylinder removal Remove the front slider 1 of the timing chain pulling it upwards Remove the cylinder 2 with its gasket 3 Piston removal Remove the piston pin retaining rings 1 slide out the piston pin 2 and remove the piston 3 ...

Page 120: ...E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA 1 2 H02350 H02243 2 3A ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Flywheel removal Loosen the rotor 2 nut 1 17 mm wrench Remove the rotor 2 using the puller 3A part no 8000 H2146 ...

Page 121: ... 2012 I E USA H11037 2 1 TE TXC H11038 2 1 TC ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Remove the key 4 from the crankshaft Kick start pedal removal Remove the pedal retaining bolt 1 12 mm wrench the washer and the pedal 2 Sprocket removal Lift the tab of the lock washer 1 using a chisel ...

Page 122: ... 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Loosen the nut 2 using a 22 mm wrench and remove sprocket 3 and spacer 4 ...

Page 123: ...TXC 250 310 2012 I E USA ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Oil filter removal Loosen the drilled nut 1 and disconnect the hose 2 from the oil pump cover 3 Loosen the three screws 4 using an 8 mm wrench Remove the cover 3 together with its filter 5 and Belleville washer 6 ...

Page 124: ...50 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Clutch cover removal Remove the nine screws 1 and the screw 2 securing the cover 3 8 mm wrench and remove the cover 3 Remove the gasket 4 and the bushings 5 ...

Page 125: ...0 310 2012 I E USA ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Clutch disassembly 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 126: ... 250 310 2012 I E USA ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Remove the plates 8 lubricate the new plates with engine oil and install them always start with a friction plate Remove the clutch pushrod 9 from the opposite side of the engine Straighten the tab of the lock washer 10 ...

Page 127: ... TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Remove the nut 11 22 mm wrench using the clutch removal tool A part no 8000 79015 Remove the washer 10 Remove hub 12 washer 13 and clutch housing 14 Remove the bushing 15 ...

Page 128: ...E USA ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Slider removal Use a 5 mm Allen wrench to loosen the screw 1 and remove the slider 2 Kick start disassembly Release the spring 1 from the casing 2 and remove the complete shaft assembly 3 Be careful not to lose the washer 11 located on the crank case ...

Page 129: ...SA TXC 250 310 2012 I E USA ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Remove the snap ring 4 the washer 5 and the timing drive gear 6 Disassemble the shaft as shown in the diagram On assembly make sure that the dot 7 on shaft end 8 and the dot 9 on the ratchet 10 are aligned ...

Page 130: ...H00753 1 H00757 2 H00759 2 ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Starter motor removal TE TXC Remove the exhaust pipe as described in the relevant paragraph Disconnect the positive power supply cable 1 loosening the hexagonal head screw 8 mm wrench Unscrew the four screws 2 using a 4 mm Allen wrench ...

Page 131: ...56 2 H00758 3 ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Slide the starter motor 3 towards the rear end of the motorcycle to remove it Upon assembly check the gasket 4 for damage and replace it if needed Make sure to position it correctly with the gasket hole 5 matching the hole 6 in the starter motor flange ...

Page 132: ... 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Starter motor disassembly TE TXC Separate the starter motor 1 from the starter drive 2 Starter drive disassembly TE TXC ...

Page 133: ...2 I E USA ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Remove flywheel and starter motor as outlined in the relevant paragraph Disassemble the starter motor as outlined in the relevant paragraph Remove the cap 1 using a 10 mm Allen wrench Remove the circlip 2 and the bearing 3 with the bevel gear ...

Page 134: ...al Ed 12 2011 Place the wormshaft 4 assembly in a vice with aluminium jaws loosen the nut 5 using a 10 mm T wrench and slide out the wormshaft 4 Upon reassembly of the locking nut 5 fit the washer 9 in the right position and tighten the nut 5 to a torque of 8 Nm 0 8 Kgm 5 90 ft lb Loctite 270 Remove the freewheel 6 Remove the needle roller bearing 7 and the thrust ring 8 ...

Page 135: ...E DISASSEMBLY Workshop Manual Ed 12 2011 Oil pump disassembly Loosen the screws 1 using a 4 mm Allen wrench and remove pump body 2 and gasket Remove the pump rotors 3 and 4 and extract the drive pin 5 to release the gear 6 Remove drive gear 7 and oil suction stub 8 Make sure to align the rotor dots 9 on assembly ...

Page 136: ...emoval To facilitate assembly mark the position of the gear shift pedal 1 on the shaft Remove the retaining screw 2 of the gear shift pedal 1 8 mm wrench and slide the pedal from the selector shaft Remove the selector shaft 3 from the right hand side Remove the two screws 4 4 mm Allen wrench and 8 mm wrench secur ing the selector retaining plate 5 and remove retaining plate and ratchet mechanism 6...

Page 137: ... 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Remove the bolt 7 of the selector drum 8 12 mm wrench Release the ratchet 10 spring 9 and remove retaining ring 11 washer 12 and ratchet 10 Be careful not to lose the roller 13 ...

Page 138: ...2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Primary drive gear removal Loosen the central nut 1 using a 22 mm wrench Remove primary gear 2 and water pump drive gear 3 ...

Page 139: ...I E USA ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Crankcase disassembly Remove the nine screws 1 from the left crankcase 2 8 mm wrench Important the screws 1 are not all the same length Refer to figure A on assembly to ensure correct installation FIG A a1 6x60 mm a2 6x55 mm a3 6x70 mm a4 6x90 mm ...

Page 140: ...A7015 using the flywheel cover holes and remove the left crankcase half 4 Tap the output shaft 5 with a rubber hammer at intervals during removal to keep the crankcase half from getting stuck Gearbox disassembly Remove the shaft 1 of the output shaft shifter forks Release the shifter forks 2 and 3 from the drum 4 and remove the forks making sure to collect the drive bushings 5 Remove the drum 4 ...

Page 141: ...TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE DISASSEMBLY Workshop Manual Ed 12 2011 Remove the retaining ring 5 and then the shaft 6 of the input shaft shifter fork 7 Remove the input shaft 8 and output shaft 9 being careful not to lose any shims if fitted ...

Page 142: ...anual Ed 12 2011 Crankshaft disassembly Slide the puller 1 part no 8000 A7015 over the right end of the crank shaft Secure the puller to the crankcase half and remove the crankshaft 2 from the opposite side In case crankshaft and or connecting rod are worn it is necessary to replace the whole crankshaft assembly and the connecting rod ...

Page 143: ...G 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA G ENGINE OVERHAUL Workshop Manual Ed 12 2011 Section ...

Page 144: ...G 9 Timing chain tensioners G 9 Cylinder G 10 Piston G 10 Cylinder to piston clearance TE TXC G 11 Piston diameter G 11 Piston pin G 11 Piston rings TE TXC G 12 Piston ring to cylinder clearance G 12 Piston ring to cylinder clearance G 12 Piston ring to groove clearance G 13 Piston pin to small end clearance A G 13 Big end axial clearance B G 13 Big end axial clearance G 13 Crankshaft G 14 Cranksh...

Page 145: ...ting conditions and maximum performance all clearances must be within the specified tolerance A tight fit will lead to seizure as moving parts heat up whereas a loose fit will cause annoying vibration resulting in early wear of moving parts Cylinder head Remove fouling deposits from the combustion chamber using a rounded scraper Do not use sharp tools or you might damage valve seats and spark plug...

Page 146: ... to the valve and rotate it in its seat using a rubber hose or other similar tool Remove the valve and measure the width X of the seating face If width is greater than 1 2 mm 0 0472 in the seat needs to be refaced The standard width measured as shown of the seating face of the valve is x 0 6 0 7 mm 0 0236 0 0275 in for INTAKE valves x 0 7 0 8 mm 0 0275 0 0314 in for EXHAUST valves Valves cannot be...

Page 147: ...rvice limit 0 05 mm Valve head out of round place valve on a V block and check with a dial gauge at right angles to the head while turning the valve Service limit 0 03 mm Valve spring Check free length L Replace springs if they exceed the service limit TE TXC Intake Spring 1 L1 25 4 mm Service limit 23 9 mm Spring 2 L2 21 4 mm Service limit 19 9 mm Exhaust Spring 1 L2 22 6 mm Service limit 21 1 mm...

Page 148: ...E OVERHAUL Workshop Manual Ed 12 2011 Check the valve springs for proper squareness Maximum acceptable deviation is 1 5 mm on each side Valve bucket inspection TE TXC Check that the valve buckets 1 slides freely in their seats If not so replace them Rocker arm check TC Make sure that the rocker arms 1 can oscillate freely ...

Page 149: ...NE OVERHAUL Workshop Manual Ed 12 2011 Valve installation Smear valve guides and stems with oil before installation Install spring seat 1 and springs 2 place spring a at head end and finally the spring retainer 3 Use tool to compress the valve springs and install the valve collets 4 Do not compress the springs too much and avoid damage to the cylinder head ...

Page 150: ...OVERHAUL Workshop Manual Ed 12 2011 Tap valve stem lightly with a plastic hammer and an aluminium punch to help the valve collets become seated Tap the valve stem tip to avoid pushing the valve off centre Valve leak check Check the valves for proper sealing before assembling the cylinder head to the engine INTAKE EXHAUST INTAKE EXHAUST ...

Page 151: ...are in pristine conditions without signs of scoring or distortion STANDARD L SERVICE LIMIT 140 mm 142 5 mm 5 51 in 5 61 in Timing chain and gears At each engine overhaul check gear teeth and chain rollers for wear If gear teeth are badly worn change both gears and the chain Hold the chain taut to take out any slack and measure across 20 links 21 pins If any one gear or the chain is worn beyond the...

Page 152: ...n two directions at right angles to each other to determine taper and out of round Max taper 0 05 mm Max out of round 0 05 mm If cylinder is worn beyond these limits replace both cylinder and piston The liner undergoes a special hardening treatment and cannot be ground Piston Clean off any carbon deposits from piston crown and grooves Perform a careful visual inspection of the piston and check its...

Page 153: ... in Cylinder to piston clearance TE TXC Cylinder diameter Measure inside diameter Dc with an internal bore micrometer 25 mm 0 9842 in below the edge distance A Piston diameter Measure piston diameter Dp 7 mm 0 2755 in above skirt edge distance B Clearance is calculated as follows Dc Dp Piston pin The piston pin 1 must be perfectly smooth with no signs of scoring dents or bluing due to overheating ...

Page 154: ... no signs of forcing or scoring Replacement pistons come with piston rings and piston pin Piston ring to cylinder clearance Insert the piston ring at the bottom of the bore where minimum wear occurs taking care to position it squarely and measure end gap Piston ring to cylinder clearance PISTON RING MOUNTING CLEARANCE H A 0 15 0 30 mm 0 00591 0 01182 in B 0 2 0 7 mm 0 00788 0 02758 in ...

Page 155: ...ngs If the piston ring is marked on one side that side must be facing up Piston pin to small end clearance A 0 019 0 01 mm 0 00075 0 00040 in Big end side clearance B 0 018 0 030 mm 0 00071 0 0012 in Big end axial clearance Measure axial clearance A between crankshaft 1 and connecting rod 2 using a feeler gauge Compare measured clearance with the table below PISTON RING MOUNTING CLEARANCE H A 0 02...

Page 156: ...n journals should show no scoring or scuffing Threads keyways and splines must be in good condition Crankshaft straightness Place the crankshaft 1 on a stand 2 with two dial gauges 3 positioned on the journals Turn the crankshaft and measure runout STANDARD than 0 02 mm 0 00078 in If the detected measure exceeds 0 04 mm 0 0016 in replace the crankshaft Crankshaft ...

Page 157: ...ure they are in the best conditions Clutch plates should show no signs of bluing scoring or distortion Measure the thickness of friction plates Plate thickness when new 3 0 mm 0 1181 in Service limit 2 9 mm 0 1141 in Clutch pack thickness 29 4 mm 1 1574 in Place each friction and steel plate on a surface plate and check for distortion using a feeler gauge Use a feeler gauge Service limit 0 2 mm ...

Page 158: ... measured clearance with the table below If measured clearance exceeds the service limit replace clutch plates or housing and repeat measurement If measurement is still outside the service limit replace the complete clutch assembly Clutch spring Measure the free length L of each spring with a calliper New spring L 37 3 mm 1 4685 in Service limit 35 mm 1 3779 in Change any spring that is outside th...

Page 159: ...or signs of wear or failure If any are found replace the part 5 Clutch hub Check the steel plate slots for signs of wear or failure If any are found replace the part 6 Clutch housing Check the friction plate slots for signs of wear or failure Check the needle roller bearing seats for signs of wear If any are found replace the part 7 Primary drive gear pair Check gear teeth for signs of wear or fai...

Page 160: ...Manual Ed 12 2011 Oil pump Loosen the screws 1 using a 4 mm Allen wrench and remove pump body 2 and gasket Remove the pump rotors 3 and 4 and extract the drive pin 5 to release the gear 6 Check gear 6 and rotors 4 for wear Replace if worn Smear the rotors with oil and make sure to align the rotor dots 9 on assembly Use a new gasket ...

Page 161: ...n 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 dru...

Page 162: ......

Page 163: ...H 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA H ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Section ...

Page 164: ...ug TC H 15 Tightening torque figures H 16 Input shaft 5 speed H 17 Output shaft 5 speed H 17 Input shaft 6 speed H 18 Output shaft 6 speed H 19 Crankcase assembly H 23 Gear shift control assembly H 28 Kick start assembly H 32 Timing chain and primary drive assembly H 33 Clutch assembly H 36 Sprocket installation H 38 Flywheel and starter motor installation TE TXC H 39 Flywheel installation TC H 41...

Page 165: ...val Bearing specifications and dimensions have been calculated for a certain life We recommend replacing the bearings especially those exposed to heavy loading also considering that checking them for wear is not an easy procedure These recommendations are in addition to the dimensional checks of individual components specified in the relevant section see Section G ENGINE OVERHAUL Cleaning all comp...

Page 166: ...12 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Assembly and lubrication instructions CRANK ALTERNATOR LUBRICATION LEFT CRANKCASE HALF ...

Page 167: ...Nm 0 6 Kgm 4 43 ft lb 3A M5 L35 6 Nm 0 6 Kgm 4 43 ft lb 3B M5 L40 6 Nm 0 6 Kgm 4 43 ft lb 19 M5x0 8 L12 Loctite 270 272 6 Nm 0 6 Kgm 4 43 ft lb 49 M5 L8 6 Nm 0 6 Kgm 4 43 ft lb ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Tightening torque figures LUBRICATION POINTS NOTES LUBRICANT INSTALLATION INSTRUCTIONS A Degrease B Apply engine oil on installation E Line up stator mark with cover mark G WATER...

Page 168: ... 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Assembly and lubrication instructions GEARBOX GEAR SHIFT CONTROL 5 speed ...

Page 169: ... M8x1 25 LOCTITE Alt 243 25 Nm 2 55 Kgm 18 44 ft lb 23A M6 L13 LOCTITE 243 8 Nm 0 8 Kgm 5 9 ft lb 23B M6 L14 LOCTITE 243 8 Nm 0 8 Kgm 5 9 ft lb 24 M5x0 8 L12 6 Nm 0 6 Kgm 4 43 ft lb 48 M6 L20 8 Nm 0 8 Kgm 5 9 ft lb LUBRICATION POINTS NOTES LUBRICANT INSTALLATION INSTRUCTIONS D Install with open end pointing to engine centre O Engine oil O G Engine oil or WATER RESISTANT grease ...

Page 170: ... 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA H11099 ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Assembly and lubrication instructions GEARBOX GEAR SHIFT CONTROL 6 speed ...

Page 171: ... M8x1 25 LOCTITE Alt 243 25 Nm 2 55 Kgm 18 44 ft lb 23A M6 L13 LOCTITE 243 8 Nm 0 8 Kgm 5 9 ft lb 23B M6 L14 LOCTITE 243 8 Nm 0 8 Kgm 5 9 ft lb 24 M5x0 8 L12 6 Nm 0 6 Kgm 4 43 ft lb 48 M6 L20 8 Nm 0 8 Kgm 5 9 ft lb LUBRICATION POINTS NOTES LUBRICANT INSTALLATION INSTRUCTIONS D Install with open end pointing to engine centre O Engine oil O G Engine oil or WATER RESISTANT grease ...

Page 172: ...2 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Assembly and lubrication instructions CLUTCH KICK START LUBRICATION RIGHT CRANKCASE HALF ...

Page 173: ... or WATER RESISTANT grease C Join crankcase halves using Loctite 5205 19 M5 L12 LOCTITE 270 or 272 6 Nm 0 6 Kgm 4 43 ft lb 26 M8 X 1 25 Al 8 Nm 0 8 Kgm 5 9 ft lb 27 M5 L16 8 Nm 0 8 Kgm 5 9 ft lb 28 M5 x 0 8 L20 6 Nm 0 6 Kgm 4 43 ft lb 29 M6 x 1 LOCTITE 243 8 Nm 0 8 Kgm 5 9 ft lb 30 M8 x 1 25 LOCTITE Alt 272 25 Nm 2 55 Kgm 18 44 ft lb 31 M6 L14 LOCTITE Alt 272 8 Nm 0 8 Kgm 5 9 ft lb 32 M6 L10 LOCTI...

Page 174: ... TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Assembly and lubrication instructions RIGHT CRANKCASE COVER ...

Page 175: ...ASSEMBLY Workshop Manual Ed 12 2011 Tightening torque figures LUBRICATION POINTS NOTES LUBRICANT INSTALLATION INSTRUCTIONS O Engine oil O G Engine oil or WATER RESISTANT grease 27 M5 L16 6 Nm 0 6 Kgm 4 43 ft lb 33 M6 L22 8 Nm 0 8 Kgm 5 9 ft lb 34 M6 x 1 L50 8 Nm 0 8 Kgm 5 9 ft lb 35 M6 x 1 L20 8 Nm 0 8 Kgm 5 9 ft lb ...

Page 176: ...0 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA H11047 TE TXC 52 ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Assembly and lubrication instructions HEAD CYLINDER PISTON TIMING SYSTEM WATER PUMP SPARK PLUG ...

Page 177: ...2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA H11048 TC 50 48 48 48 49 53 51 O O 52 O G G 54 55 O O 45 57 59 58 56 ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Assembly and lubrication instructions HEAD CYLINDER PISTON TIMING SYSTEM WATER PUMP SPARK PLUG ...

Page 178: ... ft lb 43 TE TXC M4 L10 3 Nm 0 3 Kgm 2 21 ft lb 44 TE TXC M5 L25 6 Nm 0 6 Kgm 4 43 ft lb 45 M4 L12 LOCTITE 243 8 Nm 0 8 Kgm 5 9 ft lb 46 TE TXC M5 LOCTITE 270 or 272 6 Nm 0 6 Kgm 4 43 ft lb 47 TE TXC M5 L30 1 Nm 0 6 Kgm 0 74 ft lb 48 TC Special screw M6 x 1 8 Nm 0 8 Kgm 5 9 ft lb 49 TC Screw M5 x 0 8 6 Nm 0 6 Kgm 4 43 ft lb 50 TC Screw M6 x 1 6 Nm 0 6 Kgm 4 43 ft lb 51 TC Stud bolt head fastening ...

Page 179: ...H 17 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Input shaft Output shaft ...

Page 180: ...SPEED Fit roller cage 1 and 5th gear 2 on the bushing and then install the washer 3 and the retaining ring 4 The washer must be placed between gear and retaining ring Fit 3rd gear 5 retaining ring 6 and washer 7 Fit the roller cage 8 Fit 4th gear 9 Fit 2nd gear 10 Fit the circlip 11 B with 5th gear engaged C with 4th gear engaged D lubricate with MOLYKOTE G n plus ...

Page 181: ... 1 Fit 2nd gear 2 washer 3 and retaining ring 4 Fit 4th gear 5 and retaining ring 6 Fit the washer 7 Fit roller cage 8 and 3rd gear 9 Fit washer 10 and retaining ring 11 Apply MOLYKOTE G n plus on the 3rd gear 9 Fit 5th gear 13 and washer 14 Fit roller cage 15 1st gear 16 and washer 12 A with 1st gear engaged B with 3rd gear engaged C with 2nd gear engaged D lubricate with MOLYKOTE G n plus ...

Page 182: ...12 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA H00602 1 st 2 nd 3 rd 4 th Albero secondario 6 SPEED 6 th 5 th ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Input shaft Output shaft ...

Page 183: ...ft 6 SPEED Fit roller cage 1 and 5th gear 2 on the bushing and then install the washer 3 and the retaining ring 4 The washer must be placed between gear and retaining ring Fit 3rd 4th gear 5 retaining ring 6 and washer 7 Fit the roller cage 8 Fit 6th gear 9 Fit 2nd gear 10 Fit the circlip 11 B with 5th gear engaged and 5th gear in contact with 1st gear C with 4th gear in contact with 6th gear ...

Page 184: ...ear 9 Fit washer 10 and 4th gear 11 Fit washer 12 and retaining ring 13 Apply MOLYKOTE G n plus on the 4th gear 11 Fit 5th gear 14 and washer 15 Fit roller cage 16 1st gear 17 and washer 18 A Control dimension with 1st gear engaged and 1st gear butted up on the shaft B Control dimension with 4th gear engaged and 4th gear butted up against shaft washer and circlip C Control dimension with 3rd gear ...

Page 185: ...ankcase half mating faces and place crankcase half on tool no 8A00 90662 Heat up to around 125 C and drive the ball bearings into each crankcase half using a suitable driver tool Fit the retaining plates 1 and 2 to the crankcase bearings 5 Nm 0 5 Kgm 3 6 ft lb Loctite 272 for crankshaft bearing retaining plate 1 11 Nm 1 1 Kgm 7 9 ft lb Loctite 272 for right hand bearing retaining plate 2 ...

Page 186: ...310 2012 I E USA ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Install the input and output shaft assembly making sure the output shaft 3 shim is in place Lubricate the three shifter forks 4 with engine oil and install them Make sure the bushings 5 are correctly in place grease the bushings ...

Page 187: ...REASSEMBLY Workshop Manual Ed 12 2011 Insert the selector drum 6 into its seat Install the fork shafts 7 and 8 and make sure the forks move freely Make sure the fork bushings 5 are correctly located in the drum grooves 6 Insert the circlip 9 of the input shaft fork shaft Rotate the selector drum to test operation ...

Page 188: ... I E USA ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Heat up the crankshaft bearing 10 and install the crankshaft 11 Make sure both crankcase locating bushings 12 are in place Apply a layer of LOCTITE 5205 on the right crankcase mating surface 13 making sure not to obstruct the oil passage hole 14 ...

Page 189: ...he crankcase To join the crankcase halves tap with a plastic hammer Tighten the screws 15 using an 8 mm wrench 10 Nm 1Kgm 7 25 ft lb Make sure to fit the screws in the correct positions according the specified pattern see Section F paragraph Crankcase disassembly Cover the upper section of the engine with a cloth a sponge or the like to prevent screws or other parts from accidentally falling into ...

Page 190: ...ntrol assembly Refit the spring abutment pin 1 using a 12 mm wrench apply Loctite 243 and tighten to 20 Nm 2 0 Kgm 14 5 ft lb Install ratchet 2 spring 3 washer 4 and circlip 5 Install the selector drum 6 making sure the tab 7 locates in the recess 8 and secure drum with its screw 9 Apply Loctite 243 tighten to 20 Nm 2 0 Kgm 14 5 ft lb use 12 mm wrench Engage the spring 3 ...

Page 191: ...earbox for proper operation Refit the ratchet assembly 10 together with the plate making sure ratchets and springs are in the correct positions Tighten the upper screw 11 using a 4 mm Allen wrench Loctite 243 10 Nm 1 0 Kgm 7 2 ft lb Tighten the lower screw 12 using an 8 mm wrench Loctite 243 10 Nm 1 0 Kgm 7 2 ft lb Turn the engine over and install the gear shift lever oil seal 13 and its circlip 1...

Page 192: ...ngine over Make sure the spring 15 of the gear shift lever shaft is positioned correctly Check the gear shift lever shaft 16 and the slot of the gear selector mechanism for signs of wear Lubricate the shaft with engine oil and insert the shaft 16 into the crankcase so that the fork 17 slides over the ratchet detent and the spring 18 locates to its abutment pin ...

Page 193: ... TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Install the gear shift lever 19 and operate the gearbox manually 8 mm wrench 8 Nm 0 8 Kgm 5 8 ft lb ...

Page 194: ...1 Kick start assembly Refit the starter ratchet release plate 1 use a 4 mm wrench 8 Nm 0 8 Kgm 5 8 ft lb Loctite 243 Fit the complete shaft assembly 2 to its seat B in the crankcase making sure the ratchet is correctly positioned on the shaft marks lined up and insert the spring end 3 into the hole D Fit transmission gear 4 washer 5 and snap ring 6 ...

Page 195: ...chain and primary drive assembly Install the timing chain slider 1 tighten the screw 2 using a 5 mm wrench 10 Nm 0 1 Kgm 7 3 ft lb Loctite 243 and make sure the slider moves freely Fit the oil pump drive gear 3 making sure the side with the dot is facing out side Fit the primary drive double gear 4 making sure to line up the timing dot A with the shaft dot B ...

Page 196: ... 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Install the timing chain 5 Refit the bushing 6 Refit the clutch housing 7 ...

Page 197: ...50 2012 I E USA TXC 250 310 2012 I E USA ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Place a dummy gear 8 or an aluminium shim between clutch housing 7 gear and double gear 4 and then tighten the primary drive shaft nut 9 use a 22 mm wrench 100 Nm 10 Kgm 72 50 ft lb ...

Page 198: ...2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Clutch assembly Install washer 1 hub 2 lock washer 3 and nut 4 Use the suitable tool 5 to prevent rotation and tighten to 60 Nm 6 Kgm 43 5 ft lb use a 22 mm wrench ...

Page 199: ...lates 6 install a friction plate first and then a steel plate and keep alternating between friction and steel plates the last to go in should be a steel plate Fit actuator plate 7 thrust bearing 8 thrust washer 9 pressure plate 10 and springs 11 Tighten the spring screws 12 gradually in a cross pattern 5 Nm 0 5 Kgm 3 6 ft lb Turn the engine over Install the clutch pushrod 13 ...

Page 200: ...ion Install the oil seal retaining plate 1 and tighten the screws 2 use an 8 mm wrench 5 5 Nm 0 55 Kgm 4 ft lb Fit the spacer 3 with the grooved side facing inwards Install sprocket 4 lock washer 5 and nut 6 Hold the sprocket 4 with the suitable tool 7 to prevent rotation and tighten the nut 6 use a 22 mm wrench 100 Nm 10 Kgm 72 5 ft lb Bend the tabs of the lock washer ...

Page 201: ... Flywheel and starter motor installation TE TXC Clean flywheel rotor to remove any debris suspended in swirling oil and captured by the magnets Fit the tab 1 to the crankshaft Lubricate needle roller bearing 2 and thrust ring 3 with engine oil and install them making sure the thrust ring slots are pointing outwards Lubricate the freewheel 4 with engine oil and refit it ...

Page 202: ...6 to 75 Nm 7 5 Kgm 54 3 ft lb Use a 17 mm wrench Before installing the starter motor 7 check for free clockwise rotation of the freewheel 4 while holding the rotor 5 steady Assemble the starter motor 7 On assembly check the gasket 8 for damage and replace it if needed Make sure to position it correctly with the gasket hole 9 matching the hole 10 in the starter motor flange Fit the starter motor 7 ...

Page 203: ...llation TC Clean flywheel rotor to remove any debris suspended in swirling oil and captured by the magnets Fit the tab 1 to the crankshaft Refit the rotor 2 Hold the rotor 2 to prevent rotation and place an aluminium shim or dummy gear between the primary drives gears on the right side again to prevent rotation Tighten the nut 3 to 75 Nm 7 5 Kgm 54 3 ft lb Use a 17 mm wrench ...

Page 204: ...ust be facing up A Compression ring C Oil control ring C1 Top oil rail end gap position C1 Oil rail spacer end gap position C1 Bottom oil rail end gap position Piston and cylinder installation Remove the rubber protection 1 Install a new cylinder foot gasket 2 Assemble piston 3 to connecting rod 4 lubricate with engine oil and fit the piston pin retaining rings 5 Make sure the arrow mark on the pi...

Page 205: ...SA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Lubricate the cylinder liner 7 with engine oil and slide it over the piston rings Make sure to collect the timing chain 8 Position the slider 9 ...

Page 206: ...and screws 10 and fit the appropriate head gasket Cylinder head gasket selection table TC For the TC model there is only a 0 7 mm 0 0275 in thick gasket TE TXC Bring piston to T D C at the end of the compression stroke measure distance A between piston crown and head gasket mating face and select the appropriate gasket according to the table below CONDITION see diagram A Gasket thickness Gasket pa...

Page 207: ...selection table Install the head 1 while supporting the timing chain 2 with a screwdriver or an elastic TE TXC Tighten the head bolts 3 gradually in a cross pattern to 40 Nm 4 Kgm 29 ft lb use a 12 mm wrench Refit each of the bolts 3 and 3a in its original position Bolt 3 119 5 mm long Bolt 3a 104 5 mm long TC Tighten the screws 3 gradually and in a cross pattern starting with a 20 Nm 2 0 Kgm 14 7...

Page 208: ...r shim 5 on the valves and the valve buckets 6 as marked on removal TC Lift the rocker arms 6a and refit the four pads 5 following the numbering you marked during the removal TE TXC Check the bearings of the timing drive upper gear 7 and replace them if needed The gear 7 requires no timing Refit the gear 7 with its shaft 8 and gasket 9 TC Grease the O Ring 10 before refitting the shaft 11 Check th...

Page 209: ...11065 12 TC H11066 10 10 TC H11067 12 ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Tighten the screws 10 with a Phillips screwdriver 4 Nm 0 4Kgm 2 9 ft lb Loctite 243 TE TXC Push the gear until exposing the groove and fit the retaining ring 11 Tighten the drilled bolt 12 using a 12 mm wrench at a torque of 8 Nm 0 8 Kgm 5 9 ft lb ...

Page 210: ...screws feature two differ ent lengths Screw 13A L 25 mm Screw 13 L 20 mm On assembly position the screw 13a at the uppermost position and fit the ground rings 14 before tightening IMPORTANT Do not confuse the screws and do not tighten the screw 13a unless you have fitted the ground rings RISK OF CYLINDER FAILURE Release the chain tensioner 12 using a screwdriver turn counter clockwise Tighten the ...

Page 211: ...aft manually until bringing the piston to Top Dead Centre Clean and refit the intake camshaft 2 and the outlet camshaft 3 ensuring that the gears are positioned as the figure shows Before refitting the camshafts carefully clean the seat of shafts and mounts then lubricate with engine oil Make sure that the decompressor is not locked Cover parting line A is visible through the holes 4 Make sure tha...

Page 212: ...n bring it back to Top Dead Centre position Use a feeler gauge 8 to check clearance between valve buckets and cam lobes Correct values are as follows intake 15 hundredths exhaust 20 hundredths If the value is outside the limit remove the covers and replace the shims under the valve buckets with shims of the appropriate size so as to achieve correct clearance Replacement shims are available in a 1 ...

Page 213: ...ankshaft manually until bringing the piston to Top Dead Centre Clean and refit the intake camshaft 2 and the outlet camshaft 3 ensuring that the gears are positioned as the figure shows Before refitting the camshafts carefully clean the seat of shafts and mount then lubricate with engine oil Make sure that the decompressor is not locked The engraved reference marks 4 must be positioned as shown IN...

Page 214: ...e from 7 to 14 as the diagram B shows Initially tighten them with a 7 Nm 0 7 kgm 5 16 ft lb pre tightening torque then with a 11 Nm 1 1 kgm 8 11 ft lb tightening torque Diagram B Turn thecrankshaftmanually afewturnstocheckforfree smoothrotationwithout any tight points then bring it back to Top Dead Centre position Check the valve clearance as outlined in Chapter D Grease the O Ring gasket 7 then r...

Page 215: ...the stator 1 with its mark lined up with the flywheel cover mark and tighten the retaining screws 2 use a 4 mm Allen wrench 6 Nm 0 6 Kgm 4 3 ft lb Loctite 272 Insert the cable guide 3 into its seat in the cover and tighten the two retaining screws 4 of the pick up sensor 5 with its plate 6 Nm 0 6 Kgm 4 3 ft lb Loctite 272 Install the flywheel cover 7 with its gasket and tighten the six screws 8 to...

Page 216: ... I E USA TXC 250 310 2012 I E USA ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Neutral sensor installation TE TXC Refit pin 1 and spring 2 Check the O ring 3 of the sensor 4 Refit the sensor 4 and tighten the screws 5 using an 8 mm wrench 5 5 Nm 0 55 Kgm 4 ft lb Loctite 243 ...

Page 217: ... TC 250 2012 I E USA TXC 250 310 2012 I E USA H11083 2 1 H11084 2 3 3 ENGINE REASSEMBLY Workshop Manual Ed 12 2011 Plug refitting TC Check the plug 2 O ring gasket 1 Refit the plug 2 tightening the screws 3 with an 8 mm wrench 5 5 Nm 0 55 Kgm 4 ft lb Loctite 243 ...

Page 218: ...Refit the cover 1 with its gasket making sure the arrow is pointing UP Tighten the screws 2 with the wire clip 3 placed on the upper screw Cylinder head cover spark plug TE TXC Position the central seal 1 Fit the head cover 3 with its gasket to the head 2 Tighten the screws 4 and 4a 8 Nm 0 8 Kgm 5 9 ft lb Screw 4 L 23 4 mm Screw 4a L 31 3 mm Install the spark plug 10 12 Nm 1 1 23 Kgm 7 2 8 9 ft lb...

Page 219: ...tral retaining gasket 1 Fir the cover 3 on the head 2 with the respective gasket Tighten the screws 4 to a 8 Nm 0 8 Kgm 5 9 ft lb torque During the refitting fit the longest screw 4a on the water pump side Install the ignition spark plug 10 12 Nm 1 1 2 Kgm 7 4 8 9 ft lb Make sure that the gasket 5 is correctly fitted the reference lug 6 must correspond with the retaining bracket 8 gap 7 Install th...

Page 220: ...t crankcase assembly Refit the oil pump drive gear 1 and its shaft 2 Check the O rings of the oil suction stub 3 and replace them if needed Refit the oil suction stub 3 Refit the centring bushings 4 Refit the gasket 5 Manually check for correct installation and operation of the pump 6 and make sure the crankshaft sealing ring 7 is in the correct position ...

Page 221: ... cross pattern use an 8 mm wrench 8 Nm 0 8 Kgm 5 90 ft lb Make sure pump gear and drive gear engage correctly Check the O ring 10 for damage and replace it if needed Refit the spring 11 of the oil filter 12 Refit the oil filter into its housing and tighten the screws 13 using an 8 mm wrench 5 5 Nm 0 55 Kgm 3 98 ft lb When assembling filter to cover make sure to fit the filter oil seal A first onto...

Page 222: ...d 12 2011 Filter and drain plug 250 Fit the oil filter 1 and tighten the cap 2 into place with its gasket using a 12 mm wrench 25 Nm 2 5 Kgm 18 44 ft lb Blow by tube fitting filter 310 Insert the oil filter 1 screw the hose fitting 2 insert hose 3 and screw clamp 4 Oil feed hose installation Refit the hose 1 and tighten the drilled screws 2 with their seals using a 12 mm wrench 8 Nm 0 8 Kgm 5 9 ft...

Page 223: ...kshop Manual Ed 12 2011 Gear shift and kick start pedal installation Install the gear shift pedal 1 and tighten the screw 2 using an 8 mm wrench 8 Nm 0 8 Kgm 5 8 ft lb Check the pedal 1 for damage Refit the kick start pedal 3 and tighten the screw 4 using a 12 mm wrench 25 Nm 2 5 Kgm 18 44 ft lb Loctite 272 Make sure that the pedal does not foul the cover ...

Page 224: ...e cylinder head cover Refit the oil sump guard if you had removed it Refit the coolant hoses with their clamps Refit the rear brake pedal with its bolt Refit the side guards of the chassis Refit the carburettor Refit the exhaust system Refit the fuel tank together with the scoops Refit the fuel tank front retaining screw and hook up the scoops to the spoil ers on the radiators Refit the breather h...

Page 225: ...I 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA I FRONT SUSPENSION Workshop Manual Ed 12 2011 Section ...

Page 226: ... 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA FRONT SUSPENSION Workshop Manual Ed 12 2011 Sommario Front fork removal I 4 Front suspension I 6 Service instructions for Ø48USD Kayaba fork I 6 Front suspension TC TXC I 7 Front suspension TE I 18 ...

Page 227: ...I 3 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA H09056 TE H09057 TXC H09058 TC FRONT SUSPENSION Workshop Manual Ed 12 2011 ...

Page 228: ...d to be restored to original value on assembly Set a block under the engine and see that the front wheel is lifted from the ground and then proceed as follows remove the screws 1 and the brake line clamp on the left hand side remove the six screws 2 and the fork leg guards remove the brake calliper from the L H fork leg loosening the two retaining screws 3 remove the front wheel as described in Se...

Page 229: ...2 I E USA TXC 250 310 2012 I E USA FRONT SUSPENSION Workshop Manual Ed 12 2011 loosen the bolts 4 that secure the fork legs to steering head and bottom yoke remove the fork legs Refit fork legs and front wheel as described in Section Y Set height A back to original value ...

Page 230: ...ws to drain cartridge oil INNER TUBES Special high strength steel chrome plated and TIN coated OUTER TUBES CNC machined aluminium alloy anodised and polished in side SLIDING BUSHES Teflon coated stiction free SEALS Computer designed sealing rings ensure maximum sealing on compression and minimal friction on rebound SPRINGS Steel springs different spring rates K available See Table for more detaile...

Page 231: ...handled by a KAYABA upside down telescopic hydraulic fork with advanced axle and 48 mm legs Wheel travel is 300 mm Key 1 Bottom yoke with pin 2 Steering head 3 Nut 4 Compression valve 5 RH fork leg 6 LH fork leg 7 LH fork leg 8 RH fork leg 9 Ring nut 10 RH outer tube 11 Leg protection 12 Rebound adjuster screw 13 Retaining ring 14 Bushing 15 Bushing 16 Washer 17 Sealing ring 18 Retaining ring 19 D...

Page 232: ...outer tube Note it is good practice to moderately slacken the cap nuts before removing the fork legs from the motorcycle Drain oil from the damper unit Clamp the wheel axle carrier in a vice and loosen the adjuster screw Push down the inner tube Slip the tool shown in the figure between wheel axle carrier and cartridge nut Hold the nut with a wrench and remove the adjuster screw Be careful not to ...

Page 233: ... of the outer tube Do not remove the nut at the bottom end of the cartridge Remove the bottom valve assembly from the cartridge Hold the cartridge octagonal nut with the suitable tool to prevent rotation Use a similar tool in the octagonal recess of the bottom valve assembly Use a key to slacken the bottom valve assembly Check the O rings on the bottom valve assembly for damage Replace as required...

Page 234: ...e and inner tube are still assembled together place the fork leg upside down and allow at least 20 minutes for oil to drain Remove the dust seal using a flat head screwdriver Remove the retaining ring using a flat head screwdriver Pull the inner tube until separating it from the outer tube Note to facilitate removal quickly but carefully pump the tubes back and forth until separating them ...

Page 235: ...ound adjuster rod for distortion or damage Replace as required Check the rebound adjuster Replace damaged O rings Replace the complete assembly do not reuse it Check the spring Replace it if outside diameter is damaged or exceedingly worn Free length is 449 mm 17 7 in or less Check the inner tube Replace if distorted Never attempt to repair or reuse a distorted fork tube If the tube shows surface ...

Page 236: ... sealing ring Note 2 Before sliding the sealing ring over the inner tube cover tube edge with plastic as shown in the figure This will avoid damage to the oil seal lip Fit metal bushing and washer to outer tube using an appropriate installer Fit the oil seal to the outer tube and push it home using an appropriate in staller Make sure that the retaining ring groove inside the outer tube is fully vi...

Page 237: ...he dust seal to the outer tube Make sure that there is not play between dust seal and outer tube Refit the cartridge Tighten the nut all the way onto the rebound adjuster rod Make sure rebound adjuster rod thread length is at least 15 mm 0 6 in Fill the cartridge with the specified oil 196 cm3 11 96 in3 Pump the piston rod up and down repeatedly to remove any air from the cyl inder ...

Page 238: ...way down and install the bottom valve assembly With the bottom valve assembly installed check that the piston rod is fully extended Hold the cartridge octagonal nut to prevent rotation Use a similar tool in the octagonal recess of the bottom valve assembly Tighten the bottom valve assembly to 29 Nm 21 4 ft lb using a wrench Hold the cartridge with the piston rod end pointing downwards as shown in ...

Page 239: ... Be careful not to distort or damage the piston rod or any other parts Please note that excess oil may flow out from the hole located before the res ervoir If you see no oil flowing out it means that there isn t enough oil in the car tridge Add oil to the cartridge before refitting it Drain excess oil from the reservoir Clean off any excess oil from the cartridge Install spring guide and spring on...

Page 240: ...he tool shown in the figure between wheel axle carrier and cartridge nut Insert the rebound adjuster rod into the piston rod and tighten the adjuster screw Be careful not to hurt your fingers Tighten the adjuster screw all the way in Make sure that there is some play between the bottom edge of the adjuster screw and the upper edge of the nut Tighten nut and adjuster to 28 Nm 20 6 ft lb using a wre...

Page 241: ... H06813 H06819 H06855 FRONT SUSPENSION Workshop Manual Ed 12 2011 Clamp the wheel axle carrier in a vice and tighten the adjuster screw onto the carrier to 55 Nm 40 5 ft lb Fill the outer tube with the specified quantity of oil 360 cm3 21 97 in3 Tighten the cylinder onto the outer tube to 29 Nm 21 4 ft lb ...

Page 242: ...nual Ed 12 2011 Front suspension TE Front suspension is handled by a KAYABA upside down telescopic hydraulic fork with advanced axle and 48 mm legs Wheel travel is 300 mm Key 1 Bottom yoke with pin 2 Steering head 3 Nut 4 Cap unit 5 Ring nut 6 RH fork leg 7 LH fork leg 8 LH fork leg 9 RH fork leg 10 Leg protection 11 Damper unit 12 Bottom nut 13 Spring kit 14 LH RH outer tube ...

Page 243: ...al Ed 12 2011 Loosen the cap nut at the top of each outer tube Note it is good practice to moderately slacken the cap nuts before removing the fork legs from the motorcycle Loosen the fork cap nut and the nut with a wrench Remove top cap nut spring retainer spring and rebound adjuster rod Drain the oil Pump the piston rod up and down to drain oil from the cylinder ...

Page 244: ...USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA H10061 H10062 FRONT SUSPENSION Workshop Manual Ed 12 2011 Remove nut spring guide O ring and collar bushing Hold the cartridge top end steady Loosen and remove the bottom valve assembly ...

Page 245: ... 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA H06868 H06869 FRONT SUSPENSION Workshop Manual Ed 12 2011 Take the cartridge out of the outer tube Remove the dust seal using a flat head screwdriver ...

Page 246: ...tate removal quickly but carefully pump the tubes back and forth until separating them Remove the sealing rings and the metal rings mounted on the inner tube Do not reuse any metal parts after removal Replace them with new components Replace damaged sealing rings Washer and retaining ring may be reused if they are not damaged Check the rebound adjuster rod for distortion or damage Replace as requi...

Page 247: ...rk tube If the tube shows surface defects sand the surface If repair is not possible replace the tube Never reuse an inner tube if scored or showing bulges on the outer surface Check the outer tube Replace the tube is any distortion is detected or if the sliding surface is dam aged Mount sealing rings and metal parts on the inner tube See the figure below for the installation sequence Note 1 Greas...

Page 248: ...be using an appropriate installer Fit the oil seal to the outer tube and push it home using an appropriate in staller Make sure that the retaining ring groove inside the outer tube is fully visible Install the retaining ring Make sure that the retaining ring is fully seated in the groove inside the outer tube Fit the dust seal to the outer tube Make sure that there is not play between dust seal an...

Page 249: ...A TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA H06868 H06871 FRONT SUSPENSION Workshop Manual Ed 12 2011 Insert the cartridge into the outer tube Hold the cartridge top end into place Tighten the bottom valve assembly to 55 Nm 40 5 ft lb ...

Page 250: ...ound adjuster rod into the piston rod Make sure that at least an 18 mm 0 71 in portion of the rebound adjuster rod protrudes from the piston rod Fill the damper unit with the specified quantity of oil 674 cm3 41 13 in3 Slowly pump the piston rod up and down to help oil reach all points of the car tridge Note if you haven t drained all oil from the damper unit on disassembly follow the procedure ou...

Page 251: ...w slowly pump the piston rod up and down to help oil reach all points of the cartridge Note add oil if level in the damper unit is too low Finally top up to the upper edge of the outer tube Allow the fork leg to rest until no more air bubbles can be seen then top up oil to specified level Check that the level is at distance of 115 mm 4 52 in below the upper limit of rods Insert the rebound adjuste...

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Page 253: ...J 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA J REAR SUSPENSION Workshop Manual Ed 12 2011 Section ...

Page 254: ...Workshop Manual Ed 12 2011 Sommario Rear shock absorber J 3 Lubrication points grease J 3 Rear suspension J 4 Rear shock absorber removal J 4 Disassembling and servicing the swinging arm J 5 Servicing the swinging arm shaft J 6 Servicing the rear suspension drop and drag link J 6 Chain roller chain guide chain slider J 7 ...

Page 255: ... 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA H10106 1 H10107 2 REAR SUSPENSION Workshop Manual Ed 12 2011 Rear shock absorber TIGHTENING TORQUE FIGURES 1 2 52 4 Nm 5 35 Kgm 38 6 ft lb Lubrication points grease ...

Page 256: ...raulic damping is also adjustable using outer adjuster screws Periodically check all components for wear Rear shock absorber removal Set a block under the engine and see that the rear wheel is lifted from the ground Remove saddle side panels silencer and rear chassis see Section E General Procedures Loosen the front clamp 1 of the intake coupling Remove the front bolt 2 securing the suspension lin...

Page 257: ...hassis Remove the wheel axle nut 5 and the wheel axle B There is no need to loosen the chain tensioners 6 on the swinging arm in this way the chain tension will re main unchanged after reassembly Extract the complete wheel C keeping the spacers located at the hub sides Remove the shock absorber 7 as described at page J 3 Remove the swinging arm shaft nut 8 and then the swinging arm Check swinging ...

Page 258: ...it 0 30 mm Servicing the rear suspension drop and drag link With drop link 1 and drag link 2 still in place connected to swinging arm and chassis respectively rock them both back and forth in all directions to check for radial and axial clearance Some axial clearance in the drop drag link is required for the swinging arm to achieve the ideal position for proper operation If any radial clearance is...

Page 259: ...hop Manual Ed 12 2011 Chain 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 1 Chain roller 2 Chain guide 3 Chain slider a Master link clip ...

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Page 261: ...L 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA L BRAKES Workshop Manual Ed 12 2011 Section ...

Page 262: ...0 2012 I E USA TXC 250 310 2012 I E USA BRAKES Workshop Manual Ed 12 2011 Sommario Braking system L 3 Brake disc L 4 Checking brake pads for wear replacing the pads L 5 Bleeding the front braking system L 6 Bleeding the rear braking system L 7 Changing the fluid L 8 ...

Page 263: ...two independent circuits Each system is equipped with a brake calliper connected to a master cylinder with a fluid reservoir 1 Front brake lever 2 Front brake master cylinder with fluid reservoir 3 Front brake line 4 Front brake calliper 5 Front brake disc 6 Rear brake fluid reservoir 7 Rear brake line 8 Rear brake calliper 9 Rear brake disc 10 Rear brake master cylinder 11 Rear brake control peda...

Page 264: ...other dirt or deep scoring Front brake disc diameter 260 mm Front brake disc thickness when new 3 0 mm Wear limit 2 5 mm Rear brake disc diameter 240 mm Rear brake disc thickness when new 4 0 mm Wear limit 3 5 mm Disc warpage must not exceed 0 15 mm check disc mounted on the rim with a dial gauge To remove the disc from the wheel rim you need to loosen the four retaining screws Onassembly cleanall...

Page 265: ... the pads or disc Replace the pads with new ones if they cannot be cleaned satisfactorily PADS REMOVAL Remove clips 1 Slide out pins 2 Remove pads Do not work the brake lever or pedal while removing the pads PADS INSTALLATION Install new brake pads Reassemble the two pins 2 and the clips 1 The above procedure eliminates the need to bleed the braking system after replacing the pads Simply operate t...

Page 266: ... seconds then repeat a few times the proce dure described in the line above until the liquid comes out of the transparent hose without bubbles Tighten the bleed valve to the indicated torque restore the fluid level A and refit the rubber gaiter and cover 2 of the tank Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure Brake fluid is corrosive In...

Page 267: ...will come out then close the valve 1 always keeping the pedal lowered then release the pedal Top up the fluid level wait a few seconds then repeat a few times the proce dure described in the line above until the liquid comes out of the transparent hose without bubbles Tighten the bleed valve to the specified torque and check fluid level B in the reservoir before refitting the cap A If the bleeding...

Page 268: ...ainer DOT 4 Never reuse brake fluid Avoid the ingress of contaminants such as dirt water etc into the reservoir Do not keep the reservoir open without its cover longer than nec essary this would increase the risk of contamination Handle the fluid with care to avoid damage to painted parts Do not mix two brands of fluid This would reduce boil over point leading to loss of braking efficiency or degr...

Page 269: ... lever or the pedal Repeat this operation a few times until the oil is completely drained Fill the reservoir 2 or 2A with the new fluid Pull and hold the lever 3 or press and hold the pedal 3A so that the system is under pressure loosen the valve 1 or 1A tighten the valve 1 or 1A always holding the lever pulled or the pedal pressed then release Top up the fluid level 2 or 2A and repeat a few times...

Page 270: ...E 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA BRAKES Workshop Manual Ed 12 2011 Periodicallychecktheconnectinghoses C and D seeScheduledMaintenance Chart Section B replace worn or cracked hoses ...

Page 271: ...M 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA M ELECTRICAL SYSTEM Workshop Manual Ed 12 2011 Section ...

Page 272: ...M 24 Starter motor M 24 No load test M 24 Cranking test M 24 Starter motor test curves TE TXC M 24 Solenoid starter inspection TE TXC M 24 Checking coil windings resistance TE TXC M 25 Coil windings resistance inspection TC M 26 Electronic control unit ECU M 27 Spark plug M 27 Gear position sensor inspection GPS Gear Position Sensor TE TXC M 28 Battery TE TXC M 29 Battery charger M 29 Headlamp tai...

Page 273: ...gine ground to battery cables 8 TE TXC M 47 Battery negative cable routing TE TXC M 47 Securing the voltage regulator ground cable 9 TE TXC M 48 Securing the engine ground chassis ground cables 10 M 48 Wiring connection to voltage regulator TE TXC M 48 Connection of relays and fuses TE TXC M 49 Electric fan connection TE TXC M 49 Injector connection TE TXC M 49 Ignition coil connection TE TXC M 49...

Page 274: ...M 4 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ELECTRICAL SYSTEM Workshop Manual Ed 12 2011 ...

Page 275: ...r coding key B Blue Bk Black O Orange R Red W White Br Brown G Green P Pink V Violet Y Yellow Key to wiring diagram 1 Electronic control unit 2 Control unit interface 3 Engine stop 4 Not used 5 Coil Stick coil 6 Map change connector 7 Voltage regulator 8 Alternator 9 Fuel pump 10 Condenser 11 Injector 12 Air temperature sensor 13 Coolant temperature sensor 14 Air pressure sensor 15 Throttle positi...

Page 276: ... Speed sensor 12 DC relay 13 L H switch 14 Dashboard 15 MAP change push button 16 Battery 17 Solenoid starter 18 Starter motor 19 Voltage regulator 20 Alternator 21 Gear sensor 22 M A Q S 38 39 40 23 Power relay 24 Fuses 25 Injector 26 R H switch 27 Front stop light switch 28 Rear stop light switch 29 Horn 30 Turning indicators flasher 31 Rear R H turning indicator 32 Tail light 33 Rear L H turnin...

Page 277: ...nsor 4 HT coil 5 Fuel level 6 Fuel pump 7 Electric fan relay 8 Lambda sensor 9 Cooling fan 10b Generator warning light 12V 2W RED 10a Fuel reserve warning light 12V 2W ORANGE 11 Battery 12 Solenoid starter 13 Starter motor 14 Voltage regulator 15 Alternator 16 Gear sensor 17 M A Q S 22 23 24 18 Power relay 19 Fuses 20 Injector 21 R H switch 22 Pressure sensor 17 23 Throttle position sensor 17 24 A...

Page 278: ... ignition system includes the following elements Generator 1 on the inner side of L H crankcase half cover Coil with integrated spark plug cap Stick Coil 2 fitted on the engine head Electronic control unit 3 under the fuel tank Voltage regulator 4 under the tank Throttle position sensor 5 on the LH of the throttle body Atmospheric pressure sensor 6 on the upper part of the throttle body Fuel pump ...

Page 279: ... Condenser 9 connected to a plate strapped to the throttle body Electrical components location TE The ignition system includes the following elements Generator 1 on the inner side of L H crankcase half cover Electronic ignition coil 2 under the fuel tank Electronic control unit 3 under the fuel tank Spark plug 4 on cylinder head Voltage regulator 5 under the fuel tank over the electronic control u...

Page 280: ...hop Manual Ed 12 2011 12V 350W starter motor 6 behind the cylinder Solenoid starter 7 on left side of rear chassis M A Q S sensor air temperature pressure throttle position 8 on throttle body The electrical system includes the following elements 12V 6Ah battery 9 under the saddle Turning indicators flasher 10 on left side of rear chassis ...

Page 281: ...ide of rear chassis Fan Relay 12 electric fan on right side of rear chassis DC Relay 13 light system turning indicators horn on right side of rear chassis Fuses 14 15 16 on rear mudguard right side Fuse 14 15A coil injection system fuel pump Fuse 15 15A dashboard parking lights control unit Fuse 16 20A electric fan light system turning indicators horn Electric fan 17 Coolant temperature sensor 18 ...

Page 282: ...TC 250 2012 I E USA TXC 250 310 2012 I E USA 23 H02304 ELECTRICAL SYSTEM Workshop Manual Ed 12 2011 Headlamp 20 with 12V 35 35W twin halogen bulb and 12V 5W parking light bulb LED tail light 21 Turning indicators 22 12V 10W bulbs Fuel pump 23 inside the fuel tank ...

Page 283: ...nual Ed 12 2011 Electrical components location TXC The ignition system includes the following elements Generator 1 on the inner side of L H crankcase half cover Electronic ignition coil 2 under the fuel tank Electronic control unit 3 under the fuel tank Spark plug 4 on cylinder head Voltage regulator 5 under the fuel tank over the electronic control unit 3 ...

Page 284: ...250 2012 I E USA TXC 250 310 2012 I E USA H10119 6 ELECTRICAL SYSTEM Workshop Manual Ed 12 2011 12V 350W starter motor 6 behind the cylinder Solenoid starter 7 on left side of rear chassis M A Q S sensor air temperature pressure throttle position 8 on throttle body ...

Page 285: ...ectrical system includes the following elements 12V 6Ah battery 9 under the saddle Relay 10 coil injection system fuel pump on right side of rear chassis Relay 11 electric fan on right side of rear chassis Fuses 12 13 14 on rear mudguard right side Fuse 12 15A coil injection system fuel pump Fuse 13 15A control unit Fuse 14 20A electric fan Electric fan 15 ...

Page 286: ...SA H02308 TE TXC H10991 TE TXC TC 18 H11128 ELECTRICAL SYSTEM Workshop Manual Ed 12 2011 Coolant temperature sensor 16 Lambda sensor 17 Fuel pump 18 inside the fuel tank Checking generator stator windings resistance Disconnect the stator coil connector from the wiring and measure resistance with a meter ...

Page 287: ...e terminals of the connector 1 correct value is about 0 6 If resistance is outside the specified limits replace the complete generator Generator no load performance TE TXC RPM A D C typical 1200 8 6 2000 13 8 3000 15 5 5000 16 4 6000 16 6 TC r p m Standard value 700 2 5A Min 1500 4 5A Min 10000 10A Max AT EACH ENGINE OVERHAUL CLEAN FLYWHEEL ROTOR TO REMOVE ANY DEBRIS SUSPENDED IN SWIRLING OIL AND ...

Page 288: ...d of the surrounding environment at each given moment The sensors are a crankshaft position sensor pick up a temperature sensor of the filter box ambient air a coolant temperature sensor a throttle position sensor and a pressure sensor on the throttle body 7 Voltage regulator 8 Alternator 9 Fuel pump 10 Condenser 11 Injector 12 Air temperature sensor 13 Coolant temperature sensor 14 Air pressure s...

Page 289: ...ick up a temperature sensor of the filter box ambient air and a group of sensors MAQS on the throttle body that provide information about pressure air temperature and position of the throttle opening Moreover the ECU uses a lambda probe for the constant adjustment of the air fuel ratio Euro3 mode Key 1 Electronic control unit 2 Control unit interface 3 Coolant temperature sensor 4 HT coil 6 Fuel p...

Page 290: ...y to wiring diagram 1 Electronic control unit 2 Control unit interface 3 Coolant temperature sensor 4 HT coil 6 Fuel pump 7 Electric fan relay 8 Lambda sensor 9 Cooling fan 11 Battery 12 Solenoid starter 13 Starter motor 14 Voltage regulator 15 Alternator 16 Gear sensor 17 M A Q S 22 23 24 18 Power relay 19 Fuses 20 Injector 21 R H switch 22 Pressure sensor 17 23 Throttle position sensor 17 24 Air...

Page 291: ...lator rectifier 2 Starter relay 3 Battery 4 The alternated current generated by the alternator is converted into direct cur rent by the voltage regulator rectifier The voltage regulator rectifier serves a dual purpose it provides overvoltage protection for the battery and converts alternated current into direct current All components listed above help keep voltage constant and protect the battery ...

Page 292: ...attery With the engine warmed up and running at slightly above 3000 rpm measure voltage across the positive and negative terminal of the battery using a meter the battery must be charged when performing this test If reading is outside a 12 5 14 5 V range check generator and voltage regulator rectifier as described in the relevant paragraph Voltage regulator rectifier inspection TE TXC With the ign...

Page 293: ...10124 TXC 25 37 18 17 16 ELECTRICAL SYSTEM Workshop Manual Ed 12 2011 Electrical starting system TE TXC The starting system is composed of Battery 16 Solenoid starter 17 Starter motor 18 R H switch 25 Clutch microswitch 27 TE Ignition switch 26 TE Fuses 37 For a description of wires and components please see the key to the wiring diagram ...

Page 294: ...m Cranking test Voltage 10 V Current 80 A Torque 3 5 Nm 0 35 Kgm 2 5 ft lb Starter motor test curves TE TXC 1 Output power W 2 Torque TQ 3 RPM N rpm x 1000 4 Light voltage V 5 Charging current A Solenoid starter inspection TE TXC Disconnect the cables at the battery negative terminal to avoid possible short circuits during disassembly Disconnect the starter relay connector A Disconnect the starter...

Page 295: ...e in the primary and secondary windings with a meter Inductive coil Primary winding resistance 4 5 15 at 20 C Secondary winding resistance 19 5 K 20 at 20 C without spark plug cap cable If resistance is outside the specified limits replace the coil Also check the resistance of the terminal cap contacting the spark plug Terminal cap resistance 4 5 5 5 K 5 at 20 C If resistance is outside the specif...

Page 296: ...on TC Disconnect the connector 1 from the coil 2 Remove the coil 2 as described in the relevant paragraph Measure primary and secondary winding resistance with a meter Primary winding resistance 0 09 15 at 20 C Secondary winding resistance Open circuit If resistance is outside the specified limits replace the coil Terminal cap resistance 5 7 K 20 at 20 C If resistance is outside the specified limi...

Page 297: ...d NGK CR9EI TC spark plug Check electrode gap A A wider gap may cause difficulties in starting the engine and overload the coil Agap that is too narrow may cause difficulties when accelerating when idling or poor performance at low speed Clean off any dirt around spark plug base before removing the spark plug It is good practice to closely inspect the spark plug after removal as any deposits on it...

Page 298: ...ne meter probe to engine ground and insert the other probe into the connector hole for the WHITE BLACK gear sensor wire 2 The lever 3 is placed on the left hand side of the engine After each gear shift it automatically returns to the horizontal position First gear is engaged by pushing the lever downwards for other gears push it upwards Check the read ings provided in the relevant table TE TXC A N...

Page 299: ...ling first connect the RED positive cable then the BLACK negative cable remove the battery 1 from its housing Check using a voltmeter that battery voltage is not less than 12 5 V If it is not so the battery needs to be charged Using a battery charger with a constant voltage first connect the RED positive cable to the battery positive terminal then the BLACK negative cable to the battery negative t...

Page 300: ...m the ground to the centre of the lamp and draw a cross on the wall at the same height When the low beam is on the upper edge between dark and lit zone should be at 9 10th of the height of headlamp centre from ground Beam height can be raised or lowered turning the screw 1 Headlamp bulbs replacement Proceed as follows to reach the headlamp bulbs remove the upper retaining screw securing headlamp f...

Page 301: ... Extract the tail light 2 and disconnect the connector 3 Once the tail light has been replaced reverse the above procedure to reas semble Be careful not to overtighten the screws Number plate bulb replacement Loosen screw 1 and remove the number plate bulb 2 from the mudguard Extract the bulb holder 3 with the bulb 4 from the housing Pull the bulb 4 to detach it from bulb holder Once the tail ligh...

Page 302: ... hand switch TC 1 Engine stop switch TC POSITION COLOUR Left hand switch TE 1 High beam flasher self cancelling 2 High beam switch Low beam switch 3 Left hand turning indicators self cancelling Right hand turning indicators self cancelling To deactivate the turning indicators press the control lever after it is returned to the centre 4 Horn Colour coding key B Blue Bk Black B Bk Blue Black B W Blu...

Page 303: ...2012 I E USA TXC 250 310 2012 I E USA H01040 H01041 B Bk Br Y Sb Br H10131 1 2 ELECTRICAL SYSTEM Workshop Manual Ed 12 2011 Right hand switch TE TXC 1 Engine start button 2 Engine start stop switch Colour coding key B Blue Br Brown Br Bk Brown Black Y Sb Yellow Sky blue ...

Page 304: ...e cause before replacing it Never replace a fuse with another fuse with a different rating Never use a wire or other makeshift repair techniques instead of installing a new fuse Semiconductor parts Be careful to never drop parts that incorporate a semiconductor such as the ECU or the voltage regulator rectifier Closely follow the relevant instructions when inspecting these parts An improper proced...

Page 305: ... tank as described in Section E Remove the relays 1 located on the R H side of the chassis A Set the meter to the Impedance scale and check the energiser coil for proper operation Reading should be 80 Ohm 10 at 20 C B Set the meter to Continuity mode and check the circuit is open C Feed the coil from a power supply unit with stable 12V output and make sure that the circuit closes LOWER VIEW ...

Page 306: ...hboard does not show any functions To select dashboard functions and reset functions use the SCROLL button A The functions available in the sequence are as follows 1 SPEED ODO 2 SPEED CLOCK 3 SPEED TRIP 4 SPEED LAP TIMER 5 SPEED RPM engine r p m numerical value 1 SPEED ODO IMPORTANT In the event of a FUEL INJECTION SYSTEM MALFUNCTION the word FAIL appears on the right side of the dashboard display...

Page 307: ...D TRIP 1 figure 3 SPEED speed maximum value 299 Km h or 299 mph TRIP 1 distance maximum value 999 9 km or 621 31 mi data will be lost after disconnecting the battery To reset TRIP push the SCROLL button A and hold for more than 3 sec onds 4 SPEED LAP TIMER STP figure 4 SPEED speed maximum value 299 Km h or 299 mph STP 1 miles kilometres covered time Reading from 0 00 to 99 59 59 data will be lost ...

Page 308: ...ph NUMBER OF RPM MIN 500 MAX 14250 The display also provides a fuel injection Fail indication the latter takes prior ity over any other indication FAIL a FUEL INJECTION SYSTEM MALFUNCTION indicated by the word FAIL appearing in the right hand portion of the dashboard display Warning lights panel TXC The motorcycle is fitted with a small warning lights panel with two warning lights 1 Red warning li...

Page 309: ...ragraph Checking generator stator wind ings resistance 4 incorrect no load performance of generator see paragraph Generator no load performance 5 voltage regulator malfunction see paragraph Voltage regulator rectifier inspection a battery overload indicates 1 faulty voltage regulator see paragraph Voltage regulator rectifier inspec tion 2 faulty battery see paragraph Current loss at the battery St...

Page 310: ... 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA 1 2 3 4 5 6 7 H10133 4 ELECTRICAL SYSTEM Workshop Manual Ed 12 2011 1 Engine stop button 2 Coil Stick coil 3 Control unit 4 Voltage regulator 5 Main wiring harness 6 MAP sensor 7 Condenser Wiring TC ...

Page 311: ...ructions TC Position of the coil stick coil Connect the coil stick coil 1 as the figure shows Fuel injection control unit position 2 TC Electronic control unit installed with the flat side up Position of the voltage regulator 3 TC Positioned on the RH under the tank Position of the connectors front side On the front side under the fairing the following connectors are to be found 1 Mapping connecto...

Page 312: ...l Ed 12 2011 Control unit connection TC Connect the control unit connector 4 as shown Ignition coil stick coil connection TC Connect the ignition coil stick coil connector 5 as outlined Air temperature sensor connection TC Connect the air temperature sensor 6 as outlined Connection of the injector sensor 7 throttle position sensor 9 and MAP sensor 8 Connect the connectors as outlined ...

Page 313: ...hown Securing the wiring TC Fasten the alternator cable to the clutch tube by means of the clamps 1 Fasten the condenser connector 2 to the support bracket by means of the clamp 3 Fasten the harness to the chassis with the clips 4 as shown Fasten the cables coming from the front part of the bike to the chassis by means of the openable clamp 5 Fasten the front cables with a clamp 6 Securing the eng...

Page 314: ...A TXC 250 310 2012 I E USA H11012 11 10 H11013 12 ELECTRICAL SYSTEM Workshop Manual Ed 12 2011 Voltage regulator connection TC Connect the connector 10 as shown Connection of alternator TC Connect the connector 11 as shown Condenser connection TC Connect the connector 12 as shown ...

Page 315: ...M 45 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA TE H00973 H10150 TXC ELECTRICAL SYSTEM Workshop Manual Ed 12 2011 Wiring TE TXC ...

Page 316: ...SYSTEM Workshop Manual Ed 12 2011 Cable routing and electrical parts installation instructions TE TXC Coil position TE TXC Connect the HT coil as shown in the figure Relay 1 and fuses 2 position TE TXC On right side of motorcycle Turning indicators flasher 3 TE and solenoid starter position TE TXC On left side of motorcycle ...

Page 317: ...stalled over the electronic control unit Coat voltage regulator with heat grease Securing the starter motor solenoid starter cable TE TXC Connect the starter motor solenoid starter cable 7 as shown in the figure Securing the engine ground to chassis and engine ground to battery cables 8 TE TXC The engine ground to chassis and engine ground to battery cables are secured to the timing chain tensione...

Page 318: ...ator ground cable to the right hand screw of the injection coil Securing the engine ground chassis ground cables 10 Electrical system ground Secure the engine ground chassis ground cable and the wiring harness ground eye terminal to the coil retaining screw Wiring connection to voltage regulator TE TXC Connect the connector 11 to the regulator Pay attention to the routing of radia tor breather hos...

Page 319: ...t the cable marked FAN to relay 13 Connect the cable marked DC to relay 14 TE only fuses Connect the cable marked POW to fuse 15 Connect the cable marked MAN to fuse 16 Connect the cable marked FAN TXC to fuse 17 Connect the cable marked DC FAN TE to fuse 17 Electric fan connection TE TXC Connect the electric fan connector 18 Injector connection TE TXC Connect the connector 19 to the throttle body...

Page 320: ...onnector position TE TXC Position the fuel pump connector 21 as shown MAQS connector TE TXC Connect the connector 22 as shown Engine water temperature connector TE TXC Connect the engine water temperature connectors 23 to the thermostat Lambda sensor position and connector TE TXC Tighten the Lambda sensor 24 in the corresponding seat Connect the Lambda sensor connector 25 as shown ...

Page 321: ...he ignition 26 and gear sensor 27 connectors as shown Routing of rear chassis cables tail light connection flasher contactor Route the rear end of the wiring 28 as shown in the figure Connect the tail light turning indicators connector 29 TE Connect the connector 30 to the flasher TE Connect the connector 31 to the solenoid starter Clip installation on fuse holders Install the suitable clips 33 on...

Page 322: ...n Connect the wiring connector A to the rear STOP sensor Routing of steering head tube wiring Secure the wiring harness with the suitable clip 34 Dashboard bracket connectors TE Secure the dashboard 35 and diagnostic 36 connector using the suitable clips Fit the cap 37 to the diagnostic connector 36 Headlamp front turning indicators STOP connection TE Connect the headlamp unit to the connector 38 ...

Page 323: ...H02328 40a V H03072 H11137 ELECTRICAL SYSTEM Workshop Manual Ed 12 2011 Double map connector TE Connect the connector 40 Speed sensor and ignition switch connectors TE Connect the speed sensor connector Connect the connector 41 of the ignition switch 42 Horn connector TE Connect the connector 43 to the horn ...

Page 324: ... rear chassis right side Strap wiring to rear chassis with clips as shown in the figure Securing the wiring harness to rear chassis left side Secure wiring harness with a clip as shown in the figure Securing the wiring harness to the chassis Strap wiring harness to chassis on right and left side with clips as shown in the figure Position the GPS and Pick Up connectors 27 as shown ...

Page 325: ...A ELECTRICAL SYSTEM Workshop Manual Ed 12 2011 Secure the generator connector as shown 26 Secure the ignition gear sensor and Lambda sensor wiring loom to the clutch hose with two clips Secure the ignition and gear sensor wiring loom to the clutch hose Secure the front wiring loom with two clips as shown ...

Page 326: ...ly protect the following parts from water a Rear opening of the muffler b Clutch and front brake levers handgrips handlebar switches c Air filter intake d Steering head wheel bearings e Rear suspension drag drop link In addition to these precautions NEVER ALLOW HIGH PRESSURE AIR OR WATER to get in contact with any ELECTRICAL PARTS the FUEL INJECTION SYSTEM and especially the electronic control uni...

Page 327: ...N 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA N ENGINE COOLING Workshop Manual Ed 12 2011 Section ...

Page 328: ... 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA ENGINE COOLING Workshop Manual Ed 12 2011 Sommario Coolant level check N 3 Cooling circuit TC N 4 Engine cooling system overhaul TC N 5 Cooling circuit TE TXC N 6 Engine cooling system overhaul TE TXC N 7 ...

Page 329: ...ater no heat exchange occurs between cylinder head and radiator The cylinder and piston assembly will overheat and seize and in the worst scenario crankshaft damage may result If the event of engine overheating check that the radiator is full Level in the radiator must be checked from cold see Section D In the event you need to check level when the engine is hot be sure to discharge pressure gradu...

Page 330: ...rced circulation cooling system uses a centrifugal pump located to the left of the head and two down draft radiators 1 Radiator cap 2 Right hand radiator 3 Left hand radiator 4 Fitting 5 Water pump 6 Breather hose 7 Radiator connecting pipe 8 Radiators to cylinder head pipe 9 Water pump to fitting pipe 10 Fitting to left hand radiator pipe 11 Fitting to right hand radiator pipe ...

Page 331: ...ir flow and must be removed carefully to avoid damage to radiator Straighten any bent fins to ensure free flow of air If the cooling mass is clogged or damaged no more than 20 of its surface must be affected If damage exceeds this limit the radiator must be replaced Periodically check the connecting hoses see Section B Scheduled Maintenance Chart this will avoid coolant leakage and consequent engi...

Page 332: ...rcuit TE TXC The forced circulation cooling system uses a centrifugal pump located to the left of the head and two down draft radiators 1 Radiator cap 2 Right hand radiator 3 Left hand radiator 4 Thermostat 5 Water pump 6 Breather hose 7 Radiator connecting pipe 8 Radiators to cylinder head pipe 9 Water pump to fitting pipe 10 Thermostat to radiators pipe 11 Cooling fan ...

Page 333: ... removed carefully to avoid damage to radiator Straighten any bent fins to ensure free flow of air If the cooling mass is clogged or damaged no more than 20 of its surface must be affected If damage exceeds this limit the radiator must be replaced Periodically check the connecting hoses see Section B Scheduled Maintenance Chart this will avoid coolant leakage and consequent engine seizure If hoses...

Page 334: ......

Page 335: ...P 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA P HYDRAULICALLY CONTROLLED CLUTCH Workshop Manual Ed 12 2011 Section ...

Page 336: ...A TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA HYDRAULICALLY CONTROLLED CLUTCH Workshop Manual Ed 12 2011 Sommario Hydraulic clutch system P 3 Draining clutch fluid P 4 Clutch master cylinder servicing P 5 Bleeding the clutch system P 6 ...

Page 337: ...essure plate 6 Drive is transmitted from the crankshaft a to the gearbox input shaft b via the gear on the clutch housing 8 The clutch housing accommodates friction plates 9 and steel plates 10 that operate the clutch hub 11 secured to the gearbox input shaft 1 Clutch master cylinder 2 Clutch lever 3 Master cylinder to piston hose 4 Pushrod 5 Piston assembly 6 Pressure plate 7 Bleed fitting 8 Clut...

Page 338: ...I E USA H10159 H10160 2 3 4 HYDRAULICALLY CONTROLLED CLUTCH Workshop Manual Ed 12 2011 Draining clutch fluid Connect a plastic hose to the bleed valve 1 and the loosen the valve turning it back 1 or 2 turns Remove reservoir cap 2 and gasket 3 and operate the control lever 4 until draining all fluid ...

Page 339: ...kshop Manual Ed 12 2011 Clutch master cylinder servicing Drain the circuit detach the master cylinder from the left side of the handlebar and take it apart Replace all seals reassemble the master cylinder and refit it to the handlebar Reconnect the hose and fill fresh fluid into the reservoir bleed the system as described in the relevant paragraph ...

Page 340: ... in the lubricant table see Sec tion A Pull the lever 4 and keep it pulled so that the system remains under pres sure loosen the valve 2 tighten the valve 2 always with the lever pulled then release the lever Top up the fluid level wait a few seconds then repeat a few times the proce dure described in the line above until the liquid comes out of the transparent hose without bubbles Lock the valve ...

Page 341: ...S 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA S FUEL INJECTION SYSTEM Workshop Manual Ed 12 2011 Section ...

Page 342: ...kshop Manual Ed 12 2011 Sommario Injection fuel feeding system TE TXC S 3 Injection fuel feeding system TC S 4 Operation Manual for HUSQVARNA SERVICE TOOL for injection fuel feeding system TE TXC S 5 Operation Manual for HUSQVARNA SERVICE TOOL for injection fuel feeding system TC S 7 Fuel pump test TE TXC S 8 Fuel pump test TC S 9 ...

Page 343: ...r the tank signals the injector to open and a fan shaped spray of fuel is injected into the combustion chamber The parameters that play a role in determining proper fuel delivery under all operating conditions are as follows Air temperature in the intake manifold Engine coolant temperature Atmospheric pressure in the intake manifold in current location and at cur rent altitude Throttle opening Bat...

Page 344: ...ector to open and a fan shaped spray of fuel is injected into the combustion chamber The parameters that play a role in determining proper fuel delivery under all operating conditions are as follows Air temperature in the intake manifold Engine coolant temperature Atmospheric pressure in the intake manifold in current location and at cur rent altitude Throttle opening Gear shift position Fuel inje...

Page 345: ... instructions provided in the User Guide proceed as follows Remove the front headlight fairing number holder as described in the relevant section slip off the cap B of the ECU interface connector C connect the Kit cable 3 to the connector C Connect the USB cable 4 to the PC TE Turn the ignition key F to ON TXC Check that switch G is in RUN position start the Diagnostic Tool software you have insta...

Page 346: ...at have been resolved store malfunc tions can be deleted following the instructions provided in the Operation Manual The ECU stores the number of service hours of the engine toler ance range 1 hour The first equipment ECU also stores the vehicle identification number VIN and engine number engine no of the motorcycle If ECU is replaced the new ECU will only report engine service hours For fuel pump...

Page 347: ...stic Tool Software according to the instructions provided in the User Guide proceed as follows Remove the saddle and disconnect the fuel pump connector Slip off the cap B of the ECU interface connector C Connect the Kit cable 5 to the connector C Connect the USB cable 4 to the PC Connect the cable 5 to the battery clamps cable 6 Connect the clamps to the battery according to the polarity Start the...

Page 348: ...YSTEM Workshop Manual Ed 12 2011 Fuel pump test TE TXC Remove the pump as described in Section E pump operation Connect the RED and BLACK wires on the pump connector to a power supply unit with constant 12V output and make sure that the pump runs Never keep the pump connected to the power supply unit for more than 3 seconds in a row ...

Page 349: ...l reserve sensor Make sure there is no fuel left in the sensor and then set the meter to the Impedance scale and measure across the BLUE and WHITE wires Cor rect value is as follows 1 3 KOhm 10 at 20 C B pump operation Connect the RED and BLACK wires to a power supply unit with con stant 12V output and make sure that the pump runs Never keep the pump connected to the power supply unit for more tha...

Page 350: ......

Page 351: ...W 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA W SPECIAL TOOLS Workshop Manual Ed 12 2011 Section ...

Page 352: ...L TOOLS Workshop Manual Ed 12 2011 SPECIAL TOOLS 1 8000 A7015 Crankcase puller 2 8000 A1580 T D C timing tool 3 8000 H2146 Flywheel puller 5 8000 A7345 Jig TC 8000 H7345 Jig TE TXC 7 8000 A7317 Valve installation removal tool 8 8000 A1625 Dial gauge mount 11 8000 79015 Clutch hub tool 13 1519 84701 Spring hook 16 8000 95749 Spark plug tool ...

Page 353: ... or a screw might become damaged or work itself loose causing damage to motorcycle and injury to rider An overtightened nut or screw might become damaged its thread might strip or the nut screw might fail and work itself loose Listed in the table are the tightening torque figures for the most important nuts and screws which have determined in accord ance with thread diameter pitch and specific app...

Page 354: ...d bolt TC 1 20 Nm 2 40 Nm 2 0 Kgm 4 1 Kgm Drive and transmission Flanged nut M16 Drive gear 100 Nm 10 2 Kgm Timing system Cheese headed Phillips screw M4 L10 Flanged shaft 3 Nm 0 3 Kgm Screw TEF M6 L8 D14 Chain tensioner closure 8 Nm 0 8 Kgm Screw TEF M6 L20 Chain tensioner 8 Nm 0 8 Kgm Special M6x1 screw Slider use LOCTITE 243 8 Nm 0 8 Kgm Crankcase Screw TSEI M5 L12 Crankshaft bearing plate LOCT...

Page 355: ...L20 Pressure plate 8 Nm 0 8 Kgm Screw TCEI M6 L16 Clutch cylinder 8 Nm 0 8 Kgm Screw TCEI M6 L12 Clutch cylinder 8 Nm 0 8 Kgm Starting system Screw TCEI M5 L30 Starter motor TE TXC 6 Nm 0 6 Kgm Short nut M6x1 Gear to starter motor shaft TE TXC LOCTITE 270 8 Nm 0 8 Kgm Screw TCEI M5 L20 Bevel drive body TE TXC 6 Nm 0 6 Kgm Screw TEF M8 L 15 Kick start lever TE TXC LOCTITE 272 25 Nm 2 55 Kgm Screw T...

Page 356: ...11 TIGHTENING TORQUE FIGURES 5 CHASSIS 99669 1 Nm 0 73756 ft lb NOTE 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 TIGHTENING TORQUE FIGURES 5 HANDLEBAR AND CONTROLS 99669 ...

Page 357: ... TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA TIGHTENING TORQUE FIGURES Workshop Manual Ed 12 2011 TIGHTENING TORQUE FIGURES 5 FRONT SUSPENSION 99669 TIGHTENING TORQUE FIGURES 5 REAR SUSPENSION 99669 1 Nm 0 73756 ft lb 1 Nm 0 73756 ft lb ...

Page 358: ...012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA TIGHTENING TORQUE FIGURES Workshop Manual Ed 12 2011 TIGHTENING TORQUE FIGURES 5 FAIRINGS AND MUDGUARDS 99669 1 Nm 0 73756 ft lb ...

Page 359: ...A TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA TIGHTENING TORQUE FIGURES Workshop Manual Ed 12 2011 TIGHTENING TORQUE FIGURES 5 ELECTRICAL SYSTEM 99669 1 Nm 0 73756 ft lb TIGHTENING TORQUE FIGURES 5 FUEL SYSTEM 99669 1 Nm 0 73756 ft lb ...

Page 360: ...USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA TIGHTENING TORQUE FIGURES Workshop Manual Ed 12 2011 TIGHTENING TORQUE FIGURES 5 WHEELS AND BRAKES 99669 1 Nm 0 73756 ft lb TIGHTENING TORQUE FIGURES 5 EXHAUST 99669 1 Nm 0 73756 ft lb ...

Page 361: ... 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA TIGHTENING TORQUE FIGURES Workshop Manual Ed 12 2011 TIGHTENING TORQUE FIGURES 5 INSTRUMENTS 99669 TIGHTENING TORQUE FIGURES 5 COOLING SYSTEM 99669 1 Nm 0 73756 ft lb 1 Nm 0 73756 ft lb 1 Nm 0 73756 ft lb ...

Page 362: ...crews on plastic with metal spacers M5 4 Nm 0 4 Kgm 3 ft lb Steel screws on brass copper aluminium M5 4 Nm 0 4 Kgm 3 ft lb Steel screws on iron steel M5 6 Nm 0 6 Kgm 4 4 ft lb Steel screws on plastic with metal spacers M6 6 5 Nm 0 65 Kgm 4 8 ft lb Steel screws on brass copper aluminium M6 6 5 Nm 0 65 Kgm 4 8 ft lb Steel screws on iron steel M6 10 5 Nm 1 Kgm 7 7 ft lb Steel screws on brass copper a...

Page 363: ...Y 1 TE 250 310 2012 I E TE 250 310 2012 I E USA TC 250 2012 TC 250 2012 I E USA TXC 250 310 2012 I E USA Y CHASSIS AND WHEELS Workshop Manual Ed 12 2011 Section ...

Page 364: ...ant Y 4 Front wheel Y 5 Removing the front wheel Y 6 Reassembling the front wheel Y 7 Speed sensor TE Y 7 Rear wheel Y 8 Removing the rear wheel Y 9 Wheel servicing Y 10 Wheel axle warpage Y 10 Axle runout over 100 mm Y 10 Wheel spokes Y 11 Wheel rim warpage Y 11 Rear chain sprocket secondary drive sprocket and chain Y 12 Tightening torque figures Y 12 Checking pinion and sprockets for wear Y 13 ...

Page 365: ...XC 250 310 2012 I E USA CHASSIS AND WHEELS Workshop Manual Ed 12 2011 Chassis The single frame branches off at the exhaust and is made of steel tubes with circular rectangular and ellipsoidal section the rear chassis is made from light alloy A badly damaged chassis must be replaced ...

Page 366: ... H02333 CHASSIS AND WHEELS Workshop Manual Ed 12 2011 Lubrication points lubricant 1 Steering bearings grease Check the assemblies shown in the figure for cracks or damage If any are found replace the part A ENGINE MOUNTING BOLTS B REAR CHASSIS MOUNTING BOLTS C CHAIN GUIDE ROLLER BEARING D FOOTPEGS PINS SPRINGS ...

Page 367: ...CHASSIS AND WHEELS Workshop Manual Ed 12 2011 Front wheel Legend 1 Tyre 2 Inner tube 3 Rim 4 Spoke 5 Nipple 6 Wheel axle 7 Seal 8 Bearings 9 Hub 10 Spacer 11 Brake Disc 12 Brake disc retaining screw 13 Circlip 14 Outer spacer 15 Pin retaining screw For technical characteristics regarding the front wheel see section A Gen eral Information of this manual ...

Page 368: ...k under the engine and see that the front wheel is lifted from the ground Loosen the bolts 1 holding the wheel axle 2 to the front fork mounts Hold the head of the wheel axle in place and unscrew the bolt 3 on the opposite side draw the wheel axle out Do not operate the front brake lever when the wheel has been re moved this causes the calliper pistons to move outwards After removal lay down the w...

Page 369: ...y home against the L H fork leg during this operation the wheel should be turned Tighten the screw 3 on the fork L H side but DO NOT lock it Now pump for a while pushing the handlebar downwards until you are sure that the fork legs are perfectly aligned Lock the screws 4 on the R H leg 10 4 Nm 1 05 Kgm 7 7 ft lb the screw 3 on the L H side 51 45 Nm 5 25 Kgm 38 ft lb the screws 1 on the L H leg 10 ...

Page 370: ...AND WHEELS Workshop Manual Ed 12 2011 Rear wheel Key 1 Tyre 2 Inner tube 3 Rim 4 Spoke 5 Nipple 6 Wheel axle 7 Spacer 8 Brake Disc 9 Seal 10 Circlip 11 Bearings 12 Inner spacer 13 Hub 14 Sprocket 15 Sprocket retaining screw 16 Wheel axle locking nut 17 Sealing ring For technical characteristics regarding the rear wheel see section A General Information of this manual ...

Page 371: ... wheel axle 3 and extract it It is not necessary to loosen the chain tensioners 2 in this way the chain tension will remain un changed after reassembly Extract the complete rear wheel keeping the spacers located at the hub sides To reassemble reverse the above procedure remembering to insert the brake disc into the calliper Do not operate the rear brake pedal when the wheel has been re moved this ...

Page 372: ...d use the same procedure for the other bearing Discard the bearings after removal Never reuse them Before installing the new bearings check to ensure the seat is clean and shows no grooves or scratches Lubricate the seat before installing the bearing Drive the bearing into place using the special installer that only applies pressure to the outer race Fit the spacer and the other bearing Check for ...

Page 373: ...mply tap the spokes with the tip of a metal tool such as a screwdriver a clear crisp sound indicates proper tightening a dull sound means that the spokes need to be tightened Wheel rim warpage The table below reports the allowed limits for wheel rim warpage Exceeding runout or out of round are generally due to worn bearings When this is the case replace the bearings If this does not solve the prob...

Page 374: ...dary drive sprocket and chain The figure at the side shows the profiles of a normally worn and an exceedingly worn sprocket 1 Normal wear 2 Exceeding wear If the sprocket is exceedingly worn replace it after loosening the six screws that retain it to the hub Chain and sprockets must always be replaced as a set Tightening torque figures 3 34 3 Nm 3 5 Kgm 25 3 ft lb LOCTITE 243 ...

Page 375: ...procket for damage or wear When worn down like the sprocket shown in the figure it must be replaced Wheelmisalignmentcausesabnormalwear makingthemotorcycle unsafe to ride Dirt caked on sprockets and chain collected while riding on muddy or wet terrain increases chain tension If you expect to ride on muddy or wet terrain slacken the chain a bit Riding on muddy terrain significantly increases chain ...

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