Te 250310 2012 Ie

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
Revision Record
Rev. No. Date Page Description
01 30/03/2012 F.38 Adding the "Warning" and H11258 figure.
01 30/03/2012 X.3 Paragraph " Starting system" - Short nut M6x1, correction applied: from LOC-
TITE 243 to LOCTITE 270 and the relative value from 3,9 Nm - 0,5 Kgm to
8 Nm - 0,8 Kgm.
02 03/05/2012 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 reproduction in full or in part without written authorisation.
1st edition (12-2011) - Rev. 02
FOREWORD, TABLE OF CONTENTS
lo
bo
m
si 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
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
Copyright by
HUSQVARNA MOTORCYCLES S.R.L.
BMW Group
Technical Service
Via Nino Bixio, 8
21024
(Varese) - Italy
tel. ++39 0332 75.61.11
tel. ++39 0332 756 558
www.husqvarna-motorcycles.com
1st edition (12-2011) - Rev. 02

Printed in Italy
MODELS COVERED (from serial number onwards)
1
TE 250: ZKHA300AACV000001
TE 310: ZKHA301AACV000001
TE 250 USA: ZKHKCECF#CV000001
TE 310 USA: ZKHKCEDG#CV000001
TC 250: ZKHA300AACV050001
TC 250 USA: ZKHTC253#CV000001
TXC 250 USA: ZKHTX253#CV000001
TXC 310 USA: ZKHTX313#CV000001
H09055
1. Chassis serial number
a.1
lo
bo
TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA
m
si
TC 250 2012 - TC 250 2012 I.E. USA
TXC 250 - 310 2012 I.E. USA
Foreword
This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance
and repair of the models covered in this manual. The technical information provided in this manual is a critical comple-
ment to operator training and operators should become thoroughly familiar with it.
For ease of understanding, diagrams and photographs are provided next to the text.
Notes with special significance are identified as follows throughout the manual:
Accident-prevention rules for operator and persons working nearby.
Damage to vehicle and/or its components may result from incompliance with relevant instructions.
Additional information concerning the operation covered in the text.
Useful tips
To prevent problems and ensure effective service work, observe the following HUSQVARNA recommendations:
– before repair, evaluate the customer's description of the problem and ask the appropriate questions to clearly identify
problem symptoms;
– diagnose the problem and identify the causes clearly. This manual provides basic background information that must
be supplemented with the operator's expertise and specific training available through HUSQVARNA held at regular
periods;
– plan ahead before starting work: gather any spare parts and tools to avoid unnecessary delays;
– avoid unnecessary disassembly work to get to the part that needs repairing.
Always read the relevant instructions and follow the disassembly sequence outlined in this manual.
Recommended shop practices

1 Always replace gaskets, sealing rings and split pins with new ones.
2 When loosening or tightening nuts or bolts, always begin with the bigger ones or from the centre. Tighten to the speci-
fied torque and follow a cross pattern.
3 Always mark any parts or positions that might be confused upon assembly.
4 Use genuine HUSQVARNA parts and the recommended lubricant brands.
5 Use special tools where specified.
6 Technical Bulletins might contain more up-to-date setting data and procedures than this manual. Be sure to read
them.
a.2
lo
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m 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
Table of Contents
Title Section
Foreword, table of contents.................................................................................. a
Important notices.................................................................................................. b
General information..............................................................................................A
Maintenance.........................................................................................................B
Troubleshooting................................................................................................... C
Settings and adjustments.................................................................................... D
General procedures..............................................................................................E
Engine disassembly.............................................................................................F
Engine overhaul.................................................................................................. G
Engine reassembly.............................................................................................. H
Front suspension................................................................................................... I
Rear suspension.................................................................................................. J
Brakes.................................................................................................................. L
Electrical system................................................................................................. M
Engine cooling..................................................................................................... N
Hydraulically controlled clutch..............................................................................P
Fuel injection system............................................................................................S
Special tools........................................................................................................W
Tightening torque figures......................................................................................X
Chassis and wheels.............................................................................................Y
NOTES
Unless otherwise specified, data and specifications apply to all models.
a.3
ELECTRICAL SYSTEM
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.4
IMPORTANT NOTICES
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
Section
b
b.1
IMPORTANT NOTICES
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
1) TC, TXC models are RACING motorcycles and are warranted to be free from
TE operating defects; a scheduled maintenance chart for racing use is provided in
Section B.
2) The TE model is for ROAD USE (DERATED); it is warranted to free from
defects and covered by legal warranty, provided that the STANDARD CON-
FIGURATION IS MAINTAINED and the maintenance chart provided in Section
B is observed. For TE models modified to RACING SPECIFICATIONS (FULL
POWER RATING), observe the scheduled maintenance chart for racing use
provided in Section B.
* This motorcycle has not been designed to travel over long distances with the
H09056 engine at top rpm, as in long-distance road or highway travel. Riding over long
distances at full throttle may result in severe engine damage.
* The geometry and setup of this motorcycle have been designed for racing
and to provide top performance when riding solo. We advise against riding
TC 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:
H09058
A) STANDARD MOTORCYCLE, FOR ROAD USE: DERATED;
B) RACING MOTORCYCLE, FOR RACING USE: FULL POWER RATING.
* In order to maintain the vehicle’s “Guarantee of Functionality”, the client must

TXC follow the maintenance programme indicated in Section B by having the required
maintenance inspections carried out at authorised HUSQVARNA dealers. The
cost for changing parts and for the labour necessary in order to comply with
the maintenance plan is charged to the Client. The warranty becomes NULL
AND VOID if the motorcycle is rented.
Notes
Left and right side is determined when seated on motorcycle.
Z: number of teeth
H09057 A: Austria
AUS: Australia
B: Belgium
BR: Brazil
CDN: Canada
CH: Switzerland
D: Germany
E: Spain
F: France
FIN: Finland
GB: Great Britain
I: Italy
J: Japan
USA: United States of America
Unless otherwise specified, data and instructions apply to all market variants.
b.2
GENERAL INFORMATION
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
Section
A
A.1
GENERAL INFORMATION
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
Sommario
Engine...........................................................................................................A.3
Cooling..........................................................................................................A.3
Starting..........................................................................................................A.3
Timing system...............................................................................................A.3
Lubrication.....................................................................................................A.3
Ignition...........................................................................................................A.3
Fuel system...................................................................................................A.3
Primary drive.................................................................................................A.3
Clutch............................................................................................................A.3
Transmission.................................................................................................A.4
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 location (TE)..............................................................A.6
Overall dimensions........................................................................................A.7
Weight...........................................................................................................A.8
Capacities......................................................................................................A.8
A.2
GENERAL INFORMATION
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
Type............................................................................... single cylinder, 4 stroke
Cooling
Type................................................. liquid, with electric fan on TE-TXCi models
(TC-TE-TXC 250)
Bore...........................................................................................mm 79 (3,11 in.)
Stroke.................................................................................... mm 50,9 (2.00 in.)
Displacement............................................................... cm3 249,5 (15,22 cu. in.)
Compression ratio.....................................................................................13,6:1
(TE 310)
Bore.......................................................................................... mm 82 (3,23 in.)
Stroke.................................................................................... mm 57,3 (2,26 in.)
Displacement............................................................. cm3 302,44 (18,46 cu. in.)
Compression ratio.....................................................................................12,5:1
Starting
(TC)................................................... kick start (with automatic decompressor)
(TE-TXCi)................................................................................................ electric
Timing system
(TE - TXC)
Type..................................................4 titanium valves, in 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, inductive discharge, with adjustable advance
(digital control)
(TE - TXC)
Spark plug type..............................................................................NGK CR9EB
Spark plug gap.....................................................0.027÷0,031 in. (0,7÷0,8 mm)
(TC)
Spark plug type............................................................................... NGK CR9EI
Spark plug gap.....................................................0.031÷0,035 in. (0,8÷0,9 mm)
Fuel system
Type...............................................................................Electronic injection feed
Primary drive
Drive pinion gear- Clutch ring gear . .................................................. Z 17- Z 54
Transmission ratio......................................................................................3,176
Clutch
Type..............................................oil bath multiple disc clutch, hydraulic control
A.3
GENERAL INFORMATION
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
Transmission
Type............................................................................. constant mesh gear type
Transmission ratio (TE-TXC)

1st gear....................................................................................... 2,142 (z 30/14)
2nd gear..................................................................................... 1,750 (z 28/16)
3rd gear ..................................................................................... 1,450 (z 29/26)
4th gear...................................................................................... 1,227 (z 27/22)
5 th gear..................................................................................... 1,041 (z 25/24)
6 th gear..................................................................................... 0,884 (z 23/26)
Transmission ratio (TC)

1st gear....................................................................................... 2,142 (z 30/14)
2nd gear..................................................................................... 1,750 (z 28/16)
3rd gear ..................................................................................... 1,450 (z 29/26)
4th gear...................................................................................... 1,227 (z 27/22)
5 th gear..................................................................................... 1,041 (z 25/24)
Secondary drive
Transmission sprocket- Rear wheel sprocket
(TC-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..................... ”Upside-down” telescopic hydraulic front fork with advanced
axle (adjustable in compression and rebound stroke); stanchions tubes Ø 1.89
in. / ø 48 mm
Legs axis stroke......................................................................300 mm (11.8 in.)
Rear suspension
Type....................................... progressive with hydraulic single shock absorber
Wheel stroke ......................................................................... 296 mm (11.6 in.)
Front brake
Type....................................................................fixed disc Ø 10.23 mm “Wave”
type with hydraulic control and floating caliper
A.4
GENERAL INFORMATION
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
Rear brake
Type.................................................................... floating disc, ø 9.45 in. “Wave”
type with hydraulic control and floating caliper
Rims
Front...................................................................................in light alloy: 1,6x21”
Rear (TE, TXC).................................................................in light alloy: 2,15x18”
Rear (TC)..........................................................................in light alloy: 1,85x19”
Tires
Front
(TE -TXC)............................................................................................90/90x21”
(TC).................................................................................................80/100 x 21”
Rear
(TE-TXC)...........................................................................................120/90x18”
(TC)...................................................................................................100/90x19”
(TE USA)...........................................................................................140/90x18”
Cold tire pressure

(front TC)...........................................................0,9÷1,0 Kg/cm2 (12,8÷14,2 Psi)
(front TE-TXC) (*) .............................................0,9÷1,0 Kg/cm2 (12,8÷14,2 Psi)
(front TE) (%).....................................................................1,1 Kg/cm2 (15,6 Psi)
(rear TC)............................................................ 0,8÷0,9 Kg/cm2 (11,4÷12,8 Psi)
(rear TE-TXC) (*) .............................................. 0,8÷0,9 Kg/cm2 (11,4÷12,8 Psi)
(rear TE) (%)......................................................................1,0 Kg/cm2 (14,2 Psi)
(*) In case of racing use - (%) Road use
Electrical components location (TC)

The ignition system includes 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;
- Spark plug on cylinder head;
- M.A.Q.S. sensor
- Condenser on the left of rear chassis.
Electrical components location (TXC)

- Voltage regulator under the fuel tank;
- 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 throttle
body.
The electrical system includes the following elements:
- 12V-6Ah battery under the saddle;
- Electric fan relay on right side of chassis:
- Electric fan;
- Two 15A and 20A fuses on right side of rear chassis;
- Coolant temperature sensor;
- Lambda sensor;
- Fuel pump inside the fuel tank.
- Fuel and reserve indicator.
A.5
GENERAL INFORMATION
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 components location (TE)
- Voltage regulator under the fuel tank;
- 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 throttle body.
A.6
GENERAL INFORMATION
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
- 12V-6Ah battery under the saddle;
- Turning indicator flasher on left side of rear chassis;
- Relay for electric fan, fuel injection system and lights 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.
A
H09059 B
Overall dimensions
Wheelbase A
(TE-TXC)............................................................................ mm 1460 (57.47 in.)
(TC).................................................................................... mm 1470 (57.87 in.)
Overall length B
(TC).................................................................................... mm 2215 (87.20 in.)
(TE)..................................................................................... mm 2260 (88.97 in.)
(TXC).................................................................................. mm 2176 (85.66 in.)
Overall width C..................................................................... mm 820 (32.28 in.)
Overall height D
(TE-TXC)............................................................................ mm 1290 (50.78 in.)
(TC).................................................................................... mm 1305 (51.37 in.)
A.7
GENERAL INFORMATION
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
Saddle height E
(TC)...................................................................................... mm 985 (38.77 in.)
(TE-TXC).............................................................................. mm 950 (37.40 in.)
Minimum ground clearance F
(TE-TXC)...............................................................................mm 290 (11.41 in.)
(TC)...................................................................................... mm 325 (12.79 in.)
Weight
(TC)
Kerb weight, without fuel:......................................................101,2 Kg (213,8 lb)
(TE)
Kerb weight, without fuel:..........113 Kg (249,1 lb) 250 / 113,5 Kg (250,2 lb) 310
(TXC)
Kerb weight, without fuel:...... 108,6 Kg (239,4 lb) 250 / 109,1 Kg (240,5 lb) 310
Capacities Type Quantity

Fuel tank (TC) Premium grade unleaded fuel (R.O.N. 98) 6,5 litri
Imp. Gall. 1.43
U.S. Gall. 1.72
Fuel tank (TE-TXC) Premium grade unleaded fuel (R.O.N. 98) 8,5 litri
(2,3 litri / 0.51 Imp. Qt./0.61 U.S. Qt. reserve included) Imp. Gall. 1.87,
U.S. Gall. 2.25
Gearbox/engine oil CASTROL POWER 1 RACING (SAE 10W50) 900 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 COOLANT 0.9 litres
0,24 U.S. Gall
0,2 Imp. Gall
Front brake fluid CASTROL RESPONSE SUPER (DOT 4)
Rear brake fluid CASTROL RESPONSE SUPER (DOT 4)
Clutch fluid CASTROL RESPONSE SUPER (DOT 4)
Drive chain lubrication CASTROL CHAIN LUBE RACING
Grease lubrication CASTROL LM GREASE 2
Electric contact protection CASTROL METAL PARTS CLEANER
Fillers for radiator AREXONS LIQUID FILLER
Front fork oil: Kayaba KHL15-11
Air filter oil AGIP FORMULA FILTER "Foam air filter protection oil"
Air filter detergent AGIP "Filter clean foam air detergent fluid"
IMPORTANT - Do not add any additives to fuel or lubricants.
A.8
MAINTENANCE
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
Section
B
B.1
MAINTENANCE
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
SCHEDULED MAINTENANCE CHART
TXC - TE 250 / TXC - TE 310
RACING MOTORCYCLE, FOR
(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
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
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 FILTER S, P S, P
OIL PUMP TO CRANKCASE OIL LUBRICATION

C
PIPE
PRIMARY DRIVE GEAR PAIR C
CLUTCH HUB C X
CLUTCH PLATES C S X
CLUTCH PRESSURE PLATE C
CLUTCH SPRINGS C X
CLUTCH HOUSING C
CLUTCH PUSHROD C
TRANSMISSION SPROCKET C S X
STARTER GEARS C X
B.2
MAINTENANCE
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
TXC - TE 250 / TXC - TE 310 (TO BE CARRIED OUT AT THE HUSQVARNA DEALER)

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 BUSHING C
REAR CHAIN SLIDER C X
REAR SUSPENSION LINKAGE BUSHINGS C
CHAIN GUIDE/CHAIN GUARD C X
SWINGING ARM AXLE ROLLER CAGES L
REAR SHOCK ABSORBER R
ROLLER CAGES, LINKAGE PINS OF REAR SUSP. L
COMPLETE THROTTLE CONTROL C, L
COMPLETE CLUTCH CONTROL C R
B.3
MAINTENANCE
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
TXC - TE 250 / TXC - TE 310 (TO BE CARRIED OUT AT THE HUSQVARNA DEALER)

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 BRAKE CALLIPER HOSES C
FUEL PIPES C S X
SILENCER SOUND DEADENING MATERIAL S X
EXHAUST PIPE AND SILENCER C X
WHEEL SPOKE TENSION C C

WHEEL HUB BEARINGS S X
REAR CHAIN SPROCKET S X
SPROCKET BOLT TIGHTENING C C
SECONDARY DRIVE CHAIN C, L S X
TORQUE OF NUTS AND BOLTS C C
LEGEND
h: HOURS
S: REPLACE
C: CHECK
(•): CHECK CLEARANCE
P: CLEAN
R: OVERHAUL
L: GREASE/LUBRICATE
NOTES:
- REPLACE GASKETS AND SEALS AFTER EACH REMOVAL;
- REPLACE SCREWS AND BOLTS IF DAMAGED;
- PERFORM A GENERAL INSPECTION AFTER RIDING ON MUDDY OR SANDY TERRAIN.
B.4
MAINTENANCE
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 250 / TE 310 AFTER FIRST EVERY EVERY REPLACE

- STANDARD MOTORCYCLE, FOR ROAD USE AS
(DERATED)
1000 KM 5000 KM 10000 KM REQUIRED
VALVES C (•) C (•) S
VALVE SPRINGS C X
VALVE SPRING RETAINERS, VALVE COLLETS C X
VALVE BUCKETS C X
CAMSHAFT C
TIMING CHAIN S

TIMING CHAIN SLIDER C S
TIMING DRIVEN GEAR C X
TIMING DRIVE GEAR C
INTAKE MANIFOLD AND CLAMPS C C S X
COMPLETE CYLINDER C X
COMPLETE PISTON S
COMPLETE CONNECTING ROD 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
B.5
MAINTENANCE
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

(DERATED) 1000 KM 5000 KM 10000 KM REQUIRED
SERVICE SERVICE SERVICE

PART COUPON COUPON COUPON
KICK START PEDAL L
GEAR SHIFT PEDAL C X
SPARK PLUG P S
SPARK PLUG CAP C C X
AIR FILTER P, L P, L X
RADIATORS C
WATER HOSES AND CLAMPS C C
RADIATORS TO WATER PUMP HOSE C C
REAR CHASSIS MNTG BOLTS, ENGINE MNTG BOLTS C C
SIDE STAND C
CHAIN GUIDE ROLLER, BEARING C C X
STEERING 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 CLUTCH CONTROL C R
THROTTLE CABLES C L X
FRONT BRAKE DISC C X
FRONT BRAKING SYSTEM FLUID C S
B.6
MAINTENANCE
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


(DERATED) 1000 KM 5000 KM 10000 KM REQUIRED
PART SERVICE SERVICE SERVICE

COUPON COUPON COUPON
REAR BRAKE DISC C X
REAR BRAKING SYSTEM FLUID C S
BRAKE PADS C C C X

MASTER CYLINDER TO BRAKE CALLIPER HOSES C X

FUEL PIPES C X
SILENCER SOUND DEADENING MATERIAL 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
LEGEND
S: REPLACE
C: CHECK
P: CLEAN
R: OVERHAUL
L: GREASE/LUBRICATE
NOTES:
- REPLACE GASKETS AND SEALS AFTER EACH REMOVAL;
- REPLACE SCREWS AND BOLTS IF DAMAGED;
- PERFORM A GENERAL INSPECTION AFTER RIDING ON MUDDY OR SANDY TERRAIN.
B.7
MAINTENANCE
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
TC 250
REPLACE AS
EVERY 10 h
EVERY 20 h
EVERY 30 h
EVERY 40 h
EVERY 50 h
EVERY 60 h
EVERY 70 h
EVERY 80 h
EVERY 90 h
EVERY 100 h
REQUIRED
EVERY 2,5 h
EVERY 5 h
RACING MOTORCYCLE, FOR RACING USE: FULL
POWER RATING
PART
COUPON
COUPON
COUPON
COUPON
COUPON
COUPON
COUPON
COUPON
COUPON
COUPON
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
CHECK
CHECK
AIR FILTER P,L

REAR CHASSIS MNTG BOLTS,
C
ENGINE MNTG BOLTS
WHEEL SPOKE TENSION C
SPROCKET BOLT TIGHTENING C
TORQUE OF NUTS AND BOLTS C
COOLANT
C X,
*
BRAKE PADS C X
REAR CHAIN SPROCKET C X
HANDLEBAR MOUNTS AND 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
L
SUSP.
FUEL PIPES C S X
SECONDARY DRIVE CHAIN C, L X
KICK START PEDAL L
GEAR SHIFT PEDAL C
RADIATORS C
WATER HOSES AND CLAMPS C
RADIATORS TO WATER PUMP HOSE C
STEERING HEAD, BOTTOM YOKE WITH
L
STEM
REAR CHAIN SLIDER C X
FRONT BRAKE DISC C S X
REAR BRAKE DISC C S X
CHAIN GUIDE ROLLER, BEARINGS C
B.8
MAINTENANCE
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
TC 250
REPLACE AS
EVERY 10 h
EVERY 20 h
EVERY 30 h
EVERY 40 h
EVERY 50 h
EVERY 60 h
EVERY 70 h
EVERY 80 h
EVERY 90 h
EVERY 100 h
REQUIRED
EVERY 2,5 h
EVERY 5 h
RACING MOTORCYCLE, FOR RACING USE: FULL
POWER RATING
PART
COUPON
COUPON
COUPON
COUPON
COUPON
COUPON
COUPON
COUPON
COUPON
COUPON
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
SERVICE
CHECK
CHECK
COMPLETE CLUTCH CONTROL R (#)
THROTTLE CABLES C X
FRONT BRAKING SYSTEM FLUID S
REAR BRAKING SYSTEM FLUID S
MASTER CYLINDER TO BRAKE CALLIPER
C X
HOSES
WHEEL HUB BEARINGS C
ENGINE OIL AND FILTER S
PLUG S
VALVES C (•) S
Valve springs, rocker arms and
C
plates
TIMING CHAIN / TIMING CHAIN SLIDER C
Timing chain gears C
OIL PUMP C X
Crankshaft oil seals S
PISTON S
CYLINDER S
CLUTCH HUB C X
CRANKSHAFT S
PRIMARY DRIVE GEAR PAIR C X
LEGEND
h: HOURS
S: REPLACE
C: CHECK
P: CLEAN
R: OVERHAUL
L: GREASE/LUBRICATE
*: Change and/or add if necessary
NOTES:
- REPLACE GASKETS AND SEALS AFTER EACH REMOVAL
- REPLACE SCREWS AND BOLTS IF DAMAGED
- PERFORM A GENERAL INSPECTION AFTER RIDING ON MUDDY OR SANDY TERRAIN
B.9
TROUBLESHOOTING
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
Section
C
C.1
TROUBLESHOOTING
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
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
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
C.2
TROUBLESHOOTING
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
Clutch slips 1. Weak clutch springs Replace

2. Worn clutch plates Replace
Clutch is hard to operate 1. Uneven spring load Replace

2. Bent clutch plates Replace
Gears do not engage 1. Bent or seized shifter forks Replace

2. Worn gear ratchets Replace
3. Damaged shifter fork shafts Replace
Gear shift pedal

does not return to original position 1. Weak or broken selector return spring Replace
2. Worn shifter forks Replace
Transmission jumps out of gear 1. Worn sliding gear dogs Replace

2. Worn gear grooves Replace
3. Worn dog slots in gears Replace
4. Worn selector shaft splines Replace
5. Damaged shifter fork shafts Replace
Engine has low power 1. Dirty air 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 clearances Adjust
7. Valve seats or guides faulty Replace
Engine overheats 1. Combustion chamber and/or piston crown fouled

with carbon deposits Clean
2. Insufficient oil in engine or
wrong oil Top up or change
3. Obstructions blocking air flow on radiator Clean
4. Cylinder head gasket leaking Replace
5. Clutch slips Adjust
6. Cooling fan faulty (TE-TXC) Replace thermal switch
C.3
TROUBLESHOOTING
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
CHASSIS

Handlebar turns hard 1. Insufficient tyre pressure Inflate
2. Bearing adjuster ring nut or steering stem nut overtightened Adjust
3. Bent steering stem Replace bottom yoke
4. Worn or seized steering bearings Replace
Handlebar vibration 1. Bent fork legs Replace

2. Bent front wheel axle Replace
3. Warped chassis Replace
4. Bent front wheel rim Replace
5. Worn front wheel bearings Replace
Damping is 1. Too much oil in fork legs Remove excess oil

too hard 2. Fork oil viscosity too high Change
3. Overinflated tyres Deflate
4. 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. Worn rear swinging arm bearings Replace
6. Improperly adjusted chain tensioners Adjust
7. Improperly balanced wheel Balance
Rear suspension is 1. Worn link rod spacers or bearings Replace

noisy 2. Worn shock absorber ball joints Replace
3. Shock absorber faulty Replace
Poor braking 1. Air in brake system Bleed

(front and rear) 2. Insufficient fluid in tank Top up
3. Worn brake pad and/or disc Replace
4. Damaged disc Replace
5. Improperly adjusted brake pedal Adjust
6. Water in brake system Change fluid
C.4
TROUBLESHOOTING
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 (see also Section M)
Spark plug fouls 1. Dirty air filter Clean

easily 2. Worn piston rings Replace
3. Worn piston or cylinder liner Replace

Spark plug electrodes 1. Spark plug electrode gap too close Adjust
overheat 2. Heat rating too high Replace with recommended
spark plug
Generator does not charge or 1. Cables running to voltage regulator improperly connected or Connect correctly or
is not providing enough charge shorted replace
2. Voltage regulator faulty Replace
3. Generator coil faulty Replace
Generator overcharges battery 1. Voltage regulator faulty Replace
Battery does not hold charge 1. Battery terminals dirty Clean

(TE-TXC)
Starter motor 1. Battery is flat Charge

does not start or slips 2. Control on R.H. switch faulty Replace
(TE-TXC) 3. Starter relay faulty Replace
4. Starter motor faulty Repair or replace
5. Worn starter gears Replace
6. Worn or damaged freewheel rollers Replace freewheel
C.5
SETTINGS AND ADJUSTMENTS
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
Section
D
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
Sommario
Saddle removal.............................................................................................D.4
Tank removal.................................................................................................D.4
Valve clearance adjustment (TE - TXC)........................................................D.6
Valve clearance adjustment (TC)..................................................................D.7
Adjustment throttle cable.............................................................................D.10
Enrichener lever play adjustment................................................................D.10
Idle adjustment............................................................................................D.11
Clutch plate replacement.............................................................................D.12
Hydraulic clutch lever adjustment and fluid level check .............................D.13
Front brake lever adjustment and fluid level check.....................................D.14
Rear brake pedal position adjustment.........................................................D.15
Rear brake pedal free play adjustment.......................................................D.16
Rear brake fluid level check ......................................................................D.16
Engine oil level check..................................................................................D.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-rings (TC) ....................................................D.24
Washing the chain with OR (TE - TXC).......................................................D.24
Lubricating an O-ring chain.........................................................................D.24
Suspension setup according to track condition...........................................D.25
Shock absorber adjustment.........................................................................D.26
Shock absorber spring preload adjustment.................................................D.27
Shock absorber compression and rebound damping adjustment ..............D.28
Shock absorber springs...............................................................................D.28
KAYABA front fork adjustment.....................................................................D.29
Steering bearing clearance adjustment.......................................................D.30
Steering angle adjustment . ........................................................................D.30
Supply hose check......................................................................................D.31
Exhaust system check.................................................................................D.32
D.2
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
H09056
TC
H09058
TXC
H09057
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
Saddle removal
Turn the rear fixing (1) counter clockwise, remove it and extract the saddle.
Tank removal
During the fuel tank removal operations, pay particular attention to

the couplings of the fuel hose on the pump body and on the 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 connector (6) of the reserve sensor.
6 3
4
5
5
H02181 H02183
D.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
Lift the tank and disconnect the fuel pump connector (7) from the main wiring
TC harness.
H09060
Disconnect the supply hose (8) from the outlet fitting (9) on the fuel pump, located
TE
in the rear bottom section of the tank.
7 9
H02182
TC
9
H09061
Remove the tank (10) together with the scoops.
10
H02186
D.5
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
Valve clearance adjustment (TE - TXC)
Remove saddle and tank as outlined in the relevant paragraphs.
Remove spark plug (1), both head cover screws (2) and head cover (3).
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 holes (4) in the camshaft
gears will be located at 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 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 camshaft disassembly and reassembly, see Section “F” Engine disassembly
and Section “H” Engine assembly.
D.6
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
Valve clearance adjustment (TC)
Remove saddle and tank as outlined in the relevant paragraphs.
- Remove the connector (1) from the coil (2).

1 - Loosen the two screws (3), remove coil (2) and retaining bracket (4), and
2 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).
3
4
H10948
5
7
H10949
Loosen the four screws (8) of the head cover and remove the head cover (9).
8
9
H10950
D.7
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
Engage the 2nd gear and push and pull the motorcycle back and forth to bring
10 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.
10
H10951
INTAKE OUTLET
10 10
H10952
D.8
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
Use a thickness gauge to make sure that the clearance is equal to 0.15 mm for
the INTAKE side (Figure “A”) and 0.20 mm for the OUTLET side (Figure “B”).
If not so, remove the shim from under the valve bucket and measure its 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.
Figure A For camshaft disassembly and reassembly, see Section “F” Engine disassembly
INTAKE H10953 and Section “H” Engine assembly.
Figure A
INTAKE H10954
Figure B
OUTLET H10955
Figure B
OUTLET H10956
D.9
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
Adjustment throttle cable
TC
To check the correct adjustment of the throttle operate as follows:
5 2 - Remove rubber caps (1);
- By moving the opening cable (2) back and forth, check that free play is 3
4
mm;
- By moving the closing cable (3) back and forth, check that free play is 1
4 mm;
- If it does not happen, loosen the nut (4) and appropriately turn the adjuster
screw (5);
3 (loosen it to decrease clearance, tighten it to increase it);
1 - After adjustment block the nut (4).
5
H09062
Operation with damaged throttle cable could result in an unsafe
riding condition.
TE - TXC 2
Exhaust gas contains poisonous carbon monoxide. Never run the
engine indoors.
5 3 To replace the cables, you will need to remove the fuel tank as described in the
4 relevant paragraph.
1
5
4
H09063
Enrichener lever play adjustment

The lever (1) holder features an adjuster screw (2) to adjust free play. Free play
should be about 3 mm: if not so, loosen the check nut and turn the adjuster screw
as required (loosen to decrease play or tighten to increase it).
H09064
3 mm
D.10
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
Idle adjustment
TE - TXC
Adjust the carburetor with warm engine and with the throttle control in closed
position. 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
1 (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 about 1,950 RPM (turn clockwise to increase the speed and counter
clockwise to reduce it).
H09065
TC
H09066
D.11
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
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).
H11101
D.12
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
- Remove the plates (8), lubricate the new plates with engine oil and install
them (always start with a friction plate).
Refit clutch actuator plate, bearing and pressure plate.

Tighten the spring screws gradually in a cross pattern (8 Nm - 0.8 Kgm - 5.8 ft/
lb).
When refitting the clutch cover (8 Nm - 0.8 Kgm - 5.8 ft/lb), check gasket for
wear and replace as required.
For additional information on assembly procedures, see Section

"H" Engine assembly.
Hydraulic clutch lever adjustment and 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 diaphragm from the control;
- Keep the control cylinder (3) in a horizontal position and make sure that fluid
level has not dropped lower than 4 mm (0.16 in.) below the upper edge (D)
of master cylinder body;
H10957 - If needed, top up with the fluid specified in the LUBRICANT CHART included
in Section "A".
Refit any parts you have removed.
1 2 1 Periodically check the connecting hose (see “Scheduled Maintenance Chart”);
if hose (C) is worn or cracked, its replacement is advised.
3
C
A
4mm (0,16 in.) H09067
D.13
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
Front brake lever adjustment and fluid level check
The adjuster (1) located on the control lever, allows adjusting of the free play
(a). Free play (a) must be at least 0,39 in. (10 mm).
1 The level of the fluid in master cylinder reservoir must never be below the mini-
mum value (2), which can be checked from the inspection window 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").
a
Too much brake lever free play may reduce braking action: CHECK
BRAKE PAD THICKNESS (see Section "L").
H09069
Do not spill brake fluid onto any painted surface or lens (for example
lights lens).
2
Do not mix two brands of fluid. Completely change the brake fluid
in the brake system if you wish to switch to another fluid brand.
+ A
Brake fluid may cause irritation. Avoid contact with skin or eyes.
In case of contact, flush thoroughly with water and call a doctor if
B _ your eyes were exposed.
H09070
A: to increase clearance
B: to decrease clearance
H09071
D.14
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
Rear brake pedal position adjustment
The position of the rear brake pedal with respect to the footrest may be adjusted
according to individual needs.
For adjusting, proceed as follows:
- Loosen the screw (1).
- Turn the cam (2) in order to raise or lower the brake pedal within the range
available (A).
- When 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 free play adjustment".
D.15
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
Rear brake pedal free play adjustment
The rear brake pedal should have 5 mm free play (B) before the brake begins
to bite. Should this not happen, operate as follows:
- Loosen the nut (3);
- Operate the master cylinder linkage (4) to increase or decrease free play;
- Tighten the nut (3) at the end of the operation.
When the free play requirement is not met, the brake pads will be
subjected to an early wear that may lead to TOTAL BRAKE INEF-
FECTIVENESS.
If the brake pedal feels mushy when pulled, there may be air in the
brake line or the brake may be defective. CHECK THE BRAKING
SYSTEM (see Section L).
C: to increase clearance
D: to decrease clearance
Rear brake fluid level check

Level (A) must be between the MIN and MAX notches visible on the master
cylinder reservoir.
D.16
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 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.
D.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 oil replacement and mesh filters-filter cartridge cleaning or replace-
ment
Drain the oil with WARM ENGINE; proceed as follows:
- Remove the oil filler cap (2).
- The oil sump guard (A) may be left in place. However, the procedure will be
easier with the guard removed.
- Place an oil drain pan under the engine.
(TE-TC-TXC 250)
- Remove oil drain plug (3) and filter (4), drain the oil and clean the plug mag-
net.
- Wash the filter (4) with petrol and refit it into its seat.
250
(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 plug (3) (25 Nm - 2.5 Kgm - 33.89 ft/lb) and the oil sump guard
(A).
(TE 310)
- Reassemble fitting (3c), screw clamp (3a), and refit the engine cover (A).
- Fill with the specified quantity of oil.
310 For recommended oil type and quantity, see "Capacities" table in Section
"A".
3a
3b
3c Be careful not to touch hot engine oil.
4
H02336 H02335
WARNING When assembling filter to cover, make sure to fit the filter
oil seal (A) first onto the cover (6).
A
7
6
H00977-1
D.18
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
Coolant level check
Check level (1) in right-hand radiator when engine is cold (place the motorcycle
so that it is perpendicular to the ground). The coolant should be approximately
0.39 in. above the cells.
1 The radiator cap features two locking positions: the first one is for prior discharge
of pressure from the cooling system.
Avoid removing radiator cap when engine is hot, as coolant may

spout out and cause scalding.
H09072 Difficulties may arise in eliminating coolant from painted surfaces.

If this occurs, wash off with water.
Coolant replacement
Place a vessel on the L.H. side of the cylinder, under the hose (1).
Loosen the clamp (2) on the hose (1) and detach the hose from the engine.
SLOWLY open the cap (3) of the right-hand radiator and lean the motorcycle to
the left to let the coolant drain into the vessel.
When finished, refit the hose (1) and secure it with the clamp (2).
Pour the necessary quantity of coolant in the radiator then warm up the engine
in order to eliminate any possible air bubbles.
Periodically check the connecting hoses (see “Scheduled Maintenance Chart”):
this will avoid coolant leakage and consequent engine seizure. If hoses (A) show
cracks, swelling or hardening due to sheaths desiccation, their replacement
shall be advisable.
Check the correct tightening of the clamps (B).
�
H02187
� � ��
D.19
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
Air filter check (TC)
Turn the rear fixing (1) counter clockwise, remove it and extract the saddle re-
leasing it from the front retaining screw.
Remove the screw (3), remove the complete air filter (4) 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 fire or explosion could result.
Clean the filtering element in a well ventilated area and do not allow
sparks or flames anywhere near the working area.
D.20
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
Air filter check (TE - TXC)
Turn the rear fixing (1) counter clockwise, remove it and extract the saddle re-
leasing it from the front retaining screw.
Take out the battery (A) and leave it hanging on the side of the motorcycle.
Remove the screw (3), remove the complete air 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 solvent to clean the filtering

element. A fire or explosion could result.
Clean the filtering element in a well ventilated area and do not allow
sparks or flames anywhere near the working area.
D.21
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
Assembly
TC
Grease the edge (C) of 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 = Left-hand side
A TE - TXC
B
C
H09073
D.22
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
Secondary drive chain adjustment
Chain should be checked, adjusted and lubricated as per the "Maintenance
Chart" (see Section B) to ensure safety and prevent excessive wear. If the chain
becomes badly worn or is poorly adjusted (i.e., if it is too loose or too taut), it
could escape from sprocket or break. To adjust chain tension, you need to lower
the rear end of the motorcycle so as to bring the axes of rotation of sprocket,
swinging arm and rear wheel into alignment as shown in figure "A", and then
turn the rear wheel three turns. In this condition, the chain should be neither
taut nor slack. (Fig. A).
Fig. A
Asse pignone = Sprocket axis
Asse forcellone = Swinging arm axis
Asse ruota = Wheel axis 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-
a sions) and make sure that the lower arm (C) of the chain is slightly tight.
If it is not, proceed as follows:
- Loosen the wheel axle nut (1) on the right-hand side using a 27 mm socket
wrench;
- Loosen the check nuts (2) on both chain tensioners with a 12 mm wrench
and work the screws (3) until achieving the correct tension;
- When the adjustment is completed, tighten the check nuts (2) and the wheel
axle nut (1).
After any adjustment, always check wheel alignment and tighten wheel axle
securely (142.1 Nm - 14.5 Kgm - 104.8 ft/lb).
C
H09074
Fig. B
[mm]
145 35
REGOLAZIONE CATENA *
H09077
* : Chain adjustment
1
H09075 H09076
D.23
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
Chain lubrication
Lubricate the chain following these instructions.
Never use grease to lubricate the chain. Grease helps to accumulate

dust and mud, which act as abrasive and help to rapidly wear out
the chain, the front and rear sprockets.
Disassembling and cleaning

When particularly dirty, remove and clean the chain before lubrication. Proceed as follows:
- Set a stand or a block under the engine and see that the rear wheel is lifted
from the ground.
H11142
- Remove: screws (1), sprocket guard (2), clip (3), master link (4) and chain
(5). To reassemble, reverse the above procedure.
Make sure that the chain is neither worn out nor damaged. If the rollers or the
links are damaged, replace the chain by following the instructions given in the
Scheduled Maintenance Chart. Ensure that the sprockets are not damaged.
Wash and clean the chain as described hereunder.
Washing a chain without O-rings (TC)

Wash using petroleum or naphtha. If you use fuel or especially trichloroethylene,
dry and lubricate the chain to avoid oxidisation.
Lubricating a chain without O-rings (TC)

After drying, dip the chain in Molybdenum Disulphide chain lubricant, if possible,
or in warm high-viscosity engine oil (if warmed up, oil will be more 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 suffer damages.
Use instead special sprays for chains with OR.
Lubricating an O-ring chain

Lubricate all metallic and rubber (O-ring) elements using a brush and engine oil
with SAE 80-90 viscosity, inside and outside parts.
5 Assemble the master link clip (3) by setting the closed side facing the chain
direction of rotation, as shown in the figure.
The master link is the most critical safety part in the drive chain. Even
if the master links are reusable when in good conditions, for safety
purposes we advise using a new master link when reassembling
the chain.
3
Accurately adjust the chain as described on page D.18.
4
The chain lubricant shall NEVER get in contact with the tyres or the
rear brake disc.
H09078
Chain guide roller, chain guide roller, chain guide, chain slider
Check the wear of the above-mentioned elements and replace them
when necessary.
Check the chain guide alignment, and remember that a bent element
can cause chain early wear. In this case, chain might unwrap from
the sprocket.
D.24
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
Suspension setup according to track condition
Following are a few guidelines to find the right suspension setup
for different types of terrain. Always start from the suspensions standard set-
ting before making any change. Afterwards, increase or decrease the adjusting
clicks, one at a time.
HARD GROUND
Front fork: softer compression setting.
Shock absorber: softer compression setting.
For fast tracks, a softer compression and rebound setting both front and rear
will give more grip.
SANDY GROUND
Front fork: set compression harder, or replace the standard spring with a harder
spring and set the compression softer and the rebound harder.
Shock absorber: harder compression, and especially harder rebound settings.
Work on the spring preload to lower the motorcycle riding height (rear end).
MUDDY GROUND
Front fork: set compression harder, or replace the standard spring with a harder
spring.
Shock absorber: harder compression and rebound settings
or replace the standard spring with a harder spring. Work on the spring preload
to lift the motorcycle riding height (rear end). Changing the springs front and
rear is advised in order to compensate for increased motorcycle weight due to
caked-on mud.
NOTES
If the fork remains too soft or too hard no matter what setting you choose,
check oil level in the fork tubes, as it might be too low
or too high. Remember that the more oil you add, the more frequently you will
need to bleed the forks. If changes to suspension settings take no effect, check
the adjuster assemblies, as they might be stuck.
Standard settings, available replacement springs and adjusting procedures are
outlined in the following pages.
D.25
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
Shock absorber adjustment
B
The rear shock absorber must be adjusted to suit rider weight and terrain condi-
tions.
Proceed as follows:
1. Place the motorcycle on the stand and measure distance (A).
2. Sit on the motorcycle in normal riding position with full riding gear on.
A 3. Have someone else measure distance (A) again.
4. The difference between these two measurements is the distance the rear end
settles when the rider sits on the motorcycle (RIDER SAG). Recommended
rider sag is 100 mm with a cold shock absorber and 95 mm with a warm
shock absorber.
5. To achieve correct rider sag for your weight, adjust the spring preload of the
shock absorber (see relevant paragraph).
H02180
B: panel retaining screw axis

C: rear wheel axle height
D.26
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
Shock absorber spring preload adjustment
Proceed as 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 ring nut
firmly (tightening torque 50 Nm - 5 Kgm - 67.8 ft/lb).
6. Reassemble the R.H. side panel and the saddle.
5
Be careful not to touch hot exhaust pipe while adjusting the shock
absorber.
H09079
2 2
H09080
4 5
H09082
The standard length of the preloaded spring is

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

TE: A= 247 ± 0.5 mm (9.72 ± 0.02 in.) 6
H09081
D.27
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
Shock absorber compression and rebound damping adjustment
Adjustment of the compression stroke is independent from the rebound
stroke.
_ A) COMPRESSION - Standard setting:

+
1) Low damping speed:
- TE: 14 clicks;
- TC - TXC: 12 clicks;
3 1
- TC 250 USA: 10 clicks.
(adjuster 1)
2) High damping speed:

H09083 - TE: 1+1/2 clicks;
- TC - TXC: 1+1/4 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 adjuster (2) clockwise until reaching
+
fully closed position. Then turn it back by the mentioned clicks.
In order to obtain a smooth braking action, turn the adjuster counter clockwise.
2 Vice versa to obtain a harder braking action.
H09084
H09085
Shock absorber springs (4)

STANDARD
K=5,2 kg/mm (TC - TXC)
K=5,2 - 5,8 kg/mm (TE)
4
H09086
D.28
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) KAYABA front fork adjustment
- COMPRESSION (Fig. a)
(TC - TXC: TOP ADJUSTER; TE: LOWER ADJUSTER)
A
KAYABA: -9 clicks (TC EU - TXC);
KAYABA: -12 clicks (TE);
D
- KAYABA: -10 clicks (TC 250 USA).
To reset the standard setting, turn cap nut (A) clockwise to reach the fully closed
+ position; then, turn it back by the mentioned clicks. In order to obtain a smooth
braking action, turn the adjuster counter clockwise. Vice versa to obtain a harder
braking action.
H09087 TC - TXC
- REBOUND (Fig. b)
(TC - TXC: LOWER ADJUSTER; TE: TOP ADJUSTER)
KAYABA: -13 clicks (TC EU - TXC);

KAYABA: -8 clicks (TE);
KAYABA: -12 clicks (TC 250 USA).
To reset standard setting, turn adjuster (C) clockwise to reach the fully closed
position; then, turn it back by the mentioned clicks. In order to obtain a smooth
braking action, turn the adjuster counter clockwise. Vice versa to obtain a harder
braking action.
- BLEEDING (Fig. a/b) (to carry out after each competition, or monthly).
Set the motorcycle on a central stand, release the fork fully extended and loosen
the bleed valve (D). Once this operation is over, tighten the valve.
NOTE: Never force the adjuster screws beyond the maximum open and
closed positions.
TC-TXC
H11259
D.29
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
Steering bearing clearance adjustment
For safety reasons, the steering should always be adjusted so that the handlebar
turns freely and without play. To check steering adjustment, set a stand or a block
under the engine and see that the front wheel is lifted from the ground. Press
lightly on the handlebar grips to cause the front end to rotate; the handlebar should
turn smoothly. Sit on the ground in front of the front wheel and hold the lower
ends of the fork legs. Push and pull in a front to rear motion to feel for play.
If any play is detected, adjust as follows:
- Loosen the steering head tube nut (1);
- Loosen the four bolts (3) that secure the fork legs to the steering head; -
Turn the steering head tube ring nut (2) clockwise using the special key until
achieving correct play adjustment;
- Tighten the steering head tube nut (1) to 8÷9 Kgm. (78.4÷88.3 Nm);
- Tighten the four bolts (3) on the steering head to 22.5-26.5 Nm (2.3-2.7
Kgm).
H09089
1
2
3
H09090
Steering angle adjustment

Steering angle can be modified by means of the adjuster assemblies located on
either side of the steering head tube as follows: loosen the check nut (1), turn
the adjuster screw (2) until setting the desired steering angle and then re-tighten
the check nut (1). Make the same changes on both sides.
2
H09091
D.30
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
Supply hose check
During the fuel tank removal operations, pay particular attention to

the couplings of the fuel hose on the pump body and on the throt-
tle body in order to prevent possible breakage / damages to the
parts.
1
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).
2 To replace the hose, squeeze the two retainer tabs (6) at one end of the hose
and detach hose. Repeat at the other end of the hose.
H09092
H02194
TC TE-TXC
4
2 4 6
6
3
6 6
3 H09093
H11103
3 6 TC TE-TXC
3
6
5 6
5
H09095 H11104
D.31
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
Exhaust system check
Perform 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 respective supports.
The damaged or broken parts must be replaced.
H11148
TC TE-TXC
2
H11147
H11143 TE-TXC
2
TE-TXC
1
H11146
TC
1
2
H11144 H11145
D.32
GENERAL PROCEDURES
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
Section
E
E.1
GENERAL PROCEDURES
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
Sommario
Foreword.......................................................................................................E.3
Saddle removal.............................................................................................E.4
Side panel removal........................................................................................E.4
Battery removal (TE-TCX).............................................................................E.4
Rear chassis with mudguard and air box removal (TC)................................E.5
Rear chassis with mudguard and air box removal (TE-TXC)........................E.5
Exhaust system removal...............................................................................E.8
Fuel tank, scoops and spoiler removal........................................................E.12
Fuel pump removal (TC).............................................................................E.16
Fuel pump removal (TE – TXC)...................................................................E.17
Start-up relay removal (TE-TXC).................................................................E.18
Condenser (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
Electric cooling fan removal (TE-TXC)........................................................E.23
Secondary drive chain removal...................................................................E.23
Removal of engine from motorcycle............................................................E.24
Radiator removal.........................................................................................E.31
Thermostat removal (TE-XC)......................................................................E.32
E.2
GENERAL PROCEDURES
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
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.
TE - TXC
TE - TXC
H09098
H09097
RIGHT-HAND SIDE LEFT-HAND SIDE
TC
TC
H09099
H10000
RIGHT-HAND SIDE LEFT-HAND SIDE
E.3
GENERAL PROCEDURES
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
Saddle removal
- Turn the rear fixing (1) counter clockwise and remove the saddle.
1
H10001
1 Side panel removal

1 - Remove the saddle as described in the relevant paragraph.
- Loosen the retaining screws (1) and remove the side panels (2) and (3).
2
3
H10002
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 cable); remove the battery (1) from its housing.
E.4
GENERAL PROCEDURES
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
Rear chassis with mudguard and air box removal (TC)
1
- Remove the side panels as described in the relevant paragraph.
- Lift the tank at the rear end.
- Disconnect the air temperature sensor (1).
- Remove the exhaust silencer as described in the relevant paragraph.

H10003
- Slacken clamp (2) that secures the rubber coupling of the air box (3) to the
throttle body.
3
2 - 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.
H10004
5
Rear chassis with mudguard and air box removal (TE-TXC)
- Remove the following parts in the order given: saddle, side panels, fuel tank,
silencer and battery (see relevant paragraphs for instructions).
6 H10005
- Shear the plastic clips securing wiring to rear chassis.
- Disconnect the connector (1) of the turning indicator relay (2) (TE).
- Remove the solenoid starter (3) from its mount.
2
1
H00633
E.5
GENERAL PROCEDURES
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
- 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).
8
7
H00621
E.6
GENERAL PROCEDURES
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
- 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.
E.7
GENERAL PROCEDURES
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
Exhaust system removal
TC
2
5
6
2
3
H10966
Key:
1) Silencer
2) Spring
3) Exhaust manifold
4) Flange
5) Nozzle
6) Protection
E.8
GENERAL PROCEDURES
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-TXC
1
5
3 4 H10007
Key:
1) Silencer
2) Spring
3) Exhaust manifold
4) Front protection
5) Rear protection
E.9
GENERAL PROCEDURES
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
- 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).
TC TE-TXC
2 3
3 2
2
H10008 H10010 H10009
- Disconnect the Lambda sensor connector (7) and shear the wiring clips (TE-
TXC).
E.10
GENERAL PROCEDURES
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-TXC)
TE-TXC
- Loosen the two bolts (5) and remove the exhaust pipe (6).
5
6
5
H10011
7 TC (TC)
- Detach springs (7) and remove exhaust pipe (6).
H10012
E.11
GENERAL PROCEDURES
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
Fuel tank, scoops and spoiler removal
TC 1
3
4
3 2 12
10 11
3 4
6
3
5
6
H10013
E.12
GENERAL PROCEDURES
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-TXC 3 1
4
3
2
10
11
3
6 4
H00630
6 3
5
7 9
8
H10014

1
- Remove the breather hose (1).
- Loosen the fuel tank retaining screw (2).
H10015
E.13
GENERAL PROCEDURES
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
- 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.
3
4
H02212
E.14
GENERAL PROCEDURES
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
TC Carefully disconnect the fuel hoses from the throttle body or from
the fuel pump to prevent damage to the quick coupling.
8
(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.
TC
7
H10016
7 TE-TXC
H10017
6
(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 section of the tank.
- Disconnect the fuel pump connector (12) from the main wiring harness.
H10018
TE-TXC TE-TXC
11
9
8 10
12
H10019 H10020
- Slide out the tank (13).

13
H02216
E.15
GENERAL PROCEDURES
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
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).
H00648
On assembly, make sure that the pump O-ring (3) is correctly po-
sitioned in its seat.
H02339
E.16
GENERAL PROCEDURES
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
Fuel pump removal (TE – TXC)
- Remove the tank filler cap and pour the fuel contained in the tank into a ves-
sel of adequate capacity.
2 - 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).
1
4
3 3
H02340
- Slide the fitting flange (4) out of the tank, then remove the delivery and return
hoses by releasing the quick fittings (5) and (6).
7
- Disconnect the pump supply connector (7).
5
6
4
H02341
- Slide the pump (2) with relevant small hoses out of the tank.
NOTE: To refit the pump follow the removal reverse procedure and make
sure that the seals under the flanges (2) and (4) are not worn.
H02342
E.17
GENERAL PROCEDURES
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
Start-up relay removal (TE-TXC)
- Remove saddle and left-hand side panel (in this order) as outlined in the
relevant paragraphs.
- Disconnect the negative and positive cables of the battery.
- Disconnect the starter motor positive cable (1) from the solenoid starter.
- Disconnect the connector (2) and remove the solenoid starter (3) from its
mount.
Condenser (TC)
This operation must be performed with a cool engine.
- Cut the clamp (1) and disconnect the connector (2).
- Pull outwards the condenser (3) so that it comes out of the supporting bracket
(4).
1 3
H10021 H11106
E.18
GENERAL PROCEDURES
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-TXC Electronic control unit removal CDI
Remove: saddle and fuel tank as described in the relevant paragraphs.
(TE-TXC)
1 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.
H10023
TE-TXC
1
2
H10024
TC (TC)
1 Unhook the support elastic (1) then detach the connector (2) and remove the
control unit (3).
H10025
TC
2
H10026
E.19
GENERAL PROCEDURES
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
Voltage regulator removal (TE-TXC)
- Remove the electronic control unit as described in the relevant paragraph.
- Disconnect the connector (1).

1
H11107
2 3
- Loosen the two retaining screws (2) and remove the regulator (3).
H11108
Voltage regulator removal (TC)

1
- Loosen the two screws (2) and remove the voltage regulator (3).
H11109
H11110
E.20
GENERAL PROCEDURES
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
Ignition coil removal (TE-TXC)
2 - 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).
1
H11111
Coil / Stick-Coil removal (TC)

3 - With an 8-mm wrench loosen the screws (2), then remove the floater needle
4 (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
1 respect to the plate (1).
2
H11112
5
1
H11113
E.21
GENERAL PROCEDURES
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
Clutch hose removal
- Loosen the fitting (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.
E.22
GENERAL PROCEDURES
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
Electric cooling fan removal (TE-TXC)
- Remove saddle, fuel tank and scoops (in this order) as outlined in the relevant
paragraphs.
- Loosen the screw (2) and remove the electric fan (3).
Secondary drive chain removal

1 2 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).
1
H02226
H02344
E.23
GENERAL PROCEDURES
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
Removal of engine from motorcycle
- Remove the exhaust system as described in the relevant paragraph.
- Remove the engine guard as outlined in the respective section.
TE - TXC
TE - TXC - Disconnect connectors (1) and (2) and MAQS connector (3) from the throttle
1 body (4).
- Unloose the clamps (5) and (6).
7 - Push the intake coupling (7) towards the rear end of the motorcycle to re-
2 lease the throttle body (4) and then extract it from the right-hand side of the
motorcycle.
6
4
5
H10969
TE - TXC
H10035
E.24
GENERAL PROCEDURES
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
TC
TC
- Loosen the two screws (1) of the intake manifold (2) by removing the throttle
3 body (3) from the head.
2
- Remove the connector (4) of the coil / Stick-Coil.
- Disconnect the ignition connector (5).
1
H10036
TC
1
H10037
TC
4
H10038
TC
H10039
E.25
GENERAL PROCEDURES
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
- Place a vessel on the left-hand side of the cylinder, under the engine.
8 - 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.
H10040
TE 310
- Due to the blow-by circuit structure, engine oil must be drained in the TE
310 version.
For the oil draining operation, follow the instructions outlined in the respec-
tive section.
E.26
GENERAL PROCEDURES
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
- Remove the spark plug cap (17 (TE - TXC).
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.
19
- Remove the chain as described in the relevant paragraph.
18
17
H10970
TC
19
17a
18
H10971
- Remove the chain guide plate (20) unscrewing the screw (21) with an 8 mm
wrench.
20
21
H02345
E.27
GENERAL PROCEDURES
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
- Loosen the three screws (22) and remove the clutch actuator (23).
22
23
H02231
- Remove the clip (24) that holds clutch hose and wiring harness together.
24
H02232
TE - TXC
TE - TXC - Disconnect connectors (25) and (26) that connect generator and gear sensor
26 connector (27).
25
27
H10043
- Remove the water temperature sensor connector (28).

- Remove the ground cables (29) (TE-TXC).
TE-TXC TC
28
29
H10972
28 H10045
E.28
GENERAL PROCEDURES
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
- Remove the positive power supply cable (29) of the starter motor (TE-
TE-TXC TXC).
30
H10046
- 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.
35
36
H10047
E.29
GENERAL PROCEDURES
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
- Remove the guards (37) on both sides shearing the clips (38).
38
37
H02348
- Remove 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.
41
41
H02237
- 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 stand to perform the procedures described in

Sections F-G-H.
43
42
H02238 H02239
E.30
GENERAL PROCEDURES
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
Radiator removal
- Remove the fuel tank together with scoops and spoilers as outlined in the
3 relevant paragraphs.
- Remove the electric cooling fan (TE – TXC) as described in the relevant
paragraph.
4 - Place a pan under the hose (1) to collect coolant, then loosen the clamp (2),
5 detach the hose (1) and drain all coolant.
- Loosen the clamp (3) and disconnect the hose (4) from the left-hand radiator
(5).
2
1 H00683
- Loosen the clamp (6) and disconnect the hose (7) from the right-hand radiator
(8).
6
8
13
H00685
- Remove the plastic grids (9) from the radiators.
9 - Remove the clamp (10) and disconnect the radiator connecting hose (11).
11
10
12
H00687
E.31
GENERAL PROCEDURES
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
- 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).
3 1
1
3
H00690
E.32
ENGINE DISASSEMBLY
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
Section
F
F.1
ENGINE DISASSEMBLY
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
Sommario
Layout of engine components (TE - TXC)..................................................... F.3
Layout of engine components (TC)............................................................... F.4
Cylinder head cover removal......................................................................... F.5
Camshaft removal (TE - TXC)....................................................................... F.6
Camshaft removal (TC)................................................................................. F.8
Water pump body removal...........................................................................F.11
Water pump disassembly.............................................................................F.11
Cylinder head removal................................................................................ 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)............................................................ F.36
Oil pump disassembly................................................................................. F.39
Gear shift pedal and selector assembly removal........................................ F.40
Primary drive gear removal......................................................................... F.42
Crankcase disassembly.............................................................................. F.43
Gearbox disassembly.................................................................................. F.44
Crankshaft disassembly.............................................................................. F.46
F.2
ENGINE DISASSEMBLY
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
Layout of engine components (TE - TXC)
1 Throttle body
2 2 Cylinder head cover
3 Cylinder head
4 Chain tensioner
5 Cylinder
6 Starter motor
1 7 Head lubrication pipe
8 Oil filter
9 Clutch cover
3 10 Kick start lever
11 Water pump
6 4
12 Alternator cover
13 Sprocket
5
10 7
9
8
H02240
2 11
1
3 6
5 13
12
H02241
F.3
ENGINE DISASSEMBLY
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
Layout of engine components (TC)
1 Cylinder head cover
1 2 Cylinder head
3 Chain tensioner
4 Cylinder
5 Head lubrication pipe
9 6 Oil filter
7 Clutch cover
8 Kick start lever
2 9 Water pump
10 Alternator cover
11 Coolant temperature thermostat
12
10
H10973
1 8
2
11
3 4
H11114
F.4
ENGINE DISASSEMBLY
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-TXC Cylinder head cover removal
TE - TXC:
- Remove the two retaining screws (1) (10 mm wrench) and remove the head
cover (2) with its gasket.
H10975
TC TC:
1 - Remove the four retaining screws (1) and remove the head cover (2) with its
gasket.
H10976
F.5
ENGINE DISASSEMBLY
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
Camshaft removal (TE - TXC)
1 - Remove the six retaining screws (1) of the alternator cover (2) and remove
the cover with its gasket.
1
2
H10977
- To remove the gear sensor (3), loosen the two screws (4) and its pushrod
and spring.
H10978
- 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 holes (4).

H10979
INTAKE
EXHAUST
F.6
ENGINE DISASSEMBLY
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
- 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).
F.7
ENGINE DISASSEMBLY
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
Camshaft removal (TC)
1
- Remove the six retaining screws (1) of the alternator cover (2) (4 mm Allen
wrench) and remove the cover with its gasket.
1
H10980
- With a 17mm wrench, position the piston on the TDC at the end of the com-
1 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.
1
H10981
H10989
INTAKE OUTLET
3
3 3
H11149 H10990
F.8
ENGINE DISASSEMBLY
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
- Remove the spark plug (4) (16 mm wrench) and the head lubrication pipe (5)
4 loosening the drilled screw (6) (12 mm wrench).
5 H10982
- Remove the bushing (7) from the spark plug recess.
H10983
When you refit the bushing (7) make sure not to damage the O-Ring
(8).
8
H10984
- Loosen the screws (9) with a 5-mm wrench, and remove the mount (10).
9 10
H10985
F.9
ENGINE DISASSEMBLY
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
- Remove the intake camshaft (11) and the exhaust camshaft (12).
11
12
H10987
F.10
ENGINE DISASSEMBLY
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-TXC Water pump body removal
- Remove the four screws (1) securing pump body (2) to head (4 mm Allen
wrench) and remove pump body.
H10992
TC
2
1
H10993
Water pump disassembly

- Loosen the screw (1) to disassemble the pump.
TE-TXC TC
H10994 H10996
F.11
ENGINE DISASSEMBLY
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
- Loosen the impeller (3) and remove it.
TE-TXC
H10997
TC
H10998 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).
TE-TXC
5 6 7
H10999
F.12
ENGINE DISASSEMBLY
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
TC
- Remove the oil seal (4), remove the seeger (7) and remove the gear (5).
Remove the seeger (9) and remove the bearing (6).
5 TC
9
6 1
7
4
H11001
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.
F.13
ENGINE DISASSEMBLY
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-TXC 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.
H11003
TC
1
2
H11004
• Turn the screw (3) fully clockwise with a flat head screwdriver until locking
it so as to release the spring.
TE-TXC TC
3 3
H11006 H11008
F.14
ENGINE DISASSEMBLY
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-TXC • Loosen the two screws (4) using an 8 mm wrench and remove the chain
tensioner (1).
4
1
H11009
TC
4 1
H11010
5 TE-TXC TE-TXC:
- Remove the timing gear retaining clip (5) using a screwdriver.
H11014
F.15
ENGINE DISASSEMBLY
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
- With a 12-mm wrench, loosen the drilled bolt (B) and remove the tube (C).
TE-TXC TC
C C
H11015 H11016
- Loosen the two screws (6) using a Phillips screwdriver and remove the timing
drive shaft (7) while holding the gear (8) with your hand.
TE-TXC TC
7
6
6
H11017 H11019
TE-TXC TC
8
7
H11018 H11020
F.16
ENGINE DISASSEMBLY
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
- 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.
TE-TXC TC
9
8
H11021 H11023
TE-TXC TC
9
H11022 H11025
TC
H11024
F.17
ENGINE DISASSEMBLY
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-TXC 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).
10A
H11026
TC TC:
- With a 12-mm socket wrench, loosen the four screws (10) and their wash-
ers.
10
10
10
10
H11027
- Remove the cylinder head (11) and its gasket (12).
Be careful not to lose the locating pins positioned between head

and cylinder.
TE-TXC TC
11
12
H11028 H11029
F.18
ENGINE DISASSEMBLY
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
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.
F.19
ENGINE DISASSEMBLY
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
- Use a valve spring compressor to compress the valve springs. Be careful
not too damage 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
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 compressor (1).
- Remove valve collets (2), spring retainer (3), springs (4), spring seat (5) and
remove the valve (6) from the opposite end.
Intake and exhaust valves are different, be careful not to confuse

them on assembly.
F.20
ENGINE DISASSEMBLY
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
1 Valve removal (TC)
2 - 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.
1
1
2
2
H11030
- Loosen the plugs (3) then loosen the dowels (4) and (4a) with a 5 mm Allen
wrench.
3
H11031
4a
H11032
F.21
ENGINE DISASSEMBLY
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
- Remove the pins (5) and the rocker arms (1).
Mark the position of the pins (5) and of the rocker arms (1) so that
you can refit them exactly in the same position making sure that you
centre correctly the dowel on the pin groove.
1 5
During the refit, make sure that the longest dowel (4a) is positioned
on the rocker arm pin exhaust side.
- Use a valve spring compressor to compress the valve springs. Be careful

not too damage the mating surfaces that contact the gasket or those of the
1 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.
H11033 - 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 compressor (6).
- Remove valve collets (7), spring retainer (8), springs (9), spring seat (10)
and remove the valve (11) from the opposite end.
6 Intake and exhaust valves are different, be careful not to confuse

them on assembly.
To unlock the valve, you do not need to uninstall the rocker arms.
2 2
H11034
8
7 8
7
9
7 9
8 10 10
A A
7
11 9 11
11
10
H11035
H11036
F.22
ENGINE DISASSEMBLY
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
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).
H11115
F.23
ENGINE DISASSEMBLY
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
Flywheel removal
- Loosen the rotor (2) nut (1) (17 mm wrench).
H02350
- Remove the rotor (2) using the puller (3A) (part no. 8000 H2146)

3A
H02243
F.24
ENGINE DISASSEMBLY
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
- 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).
TE-TXC TC
2
1
H11037 H11038
Sprocket removal
- Lift the tab of the lock washer (1) using a chisel.
F.25
ENGINE DISASSEMBLY
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
- Loosen the nut (2) using a 22 mm wrench and remove sprocket (3) and
spacer (4).
F.26
ENGINE DISASSEMBLY
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
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).
F.27
ENGINE DISASSEMBLY
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
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).
F.28
ENGINE DISASSEMBLY
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
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).
F.29
ENGINE DISASSEMBLY
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
- 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).
F.30
ENGINE DISASSEMBLY
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
- 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).
F.31
ENGINE DISASSEMBLY
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
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.
F.32
ENGINE DISASSEMBLY
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
- 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.
F.33
ENGINE DISASSEMBLY
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
Starter motor removal (TE-TXC)
- Remove the exhaust pipe as described in the relevant paragraph.
1
- Disconnect the positive power supply cable (1) loosening the hexagonal-head
screw (8 mm wrench).
H00753
- Unscrew the four screws (2) using a 4 mm Allen wrench.
H00757
H00759
F.34
ENGINE DISASSEMBLY
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
- Slide the starter motor (3) towards the rear end of the motorcycle to remove
it.
2
H00756
H00758
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.
F.35
ENGINE DISASSEMBLY
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
Starter motor disassembly (TE-TXC)
- Separate the starter motor (1) from the starter drive (2).
Starter drive disassembly (TE-TXC)
F.36
ENGINE DISASSEMBLY
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
- 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.
F.37
ENGINE DISASSEMBLY
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
- 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.
5
5
4 13
9
12
11 14
H00772 H11258
- Remove the freewheel (6).
- Remove the needle roller bearing (7) and the thrust ring (8).
F.38
ENGINE DISASSEMBLY
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
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.
F.39
ENGINE DISASSEMBLY
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
Gear shift pedal and selector assembly removal
- 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).
H11116
F.40
ENGINE DISASSEMBLY
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
- 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).
F.41
ENGINE DISASSEMBLY
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
Primary drive gear removal
- Loosen the central nut (1) using a 22 mm wrench.
- Remove primary gear (2) and water pump drive gear (3).
F.42
ENGINE DISASSEMBLY
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
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
F.43
ENGINE DISASSEMBLY
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
- Install the crankcase puller (3) (part no. 8000 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).
F.44
ENGINE DISASSEMBLY
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
- 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).
F.45
ENGINE DISASSEMBLY
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
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.
F.46
ENGINE OVERHAUL
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
Section
G
G.1
ENGINE OVERHAUL
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
Sommario
Cleaning parts.............................................................................................. G.3
Clearances................................................................................................... G.3
Cylinder head............................................................................................... G.3
Valve seat refacing....................................................................................... G.4
Valve............................................................................................................. G.5
Valve spring (TE-TXC).................................................................................. G.5
Valve bucket inspection (TE-TXC)................................................................ G.6
Rocker arm check (TC)................................................................................ G.6
Valve installation........................................................................................... G.7
Valve leak check........................................................................................... G.8
Camshaft...................................................................................................... G.9
Timing chain and gears................................................................................ 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
Crankshaft straightness.............................................................................. G.14
Crankshaft.................................................................................................. G.14
Clutch......................................................................................................... G.15
Friction plate to clutch housing clearance.................................................. G.16
Clutch spring.............................................................................................. G.16
Oil pump..................................................................................................... G.18
Shifter forks and gears............................................................................... G.19
Selector drum............................................................................................. G.19
Drive bushing roundness............................................................................ G.19
G.2
ENGINE OVERHAUL
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
Cleaning parts
All parts must be cleaned with gasoline and dried with compressed air.
Flammable vapours develop during this procedure and metal filings blown by compressed air may get into your eyes.
Perform this procedure away from open flames or sources of ignition and wear an eye protection.
Clearances
To ensure the best operating 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 thread.
Check the machined surface of the cylinder head for warpage using a straight-edge and a feeler gauge at the positions shown in the
figure. If warpage exceeds the service limit at any one point, grind the cylinder mating surface. Head warpage: service limit 0.05 mm
(0.0019 in.).
G.3
ENGINE OVERHAUL
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
Valve seat refacing
Clean off any fouling deposits from the valve. Apply Prussian Blue 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 ground and must be replaced if damaged.
INTAKE TE - TXC EXHAUST TE - TXC
INTAKE TC EXHAUST TC
H11150 H11151
G.4
ENGINE OVERHAUL
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
Valve
Inspect valve stem and valve seating face to make sure they are in good condi-
tion. There should be no signs of pitting, cracking, distortion or wear. Check for
the following:
- Valve stem runout: place valve on a V block and measure runout with a dial
gauge. (Service 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
Spring 2 - L2 = 19.6 mm - Service limit 15.1 mm
TC
Intake: Spring 1 - L1 = 25 mm
Spring 2 - L2 = 25 mm
Exhaust: Spring 1 - L2 = 25 mm
Spring 2 - L2 = 25 mm
Replace all valve springs whenever any one spring exceeds
the service limit.
G.5
ENGINE OVERHAUL
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
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.
1
1
H11039
G.6
ENGINE OVERHAUL
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-TXC 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.
H11040
TC
H11041
TE-TXC
H11042
TC
H11043
G.7
ENGINE OVERHAUL
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
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 TE-TXC
H11045
EXHAUST INTAKE
TC
H11046
G.8
ENGINE OVERHAUL
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
Camshaft
Check the contact faces of the lobes for streaks, scoring, dents and waviness.
Clamp the camshaft between centres and check deviation using two dial gauges.
Service limit: 0.1 mm. Check that the lobes are in pristine conditions, without
signs of scoring or distortion.
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 specified limit, replace both
gears and the chain as a set.

STANDARD "L" SERVICE LIMIT

140 mm 142.5 mm
(5.51 in) (5.61 in)
Timing chain tensioners

Chain tensioners (1) must be replaced when the wear material is worn out.
G.9
ENGINE OVERHAUL
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
Cylinder
Check the walls for dents or scuffing. Measure cylinder bore diameter at three
different positions. Measure each diameter in 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 dimensions. There should be no
signs of forcing, scuffing, cracking or other damage.
G.10
ENGINE OVERHAUL
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
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.
CLEARANCE (Dc-Dp)
0.035-0.065 mm
(0.001379-0.002561 in.)
Piston pin
The piston pin (1) must be perfectly smooth, with no signs of scoring, dents or
bluing due to overheating.
G.11
ENGINE OVERHAUL
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
Piston rings (TE-TXC)
They should show 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)
0.15 -0.30 mm
"A"
(0.00591-0.01182 in.)
0.2-0.7 mm
"B"
(0.00788-0.02758 in.)
G.12
ENGINE OVERHAUL
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
Piston ring to groove clearance
Use a feeler gauge to measure the axial clearance (H) of piston rings. If the
piston ring is marked on one side, that side must be facing up.
PISTON RING END GAP ALIGNMENT PISTON

MOUNTING CLEARANCE (H)
*: end gap position "d" RING
0.02-0.06 mm
"A"
(0.00078-0.02362 in.)
0.01-0.18 mm
"B"
(0.00039-0.00708 in.)
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.
STANDARD
0.29-0.43 mm
(0.00985-0.016942 in.)
H11117
G.13
ENGINE OVERHAUL
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
Crankshaft
Main 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
G.14
ENGINE OVERHAUL
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
Clutch
Inspect all clutch components to make sure 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.
G.15
ENGINE OVERHAUL
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
Friction plate to clutch housing clearance
Measure clearance "A" between clutch housing (2) and plate (1) with a feeler
gauge and compare measured clearance with the table below.
STANDARD SERVICE LIMIT
0.30-0.50 mm 0.6 mm
(0.012-0.020 in.) (0.024 in.)
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 the service limit.
G.16
ENGINE OVERHAUL
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
1- Pressure plate, 2- Clutch actuator plate, 3- Pushrod, 4- Piston assembly: Check these parts for 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 failure. If any are found, replace the part.
G.17
ENGINE OVERHAUL
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
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.
G.18
ENGINE OVERHAUL
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
Shifter forks and gears
Visually inspect the shifter forks (1) and replace any bent forks. A bent fork will
make gears hard to engage or let the transmission jump out of gear unexpect-
edly under loading.
Check the clearance of the each shifter fork in its gear groove using a feeler
gauge. If any one of the three gears is outside the service limit, measure the
width of gear groove and fork thickness to determine which component needs
to be replaced. Shifter fork to groove clearance (new fork and gear): 0.22 - 0.37
mm (0.008661 - 0.014566 in.)
Service limit: 0.5 mm (0.019685 in.).
Selector drum
Check the grooves "A" for wear or dents and make sure the selector drum is not
bent, worn or damaged.
Drive bushing roundness

Check the drive bushings (1) of the shifter forks for out-of-round and make sure
they slide freely in the drum grooves and on the selector shaft.
G.19
ENGINE REASSEMBLY
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
Section
H
H.1
ENGINE REASSEMBLY
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
Sommario
General..........................................................................................................H.3
Assembly and lubrication instructions ......................................................H.4
Crank- alternator- lubrication- left crankcase half..........................................H.4
Tightening torque figures . ..........................................................................H.5
Gearbox - gear shift control (5 speed) . ........................................................H.6
Tightening torque figures . ............................................................................H.7
Gearbox - gear shift control (6 speed) . ........................................................H.8
Tightening torque figures . ............................................................................H.9
Assembly and lubrication instructions ........................................................H.10
Clutch- kick start- lubrication- right crankcase half......................................H.10
Assembly and lubrication instructions .......................................................H.12
Right crankcase cover.................................................................................H.12
Assembly and lubrication instructions ....................................................H.14
Head - cylinder - piston - timing system - water pump - spark plug
(TE-TXC).....................................................................................................H.14
Assembly and lubrication instructions ....................................................H.15
Head - cylinder - piston - timing system - water pump - spark plug (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
Piston ring installation.................................................................................H.42
Piston and cylinder installation....................................................................H.42
Cylinder head gasket selection table...........................................................H.44
Cylinder head installation............................................................................H.45
Timing chain tensioner installation..............................................................H.48
Water pump installation...............................................................................H.48
Camshaft installation (TE-TXC)...................................................................H.49
Camshaft installation (TC)...........................................................................H.51
Flywheel cover installation..........................................................................H.53
Neutral sensor installation (TE-TXC)...........................................................H.54
Plug refitting (TC)........................................................................................H.55
Starter motor seat cover installation (TC)....................................................H.56
Cylinder head cover, spark plug (TE-TXC)..................................................H.56
Refitting of the head cylinder cover, spark plug, coil (TC)...........................H.57
Right crankcase assembly..........................................................................H.58
Filter and drain plug (250)...........................................................................H.60
Blow-by tube fitting/filter (310).....................................................................H.60
Oil feed hose installation.............................................................................H.60
Gear shift and kick start pedal installation...................................................H.61
Installing the engine and assembling the motorcycle..................................H.62
H.2
ENGINE REASSEMBLY
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
General
To reassemble, reverse the disassembly procedure. Any special instructions concerning reassembly
are expressly highlighted in the text. Always replace gaskets, oil seals, metal retainers, sealing washers made from
deformable material (copper, aluminium, fibre, etc.) and self-locking nuts after removal. 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 components thoroughly is critical to
reliability; bearings and any wear parts must be lubricated with engine oil before assembly. Screws, nuts and bolts must be tightened
to the specified torque (see pages H.4-H.15 and Section X "TIGHTENING TORQUE FIGURES").
H.3
ENGINE REASSEMBLY
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
Assembly and lubrication instructions
CRANK- ALTERNATOR- LUBRICATION- LEFT CRANKCASE HALF
H.4
ENGINE REASSEMBLY
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
Tightening torque figures
TE
1 M5 - L20 (Loctite 272) 6 Nm- 0,6 Kgm- 4.43 ft/lb
TXC
1 TC M4 - L30 (Loctite 272) 4 Nm- 0,4 Kgm- 2.95 ft/lb
2 M5 - L12 (Loctite 272) 6 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
LUBRICATION POINTS-NOTES LUBRICANT-INSTALLATION INSTRUCTIONS
A Degrease
B Apply engine oil on installation
E Line up stator mark with cover mark
G WATER RESISTANT grease
O Engine oil
H.5
ENGINE REASSEMBLY
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
GEARBOX - GEAR SHIFT CONTROL (5 speed)
H.6
ENGINE REASSEMBLY
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
22 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
D Install with open end pointing to engine centre
O Engine oil
O/G Engine oil or WATER RESISTANT grease
H.7
ENGINE REASSEMBLY
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
GEARBOX - GEAR SHIFT CONTROL (6 speed)
H11099
H.8
ENGINE REASSEMBLY
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
22 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
D Install with open end pointing to engine centre
O Engine oil
H.9
ENGINE REASSEMBLY
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
CLUTCH- KICK START- LUBRICATION- RIGHT CRANKCASE HALF
H.10
ENGINE REASSEMBLY
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
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 (+LOCTITE Alt. 243) 8 Nm- 0.8 Kgm- 5.9 ft/lb
40 M6 - L20 8 Nm- 0.8 Kgm- 5.9 ft/lb
O Engine oil
C Join crankcase halves using Loctite 5205
H.11
ENGINE REASSEMBLY
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
RIGHT CRANKCASE COVER
H.12
ENGINE REASSEMBLY
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
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
O Engine oil
H.13
ENGINE REASSEMBLY
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
HEAD - CYLINDER - PISTON - TIMING SYSTEM - WATER PUMP - SPARK PLUG
TE-TXC
52
H11047
H.14
ENGINE REASSEMBLY
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
HEAD - CYLINDER - PISTON - TIMING SYSTEM - WATER PUMP - SPARK PLUG
TC
50 O
48 48
48
G 52
G
O O
51
53
49
54
56
58
O
59
55 57
45
H11048
H.15
ENGINE REASSEMBLY
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
36 Special flanged screw L.23.4 8 Nm - 0,8 Kgm - 5.9 ft/lb
TXC
TE
37 Special flanged screw L.31.3 8 Nm - 0,8 Kgm - 5.9 ft/lb
TXC
TE
38 M5 x 0.8 - L8 (+LOCTITE 243) 6 Nm - 0,6 Kgm - 4.43 ft/lb
TXC
TE
39 M10 x 1.25 5 Nm - 0,5 Kgm - 3.69 ft/lb
TXC
TE
40 M10 - L104.5 40 Nm - 4 Kgm - 29.5 ft/lb
TXC
TE
41 M10 - L104.5 40 Nm - 4 Kgm - 29.5 ft/lb
TXC
42 M6 - L20 8 Nm - 0,8 Kgm - 5.9 ft/lb
TE
43 M4 - L10 3 Nm - 0,3 Kgm - 2.21 ft/lb
TXC
TE
44 M5 - L25 6 Nm - 0,6 Kgm - 4.43 ft/lb
TXC
45 M4 - L12 (+LOCTITE 243) 8 Nm - 0,8 Kgm - 5.9 ft/lb
TE
46 M5 (+LOCTITE 270 or 272) 6 Nm - 0,6 Kgm - 4.43 ft/lb
TXC
TE
47 M5 - L30 1 Nm - 0,6 Kgm - 0.74 ft/lb
TXC
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
1) - 20 Nm - 2 Kgm - 14.75 ft/lb

51 TC Stud bolt head fastening
2) - 40 Nm - 4 Kgm - 29.50 ft/lb
52 M10 x 1.5 5 Nm - 0,5 Kgm - 3.69 ft/lb
53 TC Plug M10 x 1 (+LOCTITE 243) 10 Nm - 1,0 Kgm - 7.38 ft/lb
1) - 7 Nm - 0,7 Kgm - 5.16 ft/lb

54 TC Camshaft mount retaining screw
2) - 11 Nm - 1,1 Kgm - 8.11 ft/lb
55 TC Screw M4 - L10 3 Nm - 0,3 Kgm - 2.21 ft/lb
Water pump impeller

56 8 Nm - 0,8 Kgm - 5.9 ft/lb
M5 + LOCTITE 243)
58 TC Screw M5 x 0.8 - L25 6 Nm - 0,6 Kgm - 4.43 ft/lb
F Use sealant "AREXONS RHODORSEAL 5552" on installation
G WATER RESISTANT grease
O Engine oil
H.16
ENGINE REASSEMBLY
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
Input shaft
Output shaft
H.17
ENGINE REASSEMBLY
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
Input shaft (5 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
H.18
ENGINE REASSEMBLY
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
Output shaft (5 SPEED)
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
H.19
ENGINE REASSEMBLY
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
Input shaft
Albero secondario
Output shaft
6 SPEED
th
5
st
1
th
4
rd
3
th
6
nd
2 H00602
H.20
ENGINE REASSEMBLY
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
Input shaft (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 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.
(1.4448 - 1.4251 in.)
(1.9669 - 1.8228 in.)
H.21
ENGINE REASSEMBLY
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
Output shaft (6 SPEED)
Fit 2nd gear (2), washer (3) and retaining ring (4).
Fit 6th gear (5) and retaining ring (6).
Fit the washer (7).
Fit roller cage (8) and 3rd gear (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).
(2.6502 - 2.6981 in.)
(2.2549 - 2.2953 in.)
(1.0361 - 1.0705 in.)
(0.6376 - 0.6694 in.)
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 engaged and 1st and 3rd gears and their
washers and circlips butted up together on the shaft.
D: Control dimension with 2nd gear engaged and 2nd and 1st gears butted up
together on the shaft.
H.22
ENGINE REASSEMBLY
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
Crankcase assembly
Clean the crankcase 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).
H11118
H.23
ENGINE REASSEMBLY
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
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).
H.24
ENGINE REASSEMBLY
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
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.
H.25
ENGINE REASSEMBLY
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
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).
H.26
ENGINE REASSEMBLY
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
Heat up the left crankcase bearing housings and install the 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 the engine.
H.27
ENGINE REASSEMBLY
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
Gear shift control 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).
H11119
H.28
ENGINE REASSEMBLY
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
Operate shifter and transmission shaft to test gearbox 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
(14).
H.29
ENGINE REASSEMBLY
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
Turn the engine 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.
H.30
ENGINE REASSEMBLY
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
Install the gear shift lever (19) and operate the gearbox manually (8 mm wrench,
8 Nm, 0.8 Kgm, 5.8 ft/lb).
H.31
ENGINE REASSEMBLY
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
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).
H.32
ENGINE REASSEMBLY
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
Timing 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).
H.33
ENGINE REASSEMBLY
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
Install the timing chain (5).
Refit the bushing (6).
Refit the clutch housing (7).
H.34
ENGINE REASSEMBLY
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
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).
H.35
ENGINE REASSEMBLY
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
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).
H.36
ENGINE REASSEMBLY
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
Refit the plates (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).
H11120
H11121
H.37
ENGINE REASSEMBLY
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
Sprocket installation
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.
H.38
ENGINE REASSEMBLY
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
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.
3
2
H11049
Lubricate the freewheel (4) with engine oil and refit it.
H11051
H.39
ENGINE REASSEMBLY
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
Refit the rotor (5). Hold the rotor (5) 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 (6) to 75 Nm, 7.5 Kgm, 54.3 ft/lb. Use a 17
mm wrench.
5
Before installing the starter motor (7), check for free (clockwise) rotation of the
freewheel (4) while holding the rotor (5) steady.
H02248
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.
8
10
H11052
Fit the starter motor (7) into place.
12 Tighten the bevel drive screws (11) using a 4 mm Allen wrench (6 Nm - 0.6Kgm
11 - 4.43 ft/lb).
Tighten the screws (12) (12a) using a 4 mm Allen wrench (6 Nm - 0.6Kgm - 4.43
ft/lb).
12=L= 25 mm
12a=L=30 mm
7 12a
11
H11053
H.40
ENGINE REASSEMBLY
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
Flywheel installation (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.
H11122
H.41
ENGINE REASSEMBLY
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
Piston ring installation
Fit the piston rings as shown in the diagram. If the piston ring is marked on one
side, that side must 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 piston is pointing to the front end.
Make sure that the locating pins (6) are in place.
H11123
H.42
ENGINE REASSEMBLY
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
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).
H.43
ENGINE REASSEMBLY
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
Fit screws and spacers (10) to temporarily secure the cylinder liner (7).
(3 spacers 10a, h= 44.2 mm; 1 spacer 10b, h= 29.2 mm)
Use a 12 mm wrench - 40 Nm, 4 Kgm, 29 ft/lb.
Make sure that the piston is at Top Dead Centre.
Measure distance "A" on the four machined faces of the piston and choose the
appropriate head gasket according to the table below.
Remove spacers 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 part no.
-0,1 ± 0.05 mm 0,7 mm

1) (piston lower than cylinder mating face) 8B00 A6576
-0,0039 ±0,0019 in 0,0275 in
-0.2 ± 0.05 mm 0,6 mm
1) (piston lower than cylinder mating face) 8A00 A6576
-0,0078 ±0,0019 in 0,0236 in
-0.3 ± 0.05 mm 0,5 mm
1) (piston lower than cylinder mating face) 8000 A6576
-0,0118 ±0,0019 in 0,0196 in
H.44
ENGINE REASSEMBLY
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
Cylinder head installation
TE-TXC
For valve installation instructions, please see Section "G".
Always use a new head gasket on assembly: see the "Cylinder head gasket
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
H11055
TC TC:
Tighten the screws (3) gradually and in a cross pattern, starting with a 20 Nm -
3 2.0 Kgm - 14.75 lb/ft pre-tightening torque, then with a 40 Nm - 4.0 Kgm - 29.50
lb/ft torque (12 mm wrench) .
1
3
3
2 3
H11056
Refit the water temperature sensor (4A) (use a 17 mm ring wrench 5 Nm, 0.5
Kgm, 3.69 ft/lb).
TE-TXC TC
4a
4A
H11057 H11058
H.45
ENGINE REASSEMBLY
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-TXC:
TE-TXC Refit the four shim (5) on the valves and the valve buckets (6) as marked on
removal.
H11059
6a TC TC:
6a
5 Lift the rocker arms (6a) and refit the four pads (5) following the numbering you
marked during the removal.
6a
5
6a
5
5
H11060
TE-TXC:
Check the bearings of the timing drive upper gear (7) and replace them if
needed.
TE-TXC
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 the
status of the gasket (10) and if it shows damages, replace it.
H11061
TC 11 10 TC
8
H11062 H11063
H.46
ENGINE REASSEMBLY
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-TXC 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).
H11064
TC
10
10
H11066
Tighten the drilled bolt (12) using a 12 mm wrench at a torque of 8 Nm, 0.8
Kgm, 5.9 ft/lb.
TE-TXC TC
12
12
H11065 H11067
H.47
ENGINE REASSEMBLY
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
Timing chain tensioner installation
TC
Refit the chain tensioner (12) and its gasket. Tighten the two screws (13) using
an 6 mm wrench (8 Nm, 0.8 Kgm, 5.9 ft/lb).
13
12
On TE and TCX models, the two retaining screws feature two differ-
13 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
H11068 ground rings (14) before tightening.
TE-TXC
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).
14
13a Tighten the screw (15).
15
13
H11069
Water pump installation

Refit the water pump (1) with its gasket. Avoid using excessive force to engage
pump gear with intake camshaft gear. Tighten the screws (2) with a 4 mm Allen
wrench (5.5 Nm, 0.5 Kgm, 3.98 ft/lb).
TE-TXC TC
1
2
H11070 H11071
H.48
ENGINE REASSEMBLY
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
Camshaft installation (TE-TXC)
Secure a dial gauge (1) to the spark plug hole.
Turn the crankshaft 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 that the bushings (5) are in place in the covers.
H.49
ENGINE REASSEMBLY
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
Clean and refit the camshaft mounts (6) and tighten the screws (7) in a cross
pattern as diagram “B” shows. Make sure to fit the screws in the correct position
according to their length (see diagrams “A” and “B”).
7a= M6x35 Allen screw

7b= M6x30 Allen screw
7c= M6x25 Allen screw
7d= M5x30 Allen screw
Turn the crankshaft manually a few turns to check for free, smooth rotation without
any tight points, then 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 1.60 mm to 2.60 mm thickness range, in

0.05 mm increments.
Thickness (S) of the new shim is determined as follows:
S= (G1-G)+S1
S= Thickness of new shim
G1= Measured valve clearance
G= Specified valve clearance
S1= Thickness of old shim
On assembly, check the timing of the camshaft gears and measure valve clear-
ance again.
Diagram "A"
Diagram "B"
H.50
ENGINE REASSEMBLY
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
Camshaft installation (TC)
Secure a dial gauge (1) to the spark plug hole.
1 Turn the crankshaft 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.
H11072
The engraved reference marks (4) must be positioned as shown.
2
3
INTAKE OUTLET
4 4 4
H11073 H11074
Make sure that the plugs (5) are in the correct position on the mount (6).
6
H11075
H.51
ENGINE REASSEMBLY
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
Clean the mount and tighten the screws (A) with a fitting sequence from 7 to 14 as
A the diagram “B” shows. Initially tighten them with a 7 Nm - 0.7 kgm - 5.16 ft/lb pre-
A tightening torque, then with a 11 Nm - 1.1 kgm - 8.11 ft/lb tightening torque.
Diagram "B"
13 11
A
8
9
A
H11076
7
10
12 14 H11152
Turn the crankshaft manually a few turns to check for free, smooth rotation without
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 refit the spark plug recess (8) making sure
7 that the gasket does not get damaged.
H11077
H11078
H.52
ENGINE REASSEMBLY
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
Flywheel cover installation
3 TE-TXC
Install the stator (1) with its mark lined up with the flywheel cover mark and tighten
the retaining screws (2) (use a 4 mm Allen
4 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
5 screws (4) of the pick-up sensor (5) with its plate (6 Nm, 0.6 Kgm, 4.3 ft/lb +
Loctite 272).
4 Install the flywheel cover (7) with its gasket and tighten the six screws (8) to 6
Nm, 0.6 Kgm, 4.3 ft/lb.
2
Make sure the two centring bushings (6) are in place.

2
1
H11079
4 5 4 TC
3 2
2
1
H11080
TE-TXC TC
8
8
7
8
H11081 H11082
H.53
ENGINE REASSEMBLY
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
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).
H.54
ENGINE REASSEMBLY
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
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).
2
H11083
3
H11084
H.55
ENGINE REASSEMBLY
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
Starter motor seat cover installation (TC)
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.
H11085
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).
H.56
ENGINE REASSEMBLY
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
Refitting of the head cylinder cover, spark plug, coil (TC)
- Fit the central retaining gasket (1).
H11086
4 - Fir the cover (3) on the head (2) with the respective gasket.
4 - Tighten the screws (4) to a 8 Nm - 0.8 Kgm - 5.9 ft/lb torque.
3
4
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).
4a
2 H11087
- Make sure that the gasket (5) is correctly fitted; the reference lug (6) must
correspond with the retaining bracket (8) gap (7).
- Install the coil (9) on the head.
- Tighten the screws (10) with a 6 Nm, 0.6 Kgm, 4.43 ft/lb torque.
6 11
9
8
10
5
7
8
H11088 H11089
H.57
ENGINE REASSEMBLY
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
Right 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.
H.58
ENGINE REASSEMBLY
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
Install the crankcase (8) and tighten the screws (9) following a 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 the cover (6).
H.59
ENGINE REASSEMBLY
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
Filter and drain plug (250)
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).
310 Blow-by tube fitting/filter (310)

4 Insert the oil filter (1), screw the hose fitting (2), insert hose (3) and screw clamp
(4).
3
2
1
H02352 H11090
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/lb).
TE-TXC TC
H11091 H11092
H.60
ENGINE REASSEMBLY
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
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.
TE-TXC TC
H11093 H11094
H.61
ENGINE REASSEMBLY
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
Installing the engine and assembling the motorcycle
TE 250-310
Install the engine and any parts you had removed in the order given below.
- Place the engine in the chassis.

- Insert the swinging arm shaft from the right-hand side and tighten its nut
using a 22 mm wrench.
- Tighten the engine mounting bolts to the frame using a 12 mm wrench on
the left-hand side and a 10 mm wrench on the right-hand side.
- Install the drive chain (fit the master link clip by setting the closed side facing
the chain direction of rotation).
H11095 - Install the clutch control on the engine and tighten the fitting with an 8 mm
wrench. Add clutch fluid.
- On the left-hand side, use an 8 mm wrench to install the chain guide plate.
Fit the transmission sprocket cover and tighten its screws using a 6 mm
wrench.
TXC 250-310 - Fit the spark plug cap to the spark plug. Install the rubber hose on the right-
hand side of the cylinder head cover.
- Refit the oil sump guard if you had removed it.
- 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.
H11096 - Refit the fuel tank front retaining screw and hook up the scoops to the spoil-
ers on the radiators.
- Refit the breather hose of the fuel tank plug on the steering stem. Refit the
hose running from fuel tank to carburettor.
- Refit the side panels with their retaining screws.
TC 250 - Refit the saddle and secure it with its rear fixing.
NOTES
1) Unless otherwise specified, standard torque values for the different thread
sizes are as follows
M5x0.8 (5.6-6.2 Nm; 0.57-0.63 Kgm; 4.1-4.5 ft/lb)

M6x1 (7.6-8.4 Nm; 0.80-0.85 Kgm; 5.8-6.1 ft/lb)
M8x1.25 (24-26 Nm; 2.4-2.6 Kgm; 17.3-18.8 ft/lb)
H11097
2) For electrical connections, see relevant diagram included in Section M.

3) Bleed the clutch (see Section P).
4) Pour the oil in the crankcase (for the characteristics and quantities, see Chapter
A)
5) Pour the liquid in the RH radiator (for the characteristics and quantities, see
Chapter A)
6) Check that the kick start pedal moves freely.
7) Perform the necessary adjustments as outlined in Section D "Settings and
adjustments".
H.62
FRONT SUSPENSION
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
Section
I
I.1
FRONT SUSPENSION
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
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
I.2
FRONT SUSPENSION
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
H09056
TC
H09058
TXC
H09057
I.3
FRONT SUSPENSION
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
Front fork removal
A Measure height "A" (it will need 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:
H10056
- 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 Section "Y";
I.4
FRONT SUSPENSION
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
- 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.
I.5
FRONT SUSPENSION
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
Front suspension
Service instructions for Ø48USD Kayaba fork
GENERAL
The fork uses a multi-valve damping system with rebound and compression
adjustment and spring preload adjustment for static load.
Compression damping is controlled by a special valve located at the top of each
fork leg. Rebound damping is controlled by a sealed cartridge located inside
each inner tube.
Each fork leg has outer adjusters for compression and rebound damping.
Both fork legs have bleed valves to bleed air from the outer tube and drain
screws 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 detailed information).
OIL: Special KAYABA formulation prevents foaming and retains
same viscosity under any operating conditions; stiction-free.

SPRING TABLE
Fork static load is determined by the spring contained in each upper leg: suspen-
sion response may be changed by changing the spring or the tube spacer that
determines its preload, with no need to alter fork settings. “Spring+tube spacer”
kits available as spare parts are listed below.
MODEL SPRING RATE K (N/mm)

TXC-TC 4.6
TE 4.6
I.6
FRONT SUSPENSION
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
7
8 10
3
5 6
2
20 11
11 4
21 9
13
14 22
15 23 1
12 16
17
18
19
H11100
Front suspension (TC - TXC)

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) 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) Dust seal
20) Bushing
21) Bushing
22) Spring
23) Complete damper unit
I.7
FRONT SUSPENSION
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
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).
H06813
Drain oil from the damper unit.
H06818
Clamp the wheel axle carrier in a vice and loosen the adjuster screw.
H06819
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 hurt your fingers.
H06820
I.8
FRONT SUSPENSION
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
Take the cartridge out of the outer tube.
H06821
Do not remove the nut at the bottom end of the cartridge.
H06822
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.
H06823
Check the O-rings on the bottom valve assembly for damage.

Replace as required.
H06824
I.9
FRONT SUSPENSION
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
If outer tube and inner tube are still assembled together, place the fork leg upside
down and allow at least 20 minutes for oil to drain.
H06825
Remove the dust seal using a flat head screwdriver.
H06826
Remove the retaining ring using a flat head screwdriver.
H06827
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.
H06828
I.10
FRONT SUSPENSION
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
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.
H06829
Check the rebound adjuster rod for distortion or damage.

H06830
Check the rebound adjuster.

Replace damaged O-rings.
Replace the complete assembly (do not reuse it).
H06831
Check the spring.

Replace it if:
outside diameter is damaged or exceedingly worn.
H06833 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 defects, sand the surface.
If repair is not possible, replace the tube.
H06834 (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.
H06835
I.11
FRONT SUSPENSION
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
Mount sealing rings and metal parts on the inner tube.
See the figure below for the installation sequence.
Note 1: Grease the edge of the 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.
4 6 7 8
5 9
H06836
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 visible.
H06837
Install the retaining ring.

Make sure that the retaining ring is fully seated in the groove inside the outer
tube.
H06838
I.12
FRONT SUSPENSION
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
Fit the dust seal to the outer tube.
Make sure that there is not play between dust seal and outer tube.
H06839
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.).
H06840
Fill the cartridge with the specified oil (196 cm3 - 11,96 in3).
H06841
Pump the piston rod up and down repeatedly to remove any air from the cyl-
inder.
H06842
I.13
FRONT SUSPENSION
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
Pull the piston rod until fully extended.
Check oil level. It should be about 145 mm (5.7 in.).
H06843
Push the piston rod all the way down and install the bottom valve assembly.
With the bottom valve assembly installed, check that the piston rod is fully
extended.
H06844
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.
H06845
Hold the cartridge with the piston rod end pointing downwards as shown in the
figure.
Pump the piston rod up and down a dozen times to help oil reach all points of
the unit.
H06847
I.14
FRONT SUSPENSION
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
Drain excess oil from the cartridge pushing the damper unit all the way home.
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.
H06848
Drain excess oil from the reservoir.
H06849
Clean off any excess oil from the cartridge.

Install spring guide and spring on the cartridge.
H06850
Insert the cartridge into the inner tube.
H06851
I.15
FRONT SUSPENSION
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
Push down the inner tube.
Slip the 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.
H06852
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.
H06853
Tighten nut and adjuster to 28 Nm (20.6 ft/lb) using a wrench.
H06854
I.16
FRONT SUSPENSION
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
Clamp the wheel axle carrier in a vice and tighten the adjuster screw onto the
carrier to 55 Nm (40.5 ft/lb).
H06819
Fill the outer tube with the specified quantity of oil: 360 cm3 - 21,97 in3;
H06855
Tighten the cylinder onto the outer tube to 29 Nm (21.4 ft/lb).
H06813
I.17
FRONT SUSPENSION
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
9 14 8
4
13 3
7
2
10
6
5
11
10 12
H10103
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
I.18
FRONT SUSPENSION
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
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).
H10057
Loosen the fork cap nut and the nut with a wrench.
H10058
Remove top cap nut, spring retainer, spring and rebound adjuster rod.
H10059
Drain the oil.

Pump the piston rod up and down to drain oil from the cylinder.
H10060
I.19
FRONT SUSPENSION
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
Remove nut, spring guide, O-ring and collar bushing.
H10061
Hold the cartridge top end steady.

Loosen and remove the bottom valve assembly.
H10062
I.20
FRONT SUSPENSION
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
Take the cartridge out of the outer tube.
H06868
Remove the dust seal using a flat head screwdriver.
H06869
I.21
FRONT SUSPENSION
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
Remove the retaining ring using a flat head screwdriver.
H06873
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.
H06874
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.
H06875
Check the rebound adjuster rod for distortion or damage.

H06876
Loosen and remove the bottom valve assembly.

Replace damaged O-rings.
Replace the complete assembly (do not reuse it).
H06877
I.22
FRONT SUSPENSION
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
Check the spring.
Replace it if:
outside diameter is damaged or exceedingly worn.
Free length is 457 mm (18 in.) or less.
H06878
Check the inner tube.

Replace if distorted.
(Never attempt to repair or reuse a distorted fork 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).
H06879
Check the outer tube.

Replace the tube is any distortion is detected or if the sliding surface is dam-
aged.
H06880
Mount sealing rings and metal parts on the inner tube.

See the figure below for the installation sequence.
Note 1: Grease the edge of the 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.
H06881
I.23
FRONT SUSPENSION
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
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 visible.
H06883
Install the retaining ring.

Make sure that the retaining ring is fully seated in the groove inside the outer
tube.
H06884
Fit the dust seal to the outer tube.

Make sure that there is not play between dust seal and outer tube.
H06885
I.24
FRONT SUSPENSION
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
Insert the cartridge into the outer tube.
H06868
Hold the cartridge top end into place.

Tighten the bottom valve assembly to 55 Nm (40.5 ft/lb).
H06871
I.25
FRONT SUSPENSION
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
Fit collar bushing, O-ring, spring guide and nut onto piston rod.
Insert the rebound 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.
H06886
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 outlined below (Filling oil to specified level).
H06887
I.26
FRONT SUSPENSION
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
Filling oil to specific level
Fill the damper unit with oil up to the top edge of the outer tube.
Slowly pump the outer tube up and down to help oil flow equally into both inner
and outer tube.
Now 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 adjuster rod into the piston rod.
Insert spring and spring guide retainer and tighten the cap nut.
115 mm (4.52 in.)

H10104 H10105
Tighten fork cap nut and nut to 28 Nm (20.6 ft/lb).
H06889
Tighten cap nut onto outer tube to 30 Nm (22 ft/lb).
H06890
I.27
REAR SUSPENSION
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
Section
J
J.1
REAR SUSPENSION
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
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
J.2
REAR SUSPENSION
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
Rear shock absorber
TIGHTENING TORQUE FIGURES
1, 2: 52.4 Nm/ 5.35 Kgm/ 38.6 ft/lb
2
H10107
H10106
Lubrication points (grease)
J.3
REAR SUSPENSION
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
Rear suspension
The rising-rate rear suspension is made up of a shock absorber, a linkage system
and a swinging arm. The spring preload of the shock absorber can be adjusted
to suit riding and terrain conditions. Hydraulic 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.
1 Remove saddle, side panels, silencer and rear chassis (see Section "E" - General
Procedures). Loosen the front clamp (1) of the intake coupling.
H02293
Remove the front bolt (2) securing the suspension linkage to the chassis, the
bottom (3) and top (4) shock absorber mounting bolts and remove the shock
absorber (5).
IMPORTANT: On assembly, fit the bottom locking nut (3) of the shock absorber
on the LEFT SIDE.
2
3
H10108
H10109
J.4
REAR SUSPENSION
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
Disassembling and servicing the swinging arm
Set a stand or a block under the engine and see that the rear wheel is lifted from
the ground. Remove the secondary drive chain (1) and detach the rear brake
line (2) from the swinging arm (A). Remove both chassis side guards (3). Dis-
engage the return spring (4) of the rear brake pedal from the chassis. 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 arm straightness and manually check the roller cages (D) and
their bushings (E) for wear; turn the bushing inside the roller cage: if you feel
any tightness or hear noise, replace them.
5 =142,1 Nm - 14,5 Kgm - 104,81 ft/lb

8 = 122,5 Nm - 12,5 Kgm - 90.3 ft/lb (+LOCTITE 243)
J.5
REAR SUSPENSION
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
Servicing the swinging arm shaft
Check shaft taper using a dial gauge. Place the shaft on two identical reference
blocks. Turn the shaft and move the dial gauge horizontally to determine the
amount of distortion.
Service limit: 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 detected, remove the part from swinging arm or chassis and
check inner spacer (A) and (E), bushings (C), (D) and bearings (B) for wear.
1
2 Grease the inner race of the bearings before refitting them.

H10110
J.6
REAR SUSPENSION
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
Chain roller, chain guide, chain slider
Check the wear of the above-mentioned elements and replace them when
necessary.
3
Check the chain guide alignment, and remember that a bent element
can cause chain early wear. In this case, chain might unwrap from
A the sprocket.
1 Chain roller
1 2 Chain guide
2 3 Chain slider
H01033
a Master link clip
J.7
BRAKES
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
Section
L
Workshop Manual Ed.12-2011
L.1
BRAKES
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
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
L.2
BRAKES
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
Braking system
The braking system uses 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 pedal
11
10
H11124 H02294
L.3
BRAKES
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
Brake disc
Checking the brake disc is an important safety procedure; the disc must be spot-
less, i.e. free from corrosion, oil or 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. On assembly, clean all mating surfaces thoroughly and tighten the screws
to the specified torque.
L.4
BRAKES
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
Checking brake pads for wear / replacing the pads
Check brake pad wear.
Service limit ”A”
- 3.8 mm (front and rear pads)
If service limit is exceeded, always replace the pads in pairs.

Be careful that no brake fluid or any oil gets on brake pads or discs. Clean off
with alcohol any fluid or oil that inadvertently gets on 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 the control lever several times until bringing
the pistons back to their normal position.
Drain some fluid from the reservoir when replacing the pads, or the
pistons backing up into the cylinders might cause fluid to spill out
of the reservoir.
FRONT REAR
L.5
BRAKES
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
Bleeding the front braking system
A long travel and mushy feel of the brake lever indicate that there is air in the
system and the brake needs bleeding.
Bleeding procedure is as follows:
- Take the rubber cap off the bleed valve (1).
- Attach a clear plastic hose to the calliper bleed valve and place the other
end of the hose in a vessel (make sure the hose end stays dipped in the fluid
throughout the procedure).
- Remove the reservoir plug (2) and the rubber gaiter and fill fresh fluid into
the reservoir.
- Pull the lever (3) of the brake and keep it pulled so that the system remains
under pressure, loosen the valve (1), tighten the valve (1) 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.
- 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 the event of contact with eyes, rinse with
abundant water.
Motorcycle handlebar must be turned to the left during the bleed-

ing procedure. This will keep the master cylinder reservoir higher,
making bleeding easier.
The bleeding procedure does not remove all air from the circuit; any
small amounts of air left in the circuit will disappear after a short
period of usage; this will eliminate the mushy feel of the lever and
restore its travel to proper length.
If brake lever or brake pedal feel mush after a fall or a repair result-
ing in loss of braking, bleed the circuit as described above.
Bleed valve tightening torque: 12-16 Nm, 1.2-1.6 Kgm, 8.8-11.8 ft/
lb.
L.6
BRAKES
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
Bleeding the rear braking system
A long travel and mushy feel of the brake pedal indicate that there is air
A
in the system and the brake needs bleeding.
- Remove the protection cap and connect a clear hose to the bleed valve (1)
of the calliper. Insert the other end of the hose in a container.
- Remove reservoir cap (A) (21 mm wrench) and diaphragm and fill with fluid
B (DOT 4).
- Press the pedal (2) fully down.
- With the lowered pedal (2), loosen the bleed valve (1) so the fluid can come
out of the small tube (initially only air will come out), then close the valve (1)
always keeping the pedal lowered, then release the pedal.
H02295 - Top up the fluid level, wait a few seconds, then repeat a few times the proce-
- Tighten the bleed valve to the specified torque and check fluid level (B) in the
reservoir before refitting the cap (A). If the bleeding procedure was performed
correctly, the pedal will no longer have that mushy feel. If not so, repeat the
procedure.
1
Brake fluid is corrosive. In the event of contact with eyes, rinse with
abundant water.
H02296
If brake lever or brake pedal feel mush after a fall or a repair result-
ing in loss of braking, bleed the circuit as described above.
lb.
L.7
BRAKES
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
Changing the fluid
Brake fluid should be checked and changed as per the "Maintenance Chart"
(see Section B), or earlier if contaminated with debris or water.
Do not change brake fluid in the rain or with a strong wind.
Use only fluid taken from a sealed container (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.
1A Do not mix two brands of fluid. This would reduce boil-over

point, leading to loss of braking efficiency or degrading of rubber
parts.
Replacement procedure is as follows:

- Take the rubber cap off the bleed valve (1) or (1A).
- Attach a clear plastic hose to the calliper bleed valve and place the other end
of the hose in a vessel.
H02297
H11125
L.8
BRAKES
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
- Remove the reservoir cover (2) or (2A) and the rubber gaiter.
- Pull the lever (3) and hold it pulled, or press the pedal (3A) and hold it pressed
so that the system is under pressure.
- Loosen the valve (1) or (1A) and wait for the oil to come out, then tighten the
valve (1) or (1A) and release the 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.
2A - Top up the fluid level (2) or (2A) and repeat a few times the procedure de-
scribed in the line above until the system is completely full and the clear fluid
begins to come out without bubbles from the transparent hose.
- After changing the fluid, you will need to bleed air from the circuit.
H02298
L.9
BRAKES
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
Periodically check the connecting hoses (C) and (D) (see Scheduled Maintenance
Chart, Section B): replace worn or cracked hoses.
L.10
ELECTRICAL SYSTEM
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
Section
M
M.1
ELECTRICAL SYSTEM
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
Sommario
Wiring diagram (TC)..................................................................................... M.5
Wiring diagram (TE)..................................................................................... M.6
Wiring diagram (TXC)................................................................................... M.7
Electrical components location (TC) (Battery-less)...................................... M.8
Condenser (TC)............................................................................................ M.9
Electrical components location (TE)............................................................. M.9
Electrical components location (TXC)........................................................ M.13
Checking generator stator windings resistance.......................................... M.16
Generator no-load performance................................................................. M.17
Ignition and starter system (TC)................................................................. M.18
Ignition and starter system (TE-TXC)......................................................... M.19
Charging system (TE-TXC)........................................................................ M.21
Charging system wiring diagram................................................................ M.21
Charging system inspections..................................................................... M.22
Current loss at the battery (TE-TXC).......................................................... M.22
Regulated voltage (TE-TXC)...................................................................... M.22
Voltage regulator/rectifier inspection (TE-TXC).......................................... M.22
Voltage regulator........................................................................................ M.22
Voltage regulator/rectifier wiring diagram................................................... M.22
Electrical starting system (TE-TXC)........................................................... M.23
Starting system inspection......................................................................... M.24
Starter motor inspection (TE-TXC)............................................................. 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, tail light (TE)............................................................................. M.30
Headlamp adjustment ............................................................................... M.30
Headlamp bulbs replacement..................................................................... M.30
Tail light replacement.................................................................................. M.31
Number plate bulb replacement................................................................. M.31
Handlebar switches.................................................................................... M.32
Left-hand switch (TC)................................................................................. M.32
Left-hand switch (TE)................................................................................. M.32
Right-hand switch (TE-TXC)...................................................................... M.33
Fuses (TE-TXC)......................................................................................... M.34
Semiconductor parts.................................................................................. M.34
Relay test (TE - TXC)................................................................................. M.35
Digital dashboard, warning lights (TE)....................................................... M.36
Warning lights panel (TXC)........................................................................ M.38
Dashboard replacement (TE)..................................................................... M.39
Troubleshooting.......................................................................................... M.39
Charging system (TE-TXC)........................................................................ M.39
Starting system (TE-TXC).......................................................................... M.39
Electronic ignition system........................................................................... M.39
Wiring (TC)................................................................................................. M.40
Cable routing and electrical parts installation instructions (TC)................. M.41
• Position of the coil / stick-coil................................................................... M.41
• Fuel injection control unit position (2) (TC)............................................. M.41
• Position of the voltage regulator (3) (TC)................................................ M.41
M.2
ELECTRICAL SYSTEM
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
• Position of the connectors front side....................................................... M.41
• Control unit connection (TC)................................................................... M.42
• Ignition coil / stick-coil connection (TC).................................................. M.42
• Air temperature sensor connection (TC)................................................. M.42
• Connection of the injector sensor (7), throttle position sensor (9),
and MAP sensor (8)................................................................................ M.42
• Fuel pump connector position (TC)........................................................ M.43
• Securing the wiring (TC)......................................................................... M.43
• Securing the engine stop button cable (TC)............................................ M.43
• Voltage regulator connection (TC).......................................................... M.44
• Connection of alternator (TC)................................................................. M.44
• Condenser connection (TC).................................................................... M.44
Wiring (TE-TXC)......................................................................................... M.45
Cable routing and electrical parts installation instructions "TE-TXC" ........ M.46
• Coil position TE-TXC............................................................................... M.46
• Relay (1) and fuses (2) position (TE-TXC).............................................. M.46
• Turning indicators flasher (3) (TE) and solenoid starter ........................... M.3
position (TE-TXC)................................................................................. M.46
• Position of control unit (5) and voltage regulator (6) (TE – TXC)............ M.47
• Securing the starter motor/solenoid starter cable (TE-TXC)................... M.47
• Securing the engine ground to chassis and engine 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
• Fuel pump connector position (TE-TXC)................................................ M.50
• MAQS connector (TE-TXC).................................................................... M.50
• Engine water temperature connector (TE-TXC)..................................... M.50
• Lambda sensor position and connector (TE-TXC)................................ M.50
• Ignition and gear sensor cable connection............................................. M.51
• Routing of rear chassis cables, tail light connection, flasher contactor... M.51
• Clip installation on fuse holders.............................................................. M.51
• Clip installation on fuse holders.............................................................. M.52
• Rear stop connection.............................................................................. M.52
• Routing of steering head tube wiring...................................................... M.52
• Dashboard bracket connectors (TE)....................................................... M.52
• Headlamp, front turning indicators, STOP connection (TE).................... M.52
• Double map connector (TE).................................................................... M.53
• Speed sensor and ignition switch connectors (TE)................................. M.53
• Horn connector (TE)............................................................................... M.53
• Securing the wiring harness to rear chassis right side........................... M.54
• Securing the wiring harness to rear chassis left side.............................. M.54
• Securing the wiring harness to the chassis............................................ M.54
Important.................................................................................................... M.56
M.3
ELECTRICAL SYSTEM
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.4
ELECTRICAL SYSTEM
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
Wiring diagram (TC)
TC
2 3 4 5 6
1
16
11 10 9 8 7
15 14 13 12
H10111
Key to wiring diagram Colour coding key

1. Electronic control unit B.................... Blue
2. Control unit interface Bk.................. Black
3. Engine stop O.................... Orange
4. Not used R.................... Red
5. Coil / Stick coil W................... White
6. Map change connector Br................... Brown
7. Voltage regulator G.................... Green
8. Alternator P.................... Pink
9. Fuel pump V.................... Violet
10. Condenser Y.................... Yellow
11. Injector
12. Air temperature sensor
13. Coolant temperature sensor
14. Air pressure sensor
15. Throttle position sensor
16. Spark plug
M.5
ELECTRICAL SYSTEM
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
Wiring diagram (TE)
37 TE
13
14 12 11 10 9 8 7 6 5 4 3 2 1
31
34 32
33
35
36
39
38 40
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15
H10112
Key to wiring diagram 30. Turning indicators flasher

1. Electronic control unit 31. Rear R.H. turning indicator
2. Control unit interface 32. Tail light
3. Coolant temperature sensor 33. Rear L.H. turning indicator
4. HT coil 34. Front R.H. turning indicator
5. Fuel level 35. Headlamp
6. Fuel pump 36. Front L.H. turning indicator
7. Solenoid valve relay 37. Spark plug
8. Ignition switch 38. Pressure sensor (22)
9. Lambda sensor 39. Throttle position sensor (22)
10. Cooling fan 40. Air temperature sensor (22)
11. Speed sensor
12. DC relay Colour coding key
13. L.H. switch B.................... Blue
14. Dashboard Bk.................. Black
15. MAP change push-button Br................... Brown
16. Battery G.................... Green
17. Solenoid starter Gr................... Grey
18. Starter motor O.................... Orange
19. Voltage regulator Pk.................. Pink
20. Alternator R.................... Red
21. Gear sensor Sb.................. Sky blue
22. M.A.Q.S. (38+39+40) V.................... Violet
23. Power relay W................... White
24. Fuses Y.................... Yellow
25. Injector
26. R.H. switch
27. Front stop light switch
28. Rear stop light switch
29. Horn
M.6
ELECTRICAL SYSTEM
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
Wiring diagram (TXC)
10b 10a 9 8 7 6 5 4 3 2 1 TXC
25
23
22 24
21 20 19 18 17 16 15 14 13 12 11
H10113
Key to wiring diagram Colour coding key

1. Electronic control unit B.................... Blue
2. Control unit interface Bk.................. Black
3. Coolant temperature sensor Br................... Brown
4. HT coil G.................... Green
5. Fuel level Gr................... Grey
6. Fuel pump O.................... Orange
7. Electric fan relay R.................... Red
8. Lambda sensor V.................... Violet
9. Cooling fan W................... White
10b.Generator warning light (12V-2W) RED Y.................... Yellow
10a.Fuel reserve warning light (12V-2W) ORANGE Sb.................. Sky blue
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 temperature sensor (17)
25. Spark plug
M.7
ELECTRICAL SYSTEM
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 components location (TC)
- Generator (1), on the inner side of L.H. crankcase half cover;
1
H10114
- Coil with integrated spark plug cap (Stick-Coil) (2) fitted on the engine
head;
2 - 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;
4 - Atmospheric pressure sensor (6) on the upper part of the throttle body.
- Fuel pump (7)
- Coolant temperature sensor (8) on the cylinder.
H10115
3
7
H11126 H02305
H10117 H10118
M.8
ELECTRICAL SYSTEM
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
Condenser (TC)
- Condenser (9) connected to a plate strapped to the throttle body.
9
H10988
Electrical components location (TE)

4 - Generator (1), on the inner side of L.H. crankcase half cover;
H02307
- Electronic ignition coil (2) under the fuel tank;

- Electronic control unit (3) under the fuel tank;
- Spark plug (4) on cylinder head;
2
H02354
- Voltage regulator (5) under the fuel tank, over the electronic control unit
(3);
5
H02355
M.9
ELECTRICAL SYSTEM
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
- 12V-350W starter motor (6) behind the cylinder;
H10119
- Solenoid starter (7) on left side of rear chassis;
- M.A.Q.S. sensor (air temperature, pressure, throttle position) (8) on throttle

body.

- 12V-6Ah battery (9) under the saddle;
- Turning indicators flasher (10) on left side of rear chassis;
M.10
ELECTRICAL SYSTEM
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
- Power Relay (11): coil, injection system, fuel pump, on right side 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);

- Lambda sensor (19);
H11127
M.11
ELECTRICAL SYSTEM
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
- 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.
23
H02304
M.12
ELECTRICAL SYSTEM
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 components location (TXC)
- Generator (1), on the inner side of L.H. crankcase half cover;
4
H02307
- 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);
H02355
M.13
ELECTRICAL SYSTEM
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
- 12V-350W starter motor (6) behind the cylinder;
H10119
- Solenoid starter (7) on left side of rear chassis;
- M.A.Q.S. sensor (air temperature, pressure, throttle position) (8) on throttle

body.
M.14
ELECTRICAL SYSTEM
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
- 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);
M.15
ELECTRICAL SYSTEM
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
- Coolant temperature sensor (16);
- Lambda sensor (17);
- Fuel pump (18) inside the fuel tank.
18
H11128
Checking generator stator windings resistance

Disconnect the stator coil connector from the wiring and measure resistance
with a meter. TE - TXC
TE - TXC TC
H02308 H10991
M.16
ELECTRICAL SYSTEM
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
1) Measure across the terminals of the connector (1); correct value is about
TE - TXC
0.6 .
1 If resistance is outside the specified limits, replace the complete generator.
H10120
TC
1
H10995
Generator no-load performance
TE - TXC
H02309
TE - TXC
RPM A D.C.
(typical)
1200 8.6
2000 13.8
3000 15.5
5000 16.4
6000 16.6
TC
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
CAPTURED BY THE MAGNETS.
H11000
M.17
ELECTRICAL SYSTEM
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
Ignition and starter system (TC)
The engine injection and starter system is controlled by the control unit (ECU);
by means of a series of sensors, the ECU controls the status of the engine and
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.
TC
2 3 4 5 6
1
16
11 10 9 8 7
15 14 13 12
H10111
Key to wiring diagram 7. Voltage regulator 13. Coolant temperature sensor

1. Electronic control unit 8. Alternator 14. Air pressure sensor
2. Control unit interface 9. Fuel pump 15. Throttle position sensor
3. Engine stop 10. Condenser 16. Spark plug
4. Not used 11. Injector
5. Coil / Stick coil 12. Air temperature sensor
6. Map change connector
M.18
ELECTRICAL SYSTEM
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
Ignition and starter system (TE-TXC)
The engine injection and starter system is controlled by the control unit (ECU);
by means of a series of sensors, the ECU controls the status of the engine and
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, 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)
37 TE
13
14 12 11 10 9 8 7 6 5 4 3 2 1
31
34 32
33
35
36
39
38 40
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15
H10112
Key 20. Alternator

1. Electronic control unit 21. Gear sensor
2. Control unit interface 22. M.A.Q.S. (38+39+40)
3. Coolant temperature sensor 23. Power relay
4. HT coil 24. Fuses
6. Fuel pump 25. Injector
7. Electric fan relay 26. R.H. switch
8. Ignition switch 37. Spark plug
9. Lambda sensor 38. Pressure sensor (22)
10. Cooling fan 39. Throttle position sensor (22)
12. DC relay 40. Air temperature sensor (22)
13. L.H. switch
16. Battery
18. Starter motor
M.19
ELECTRICAL SYSTEM
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
10b 10a 9 8 7 6 5 4 3 2 1 TXC
25
23
22 24
21 20 19 18 17 16 15 14 13 12 11
H10113
Key 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
13. Starter motor
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 temperature sensor (17)
25. Spark plug
M.20
ELECTRICAL SYSTEM
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
Charging system (TE-TXC)
The charging system is composed of:
- Alternator (1);
- Voltage regulator/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 against overloading.
Charging system wiring diagram
1 2 3 4
H01035
M.21
ELECTRICAL SYSTEM
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
Charging system inspections
Current loss at the battery (TE-TXC)

Remove the saddle (as described in the relevant paragraph) to gain access to
the battery (1).
Disconnect the BLACK negative cable from the battery.
Measure current across the negative terminal of the battery and the negative
cable using a meter. A reading greater than 1 mA indicates current loss.
If the vehicle is to remain unused for long periods, it is recom-

mended to disconnect the battery from the electrical system and
store it in a dry place.
Regulated voltage (TE-TXC)

Remove the saddle (as described in the relevant paragraph) to gain access to
the battery.
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 ignition on and the battery charged (12.5-13 V), start the engine: if bat-
TE - TXC
tery voltage fails to rise (14 V) within the next two minutes, change the regulator
(1) as outlined in the relevant paragraph.
Voltage regulator
The voltage regulator (1) incorporates the diodes used to rectify the generator
current output.
It also incorporates an electronic device that adjusts charging voltage to battery
charge: if battery charge is low, charging voltage will be lower.
Do not disconnect the battery cables while the engine is running,

or the regulator will suffer irreparable damage.
H10122
Voltage regulator/rectifier wiring diagram

TC TE-TXC
H11002 H10123
M.22
ELECTRICAL SYSTEM
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 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
TE TXC
26 27
37 16
25
18 17 25 37 18 17 16
H01036 H10124
M.23
ELECTRICAL SYSTEM
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
Starting system inspection
Starter motor inspection (TE-TXC)

Remove the starter motor (1) as described in the relevant paragraph.
Whenever a starter motor fault is detected, check the starter motor as follows:
- connect a meter across ground and starter motor contact.
- Check for continuity between the positive pole and motor ground. If no conti-
nuity is found, replace the starter motor. On assembly, apply a small amount of
LOCTITE 243 to the starter motor retaining screws.
Starter motor
Rated voltage: 12V
Current draw: 350 W
No-load test
Voltage: 11.2 V
Current: 30 A
Speed: 12,000 rpm

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 motor and battery positive cable wires at relay end. Apply
12 Volts to relay terminals (1) and (2) and check for continuity between terminals
B-M. Do not feed battery voltage to the relay longer than 5 seconds or the
relay might overheat, leading to winding damage. Use a multimeter to establish
whether the winding is open circuit or resistance exists. A winding in good condi-
tion will give the following resistance readings.
Meter scale setting: Ohm
Starter relay resistance. Standard: 3-6 .
Solenoid starter wiring

diagram
1= GROUND
2= + 12 V
H11129
M.24
ELECTRICAL SYSTEM
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
Checking coil windings resistance (TE-TXC)
Remove saddle and fuel tank (see relevant paragraph) to gain access to the
coil (1).
Disconnect the coil connector from the wiring, remove retaining screws and coil
and measure resistance 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 specified limits, replace the cap.
NOTE: The area where the coil is secured must be totally free from oxide
and paint. A faulty ground contact will damage the coil and cause
ignition problems.
H11130
M.25
ELECTRICAL SYSTEM
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
Coil windings resistance inspection (TC)
1 Disconnect the connector (1) from the coil (2).
- Remove the coil (2) as described in the relevant paragraph.
2 - 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.
H10125 If resistance is outside the specified limits, replace the cap.
H11005
H11007 H11011
M.26
ELECTRICAL SYSTEM
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
Electronic control unit (ECU)
Remove saddle and fuel tank (see Section E) to gain access to the electronic
control unit (1).
It is composed of a capacitor, a rectifier circuit that handles input signals received
from the pick-up sensor, a circuit that controls ignition timing advance in accordance
with pick-up sensor inputs and a switching circuit for capacitor discharge.
TE-TXC TC
1 1
H11131 H10127
TE-TXC Spark plug

A= 0,7÷0,8 mm The spark plug (1) is an "NGK" CR9EB (TE-TXC) and "NGK" CR9EI (TC) spark
0,028 ÷ 0,031 in plug. Check electrode gap "A". A wider gap may cause difficulties in starting the
engine and overload the coil. A gap that is too narrow may cause difficulties when
TC accelerating, when idling or poor performance at low speed. Clean off any dirt
A= 0,8÷0,9 mm around spark plug base before removing the spark plug. It is good practice to
0,031 ÷ 0,035 in closely inspect the spark plug after removal, as any deposits on it and the colour
of the insulator provide useful indications on spark plug heat rating, carburetion,
ignition and the general condition of the engine. Before refitting the spark plug,
accurately clean the insulator with a wire brush. Smear some graphite grease
on spark plug thread, do it fully home finger tight then tighten it to 10÷12 Nm
torque. Loosen the spark plug then tighten it again to 10÷12 Nm. Spark plugs
which have cracked insulators or corroded electrodes should be replaced.
TC TE-TXC
H10129 H11132
M.27
ELECTRICAL SYSTEM
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
Gear position sensor inspection (GPS: Gear Position Sensor) (TE-TXC)
Set the meter to the “Ohm” scale and disconnect the six-way connector (1) of the
alternator from the main wiring harness (the gear sensor wiring is secured to the
alternator wiring with a clip). Touch one 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 NEUTRAL 312-319
B 1st 725-739
C 2nd 1,31-1,34
3 D 3rd 2.18-2.23 K
E 4th 3.61-3.68 K
F 5th 6.58-6.71 K
G 6th 15.2-15.5 K
H02362
NOTE: The TC version does not have the gear sensor as the control
unit does not need this type of signal.
M.28
ELECTRICAL SYSTEM
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
Battery (TE-TXC)
The battery (1) is a sealed-for-life, maintenance-free battery. If the vehicle
remains unused for long periods, it is recommended to disconnect the battery
from the electrical system and store it in a dry place. After an intensive use of
the battery, it is advisable to carry out a standard slow charging cycle (12V-6Ah
battery: 0.6A for 8 hours).
Quick charging is advised only in situations of extreme necessity since the life
of lead elements is drastically reduced by such cycle (12V-6Ah battery: 6A for
0.5 hours).
Battery charger
To gain access to the battery (1):
- remove the saddle (as outlined in the relevant paragraph);
- first remove the BLACK negative cable, then the RED positive cable (when
reassembling, 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 terminal. At a constant voltage
level of 14.4 V, apply “x” Amps according the battery's charge percentage as
indicated in the table below. The voltage reaches a constant value only after a
few hours, therefore it is suggested NOT to measure it immediately after hav-
ing charged or discharged the battery. Always check the battery charge before
reinstalling it on the vehicle. The battery should be kept clean and the terminals
coated with grease.
INDICATIVE CHARGE TIMES DEPENDING ON BATTERY CHARGE STATUS
AT-REST VOLTAGE * (V) % OF CHARGE CHARGE TIME (RATED CURRENT IN AMPS

TO BE APPLIED: 0.1x BATTERY RATED CAPACITY)
> 12.7 100 _

~ 12.5 75 4h
~ 12.2 50 7h
~ 12.0 25 11h
~ 11.8 0 14h
M.29
ELECTRICAL SYSTEM
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
Headlamp, tail light (TE)
Headlamp adjustment
The headlamp features a twin bulb for low and high beam and a festoon bulb
for the city or parking light. Beam setting needs to be performed accurately;
proceed as follows:
- Place the motorcycle 10 metres away from a vertical wall;
- The motorcycle must be on level ground and the optical axis of the headlamp
must be perpendicular to the wall;
- The motorcycle must be upright;
- Measure the height from 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 fairing to dashboard
bracket (A);
- slide the headlamp fairing (B) forward and pull upwards (C) to ease it off the
two lower mounts;
- remove the headlamp fairing (1);
- slide off the rubber boot (2);
- release the clip (3) and remove the bulb holder (4);
- remove the bulb (5).
To replace the parking light bulb (6) extract it from the inside cover.
Once the tail light has been replaced, reverse the above procedure to reas-
semble.
A
H11133
M.30
ELECTRICAL SYSTEM
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
Tail light replacement
Remove the tail light as follows:
- Loosen the two screws (1) under the rear mudguard.
- Extract the tail light (2) and disconnect the connector (3).
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.
semble.
H11134
M.31
ELECTRICAL SYSTEM
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
Handlebar switches
Measure continuity on the different switches using a meter. Replace any part
found to be faulty.
Left-hand switch (TC)

1 Engine stop switch (TC)
COLOUR
B-W Bk
POSITION
ON
OFF
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 G-Bk
B.................... Blue
Bk.................. Black W
B-Bk............... Blue-Black Bk
B-W................ Blue-White
G.................... Green W
G-Bk.............. Green-Black W-B
G-W............... Green-White Sb
Gr................... Grey
Y.................... Yellow
R.................... Red R
Sb.................. Sky blue B-Bk
W................... White Gr
W-B................ White-Blue G
W-Bk.............. White-Black H01039
M.32
ELECTRICAL SYSTEM
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
Right-hand switch (TE-TXC)
1. Engine start button
2. Engine start/stop switch
2
H10131
H01040
Bk-Br
Y-Sb
Br
H01041
Colour coding key

B.................... Blue
Br................... Brown
Br-Bk.............. Brown-Black
Y-Sb............... Yellow-Sky blue
M.33
ELECTRICAL SYSTEM
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
Fuses (TE-TXC)
• When you find a blown fuse (1), always investigate and eliminate the
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 procedure may lead to severe damage.
M.34
ELECTRICAL SYSTEM
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
Relay test (TE - TXC)
Remove saddle and fuel 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
M.35
ELECTRICAL SYSTEM
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
Digital dashboard, warning lights (TE)
The motorcycle is fitted with a digital dashboard on which 3 warning lights are
also available for: high beam, turning indicators and fuel reserve.
1- BLUE warning light “High beam”

2- GREEN warning light “Turning indicators”
3- ORANGE warning light “Fuel reserve” (2.3 l)
When the ignition key is turned to the IGNITION position, the dashboard display
lights up (amber colour).
NOTE:
- At every connection with the battery, the dashboard shows the version of the
test SW for the first 2 seconds; after the check routine, the dashboard shows
the last planned function.
- When the engine is turned off, the dashboard 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 (see page 14).
When this is the case, contact your HUSQVARNA dealer.
1- SPEED (Km/h or mph) / ODO (figure 1)
- SPEED: vehicle speed - maximum value: 299 Km/h or 299 mph;

- ODO: odometer - maximum value: 99999 Km.
To change unit from kilometres to miles or miles to kilometres, proceed as fol-

lows:
1) set to figure 1, turn the key to OFF and push SCROLL (A);
2) place the ignition key in the IGNITION position and hold down the SCROLL
button (A) until the word “Km/h” is displayed;
3) the display will now alternate between “Km/h” and “Mph Miles”, push the
SCROLL button (A) again while the desired unit is displayed.
M.36
ELECTRICAL SYSTEM
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
2 - SPEED / CLOCK (figure 2)
- SPEED: speed - maximum value: 299 Km/h or 299 mph;
- CLOCK: clock - reading from 0:00 to 23:59:59.
To reset the clock, push the SCROLL button (A) and hold for more than 3 sec-
onds in order to increase the hour value; release button and after 3 seconds the
minutes can be increased;
3 - SPEED / 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 after disconnecting the bat-
tery).
To activate the function STP, push the SCROLL button (A) and hold for more
than 3 seconds.
- 1st step: activate function;

- 2nd step: stop counters.
- 3rd step: reset STP;
- 4th step: activate function;
- 5th step: stop counters.
.............................
and so on.
M.37
ELECTRICAL SYSTEM
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
5 - SPEED / NUMBER of RPM (figure 5)
- SPEED: speed - maximum value: 299 Km/h or 299 mph

- 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.
H02363
Warning lights panel (TXC)

The motorcycle is fitted with a small warning lights panel with two warning
lights:
1
1 - Red warning light “POWER”
2 - Yellow warning light “FUEL RESERVE”
H10132
M.38
ELECTRICAL SYSTEM
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
Dashboard replacement (TE)
- . Remove the upper retaining screw securing headlamp fairing to dashboard
bracket (A);
- . slide the headlamp fairing (B) forward and pull upwards (C) to ease it off the
two lower mounts;
- . disconnect the connector (2) and remove the headlamp fairing (1);
Remove the two retaining screws (3) securing the dashboard to its bracket,
disconnect the connector (4) and remove the dashboard (5).
To refit the dashboard, reverse the disassembly procedure.
Troubleshooting
Charging system (TE-TXC)

A battery that does not hold charge might be a symptom of:
1) current loss (see paragraph "Current loss at the battery");
2) incorrect voltage (see paragraph "Regulated voltage");
3) no continuity in generator (see paragraph "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").
Starting system (TE-TXC)

If the starter motor does not start, this might be a symptom of:
1) faulty solenoid starter (see paragraph "Solenoid starter inspection");
2) loose starter motor cable;
3) faulty starter motor (see paragraph "Starter motor inspection");
4) flat battery (see paragraph "Battery charger").
Electronic ignition system

A A weak or missing spark might be a symptom of:
1) incorrect connections in the electrical system;
2) faulty spark plug or wrong heat rating or incorrect spark plug gap (see para-
H10130
graph "Spark plug");
3) faulty ignition coil (see paragraph "Checking coil windings resistance");
4) faulty spark plug cap (see paragraph "Checking coil windings resistance").
M.39
ELECTRICAL SYSTEM
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
Wiring (TC)
5
3
4 4
6
2
H10133
1 Engine stop button

2 Coil / Stick-coil
3 Control unit
4 Voltage regulator
5 Main wiring harness
6 MAP sensor
7 Condenser
M.40
ELECTRICAL SYSTEM
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
Cable routing and electrical parts installation instructions (TC)
• Position of the coil / stick-coil

Connect the coil / stick-coil (1) as the figure shows.
1
H10135
• Fuel injection control unit position (2) (TC)

2
Electronic control unit installed with the flat side up.
H10134
• Position of the voltage regulator (3) (TC)

Positioned on the RH under the tank.
3
H10136
• Position of the connectors front side

2 On the front side, under the fairing, the following connectors are to be found:
1) Mapping connector
2) Diagnostic connector
1 3) Connector not in use
3 H10137
M.41
ELECTRICAL SYSTEM
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
• Control unit connection (TC)
4 Connect the control unit connector (4) as shown.
H10138
• Ignition coil / stick-coil connection (TC)

Connect the ignition coil / stick-coil connector (5) as outlined.
H10139
• Air temperature sensor connection (TC)

Connect the air temperature sensor (6) as outlined.
H10140
• Connection of the injector sensor (7), throttle position sensor (9), and
MAP sensor (8)
Connect the connectors as outlined.
8
H11135 H10142
M.42
ELECTRICAL SYSTEM
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
• Fuel pump connector position (TC)
21 Position the fuel pump connector (21) as shown.
H10143
4 • 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).
3
2
1
H10144
5
H10146 H11136
• Securing the engine stop button cable (TC)

9
Secure the engine stop button cable (8) with two clips (9).
8
H10145
M.43
ELECTRICAL SYSTEM
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
• Voltage regulator connection (TC)
11 Connect the connector (10) as shown.
• Connection of alternator (TC)

Connect the connector (11) as shown.
10
H11012
• Condenser connection (TC)

12
H11013
M.44
ELECTRICAL SYSTEM
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
Wiring (TE-TXC)
TE
H00973
TXC
H10150
M.45
ELECTRICAL SYSTEM
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
Cable routing and electrical parts installation instructions "TE-TXC"
• Coil position TE-TXC

Connect the HT coil as shown in the figure.
H02367
• 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.
M.46
ELECTRICAL SYSTEM
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
• Position of control unit (5) and voltage regulator (6)
(TE – TXC)
Electronic control unit installed with the flat side down.
Voltage regulator installed 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 tensioner screw.
• Battery negative cable routing (TE-TXC)

8 Routing of engine ground to battery negative cable (8).
H00924
M.47
ELECTRICAL SYSTEM
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
• Securing the voltage regulator ground cable (9) (TE-TXC)
Secure the regulator 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 hose and throttle cables.
M.48
ELECTRICAL SYSTEM
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
• Connection of relays and fuses (TE-TXC)
12
13 RELAYS
14 Connect the cable marked “POW” to relay (12)
Connect the cable marked “FAN” to relay (13)
Connect the cable marked “DC” to relay (14) (TE only)
fuses
15 Connect the cable marked “POW” to fuse (15)
Connect the cable marked “MAN” to fuse (16)
H00939 Connect the cable marked “FAN” (TXC) to fuse (17)
16 17 Connect the cable marked “DC+FAN” (TE) to fuse (17)
• Electric fan connection (TE-TXC)

Connect the electric fan connector (18).
18
H00940
• Injector connection (TE-TXC)

Connect the connector (19) to the throttle body.
• Ignition coil connection (TE-TXC)

Connect the ignition coil connector (20) as shown.
M.49
ELECTRICAL SYSTEM
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
• Fuel pump connector position (TE-TXC)
Position the fuel pump connector (21) as shown.
21
H02325
• MAQS connector (TE-TXC)

22
H02326
• 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.
M.50
ELECTRICAL SYSTEM
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
• Ignition and gear sensor cable connection
Connect the ignition (26) and gear sensor (27) connectors as shown.
• Routing of rear chassis cables, tail light connection, flasher contactor

28
Route the rear end of the wiring (28) as shown in the figure.
29
Connect the tail light/turning indicators connector (29) (TE).
31 - Connect the connector (30) to the flasher (TE).
- Connect the connector (31) to the solenoid starter.
30
H00947
• Clip installation on fuse holders

Install the suitable clips (33) on the three fuse holders.
M.51
ELECTRICAL SYSTEM
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
• Clip installation on fuse holders
Secure the three fuses to the suitable perforated panel of the rear mudguard.
• Rear stop connection

Connect the wiring connector (A) to the rear STOP sensor.
H10151
• Routing of steering head tube wiring

Secure the wiring harness with the suitable clip (34).
34
H02327
• 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).
Connect the connectors (39) to the turning indicators.
Connect the connector (40) to the front brake lever.
M.52
ELECTRICAL SYSTEM
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
• Double map connector (TE)
Connect the connector (40).
40a
H02328
• Speed sensor and ignition switch connectors (TE)

Connect the speed sensor connector.
Connect the connector (41) of the ignition switch (42).
H11137 H03072
• Horn connector (TE)

Connect the connector (43) to the horn.
M.53
ELECTRICAL SYSTEM
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
• Securing the wiring harness to 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.
M.54
ELECTRICAL SYSTEM
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
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.
M.55
ELECTRICAL SYSTEM
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
Important
Before washing the motorcycle, it is necessary to duly 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 unit (1) and the digital dashboard (2).
H02368 H11138
M.56
ENGINE COOLING
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
Section
N
N.1
ENGINE COOLING
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
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
N.2
ENGINE COOLING
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
Coolant level check
Coolant takes the heat from the piston-cylinder-and-head assembly and transfers
it to the radiator, where it is released to the atmosphere. Checking coolant level at
regular periods is critical to ensuring proper operation of the cooling system.
Without cooling medium (water), 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 gradually.
The radiator cap (1) has a pressure-relief position to depressurize the system
safely.
Failure to follow the above instructions will create a risk of scalding

for operator and any persons standing nearby.

A. Coolant level
B. Breather hose
H10153
N.3
ENGINE COOLING
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
Cooling circuit (TC)
H10154
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 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
N.4
ENGINE COOLING
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 cooling system overhaul (TC)
1
If the coolant runs too hot, check the radiators. Any foreign matter trapped
between the fins (such as leaves, bugs, mud, etc.) will obstruct air flow and
11 must be removed carefully to avoid damage to radiator. Straighten any bent
2 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 show cracks, swelling or hardening due
to sheaths desiccation, their replacement shall be advisable. Check the correct
tightening of the clamps.
8
H10155
10 9
9 8
H10156 H10157
N.5
ENGINE COOLING
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
Cooling circuit (TE-TXC)
TE-TXC
H10158
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
N.6
ENGINE COOLING
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 cooling system overhaul (TE-TXC)
If the coolant runs too hot, check the radiators. Any foreign matter trapped
between the fins (such as leaves, bugs, mud, etc.) will obstruct air 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 engine seizure. If hoses show cracks, swelling or hardening due
to sheaths desiccation, their replacement shall be advisable. Check the correct
tightening of the clamps.
N.7
HYDRAULICALLY CONTROLLED CLUTCH
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
Section
P
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
Sommario
Hydraulic clutch system................................................................................. P.3
Draining clutch fluid....................................................................................... P.4
Clutch master cylinder servicing.................................................................... P.5
Bleeding the clutch system............................................................................ P.6
P.2
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
Hydraulic clutch system

The hydraulic circuit is composed of a master cylinder with its reservoir located
on the left side of the handlebar, and a piston installed on the left crankcase
half. The clutch is disengaged by the piston (5) that actuates the pushrod (4)
to operate the pressure 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 Clutch housing with clutch ring gear
9 Steel plate
10 Friction plate
11 Clutch hub
a Crankshaft
b Gearbox input shaft
The fluid used in the hydraulic circuit will damage painted parts if
spilt on them. Handle it with care when servicing the system.
P.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
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.
H10159
2
3
4 H10160
P.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
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.
H10161
P.5
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
Bleeding the clutch system
A long travel and mushy feel of the clutch lever indicate that there is air in the
system and the clutch hydraulic system needs bleeding.
- Take the rubber cap off the bleed valve (1).
- Attach a clear plastic hose to the bleed valve and place the other end of the
hose in a vessel (make sure the hose end stays dipped in the fluid throughout
the procedure).
- Remove the reservoir cover (2) and the rubber diaphragm (3) and fill fresh
fluid into the reservoir. Use the fluid specified 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-
- Lock the valve (1) to the prescribed torque.
- Top up fluid level (A) and refit rubber diaphragm (3) and reservoir cover
(2).
Hydraulic fluid is corrosive. In the event of contact with eyes, rinse

with abundant water.
Motorcycle handlebar must be turned to the right during the bleed-

ing procedure. This will keep the master cylinder reservoir higher,
making bleeding easier.
lb.
2
4
H11139 H11140
P.6
FUEL INJECTION SYSTEM
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
Section
S
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
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
S.2
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
Injection fuel feeding system (TE-TXC)
The injection fuel feeding system is composed of fuel tank (1), electric pump
(2), pipe (3) and injector (4). The fuel in the tank is pumped by the pump. The
pressurised fuel flows into the injector installed on the throttle body (6). The
electronic control unit (5) located under the tank signals the injector to open and
a fan-shaped spray of fuel is injected into the combustion chamber.
2 The parameters that play a role in determining proper fuel delivery under all
operating conditions are as follows:
a
- Air temperature in the intake manifold;
1 - Engine coolant temperature;
- Atmospheric pressure in the intake manifold (in current location and at cur-
rent altitude);
- Throttle opening;
a - Battery voltage;
a - Gear shift position;
- Fuel injection pulse width;
- Lambda sensor heater;
- Lean or rich mixture (LAMBDA sensor).
3
The "HUSQVARNA SERVICE TOOL" provides a tool to check these parameters
in the event the fuel injection malfunctions.
The electric fuel pump (2) is installed on the bottom of the tank (1) and is com-
posed of rotor, magnet, impeller, brushes, pressure regulator.
H02371
The electronic control unit (5) switches the pump ON/OFF.
To remove the fuel pump (2) see section “E”.
5 4 6
H03070 H11141
f a- Fuel pump retaining screw

c b- Delivery fitting
e c- Pump filter
d- Pump electric connector
e- Delivery/return hose quick fit-
ting
b f- Pressure regulator
2 H02373
S.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
Injection fuel feeding system (TC)
The injection fuel feeding system is composed of fuel tank (1), electric pump (2),
pipe (3) and injector. The fuel in the tank is pumped by the pump. The pressurised
fuel flows into the injector installed on the throttle body. The electronic control
unit (5) located under 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;
- Gear shift position;
2 - Fuel injection pulse width;
The "HUSQVARNA SERVICE TOOL" provides a tool to check these parameters

d in the event the fuel injection malfunctions.
The electric fuel pump (2) is installed on the bottom of the tank (1) and is com-
posed of rotor, magnet, impeller, brushes, control valve and relief valve. The
c electronic control unit (5) switches the pump ON/OFF.
To remove the fuel pump (2) see section “E”.
b H11044
H02330
a- Fuel pump retaining screw

b- Delivery fitting
c- Pump filter
d- Fuel filter
S.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
TE F Operation Manual for "HUSQVARNA SERVICE TOOL" for injection fuel
feeding system (TE-TXC)
The injection fuel feeding system does not require scheduled maintenance.
The "HUSQVARNA SERVICE TOOL" part no. 8000 H3898 lets you test system
components in the event of a malfunction.
TE = A malfunction is indicated by the word "FAIL" appearing in the right-hand
portion of the dashboard display when the ignition key is set to ON and the right
switch is set to RUN.
The "HUSQVARNA SERVICE TOOL" is composed of:

1) "Diagnostic Tool" Software CD-ROM, including User Guide (PDF), Operation
Manual (PDF);
H10164
- User Guide hard-copy;
- Operation Manual hard-copy;
6 2) Diagnosis module part no. 8000H3902
5 3) Bike-module connection cable part no. 8000 H3899 (KEIHIN, MIKUNI
3 MY11)
4) Module-PC USB cable part no. 8000 H3903
5) Do not use
6) Do not use
1 After installing the Diagnostic Tool Software according to the instructions provided
in the User Guide, proceed as follows:
- Remove the front headlight fairing/number holder as described in the relevant
4 section;
- slip off the cap (B) of the ECU interface connector (C);
2 - connect the Kit cable (3) to the connector (C);
- Connect the USB cable (4) to the PC;
H02374 TE = Turn the ignition key (F) to ON
TXC = Check that switch (G) is in 'RUN position';
- start the "Diagnostic Tool" software you have installed and perform the
required tests.
In case of throttle body (H) removal and/or replacement, it is nec-

essary to carry out the T.P.S. adjustment again by selecting the
relevant option (“T.P.S. idle adjustment”).
This diagnostic software can check the following injection param-

eters:
1 - AIR TEMPERATURE (air temperature in the intake manifold);

2 - WATER TEMPERATURE (engine coolant temperature);
3 - AIR PRESSURE (atmospheric pressure in current location and at current
G altitude);
4 - THROTTLE POSITION (throttle opening rate);
5 - BATTERY (battery voltage);
6 - GEAR SHIFT POSITION (currently selected gear shift position);
7 - INJECTOR (fuel injection pulse width);
8 - IGNITION COIL (device that stores energy in the reel and discharges it to
the spark plug);
9 - O2 SENSOR HEATER (heats O2 sensor up to a temperature that will
provide a stable output);
10 - O2 SENSOR (detects lean or rich mixture).
H10165
S.5
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
In addition to identifying any current malfunction, the software

stores past malfunctions that 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 and relay inspections, see relevant paragraphs.
S.6
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
Operation Manual for "HUSQVARNA SERVICE TOOL" for injection fuel
6 feeding system (TC)
5 3
The injection fuel feeding system does not require scheduled maintenance.
The "HUSQVARNA SERVICE TOOL" part no. 8000 H3898 lets you test system
components in the event of a malfunction.
The "HUSQVARNA SERVICE TOOL" is composed of:

1 1) "Diagnostic Tool" Software CD-ROM, including User Guide (PDF), Operation
Manual (PDF);
- User Guide hard-copy;
4 - Operation Manual hard-copy;
2) Diagnosis module part no. 8000H3902
2 3) Do not use
4) Module-PC USB cable part no. 8000 H3903
H02374 5) Diagnostic cable TC250 part no. 8000 H5153
6) Battery clamps cable part no. 8000 H5952
After installing the Diagnostic Tool Software according to the instructions

B 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);
C - Connect the clamps to the battery according to the polarity;
- Start the "Diagnostic Tool" software you have installed and perform the
required tests.
H10166
This diagnostic software can check the following injection param-

eters:
1 - AIR TEMPERATURE (air temperature in the intake manifold);

2 - WATER TEMPERATURE (engine coolant temperature);
3 - AIR PRESSURE (atmospheric pressure in current location and at current
altitude);
4 - THROTTLE POSITION (throttle opening rate);
5 - GEAR SHIFT POSITION (currently selected gear shift position);
6 - INJECTOR (fuel injection pulse width);
7 - IGNITION COIL (device that stores energy in the reel and discharges it to
the spark plug);
For fuel pump and relay inspections, see relevant paragraphs.
S.7
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
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.
1
H03073
S.8
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
Fuel pump test (TC)
Remove the pump as described in Section "E".
A: fuel 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
than 3 seconds in a row.
S.9
SPECIAL TOOLS
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
Section
W
W.1
SPECIAL TOOLS
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
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
13
3
5
16
2 8
11
H02376
W.2
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
Section
X
Tighten all nuts and screws to the specified torque using a torque wrench. If not tightened securely, a nut 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 application. These figures are obtained after cleaning the threads with
solvent.
X.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
TIGHTENING TORQUE FIGURES (+/- 5%) ENGINE
Cylinder head
Special screw Fastening camshaft mount (TC) 1) 7 Nm 0,7 kgm
2) 11 Nm 1,1 kgm
Special screw M6x1 Fastening head cover (TC) 8 Nm 0,8 kgm
Special screw M3x0.5 Screw rocker arm lock pin (TC)
Screw TFEI M6x1 Water drain (TC) 8 Nm 0,8 kgm
Plug M10x1 Rocker arm shaft hole plug (+LOCTITE 243) (TC) 10 Nm 1,0 kgm
Screw TFEI M6x1-L30 Cap (TE - TXC) 10 Nm 1.02 Kgm
Screw TFEI M6x1-L35 Cap (TE - TXC) 10 Nm 1.02 Kgm
Screw TFEI M5-L30 Cap (TE - TXC) 5.5 Nm 0.56 Kgm
Screw TFEI M5-L25 Cap (TE - TXC) 5.5 Nm 0.56 Kgm
Screw TTEI M5x0.8 L.8 Blow-by labyrinth plate (+LOCTITE 243) 6 Nm 0.6 Kgm
Special flanged screw L.23.4 Head cover and fuel (TE - TXC) 8 Nm 0.8 Kgm
Special flanged screw L.31.3 Head cover (TE - TXC) 8 Nm 0.8 Kgm
Water temperature sensor M10x1.25 5 Nm 0.5 Kgm
Hole plug (water sensor) M10x1.25 8 Nm 0.8 Kgm
Head stud bolt (TE-TXC) 40 Nm 4.1 Kgm
Head stud bolt (TC) 1) 20 Nm 2.0 Kgm
2) 40 Nm 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 6 Nm 0.6 Kgm
(+LOCTITE 270 or LOCTITE 272)
Screw TEF M5x0.8-CH8-L8 For oil seal retaining plate 6 Nm 0.6 Kgm
Screw TSEI M6-L10 Desmo bearing plate 8 Nm 0.8 Kgm
(use LOCTITE 270 - or LOCTITE 243)
Selector spring pin M8x1.25 Use LOCTITE 270 - or LOCTITE 272 25 Nm 2.55 Kgm
Screw TSEI M6-L14 Starter plate (use LOCTITE 270 - or LOCTITE 272) 8 Nm 0.8 Kgm
Screw TEF M6x1-L55 Crankcase joining 8 Nm 0.8 Kgm
Screw TEF M6x1-L20 R.H. cover 8 Nm 0.8 Kgm
Screw TEF M6x1-L50 R.H. cover and clutch cover 8 Nm 0.8 Kgm
Screw TEF M6-L22 Clutch cover 8 Nm 0.8 Kgm
Screw TEF M5-L16 Oil filter cover 6 Nm 0.6 Kgm
Screw TCEI M5 L35 Ignition cover 6 Nm 0.6 Kgm
Screw TCEI M5 L40 Ignition cover 6 Nm 0.6 Kgm
X.2
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
Lubrication
Screw TCEI M5x0.8 L20 Oil pump body 6 Nm 0.6 Kgm
Oil drain plug M14x1.5 25 Nm 2.55 Kgm
Drilled screw TEF M8x1.25 (alu- Pipe 8 Nm 0.8 Kgm
minium)
Oil filler plug Finger-tight
Fuel system
Screw M6x1 L20 Fastening intake manifold 8 Nm 0.8 Kgm
Electrical System
Screw TEF M6x1-CH8-L20 Coil to chassis (TE - TXC) 8 Nm 0.8 Kgm
Screw TCEI M5-L12 Stator (use LOCTITE 272) (TE - TXC) 6 Nm 0.6 Kgm
Screw TCEI M4-L30 Fastening stator (fit with LOCTITE 272) (TC) 4 Nm 0.4 Kgm
Screw TCEI M5-L20 Pick-up sensor (use LOCTITE 272 - 270) 6 Nm 0.6 Kgm
Flanged nut M12x1 Flywheel 75 Nm 7.65 Kgm
Screw TEF M6x1-CH8-L20 Regulator to chassis 8 Nm 0.8 Kgm
Screw TCEI M5x08 L8 Fastening coil safety plate (TC) 6 Nm 0.6 Kgm
(fit with LOCTITE 272 - 270)
Spark plug M10x1 (*)
Clutch
Nut M16x1-CH27-SP7 Clutch hub 65 Nm 6.6 Kgm
Screw TEF M6x1-CH8-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 TSEI M6 L14 Fastening start-up lever (TC) (+LOCTITE 272) 10 Nm 1.0 Kgm
Gearbox
Nut M16x1 Sprocket 90 Nm 9.2 Kgm
Gear shift control
Selector drum rtng screw M8x1.25 Use LOCTITE 270 (or LOCTITE 243) 25 Nm 2.55 Kgm
Screw TSEI M6-L14 Selector rtng plate (+LOCTITE 243) 8 Nm 0.8 Kgm
Screw TEF M6-L14 Selector rtng plate (+LOCTITE 243) 8 Nm 0.8 Kgm
Screw TEF M5x0.8-CH8-L12 Indicator 6 Nm 0.6 Kgm
Screw TEF M6x1-CH8-L20 Gear shift lever 8 Nm 0.8 Kgm
Cooling
M5 x 8 Water pump impeller (+LOCTITE 243) 8 Nm 0.8 Kgm
Screw TCEI M5 Cover 6 Nm 0.6 Kgm
Cheese-headed Phillips screw M4- Fitting (+LOCTITE 243) 3 Nm 0.3 Kgm
L12
(*): Smear some graphite grease on spark plug thread, do it fully home finger tight then tighten it to 10÷12 Nm torque. Loosen the
spark plug then tighten it again to 10÷12 Nm.
X.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
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)
X.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
TIGHTENING TORQUE FIGURES (+/- 5%) FRONT SUSPENSION (99669)
1 Nm = 0.73756 ft/lb
TIGHTENING TORQUE FIGURES (+/- 5%) REAR SUSPENSION (99669)
1 Nm = 0.73756 ft/lb
X.5
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
TIGHTENING TORQUE FIGURES (+/- 5%) FAIRINGS AND MUDGUARDS (99669)
1 Nm = 0.73756 ft/lb
X.6
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
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
X.7
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
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
X.8
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
TIGHTENING TORQUE FIGURES (+/- 5%) INSTRUMENTS (99669)
1 Nm = 0.73756 ft/lb
TIGHTENING TORQUE FIGURES (+/- 5%) COOLING SYSTEM (99669)
1 Nm = 0.73756 ft/lb
1 Nm = 0.73756 ft/lb
X.9
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
NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows (+/- 5%)
Steel screws on plastic, with metal spacers M4 2 Nm 0.2 Kgm 1.45 ft/lb
Steel screws on brass, copper, aluminium M4 2 Nm 0.2 Kgm 1.45 ft/lb
Steel screws on iron, steel M4 3 Nm 0.3 Kgm 2.2 ft/lb
Steel screws 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 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, aluminium M8 16 Nm 1.6 Kgm 11.8 ft/lb
Steel screws on iron, steel M12 100 Nm 10 Kgm 73.8 ft/lb
Steel screws on iron, steel M14 145 Nm 14.5 Kgm 107 ft/lb
X.10
CHASSIS AND WHEELS
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
Section
Y
Y.1
CHASSIS AND WHEELS
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
Sommario
Chassis.......................................................................................................... Y.3
Lubrication points (lubricant)......................................................................... 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
Y.2
CHASSIS AND WHEELS
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
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.
Y.3
CHASSIS AND WHEELS
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
ubrication points (lubricant)
L
1 Steering bearings (grease)
H02333
H02332
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
Y.4
CHASSIS AND WHEELS
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
Front wheel
6
8
9
3 10 11
8 13
8
7
14
4
5
15
12
H06832
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.
Y.5
CHASSIS AND WHEELS
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
Removing the front wheel
Set a stand or a block under the engine and see that the front wheel is lifted
from the ground.
H10167
Loosen the bolts (1) holding the wheel axle (2) to the front fork mounts.
2 H10168
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-
3 moved; this causes the calliper pistons to move outwards.
H10169 After removal, lay down the wheel with brake disc on top.
Y.6
CHASSIS AND WHEELS
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
Reassembling the front wheel
Fit the L.H. spacer (1) on the wheel hub.
Fit the wheel between the fork legs so as to set the brake disc into the calliper.
4
Fit the wheel axle (2) from the R.H. side, after greasing it and push it fully
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
2 H10170 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 ( 10.4 Nm, 1.05 Kgm, 7.7 ft-lb).
After reassembly, pull the brake control lever until the pads are
against the brake disc.
4
H10171
Speed sensor (TE)

Check the gap “B” between magnet (6) on brake disc and sensor (7) on brake
calliper.
H02632
Y.7
CHASSIS AND WHEELS
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
Rear wheel
2
17 7
5 11
16
4
13
12
11 15
6 9 10
14
3
8
7
H06860
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.
Y.8
CHASSIS AND WHEELS
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
Removing the rear wheel
Set a stand or a block under the engine and see that the rear wheel is lifted
from the ground.
Unscrew the nut (1) of the 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.
1 Do not operate the rear brake pedal when the wheel has been re-
moved; this causes the calliper pistons to move outwards.
2 After removal, lay down the wheel with brake disc on top.
H10172 After reassembly, depress the brake pedal until the pads are against
the brake disc.
1: 142.1 Nm, 14.5 Kgm, 104.8 ft/lb

2
3
H10173
Y.9
CHASSIS AND WHEELS
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
Wheel servicing
Check the wheel hub bearings for wear. If you find too much (radial or axial)
clearance, replace the bearings as follows:
- place the hub on a flat surface with an appropriate hole (for when you knock
out the bearing);
- use a hammer and a punch to knock out the bearing; apply pressure only on
the inner race of the bearing (see figure);
- tap at different positions so as to keep the bearing square in its seat;
- remove the spacer and 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 perfect alignment as
you slide the axle into place.
Wheels should be balanced after each service.

Wheel axle warpage

If warped beyond the maximum limit allowed, the axle must be straightened or
replaced. Replace the axle if it cannot be straightened so as to meet the maxi-
mum limit allowed.
Axle runout over 100 mm
Wheel axle Standard Max limit

Wheel axle less than 0.1 mm 0.2 mm (0.0078 in.)
Y.10
CHASSIS AND WHEELS
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
Wheel spokes
Make sure all nipples are firmly tightened (4.4 Nm, 0.45 Kgm, 3.2 ft/lb). Re-
tighten if needed. Improper tightening will affect motorcycle stability; for a quick
check, simply 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 problem, change the wheel rim
or the wheel.
Standard Max limit
Side runout less than 0.5 mm

2 mm (0.078 in.)
Out-of-round less than 0.8 mm
Y.11
CHASSIS AND WHEELS
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
Rear chain sprocket, secondary 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.

3: 34.3 Nm, 3.5 Kgm, 25.3 ft/lb + LOCTITE 243
Y.12
CHASSIS AND WHEELS
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
Checking pinion and sprockets for wear
Check the transmission sprocket for damage or wear. When worn down like the
sprocket shown in the figure, it must be replaced.
Wheel misalignment causes abnormal wear, making the motorcycle

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 and sprocket wear.
Y.13

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TE 250 - 310 2012 I.E.

TE 250 - 310 2012 I.E. USA

Workshop Manual Ed. 12-2011

TE 250 - 310 2012 I.E.

1st edition (12-2011) - Rev. 02

MODELS COVERED (from serial number onwards)

1. Chassis serial number

Workshop Manual Ed. 12-2011

Accident-prevention rules for operator and persons working nearby.

Additional information concerning the operation covered in the text.

Recommended shop practices

Workshop Manual Ed. 12-2011

Unless otherwise specified, data and specifications apply to all models.

Workshop Manual Ed. 12-2011

Workshop Manual Ed. 12-2011

Workshop Manual Ed. 12-2011

* ALWAYS remember that these motorcycles are specifically designed for

* In order to maintain the vehicle’s “Guarantee of Functionality”, the client must

Workshop Manual Ed. 12-2011

Workshop Manual Ed. 12-2011

Workshop Manual Ed. 12-2011

Valve clearance (with engine cold)

Workshop Manual Ed. 12-2011

Transmission ratio (TE-TXC)

Transmission ratio (TC)

Final ratios (TE-TXC)

Final ratios (TC)

Workshop Manual Ed. 12-2011

Cold tire pressure

Electrical components location (TC)

Electrical components location (TXC)

Workshop Manual Ed. 12-2011

Workshop Manual Ed. 12-2011

Workshop Manual Ed. 12-2011

Capacities Type Quantity

Oil quantity in each fork leg (TE)

Rear shock absorber oil CASTROL SYNTHETIC FORK OIL (5W)

IMPORTANT - Do not add any additives to fuel or lubricants.

Workshop Manual Ed. 12-2011

Workshop Manual Ed. 12-2011

PART AFTER FIRST EVERY EVERY EVERY EVERY EVERY REPLACE

VALVES C (•) C (•) S

VALVE SPRING RETAINERS, VALVE COLLETS C X

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 CONNECTING ROD S

OIL FILTER/MESH FILTER S, P S, P

OIL PUMP TO CRANKCASE OIL LUBRICATION

PRIMARY DRIVE GEAR PAIR C

CLUTCH PRESSURE PLATE C

Workshop Manual Ed. 12-2011

PART AFTER FIRST EVERY EVERY EVERY EVERY EVERY REPLACE

KICK START PEDAL L

GEAR SHIFT PEDAL C

SPARK PLUG CAP C

WATER HOSES AND CLAMPS C