TC 250

01. Faster and wiser

Engine

The TC 250 engine is at the pinnacle of 2-stroke performance and weighs just 52.6 lb (23.9 kg). Complete with the latest technical innovations, the TC 250 comes with electronic fuel injection (EFI) which reduces running costs, removes the need for jetting changes, and ensures reliability. The addition of electric start adds to the simplicity of this popular model, and guarantees fast starting in all situations.

Cylinder

The cylinder has a 66.4 mm bore but with the introduction of EFI, the traditional powervalve is replaced with an electronic exhaust control system. This highly innovative technology manages the opening of the lateral exhaust ports before the main exhaust ports open to deliver strong, controllable power. The upper contour of the exhaust port features a machined finish for improved port timing and unrivalled performance.

Crankshaft

The crankshaft is designed with weight reduction in mind to increase throttle response. The perfect balance of rotating masses is achieved by balancing the weights of the crankshaft flywheel, the rotor, and the counter balancer shaft.

Crankcases

High-pressure die cast production processes allow for the crankcases to be manufactured with a thinner wall thickness to keep the overall weight to a minimum, and to position the shaft arrangements perfectly for optimized mass centralization. This clever design aids the overall balance and agility of the TC 250 while the symmetrical engine mounts aid handling by contributing to the flex characteristics of the chassis.

Counter balancer shaft

The TC 250 features an innovative laterally mounted counter balancer shaft. This shaft significantly reduces engine vibration, resulting in a smoother and more comfortable ride.

DDS clutch

The damped diaphragm steel (DDS) clutch fitted to the TC 250 is unique as a single diaphragm steel pressure plate is utilized instead of traditional coil springs. Housed inside a CNC machined steel basket, the overall clutch design contributes to the compact engine layout and features a damping system for improved traction and durability.

Gearbox

The TC 250 features a 5-speed gearbox manufactured exclusively by Pankl Racing Systems for the highest level of durability and ensures smooth and precise shifting. In addition, the gear lever tip design offers improved leverage and prevents dirt build-up, even in the toughest conditions.

Engine

Cylinder

Crankshaft

Crankcases

Counter balancer shaft

The TC 250 features an innovative laterally mounted counter balancer shaft. This shaft significantly reduces engine vibration, resulting in a smoother and more comfortable ride.

DDS clutch

Gearbox

02. Ride easier

Chromium molybdenum frame

With an optimized distribution of material around the steering head and upper shock mount, the frame delivers confidence-inspiring handling and assured stability when entering corners. To complement the overall look of the machine, the chromium molybdenum chassis is finished with a premium, metallic blue powder coating. The finishing touches are the frame protectors, which not only protect the paintwork, but also provide riders with additional grip, even in the toughest conditions.

Polyamide-reinforced aluminium subframe

Made from 60% polyamide and 40% aluminum, the two-piece subframe ensures exceptional strength and durability at an overall weight of just 3.9 lb (1.8 kg). The lower subframe spars and frame mounts are manufactured from cast aluminum for reliability. The upper section of the subframe is made from injection-molded polyamide to enable specific flex characteristics and ensure a lightweight construction.

Triple clamps

Working in unison with the frame design and suspension set-up, the CNC-machined triple clamps provide precisely calculated geometry for stability. Handlebar flex can be customized with the handlebar clamp, which offers two mounting options - rubber-damped for less vibration, or fixed for enhanced front-end feedback. The upper triple clamp is stiffer to ensure a smoother fork action, and plays a vital role in the perfect alignment of the front wheel for superior handling.

WP XACT-AER front suspension

Rigorously tested by the WP research and development department, the 48 mm WP XACT closed cartridge spring forks fitted to the TC 250 provide exceptional comfort. Inside the forks, mid-valve pistons optimize oil flow and prevent foaming for consistent and predictable damping at all times. A hydrostop, active in the final 40 mm of travel, reduces the impact of harsh and high-speed landings to maintain forward momentum. Both compression and rebound settings can be quickly adjusted by hand using the easily accessible clickers located on top of each fork leg.

WP XACT shock absorber

The WP XACT rear shock features a Computational Fluid Dynamics (CFD) optimized main piston, ensuring superior initial comfort and predictable performance in all conditions. To give riders the option of creating a personalized set-up, rebound, as well as the high and low-speed compression settings, can all be adjusted easily by hand.

Swingarm

The swingarm is manufactured using a die-cast production process and designed with a calculated level of rigidity. To further complement and optimize the flex characteristics of the chassis, a 22 mm rear wheel axle is utilized. A durable chain slider is neatly integrated into the swingarm, ensuring uninterrupted forward momentum through deeply rutted corners.

Chromium molybdenum frame

Polyamide-reinforced aluminium subframe

Triple clamps

WP XACT-AER front suspension

WP XACT shock absorber

Swingarm

03. Effortless ergonomics

Functional bodywork

The ergonomic bodywork was designed to ensure that riders can perform at their best throughout every race. This was achieved through extensive testing, with the smooth contact points in the rider triangle allowing racers to grip the machine tightly with their legs, reducing fatigue. The radiator shrouds, featuring in-mold graphics, contribute to the progressive appearance of the machine, while a tall, wide seat offers unrestricted movement. A high-grip seat cover also helps keep riders securely in place under hard acceleration.

Airbox

A strong, one-piece airbox optimizes air intake by reducing deformation. This design provides an unrestricted flow of air for maximum power, without compromising filter protection. The Twin Air filter can be easily inspected without tools by simply removing the left side panel.

Hydraulic clutch

The high-performance Brembo hydraulic clutch system guarantees even wear, near maintenance-free operation, and perfect action in every condition. With this hydraulic system, free play is constantly compensated so that the pressure point and function of the clutch remain identical in cold or hot conditions, as well as over time. Countless hours of race-focused testing have proven the exceptional reliability of the high-quality, Italian-made Brembo hydraulic systems.

Hydraulic brakes

Class-leading Brembo brake calipers, made from single pieces of aluminum for strength, are fitted front and rear to ensure high braking performance. Together with 260 mm front and 220 mm rear discs, both designed to prevent mud build-up, effective stopping power in all conditions is assured. The strong rear brake pedal is highly durable, and less susceptible to damage when riding through deep ruts.

ProTaper handlebar

Developed between Husqvarna Motorcycles and leading handlebar manufacturer, ProTaper, the exclusive bend offers superior comfort, class-leading strength, and fatigue resistance at the lowest possible weight.

ODI grips

ODI lock-on grips feature an innovative, integrated throttle mechanism and are installed without using glue. The throttle assembly offers easy free-play adjustment with the option to fit alternative cams for a personalized throttle action.

Footrests

The CFD-designed footrests are extra wide to ensure better control of the machine while at the same time are less susceptible to catching on deep ruts, take-offs when scrubbing, and trackside barriers. This is achieved by a narrower mounting design in the frame layout, which also helps reduce overall weight.

Functional bodywork

Airbox

Hydraulic clutch

Hydraulic brakes

ProTaper handlebar

ODI grips

Footrests

04. Master your art

Wheels and tires

CNC-machined hubs, strong spokes, and high-strength, black-anodized alloy rims by D.I.D are used to assemble the wheels. They are complete with the latest Dunlop MX34 tires, with the front ensuring precise cornering, while the rear provides excellent traction across varied terrain.

Exhaust system

The header pipe on the TC 250 is designed using innovative 3D modelling. The result is a perfect shape designed to deliver optimum performance across the rev-range while also being very compact to ensure sufficient clearance through deep ruts.

Cooling system

Manufactured from high-strength aluminum, the radiators are designed using Computational Fluid Dynamics (CFD) to channel air through them in the most effective way. A large center tube through the frame reduces pressure at this point in the system for a consistent coolant flow, while an internal thermostat further enhances reliability. A new threaded radiator cap allows for easy inspection of the coolant level before each ride.

Fuel tank

The 1.9-gallon (7.2-liter) fuel tank integrates neatly within the ergonomic bodywork and features a strong rubber cushion beneath it to protect the frame from wear. For maximum durability, the external fuel line is specifically routed to make it less exposed and susceptible to damage. Additionally, the protective cap for the fuel filter prevents dirt and water from entering the system and shields it from impact damage.

Wheels and tires

Exhaust system

Cooling system

Fuel tank

05. Technologically advanced

EFI

The electronic fuel injection system on the TC 250 brings many benefits. The ECU from Vitesco constantly analyses the running condition of the engine and delivers the perfect air/fuel ratio at all times through the state-of-the-art 39 mm Keihin throttle body. EFI also introduces two different engine maps, which can easily be activated via the handlebar-mounted switch for a personalized riding experience. Map 1 is backlighted in white, while Map 2 is backlighted in green. Additionally, the reed valve system is designed to prevent excess fuel build up, which would lead to rich running of the engine in extreme up or downhill sections.

E-Start

For guaranteed, easy starting in all conditions, the TC 250 features highly reliable electric start technology with the system removing the need for a kickstart completely. The 12.8V 2 Ah Lithium-Ion battery is positioned neatly under the seat and close to the center of gravity for uncompromised handling. Stopping of the engine is achieved via the same handlebar-mounted switch for ease of use and a simplified operation.

Map switch

The electronic fuel injection (EFI) on the TC 250 allows for the introduction of two engine maps that cater for riders of all abilities. Map 1 (white) is the standard option and delivers linear, predictable power, while Map 2 (green) is more aggressive with a quicker throttle response and a sharper, more explosive power output. By simply pressing a button on the handlebar-mounted Map Select Switch, riders can toggle between the two options and select their chosen map.

EMS

The engine management system (EMS) is designed to be small, light, and fast at processing data. It incorporates a Rollover Sensor (ROS) that cuts the ignition and shuts off the engine in the event of a severe crash for an additional layer of safety.

Hour meter

The hour meter comes with an integrated fuel level indicator, which is visible on the FI status LED, and warns the rider when the fuel level is getting too low.

Start/stop switch

The combined engine start/stop switch is located on the right side of the handlebar for easy, thumb-operated use. Not only simplifying the starting and stopping of the engine, but the removal of an additional stop only button from the handlebar reduces the risk of potential damage or activation in the event of a fall.

EFI

E-Start

Map switch

EMS

Hour meter

The hour meter comes with an integrated fuel level indicator, which is visible on the FI status LED, and warns the rider when the fuel level is getting too low.

Start/stop switch

01. Faster and wiser

Engine

Cylinder

Crankshaft

Crankcases

Counter balancer shaft

DDS clutch

Gearbox

Engine

Cylinder

Crankshaft

Crankcases

Counter balancer shaft

DDS clutch

Gearbox

02. Ride easier

Chromium molybdenum frame

Polyamide-reinforced aluminium subframe

Triple clamps

WP XACT-AER front suspension

WP XACT shock absorber

Swingarm

Chromium molybdenum frame

Polyamide-reinforced aluminium subframe

Triple clamps

WP XACT-AER front suspension

WP XACT shock absorber

Swingarm

03. Effortless ergonomics

Functional bodywork

Airbox

Hydraulic clutch

Hydraulic brakes

ProTaper handlebar

ODI grips

Footrests

Functional bodywork

Airbox

Hydraulic clutch

Hydraulic brakes

ProTaper handlebar

ODI grips

Footrests

04. Master your art

Wheels and tires

Exhaust system

Cooling system

Fuel tank

Wheels and tires

Exhaust system

Cooling system

Fuel tank

05. Technologically advanced

EFI

E-Start

Map switch

EMS

Hour meter

Start/stop switch

EFI

E-Start

Map switch

EMS

Hour meter

Start/stop switch

Technical Details

Engine

Chassis