Forever Bike Husqvarna TC250 Build

So at the beginning of the year I decided my 2017 Husqvarna TC250 would become a 'Forever Bike'. Meaning, I would keep this bike 'forever' (hey nothing in life is guaranteed eh?).

The premise is simple, and revolves around money + age. There is a point in your life where you no longer have to sell each bike to finance the next one (money) along with the fact you are getting older... and probably not faster (age).

At the start of 2020 I realized my beloved TC250, which I bought in October of 2016, is the best damn motocross bike I'd ever ridden... and every time I rode it I was amazed at how good it is. To this point I'd be slowly building it up with some nice parts, but nothing too crazy. Just some bits that helped with power, rideability, and comfort... with some bling in there for good measure.

The catalyst for 'Forever Bike' status was the crossroads of really spending money on it versus doing the same old thing and probably selling it a few more years down the road, and getting another one. See previously I had a 2013 KTM 250SX, which was a nice bike, but a bit unruly... (the 2017+ generations are head and shoulders better) and I kind of always knew I'd sell the 250SX one day...

But with the TC250, I'd decided in January 2020 that NAY SIR, YOU WILL NOT BE SOLD INTO THE NIGHT. YOU WILL BE KEPT FOR ALL TIME TO BE THE ULTIMATE, THE VERY BEST, THE CULMINATION OF MY CHILDHOOD VISION. A BEACON FOR ALL TWO STROKES ACROSS THE LAND.

Hyperbole aside, it was neat to come to this realization and feel like I could really plan out a killer build, like I'd always dreamed of, and not worry about 'losing all my money down the road when I sell it used'. At this point who gives a shit! I see guys still riding and having fun on 2003 CR125s, a 17 year old bike! I was certain that in the year 2034 when my TC250 is 17 years old, and I'm 56, it'll still be an amazingly fun bike.

So, here we go, here's the bike's build history and kick-off for its next, major, evolution. I keep a spreadsheet with all parts bought and prices, so easy to copy / paste here. I'll add some notes with each and hopefully this is useful for other TC250/250SX riders.

For the historical record, here's my old 2013 KTM 250SX. Fully revalved WP suspension by WP North America, Pro Circuit pipe + silencer, reeds, and that's about it. This bike was an arm ripper.



October 2016: The TC250 brand new in the back of the truck outside of Moto Forza's old building, prior to the fire


Late 2016/early 2017: At this point our bike build mainly consists of some comfort changes and bling. My biggest changes here were the Day 1 Lectron HV carb (because fuck jets), lower footpegs, and CR High bars. I'm 6'1" with a long torso and the lower Fastway pegs plus CR High bars made a nice improvement in cockpit comfort.

- Lectron HV carb + Domino throttle assembly
- Husqvarna Factory Parts metal gas cap
- Decal Works 434 number plates
- Fastway AIR EXT footpegs w/fit kit & F6 cleats (blue)
- Works Connection brake cap (blue)
- Works Connection engine oil plug (blue)
- Works Connection steering nut (blue)
- Husqvarna Factory Parts brake master cover (blue)
- Husqvarna Factory Parts clutch master cover (blue)
- Husqvarna Factory Parts air filter cover for cleaning
- Pro Taper Contour CR High bars



2017 and 2018: I didn't get to ride (this bike) as much as I'd have liked over the next year or so, but did just pick away at the bike and make a few more small changes. Mainly going to a 49t in the back along with the Moto Tassarini VForce 4VR reeds. That coupled with some Lectron tweaks had the bike running well. Other things were little quality of life improvements.

- Renthal 49t rear sprocket. (blue)
- Moto Tassarini VForce4VR reeds
- DT-1 air filters (4)
- Factory Husqvarna power valve cover (blue)
- Fasst Company rear brake return spring
- Motion Pro Micro Bleeders for AER48's
- Top cover gasket for Lectron
- Slide spring for Lectron



2019: Finally got around to making some more serious changes to the bike and getting a proper pipe and silencer on there. Got a beautiful Scalvini cone pipe + FMF Powercore 2.1 Shorty off Jeffro here on Vital along with some killer carbon bling skidplate and tank cover. Also found Justin Starling selling some of his SX parts and snagged the oversized rotor to beef up the already awesome brakes. Few more quality of life improvements with the map switch on the bars and power valve dial. Bike was looking primo and riding even better! The addition of the pipe + silencer along with moving to the 'softer' ignition map really made this bike ride well.

- Sicass Racing Ignition map switch
- Kreft Moto PowerDial 3.0 Blue
- Scalvini factory works pipe
- FMF Husqvarna Edition Powercore 2.1 silencer
- Pro Carbon skid plate
- Pro Carbon tank cover
- Galfer 280mm Oversized Tsunami Wave Rotor



Early 2020: This is when we decided the bike would be a Forever Bike and started getting some slick bits. Fella on Vital here (Team Green maybe? Sort of forget...) makes the factory master cylinder covers and I thought those were pretty cool, so nabbed those. Read about the rear floating axle mod, and that wasn't too much hassle, so picked a CRF axle up off eBay and got the Ride Engineering blocks... and lastly was the big piece, the sano REP factory knuckle and dogbones... just so trick. I also had some extra vinyl laying around from my Superbike R1 build... so was bored in the shop one night and started messing around with my getting a little beat stock plastics. It gives a few ideas for the future.

- CDG Magura/Brembo carbon fiber mc covers
- Ride Engineering billet axle blocks
- 2017 Honda CRF450 rear axle
- REP Factory suspension linkage kit




Late 2020: This is where the build starts to go into the stratosphere... I'm just getting ready to start pulling parts and slapping on the new new... and figured as good a time as any to document. At the end of this phase the TC250 will truly be in Dream Bike territory and the young kid who plastered his walls with moto magazine pages (me) is pumped. I also recently bought a small business (lost job due to covid, needed something to do to keep busy) and have been flat out for almost 4 months... aka no life no spending money no nothing just grinding... so the wife gave the big thumbs up to get the TC250 build done. (Hey I bought some parts for her bikes also...)

The big kitty items here, and what I lost my shit over when it arrived, are the WP kit boingers. That plus the factory wheelset and triples.. whooooaaamamma.

I'm dropping the suspension off at AEO/REP on Tuesday.. and once those are done, and I finish getting my graphics kit designed (do that myself) and installed, it will be time to ride \oo/.

- Michelin Starcross 5s + lightweight tubes
- Acerbis X-Brake vented carbon fiber disc cover & mount
- Warp 9 titanium sprocket bolt set
- Warp 9 titanium rear disc brake bolts (F & R)
- Husqvarna Factory Parts rear caliper carrier (black)
- Husqvarna Factory Parts rear wheel (blue)
- Husqvarna Factory Parts front wheel (blue)
- Husqvarna Factory Parts chain
- Dirt Tricks front sprocket
- Dirt Tricks chromatic 49t rear sprocket
- Husqvarna Factory Parts brake pedal step plate +8mm (blue)
- Husqvarna Factory Parts gear shift lever tip +7mm (blue)
- Husqvarna Factory Parts carbon rear disc guard
- Husqvarna Factory Parts carbon rear caliper guard
- Husqvarna Factory Parts clutch slave cylinder protection (blue)
- 2020 WP XACT Pro fork (Cone Valve, spring)
- 2020 WP XACT Pro shock (Trax)
- Husqvarna Factory Parts triple clamp (blue)
- Husqvarna Factory Parts PHDS handlebar clamps
- Husqvarna Factory Parts clutch cover
- Husqvarna Factory Parts rear brake master cylinder extension
- Husqvarna Factory Parts chain slider upper (blue)
- Husqvarna Factory Parts chain slider lower (blue)
- RaceTech titanium triple clamp bolts
- TM Designworks chain guide
- FMF Powercore 2.1 Titanium silencer (full size)
- Pistonbone custom graphics (self-designed)
- New OEM plastics kit



At the end of this stage the TC250 will be pretty insano but of course... it's never fully done. I have a couple more things I'd like to do, but will ride this version for a while and see what 2021 brings for next steps.

PS: If Ryno sees this, go fuck yourself. My non-pro ass will enjoy ever second of riding this bike for a very long time.