Small in capacity while big on capability, the 2024 TC 125 receives multiple technical upgrades headlined by the inclusion of EFI and E-Start technology. These revisions are instantly noticeable as after a simple push of a button, the engine starts easily, and, once out on track, the TC 125 delivers an improved experience for all riders. Further changes include a new cylinder with a highly innovative electronic exhaust control system, and a lighter crank for improved throttle response and reduced vibration. Continuing to benefit from class-leading components including WP Suspension, a ProTaper handlebar, and a polyamide-reinforced subframe, the TC 125 receives all-new bodywork and a striking new look to remain at the forefront of the highly competitive 125cc class.
The TC 125 engine sets the standard for performance in the highly competitive 125cc class and weighs in at just 17.9kg. The lightweight engine features the latest innovations to produce more torque while retaining its high-revving 2-stroke character. These revisions ensure both beginners and seasoned professionals can ride faster on the race track while further centralisation of rotating mass inside the engine significantly benefits the overall handling of the TC 125.
The cylinder features a 54 mm bore and due to the introduction of EFI on the TC 125, the powervalve is replaced with an innovative electronic exhaust control system. Using an actuator, the lateral exhaust port and main exhaust port open simultaneously for maximum power delivery.
A redesigned crankshaft is 300 g lighter for improved throttle response and minimal vibration. The component is precisely positioned to ensure rotational mass has very little effect on the overall handling of the motorcycle.
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 in the perfect position for optimised mass centralisation. This clever design aids the overall balance and agility of the TC 250 while redesigned, symmetrical engine mounts further improve flex characteristics.
The 6-speed gearbox is manufactured exclusively by Pankl Racing Systems and ensures the highest level of durability and reliability. For 2024, a redesigned shift drum and shift fork improve overall leverage, which ensures significantly smoother and more precise shifting. A revised gear lever tip design prevents dirt build-up.
The DS (Diaphragm Steel) clutch fitted to the TC 125 features a unique design where a single diaphragm steel pressure plate is used instead of traditional coil springs. Housed inside a CNC machined steel basket, the overall clutch design is highly durable and contributes to the compact layout of the engine.
The proven chromium molybdenum steel frame is refined for 2024. A shock mounting, which is no longer connected to the main tube, significantly improves the anti-squat behaviour of the chassis. With optimised wall thickness in high stress areas improving reliability, the frame continues to offer advanced geometries and flex characteristics aimed at providing unparalleled rider feedback, energy absorption, and exceptional straight-line stability. The frame is finished off in a premium metallic blue powder coating with redesigned standard frame protectors offering superior protection, durability, and grip in any condition. Additionally, the inclusion of forged brackets on the lower frame rails allows for easy installation of the skid plate, which is available as a technical accessory.
Made from 60% polyamide and 40% aluminium, the two-piece subframe for 2024 ensures exceptional strength and durability at an overall weight of just 1.8 kg. The lower subframe spars and frame mounts are manufactured from cast aluminium for significantly improved reliability. The upper section of the subframe is made from injection-moulded polyamide to enable specific flex characteristics and ensure a lightweight construction.
Matching the frame design and suspension set-up, the CNC-machined triple clamps provide precisely calculated geometry for increased stability. Customised handlebar flex can be achieved by 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 FRONT SUSPENSION
The 48 mm split air forks now offer improved bottoming resistance thanks to a hydrostop, which applies a progressive damping force in the last 40 mm of travel for even greater comfort. The WP forks are designed with a capsulated, adjustable air spring and pressurized oil chamber for smooth action and consistent damping. Oil and air bypasses reduce pressure peaks and in combination with a midvalve damping system, the forks provide precise feedback to the rider. The settings are easily adjusted via the single air pressure pre-load valve, as well as through easy access click adjusters for compression and rebound. For improved durability, fork protection rings prevent dirt intrusion. Additionally, the air pump needed to adjust the fork’s air pressure is provided as standard.
WP XACT SHOCK ABSORBER
A 15 mm shorter rear shock, which is 100 g lighter compared to the previous generation while the rear wheel travel is set at 293 mm. Inside the shock is a Computational Fluid Dynamics (CFD) optimised main piston for improved initial comfort which provides strong hold-up in all conditions. Different sized holes in the shims allow them to open more easily which reduces the overall stress of the oil flow. Complete with low friction SKF seals and a revised linkage system, consistent damping, comfort, and traction are guaranteed with rebound and both high and low speed compression now adjustable by hand.
The hollow die-cast aluminium swingarm is manufactured from a single piece of aluminium using an improved die-cast production process for optimal stiffness and a 190 g weight reduction over previous versions. In order to optimise and match the flex characteristics from the frame, a 22 mm rear axle is fitted. Additionally, the chain guard and chain slider have been completely redesigned for improved durability and are less prone to hooking on external objects.
Clean, Swedish-inspired design and ergonomics are tailored to allow riders to perform at their best for extended periods of time. Adapted after countless hours of testing, the contact points and surfaces in the rider triangle have been repositioned for 2024 to improve comfort on the motorcycle. A flatter seat offers unrestricted movement with a high grip cover ensuring riders stay firmly in place under hard acceleration.
Designed with precisely positioned inlet ducts aimed at reducing drag and air flow deformation, the airbox ensures unrestricted airflow with maximum filter protection. The TWIN AIR filter is easily accessed without tools, by simply removing the left side panel for easy maintenance.
The high-performance Brembo hydraulic clutch system guarantees even wear, near maintenance-free operation and perfect modulation in every condition. Meaning that 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 high-quality, Italian-made Brembo hydraulic systems’ exceptional reliability.
The highest level of quality is guaranteed with class-leading Brembo callipers made from single pieces of aluminium for strength at the lowest possible weight. Together with a 260 mm front and a 220 mm rear disc which offer improved dirt removal, superior stopping power and braking confidence is guaranteed in all conditions.
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 lock-on grips feature an innovative integrated throttle mechanism and a glue-free installation. The throttle assembly offers easy free-play adjustment with the option to fit alternative cams for a personalised throttle action.
CFD-designed footrests offer a 26.8% larger contact area to ensure better control of the machine while being less susceptible to hooking on deep ruts, take-offs when scrubbing, or trackside barriers. This was achieved by a narrower mounting design in the frame layout, which also helps reduce overall weight.
The implementation of Electronic Fuel Injection on the TC 125 brings many benefits. The ECU constantly analyses the running condition of the engine and guarantees to deliver 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 selected via the handlebar-mounted switch for a personalised riding experience. Additionally, a redesigned reed valve system improves intake tract sealing and prevents excess fuel building up and creating rich running of the engine in extreme up or downhill sections.
To ensure fast starting in all conditions, the TC 125 now features a highly convenient electric start. The reliable system removes the need for a kickstart completely with the space on the engine used for the EFI and electronic exhaust control. With the 12.8V 2 Ah Lithium-Ion battery located under the seat and close to the centre of gravity, the handling of the TC 125 is uncompromised. The engine is easily started and stopped via the same handlebar-mounted switch for improved ease of use.
Adding Electronic Fuel Injection (EFI) to the TC 125 allows for the introduction of two engine maps which cater for riders of all abilities. Map 1 is the standard option that delivers linear, predictable power, while map 2 is aggressive with immediate throttle response and a sharper, explosive power output. By simply pressing a button on the handlebar-mounted map switch, riders can toggle between the two options and select their chosen map.
The Engine Management System (EMS) is designed to be smaller and lighter while being faster at processing data. It incorporates a rollover sensor (ROS) which cuts the ignition and shuts off the engine for safety in the event of a severe crash, adding another level of safety to the Husqvarna Motorcycles’ motocross line-up.
An hour meter comes with an integrated fuel level indicator, which is visible on the FI status LED, indicating to the rider when the fuel level is becoming low.
The combined 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, the removal of a designated stop only button from the handlebar reduces the risk of potential damage or activation in the event of a fall.
WHEELS AND TYRES
Assembled with CNC-machined hubs, strong spokes, and black-anodised alloy rims by D.I.D, the wheels of the TC 125 are fitted with DUNLOP GEOMAX MX33 Motocross tyres which feature a proven block-within-a-block design for more progressive cornering and superior grip. For improved on-track agility, the TC 125 is fitted with a 100/90-19 rear tyre while a 80/100-21 front tyre ensures optimal handling on a variety of riding surfaces.
Tailored specifically to the TC 125 engine using an innovative 3D design process, the header pipe ensures maximum power across the rev range. The muffler features an aluminium mounting bracket for strength at the lowest possible weight, with an advanced internal construction ensuring excellent noise damping without sacrificing performance.
Manufactured from high-strength aluminium, the radiators are designed using Computational Fluid Dynamics (CFD) to channel air in the most effective way. A large centre tube channels coolant through the frame to reduce pressure at this point in the system for a more consistent flow while an internal thermostat further enhances reliability.
A 7.2 litre fuel tank integrates neatly into the revised bodywork. Due to the fuel pump design and position, the tank is emptied further for increased running times. For improved safety, the external fuel line is specifically routed to make it less exposed and susceptible to damage.