Vehicle Segment:
High-performance motocross/off-road competition motorcycle.
Target Audience:
Motocross racers, off-road enthusiasts, and owners requiring in-depth technical knowledge for maintenance and repair.
Key Competitors:
KTM EXC/SX series, Yamaha YZ/WR series, Honda CRF series, Suzuki RM-Z/DR-Z series, Kawasaki KX/KLX series.
Performance Focus:
Designed for aggressive off-road riding, emphasizing power delivery, suspension performance, and agility.
Manual Advantage:
Provides the detailed technical information necessary to maintain and repair these specialized machines, often beyond basic owner's manual capabilities.
Primary Coverage:
Comprehensive service and repair for Husqvarna TC450 models of 2007 and 2008.
Secondary Coverage:
Maintenance, diagnostics, troubleshooting, and component-level repair.
Estimated Page Count:
Typically 300-500 pages for this type of comprehensive service manual. Exact count not specified.
Manual Type:
Service Repair Manual
Language:
English (Assumed, standard for most international service manuals)
Engine Systems:
Engine disassembly, assembly, tuning, lubrication, cooling, ignition, fuel delivery (carburetion), exhaust.
Drivetrain Systems:
Clutch operation, transmission disassembly/assembly, gear ratios, chain and sprocket maintenance.
Suspension Systems:
Front fork (USD forks, e.g., Marzocchi Shiver or similar) servicing, rear shock absorber maintenance and adjustment.
Braking Systems:
Hydraulic brake system maintenance (front and rear calipers, master cylinders), bleeding procedures, pad replacement.
Electrical Systems:
Wiring diagrams, lighting system, ignition system components, battery maintenance, starter system.
Chassis And Bodywork:
Frame inspection, seat removal, fuel tank maintenance, handlebar assembly, footpeg mounting.
Routine Maintenance:
Oil changes, filter replacements (oil, air), chain adjustment, spark plug inspection/replacement, valve clearance checks.
Diagnostic Procedures:
Troubleshooting guides for common starting issues, running problems, electrical faults, and performance degradation.
Repair Procedures:
Step-by-step instructions for engine rebuilds, transmission overhauls, suspension fork servicing, brake caliper rebuilding.
Adjustment Procedures:
Carburetor tuning, idle speed adjustment, clutch cable adjustment, suspension sag settings.
Depth Of Coverage:
Comprehensive, covering everything from basic pre-ride checks to full engine and transmission overhauls. Suitable for both home mechanics and professional technicians.
Diagnostic Capabilities:
Detailed troubleshooting flowcharts and symptom-based diagnostic trees.
Rebuild Instructions:
Detailed instructions for rebuilding major engine components, transmission gears, and suspension units.
Engine Type:
Single-cylinder, 4-stroke
Displacement:
Approximately 449cc (specific internal codes may vary by Husqvarna variant).
Bore X Stroke:
Likely around 95mm x 63.4mm, but specific figures would be in the manual.
Cooling System:
Liquid-cooled
Valve Train:
SOHC (Single Overhead Camshaft) with 4 valves. Specific camshaft profiles and lift would be detailed.
Horsepower Estimate:
Estimated 50-55 HP at peak RPM (typical for this class and era).
Torque Estimate:
Estimated 40-45 Nm at peak RPM.
Carburetor:
Typically a large-bore Keihin FCR (e.g., FCR41) or Mikuni carburetor. Jetting specifications, adjustment procedures, and troubleshooting are covered.
Fuel Type:
Unleaded gasoline, octane rating specified in manual (e.g., 91 or higher).
Ignition Type:
Digital CDI (Capacitor Discharge Ignition) with variable timing.
Oil Type And Capacity:
Specific motorcycle-specific synthetic oil (e.g., SAE 10W-50 or 15W-50) with a capacity around 1.0-1.2 liters. Manual will specify exact type and capacity.
Transmission Type:
5-speed sequential manual transmission.
Clutch Type:
Hydraulically operated, multi-plate wet clutch.
Gear Ratios:
Specific gear ratios for each of the 5 gears and final drive are detailed in the manual.
Transmission Fluid:
Manual will specify the required transmission oil grade and quantity. Often shares oil with the engine, but manual confirmation is essential.
Safety Ratings:
N/A (As a competition off-road motorcycle, it is not subject to standard road vehicle safety ratings like NHTSA or Euro NCAP. Safety focuses on rider protection and machine reliability.)
Braking Performance:
High-performance hydraulic disc brakes (front and rear) with specific caliper and rotor specifications detailed. Manual covers bleeding and pad replacement.
Frame Construction:
Robust perimeter frame (likely aluminum alloy) designed for torsional rigidity and impact resistance.
Oil Change Interval:
Typically every 10-15 hours of riding or annually. Manual will provide precise recommendations.
Air Filter Cleaning:
Recommended after every few rides, especially in dusty conditions. Manual details cleaning and oiling procedure.
Valve Clearance Check:
Generally recommended every 20-30 hours of riding. Critical for engine performance and longevity.
Engine Oil Specification:
High-quality motorcycle-specific 4-stroke synthetic oil, e.g., Motul 300V 15W-50 or equivalent. Manual will list exact API/JASO ratings.
Coolant Specification:
A mixture of distilled water and ethylene glycol-based antifreeze, typically a 50/50 mix. Manual will specify the correct type and capacity.
Brake Fluid Specification:
DOT 4 or DOT 5.1 hydraulic brake fluid. Manual will specify the exact requirement.
Common Wear Items:
Clutch plates, chain and sprockets, brake pads, wheel bearings, fork seals are common wear items that require regular inspection and replacement.
Engine Wear Points:
Valve train components (cam, rockers) and piston rings can show wear over extended use; regular checks are crucial.
Suspension Maintenance:
Fork and shock oil changes and seal replacements are critical for maintaining optimal suspension performance.
Heritage Overview:
Husqvarna Motorcycles, a Swedish brand with a long history dating back to 1903, is renowned for its off-road racing pedigree, particularly in motocross and enduro.
Tc450 Context:
The TC450 represented Husqvarna's entry and continued development in the highly competitive 450cc motocross class during the mid-2000s, a period of significant technological advancement in the sport.
Manufacturing Location:
Manufactured in Italy during this period under BMW ownership (prior to KTM acquisition).
