Husqvarna TE TC 250 450 SM400 4-Strokes 2004 Motorcycle Repair Manual

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Stichworte: 2004 Husqvarna Misc Motorcycle Motorcycles SM400 TC 450 TE 250

Produktvarianten

Beschreibung

This manual covers the 2004 TE/TC 250, TC 450, and SM400 motorcycles. These high-performance, four-stroke machines are renowned for their robust engines, competitive performance, and specialized capabilities, catering to both off-road enthusiasts and supermoto riders. With a heritage rooted in Swedish engineering and a reputation for durability, these motorcycles represent a significant era in motocross and enduro technology. They are designed for demanding use, offering a powerful and engaging riding experience. This comprehensive repair workshop manual provides full and complete repair and workshop procedures for the specified motorcycle series. It details essential maintenance, troubleshooting, and repair processes across all major systems, including the engine, fuel, ignition, transmission, suspension, brakes, and electrical components. The manual is an indispensable resource for owners and technicians, offering factory-level information from basic checks and routine maintenance to complete engine overhauls and component replacements, ensuring optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

TE/TC 250, TC 450, SM400

Year:

Vehicle Type:

Motorcycle

Engine Type:

4-Stroke

👋 Introduction

Market Position

Segment:

High-performance off-road and supermoto motorcycles

Competitive Analysis

Competitors 2004:

KTM EXC/SX, Yamaha YZ/WR, Honda CR/CRF, Suzuki RM/DRZ, Kawasaki KX/KLX

Key Features

Husky Reputation:

Known for robust engines, competitive performance, and specialized off-road capabilities

Manual Value:

Essential for owners and mechanics to maintain and repair these specialized machines

Document Type:

Factory-level repair information

📋 Manual Details

Coverage Areas

Primary Coverage:

Full and complete repair and workshop procedures

Model Coverage Note:

Covers 2004 models and onwards within the specified series

Page Count

Estimated Pages:

Varies by specific model/engine, typically 300-500+ pages for comprehensive manuals

Manual Type

Type:

Repair Workshop Manual

Language

Language:

English (assumed based on product description)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, disassembly, assembly, tuning, and troubleshooting (including top-end, bottom-end, lubrication, cooling)

Fuel System:

Carburetor service, fuel pump, fuel lines, fuel tank maintenance and repair

Ignition System:

Ignition coil, stator, CDI unit, spark plug diagnosis and replacement

Transmission Drivetrain:

Clutch operation, gearbox disassembly/assembly, gear selection, chain/sprocket maintenance

Suspension:

Front fork service (seals, oil, springs), rear shock absorber maintenance and adjustment

Brakes:

Hydraulic brake system overhaul (master cylinders, calipers, lines), bleeding procedures, pad replacement

Electrical System:

Wiring diagrams, battery service, lighting, starter motor, charging system troubleshooting

Chassis Frame:

Frame inspection, steering head bearing service, swingarm maintenance

Bodywork Trim:

Fairing removal/installation, seat, fenders, and other trim components

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, chain adjustment, spark plug checks, air filter cleaning/replacement

Troubleshooting:

Diagnostic procedures for common starting, running, and electrical issues

Repair Overhaul:

Detailed step-by-step instructions for complete engine, transmission, and component rebuilds

Component Replacement:

Instructions for replacing parts like brake pads, clutch plates, bearings, seals, and cables

Diagnostics:

Fault finding charts and diagnostic flowcharts for various systems

Technical Depth

Depth:

Comprehensive (A-Z repair, from basic checks to complete engine rebuilds)

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF, allowing for quick information retrieval

Print Quality

Quality:

Professional quality, suitable for printing sections or the entire manual

Binding Type

Binding:

N/A (Digital PDF download)

Paper Type

Paper:

N/A (Digital PDF download)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Husqvarna 4-stroke single cylinder

Te Tc 250 Displacement:

Approximately 250cc (specific bore/stroke may vary)

Tc 450 Displacement:

Approximately 450cc (specific bore/stroke may vary)

Sm400 Displacement:

Approximately 400cc (specific bore/stroke may vary)

Cooling System:

Liquid-cooled

Valve Train:

SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) depending on specific model variant

Performance

Power Output Approx:

250cc: ~30-35 HP, 400/450cc: ~40-45 HP (estimates, actual may vary)

Torque Spec:

Not specified in product info, requires manual lookup

Fuel System

Carburetor Type:

Mikuni or Keihin flat-slide carburetors common (e.g., VM34, VM36, MX series)

Fuel Type:

Unleaded gasoline

Ignition System

Ignition Type:

Digital CDI (Capacitor Discharge Ignition)

Lubrication

Oil Type Recommendation:

High-quality motorcycle-specific 4-stroke engine oil (e.g., SAE 10W-40, consult manual for exact specs)

🔧 Transmission

Standard

Type:

Manual

Gear Count:

Typically 5 or 6 speed

Clutch Type:

Wet multi-plate

Features

Primary Drive:

Gear drive

Final Drive:

Chain drive

Transmission Oil Spec:

Dedicated transmission oil or engine oil depending on design (consult manual)

📐 Dimensions

Exterior

Wheelbase Approx:

Varies by model (e.g., 57-58 inches)

Seat Height Approx:

Varies by model (e.g., 36-38 inches)

Weights

Dry Weight Approx:

Varies by model (e.g., 230-260 lbs)

Fuel Capacity Approx:

Varies by model (e.g., 2.0-3.0 gallons)

🛡️ Safety Features

Ratings

Safety Certification:

Designed for off-road competition or street legality (SM models) - meets applicable standards

Active Features

Brakes:

Hydraulic disc brakes (front and rear)

Tires:

Off-road knobby tires (TE/TC) or street-legal tires (SM)

Passive Features

Frame Construction:

Steel perimeter frame (typical for Husqvarna)

Handlebar:

Fat bar or standard diameter handlebars with handguards (often standard)

💡 Technology Features

Infotainment

Features:

N/A (Performance-oriented off-road/supermoto motorcycles focus on mechanical function)

Driver Assistance

Features:

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 10-15 hours of use or annually (recommendation, consult manual)

Air Filter Cleaning:

Clean or replace every 5-10 hours of use or as needed based on conditions

Chain Lubrication:

Lubricate every 300-500 miles or after washing/rain

Valve Clearance Check:

Every 20-30 hours of use (critical for engine health)

Fluid Specifications

Engine Oil Capacity:

Varies by model (e.g., 1.0-1.5 liters), consult manual

Brake Fluid Type:

DOT 4 hydraulic fluid

Coolant Type:

Ethylene glycol based coolant with corrosion inhibitors (50/50 mix with distilled water)

Known Issues

Common Wear Items:

Clutch plates, piston rings, valve seals, wheel bearings, fork seals

Electrical Connections:

Potential for corrosion on connectors in off-road environments

Carburetor Tuning:

May require periodic tuning due to altitude or temperature changes

📚 Vehicle History

Brand Heritage

Origin:

Swedish brand with a long history in motorcycle manufacturing, particularly off-road

Model Evolution

4-Stroke Development:

Husqvarna has a history of developing competitive 4-stroke off-road and motocross bikes

2004 Context:

Represents a period of significant advancement in motocross and enduro technology

Production

Manufacturing Location:

Typically Italy for Husqvarna motorcycles in this era

🏆 Awards & Recognition

Recognitions

Brand Accolades:

Husqvarna has a strong heritage and numerous wins in enduro and motocross racing

Ratings

Performance Reviews:

Generally well-regarded for their power, handling, and durability in their respective classes