Model:
TE 250, TE 450, TC 250, TC 450, SM 450 R, SM 400, TE 510, TE 510 Centennial
Model Years Covered:
2003, 2004
Engine Codes:
Likely Husky 4-stroke variants (specific codes depend on engine configuration, e.g., 450cc engine family)
Chassis Codes:
Likely specific to the model variants (e.g., for TE, TC, SM chassis)
Segment:
Performance Off-Road Motorcycles (Enduro, Motocross) and Supermotos.
Target Audience:
Husqvarna owners, dealership technicians, independent repair shops, experienced DIY mechanics.
Competitors:
KTM EXC/SX series, Yamaha WR/YZ series, Honda CRF/XR series, Suzuki RM/DR series, Kawasaki KX/KLX series.
Manual Value Proposition:
The most complete OEM source for servicing these specific Husqvarna models, ensuring accuracy and completeness for all repair and maintenance tasks. Crucial for maintaining optimal performance and longevity.
Vehicle Characteristics:
Known for their Italian heritage, high-performance engines, and capable chassis designed for competitive off-road and street-legal (SM variants) use.
Countries Of Origin:
Italy (Husqvarna manufacturing at the time)
Estimated Pages:
Detailed page count not specified, but OEM workshop manuals are typically extensive, ranging from 300 to 800+ pages depending on the scope of coverage.
Type:
Workshop Service Repair Manual
Language:
English (primary, though OEM manuals may have sections in other languages depending on origin).
Powertrain:
Engine (internal components, lubrication, cooling, fuel delivery, ignition), Transmission (clutch, gearbox, shifting mechanisms), Exhaust System.
Chassis:
Frame, Suspension (forks, rear shock, linkages), Steering, Wheels, Tires, Brakes (hydraulic systems, calipers, master cylinders, discs), Swingarm.
Electrical:
Wiring Diagrams, Lighting System, Ignition System, Battery, Charging System (alternator/stator), Starter Motor, Instruments, Controls.
Bodywork:
Body panels, fuel tank, seat, fenders, plastics, graphics.
Maintenance:
Routine maintenance (oil changes, filter replacements, chain adjustment, spark plug checks), valve clearance adjustment, lubrication points.
Troubleshooting:
Diagnostic procedures for common and uncommon problems, fault finding guides, error code interpretation (if applicable).
Repair:
Step-by-step instructions for component disassembly, inspection, repair, and reassembly. Includes engine rebuild, transmission overhaul, suspension servicing, brake system bleeding and component replacement.
Technical Adjustments:
Carburetor tuning/adjustment (for TE/TC models), ignition timing checks (if adjustable), suspension sag and damping adjustments.
Depth:
Comprehensive OEM level. Covers everything from basic rider maintenance to full engine and transmission rebuilds, including electrical system diagnostics and chassis component servicing.
Diagnostic Capabilities:
Detailed diagnostic charts and procedures, often including electrical resistance values, voltage checks, and component testing specifications.
PDF Quality:
Assumed high-quality PDF with searchable text and clear, legible diagrams and illustrations, consistent with professional OEM manual standards.
Printability:
Designed to be printable for workshop use. Pages are typically formatted for standard paper sizes (A4/Letter).
Original Binding:
Spiral-bound or perfect-bound (for physical copies). Digital PDF bypasses this.
Original Paper:
High-quality, durable paper stock designed for workshop environments (for physical copies).
Engine Type:
4-Stroke Single-Cylinder
Displacement 250:
Approximately 250cc
Displacement 450:
Approximately 450cc
Displacement 510:
Approximately 510cc
Bore X Stroke:
Varies by displacement, specific values detailed in manual (e.g., 450cc likely around 97mm x 60.8mm).
Cooling System:
Liquid-cooled
Valvetrain:
DOHC (Double Overhead Camshaft), 4 Valves
Horsepower 250:
Approx. 30-35 HP (stock, varies by model/tuning)
Horsepower 450:
Approx. 40-45 HP (stock, varies by model/tuning)
Horsepower 510:
Approx. 45-50 HP (stock, varies by model/tuning)
Torque:
Specific torque figures vary by displacement and tune; manual will provide detailed specs.
Carburetion:
Mikuni Flat Slide Carburetor (e.g., TM40, VM38) or Keihin FCR (for some models/years), specific size varies by displacement and model designation.
Fuel Type:
Unleaded Gasoline (minimum Octane rating specified in manual, typically 91 or higher)
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Oil Capacity:
Specific capacity depends on model and engine variant; manual will list precise amount for oil change and overhaul.
Oil Type:
Specific motorcycle-specific 4-stroke engine oil with appropriate API and JASO ratings (e.g., JASO MA/MA2). Manual will specify viscosity (e.g., 10W-40, 15W-50).
Piston Design:
Typically forged pistons for performance and durability.
Crankshaft:
Robust design suited for off-road demands.
Transmission Type:
6-Speed Manual Sequential
Transmission Options:
None specified for this era; standard 6-speed.
Clutch Type:
Wet, Multi-plate
Gear Ratios:
Specific ratios for each gear are provided in the manual, tailored for performance in different disciplines (Enduro, MX, Supermoto).
Transmission Fluid:
Typically shares engine oil. Manual will specify type and capacity.
Wheelbase:
Varies by model (e.g., TE models typically longer for stability, TC models shorter for agility). Manual provides exact figures.
Seat Height:
Varies by model; generally high for off-road clearance. Manual provides precise specification.
Ground Clearance:
Varies by model; designed for off-road terrain. Manual provides precise specification.
Dry Weight:
Varies by model (e.g., 250cc models lighter than 510cc). Manual will provide specific weights for each variant.
Wet Weight:
Dry weight plus all fluids and fuel. Manual will provide specific figures.
Fuel Tank Capacity:
Typically around 8-10 liters (2.1-2.6 gallons) for TE/TC models, potentially larger for specific race variants. SM models might differ. Manual specifies exact capacity.
Safety Certifications:
Not typically rated by NHTSA or Euro NCAP as they are off-road vehicles or not designed for highway speeds in all configurations. SM models would be subject to street-legal requirements.
Braking System:
Hydraulic Disc Brakes (Front and Rear). Specific caliper and master cylinder details in manual. SM models often feature larger front discs.
Suspension Tuning:
Adjustable suspension (compression, rebound damping, preload) for optimal handling and safety across different terrains. Manual details adjustment procedures.
Frame Design:
High-strength steel or chromoly frame providing rigidity and impact absorption.
Handguards:
Standard on TE/TC models for hand protection from roost and impacts.
Infotainment Features:
Minimal on these performance-oriented models. Primarily focused on essential rider information.
Driver Assistance Systems:
None in the modern automotive sense. Focus is on rider control and machine feedback.
Connectivity Features:
None.
Instrument Panel:
Digital or Analog/Digital combination LCD display providing speed, odometer, trip meter, engine hour meter, neutral indicator, turn signals (on street-legal models), and warning lights.
Oil Change Interval:
Typically every 10-15 hours of riding for off-road use, or as specified in the manual. For SM models, could be closer to street bike intervals.
Air Filter Cleaning:
Frequent cleaning/replacement recommended, especially in dusty conditions. Daily or every few rides.
Spark Plug Inspection:
Inspect and gap every 20-30 hours of riding. Manual will specify recommended plug type and gap.
Valve Clearance Check:
Critical maintenance item. Typically every 50-100 hours of riding. Manual provides exact intervals and procedures.
Chain And Sprockets:
Regular cleaning, lubrication, and adjustment (tension). Replacement based on wear. Manual details procedures.
Engine Oil Viscosity:
Typically 10W-40 or 15W-50, depending on ambient temperature. Manual is the definitive source.
Coolant Type:
Ethylene Glycol based coolant (50/50 mix with distilled water). Manual specifies type and mixture ratio.
Brake Fluid Type:
DOT 4 or DOT 5.1 Hydraulic Brake Fluid. Manual specifies the exact type.
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, fork seals, swingarm pivot bearings due to off-road stress.
Engine Considerations:
Valve adjustment is crucial to prevent seating damage. Regular oil analysis can help detect early wear in critical components.
Electrical Quirks:
Wiring harness integrity is important for off-road vibrations. Manual's wiring diagrams are essential for troubleshooting.
Brand Origin:
Husqvarna is one of the oldest motorcycle manufacturers in the world, founded in Sweden in 1689, originally producing firearms. It began producing motorcycles in 1903.
Off Road Focus:
Husqvarna has a strong legacy in off-road racing, including motocross and enduro. The TE and TC lines are direct descendants of this heritage.
Supermoto Development:
The SM models represent Husqvarna's expansion into the street-legal supermoto segment, adapting their off-road platforms for road use with different suspension, brakes, and tires.
Manufacturing Era:
These models were produced during a period when Husqvarna was under Italian ownership (Cagiva Group) before being acquired by BMW Motorrad.
