Target User:
Owners of Husqvarna TC 250, TC 450, TC 510 motorcycles from 2007-2008 seeking in-depth repair and maintenance guidance.
Value Proposition:
Provides factory-level technical information to empower owners and independent shops to perform complex repairs and maintenance accurately, reducing reliance on expensive dealership services.
Content Breadth:
Covers the full spectrum of servicing, from routine checks to complete engine overhauls.
Diagnostic Focus:
Emphasis on systematic troubleshooting and diagnostic procedures.
Primary Focus:
Mechanical, electrical, and body repair for TC 250, TC 450, TC 510 models
Geographic Applicability:
Global (based on common service procedures, may vary by regional specification)
Estimated Pages:
Extensive (typically 500+ pages for comprehensive manuals of this era)
Type:
Workshop Repair Manual
Language:
English (typically)
Engine:
Complete engine disassembly, assembly, tuning, diagnostics, troubleshooting for all specified displacements.
Fuel System:
Carburetor (if applicable) or Fuel Injection system service, cleaning, adjustment, component testing, diagnostics.
Ignition System:
Spark plug, coil, ECU, and sensor testing and replacement procedures.
Transmission:
Clutch service, gearbox inspection, maintenance, and overhaul for the specific models.
Cooling System:
Radiator, hoses, thermostat, water pump service and leak testing.
Exhaust System:
Exhaust pipe, muffler, and catalytic converter (if applicable) inspection and replacement.
Suspension:
Front fork (telescopic), rear shock absorber, linkage service, adjustments, and component replacement.
Brakes:
Hydraulic brake system (front and rear), caliper, master cylinder, brake lines, rotor, and pad service and bleeding procedures.
Wheels And Tires:
Wheel bearing service, tire installation and balancing, spoke tensioning (if applicable).
Steering:
Handlebar, steering stem, and steering bearing inspection and service.
Electrical System:
Wiring diagrams, battery, lighting system, starter motor, charging system, fuses, and relays.
Bodywork:
Fairings, seat, fuel tank, fenders, and plastic component removal, installation, and repair.
Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, chain adjustment, general inspection checklists.
Troubleshooting:
Diagnostic flowcharts, common problems and their solutions, error code interpretation (if applicable).
Repair:
Step-by-step instructions for component removal, repair, and reinstallation for all major systems.
Rebuild:
Detailed procedures for engine and major component rebuilds.
Diagnostics:
Guidance on diagnosing electrical and mechanical faults.
Level:
Comprehensive workshop level, suitable for professional mechanics and advanced DIY enthusiasts.
Detail Level:
Includes torque specifications, tolerances, special tool requirements, and detailed diagrams.
Illustrations:
Richly illustrated with clear line drawings and exploded views.
Engine Type:
Single-cylinder, 4-stroke, liquid-cooled (typical for these models)
Bore X Stroke:
Varies by model (e.g., TC 250: ~76 x 54.8 mm; TC 450: ~97 x 60.8 mm; TC 510: ~98 x 71.8 mm - refer to manual for exact specifications)
Displacement:
250cc, 450cc, 510cc
Horsepower:
Varies by model and tune (e.g., TC 250 ~35-40 HP, TC 450 ~45-50 HP, TC 510 ~50-55 HP - refer to manual for precise figures)
Torque:
Varies by model and tune (refer to manual for precise figures)
Fuel Delivery:
Carburetor (likely Keihin FCR variants) or Electronic Fuel Injection (EFI) depending on specific sub-model and market.
Fuel Type:
Unleaded gasoline (Octane rating specified in manual)
Type:
DOHC (Double Overhead Camshaft), 4 valves per cylinder
System:
Wet sump, with separate oil for gearbox/clutch (common in Husqvarnas of this era).
Capacity:
Varies by model (e.g., ~1.1-1.5 liters - consult manual for exact figure and oil separation)
Length:
Varies by model (refer to manual for exact specifications)
Width:
Varies by model (refer to manual for exact specifications)
Height:
Varies by model (refer to manual for exact specifications)
Dry Weight:
Varies by model (e.g., TC 250 ~105 kg, TC 450 ~110 kg, TC 510 ~112 kg - refer to manual for exact figures)
Wet Weight:
Varies by model and fluids (refer to manual for exact figures)
Tank Capacity:
Typically around 7-8 liters for these models (consult manual for precise figure)
Safety Ratings:
Not applicable to off-road competition motorcycles in terms of traditional automotive crash ratings.
Braking System:
High-performance hydraulic disc brakes front and rear, designed for off-road use.
Suspension Performance:
Advanced adjustable suspension systems (e.g., Kayaba or Marzocchi forks, Sachs or Öhlins rear shocks) for optimal control and stability.
Frame Construction:
Robust steel or aluminum alloy frame designed for durability and handling.
Handguards:
Standard on most models for hand protection.
Infotainment System:
None (basic motocross/off-road bike, typically no integrated infotainment features).
Assistance Features:
None (designed for pure off-road riding, no rider aids like ABS or traction control common on street bikes).
Connectivity Features:
None (basic electronics for ignition, lighting, and instrumentation only).
Dashboard:
Digital or analog instrument cluster with speedometer, odometer, trip meter, and indicator lights (refer to manual for specific display functions).
Oil Change Interval:
Typically every 15-20 hours of riding or annually (refer to manual for exact specification and conditions).
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (after every few rides).
Chain Lubrication:
Recommended after every ride or as needed, depending on conditions.
Valve Clearance Check:
Typically every 50-100 hours of riding (refer to manual for specific interval and procedure).
Engine Oil Grade:
Refer to manual for recommended oil viscosity (e.g., 10W-40 or 15W-50) and specific motorcycle oil formulation.
Coolant Type:
Ethylene glycol-based antifreeze and distilled water mixture (typically 50/50 ratio - consult manual).
Brake Fluid Type:
DOT 4 hydraulic brake fluid (consult manual for specific type and DOT rating).
Common Wear Items:
Clutch plates, brake pads, wheel bearings, swingarm/linkage bearings, fork seals, piston rings, and valve guides are common wear items on performance off-road motorcycles.
Electrical Gremlins:
Older wiring harnesses can develop issues with corrosion or loose connections, particularly in off-road environments. Manual will cover troubleshooting these.
Brand Origin:
Husqvarna Motorcycles, a Swedish brand with a long history dating back to 1903, known for its off-road prowess.
Model Lineage:
The TC (Cross-Country) line has been a cornerstone of Husqvarna's motocross and enduro offerings, evolving significantly with engine sizes and chassis updates throughout the years.
Manufacturing Era:
2007-2008 models represent a specific generation of Husqvarna's off-road motorcycles, often developed under BMW ownership (which acquired Husqvarna in 2007). These bikes were known for their Italian design influence and competitive performance.
