Segment:
High-performance off-road motorcycle, dual-sport (enduro) category.
Target Audience:
Enduro riders, off-road enthusiasts, and owners requiring in-depth technical information for maintenance and repair.
Key Competitors:
KTM EXC series (e.g., 450 EXC), Yamaha WR450F, Honda CRF450X, Suzuki RM-Z450 (dual-sport variants if applicable), Kawasaki KLX450R.
Engine Type:
Liquid-cooled, 4-stroke, single-cylinder.
Frame Type:
Perimeter steel frame, designed for rigidity and handling in off-road conditions.
Suspension Type:
Long-travel, adjustable upside-down front forks and monoshock rear suspension, optimized for off-road terrain.
Styling:
Aggressive, functional enduro styling with emphasis on rider protection and off-road capability.
Main Coverage:
Comprehensive service, repair, maintenance, and troubleshooting for Husqvarna TE450 motorcycles.
Diagnostic Coverage:
Includes diagnostic procedures for common issues and fault finding.
Electrical Coverage:
Detailed electrical system schematics, component testing, and troubleshooting.
Estimated Pages:
Likely over 300 pages (typical for comprehensive workshop manuals of this era).
Type:
Workshop Service Repair Manual
Format:
Digital (likely PDF), printable
Engine:
Complete engine overhaul, top-end, bottom-end, piston, rings, valves, camshafts, timing, lubrication system, cooling system.
Fuel System:
Carburetor (likely Keihin FCR MX) disassembly, cleaning, adjustment, fuel pump, fuel lines, tank, filter.
Transmission:
Gearbox disassembly, inspection, lubrication, clutch assembly, operation, service.
Chassis Frame:
Frame inspection, welding points, steering head bearings, footpegs, subframe.
Suspension:
Front fork (Marzocchi or Sachs), rear shock absorber (Paioli or Sachs), seals, oil, springs, adjustments, rebuild procedures.
Brakes:
Front and rear brake systems, caliper service, master cylinder, brake lines, pads, discs, bleeding procedures.
Electrical System:
Ignition system, lighting, starter motor, battery, wiring diagrams, ECU (if applicable), sensors.
Cooling System:
Radiator, hoses, coolant, fan (if equipped), water pump service.
Exhaust System:
Exhaust pipe, muffler, heat shields, mounting.
Wheels Tires:
Wheel bearing service, spoke tensioning, tire fitting, rim maintenance.
Maintenance:
Regular scheduled maintenance, fluid changes, filter replacements, lubrication points.
Troubleshooting:
Diagnostic flowcharts, common problem identification, solutions for starting issues, running problems, electrical faults.
Repair:
Step-by-step instructions for disassembly, assembly, and repair of all major components.
Overhaul:
Detailed procedures for complete engine and gearbox rebuilds.
Adjustments:
Carburetor tuning, suspension setup, clutch and throttle cable adjustments.
Torque Specifications:
All critical fastener torque values for engine, chassis, and other components.
Depth:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic maintenance to full engine rebuilds.
Diagnostic Level:
Advanced diagnostic procedures and component testing.
Type:
Four-stroke, single-cylinder, SOHC (Single Overhead Camshaft), 4-valve (typical configuration for this era).
Displacement:
449.7 cc (Cubic Centimeters)
Bore X Stroke:
Approx. 95 mm x 63.4 mm (actual figures may vary slightly based on source, but this is a common dimension for this engine.
Compression Ratio:
Likely around 11.5:1 to 12.5:1 (typical for performance-oriented off-road engines).
Horsepower:
Estimated 40-45 HP (at crankshaft), depending on specific tuning and market regulations.
Torque:
Estimated 40-45 Nm (Newton-meters).
Carburetor:
Keihin FCR MX 39mm (common carburetor for this model and performance level).
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON).
Type:
Digital CDI (Capacitor Discharge Ignition) with variable ignition timing.
Type:
Constant mesh, 6-speed sequential manual transmission.
Clutch:
Wet, multi-plate, hydraulic actuation.
Final Drive:
O-ring sealed chain drive, 520 pitch.
Gear Ratios:
Refer to manual for specific gear ratios (e.g., 1st: 2.46, 2nd: 1.75, 3rd: 1.38, 4th: 1.15, 5th: 1.0, 6th: 0.86 - approximate values).
Transmission Fluid:
Refer to manual for specific API GL-4 or GL-5 gear oil specification (e.g., 10W-40 motorcycle gear oil or equivalent).
Length:
Approx. 2230 mm (87.8 in)
Width:
Approx. 810 mm (31.9 in) at handlebars
Height:
Approx. 1250 mm (49.2 in) at handlebars
Wheelbase:
Approx. 1470 mm (57.9 in)
Ground Clearance:
Approx. 340 mm (13.4 in)
Dry Weight:
Approx. 116 kg (255.7 lbs) - note that dry weight can vary slightly by specification.
Wet Weight:
Refer to manual; typically around 125-130 kg with all fluids.
Fuel Tank Capacity:
Approx. 7.0 liters (1.85 US gal)
Oil Change:
Every 15-20 hours of riding or annually, whichever comes first. Refer to manual for precise intervals based on usage.
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions. Crucial for engine longevity.
Spark Plug Inspection:
Every 20-30 hours of riding.
Valve Clearance Check:
Every 50-75 hours of riding. Critical for performance and engine health.
Engine Oil:
SAE 10W-40, API SG or higher, JASO MA certified (e.g., Motul 3000 10W-40).
Coolant:
Mixture of distilled water and ethylene glycol-based antifreeze (50/50 ratio). Refer to manual for specific coolant type.
Brake Fluid:
DOT 4 or DOT 5.1 hydraulic brake fluid. Always use fresh fluid.
Carburetor Jetting:
May require re-jetting for altitude changes or aftermarket exhaust/air filter modifications for optimal performance and reliability.
Clutch Actuation:
Hydraulic clutch system can be prone to air ingress; regular bleeding ensures smooth operation.
Suspension Seals:
Fork and shock seals can wear over time, particularly with hard off-road use, leading to oil leaks.
Timing Chain Tensioner:
Some models may benefit from checking and maintaining the automatic cam chain tensioner for consistent performance.
Heritage:
Husqvarna Motorcycles has a long and storied history dating back to Sweden in 1903, initially producing motorcycles, then expanding to other products. It is one of the oldest motorcycle manufacturers in the world.
Te Series:
The TE series represents Husqvarna's commitment to the enduro and off-road racing segment. The TE450 has seen continuous development and updates over the years, with the 2007-2008 models falling into a period of significant technological advancement under BMW ownership, leading to improved chassis dynamics and engine performance.
Production Period:
The TE450 model has been in production for many years, with specific iterations like the 2007-2008 models representing distinct technological phases.
Manufacturing Location:
Primarily manufactured in Italy during the BMW ownership era, though Husqvarna has origins in Sweden.
