Model:
TC450, TC510, TXC250, TXC450, TXC510, TE250, TE310, TE450, TE510, SMR450, SMR510
Tc450 Serial Prefix:
ZKHA202AA9V050001
Tc510 Serial Prefix:
ZKHA203AA9V050001
Tc450 Usa Serial Prefix:
ZKHTC450*9V100000
Tc510 Usa Serial Prefix:
ZKHTC510*9V100000
Te250 Serial Prefix:
ZKHA200AA9V000001
Te310 Serial Prefix:
ZKHA204AA9V000001
Te450 Serial Prefix:
ZKHA202AA9V000001
Te510 Serial Prefix:
ZKHA203AA9V000001
Te250 Usa Serial Prefix:
ZKHKBECF*9V100001
Te310 Usa Serial Prefix:
ZKHKBEDF*9V100001
Te450 Usa Serial Prefix:
ZKHKBEFF*9V100000
Te510 Usa Serial Prefix:
ZKHKBEHF*9V100000
Txc250 Usa Serial Prefix:
ZKHTX250*9V000001
Txc450 Usa Serial Prefix:
ZKHTX450*9V000001
Txc510 Usa Serial Prefix:
ZKHTX510*9V000001
Smr450 Serial Prefix:
ZKHA202AB9V000001
Smr510 Serial Prefix:
ZKHA203AB9V000001
Models Covered:
TC450, TC510, TXC250, TXC450, TXC510, TE250, TE310, TE450, TE510, SMR450, SMR510
Production Years Covered:
2009
Regions Covered:
Includes variations for USA market models where applicable (e.g., USA serial number prefixes, specific electrical component listings).
Type:
Service Repair Manual
Viewing Requirements:
Adobe PDF Reader
Compatibility:
Windows, Mac, Linux OS, iPhone, iPad, Android
Engine And Drivetrain:
Cylinder, Piston, Cylinder Head, Crankshaft, Primary Drive, Clutch, Valve Timing, L.H. Half Crankcase, R.H. Half Crankcase, R.H. Half Crankcase Covers, L.H. Half Crankcase Covers, Oil Pump, Carburetor (Keihin for TC/TXC), Mikuni Throttle Body (for TE/SMR), Ignition System, Starting System, Transmission, Shifter (TC specific), Transmission, Shifter (TE/TXC/SMR specific)
Chassis And Suspension:
Cooling System, Air Filter, Frame, Foot Rests, Front Fork Assembly (TE/SMR), Front Fork Assembly (TC/TXC), Rear Swing Arm, Rear Shock Absorber, Rear Suspension Linkage, Handlebar and Controls, Rear Hydraulic Brake, Front Hydraulic Brake (TE/TC/TXC), Front Hydraulic Brake (SMR), Front Wheel (TE/TC/TXC), Front Wheel (SMR), Rear Wheel
Electrical And Bodywork:
Digital Instrument, Blinkers, Horn (TE/SMR), Main Wiring Harness, Electrical Parts (TC/TXC/TE-USA), Main Wiring Harness, Lights, Electrical Parts (TE-SMR), Side Panels, Fenders, Seat, Plate Holder, Gas Tank, Panels, Exhaust System (TE/TC/TXC), Exhaust System (SMR), Transfer (TE - color code G), Transfer (TC/TXC - color code G), Transfer (SMR - color code G), Canister (TE-SMR / USA)
Exhaust Systems:
Covers both standard TE/TC/TXC exhaust systems and specific SMR exhaust systems, likely detailing mounting, baffles, and any necessary heat shielding.
Repair And Rebuild:
Complete tear down and rebuild procedures, detailed step-by-step instructions based on complete disassembly
Maintenance:
Routine maintenance, service schedules, fluid checks and changes
Troubleshooting:
Diagnostic procedures, fault finding and rectification
Technical Specifications:
Torque specifications, wiring schematics, detailed illustrations and diagrams, part diagrams
Special Tools:
Manual lists required service tools for specific procedures, such as engine assembly tools, suspension tools, and diagnostic equipment.
Parts Diagrams:
Provides visual part diagrams for all major assemblies, crucial for identification and ordering correct replacement components.
Depth:
Comprehensive diagnostic and repair procedures, suitable for both do-it-yourselfers and experienced mechanics
Wiring Diagrams:
Includes detailed wiring harnesses and electrical parts diagrams for TC, TXC, TE (USA), and TE/SMR models.
Engine Type:
Single-cylinder, 4-stroke (likely SOHC, though specific details vary by model displacement)
Cooling System:
Liquid-cooled (radiator and fan system typical for these models)
Ignition System:
Electronic ignition (details on CDI unit and components provided)
Displacement Range:
250cc to 510cc (covering TE250, TE310, TXC250, TC450, TXC450, SMR450, TC510, TE450, TE510, TXC510, SMR510)
Carburetion Or Injection:
Carburetor (Keihin for TC/TXC models), Throttle Body (Mikuni for TE/SMR models) - specific details would be in manual
Oil Change Interval:
Typically every 10-15 engine hours or annually, as detailed in the manual.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (every few rides), as per manual guidance.
Engine Oil Type:
Full synthetic 4-stroke motorcycle oil, SAE 10W-50 or 15W-50 typically recommended (verify specific viscosity and API rating in manual).
Coolant Type:
Ethylene glycol-based coolant mixed with distilled water (50/50 ratio) recommended.
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid (verify specific type and DOT rating in manual).
Transmission Oil Type:
SAE 75W/90 or SAE 80W/90 gear oil (verify specific type and API rating in manual).
Common Wear Items:
Clutch plates, piston rings, valve guides, wheel bearings, chain and sprockets are common wear items on high-performance off-road motorcycles.
Electrical Connections:
Corrosion or loose connections in off-road environments can sometimes affect lighting or ignition systems.