HUSQVARNA TC 250 450 510 Service Repair Manual 07

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🏷️ Basic Information Identification Make: Husqvarna Model: TC Year: 2007 Engine Variants: 250cc, 450cc, 510cc Codes Product Identifier: HUSQVARNA_TC_250_450_510_Service_Repair_Manual_07 👋 Introduction Market Position Segment: High-performance motocross/off-road motorcycles Target Audience: Motocross...

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UGS: 267732

Mots clés: 2007 Husqvarna Motorcycle Motorcycles TC 250 TC 450 TC 510 TC Models

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

Year:

Engine Variants:

250cc, 450cc, 510cc

Codes

Product Identifier:

HUSQVARNA_TC_250_450_510_Service_Repair_Manual_07

👋 Introduction

Market Position

Segment:

High-performance motocross/off-road motorcycles

Target Audience:

Motocross racers, off-road enthusiasts, mechanics, DIY repairers

Competitive Analysis

Competitors 2007:

KTM EXC series, Yamaha WR series, Honda CRF-X series, Kawasaki KX-F series, Suzuki RM-Z series

Key Features

Performance Focus:

Emphasis on engine power delivery, handling, and suspension performance for competitive riding

Manual Utility:

Enables owners to perform all necessary maintenance and repairs, reducing reliance on external workshops.

📋 Manual Details

Coverage Areas

Engine:

Complete overhaul, component diagnosis, tuning, fuel system, lubrication, cooling

Transmission:

Clutch, gearbox, shift mechanism, lubrication

Chassis:

Frame, suspension (front and rear), steering, wheels, tires, brakes

Electrical System:

Ignition, lighting, charging system, starter, wiring diagrams, sensors

Bodywork:

Fairings, seat, fuel tank, handlebars, footpegs, plastics

Maintenance:

Scheduled service, fluid changes, filter replacement, lubrication points

Troubleshooting:

Diagnostic charts, symptom analysis, common problems and solutions

Page Count

Number Of Pages:

Hundreds

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Systems:

Top-end rebuild (cylinder head, piston, valves), bottom-end rebuild (crankshaft, connecting rod, bearings), cylinder block, cam timing, valve clearance adjustment

Fuel And Emission Systems:

Carburetor overhaul and adjustment (specific to engine variant), fuel pump, fuel filter, emissions control components

Ignition System:

Ignition coil testing, spark plug specifications, CDI unit diagnosis, timing adjustment

Cooling System:

Radiator maintenance, coolant type and capacity, water pump inspection, thermostat operation

Transmission And Drivetrain:

Clutch operation and adjustment, gear selection linkage, transmission lubrication, chain maintenance and adjustment

Suspension System:

Front fork service (oil change, seal replacement, spring preload), rear shock absorber maintenance, linkage lubrication

Braking System:

Brake fluid type and replacement schedule, caliper overhaul, pad replacement, rotor inspection, bleeding procedure

Electrical And Lighting:

Headlight, taillight, brake light operation, wiring harness inspection, battery maintenance, fuse identification

Frame And Bodywork:

Handlebar removal and installation, seat removal, fuel tank mounting, fender replacement, decal application

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, spark plug inspection, chain lubrication, tire pressure checks

Engine Repair:

Complete engine disassembly and reassembly, piston ring replacement, valve stem seal replacement, gasket replacement

Transmission Repair:

Gearbox disassembly and inspection, shift drum and fork alignment, clutch plate replacement

Suspension Rebuild:

Front fork seal and oil replacement, rear shock absorber servicing, linkage bearing inspection and greasing

Brake System Maintenance:

Brake fluid flush and bleed, brake pad and disc replacement, caliper seal replacement

Electrical Diagnostics:

Wiring diagram interpretation, fault finding for ignition and charging systems, component testing

Carburetor Tuning:

Jetting adjustments, idle speed settings, mixture screw adjustments for optimal performance

Troubleshooting Guides:

Step-by-step guides for diagnosing common engine, transmission, and electrical issues

Technical Depth

Depth:

Comprehensive (from basic maintenance to full engine rebuild)

Detail Level:

Detailed step-by-step instructions with clear diagrams and specifications

Diagnostic Capability:

Advanced diagnostic procedures for identifying complex faults

Rebuild Scope:

Full component rebuilds, including engine internals, gearbox, and suspension units

📊 Manual Specifications

File Format

Format:

Portable Document Format (PDF)

Searchability:

Text-searchable for quick information retrieval

Print Quality

Printability:

Optimized for printing of individual pages or sections

Image Resolution:

High-resolution images and diagrams for clarity

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Type 250:

Single-cylinder, four-stroke

Engine Type 450:

Single-cylinder, four-stroke

Engine Type 510:

Single-cylinder, four-stroke

Performance

Horsepower 250 Approx:

35-40 HP (estimated, varies by tuning)

Horsepower 450 Approx:

45-50 HP (estimated, varies by tuning)

Horsepower 510 Approx:

50-55 HP (estimated, varies by tuning)

Torque Bands:

Designed for strong mid-range and top-end power delivery

Fuel System

Carburetor Type:

Mikuni VM Series (typical for the era, specific model varies)

Fuel Type:

Unleaded gasoline, premium octane recommended

Lubrication

Oil Type:

High-performance motorcycle-specific 4-stroke engine oil (e.g., Motul 300V, Bel-Ray EXS)

Oil Capacity Approx 250:

Approx. 1.5 - 1.7 Liters (check manual for exact)

Oil Capacity Approx 450 510:

Approx. 1.7 - 1.9 Liters (check manual for exact)

Cooling

Cooling Method:

Liquid-cooled

Coolant Type:

Mixture of distilled water and antifreeze (ethylene glycol-based)

🔧 Transmission

Standard

Gearbox:

5-speed constant mesh

Optional

Transmission Options:

N/A (Standard 5-speed gearbox)

Features

Clutch Type:

Wet, multi-plate, hydraulic actuation

Final Drive:

Chain drive

Transmission Fluid

Gearbox Oil Type:

Motorcycle-specific gear oil or shared engine oil (check manual for exact system)

📐 Dimensions

Exterior

Wheelbase Approx:

Approx. 1470-1480 mm (varies by model)

Seat Height Approx:

Approx. 950-960 mm (varies by model)

Weights

Dry Weight Approx 250:

Approx. 102 kg (varies by model)

Dry Weight Approx 450:

Approx. 107 kg (varies by model)

Dry Weight Approx 510:

Approx. 110 kg (varies by model)

Fuel Tank Capacity Approx:

Approx. 7.5 - 8.5 Liters

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Off-road motorcycles are not subject to typical road vehicle safety ratings like NHTSA or Euro NCAP)

Active Features

Braking System:

Hydraulic disc brakes front and rear for effective stopping power

Suspension Stability:

Performance-oriented suspension provides stability and control over varied terrain

Passive Features

Frame Strength:

Robust chassis design for durability and rider protection

💡 Technology Features

Infotainment

Infotainment System:

N/A (Pure performance off-road motorcycle, no infotainment features)

Driver Assistance

Driver Assistance Features:

N/A (No electronic rider aids like ABS or traction control on this model year)

Connectivity

Connectivity Features:

N/A (No onboard electronics beyond basic engine management and lighting)

🔧 Maintenance

Service Intervals

Engine Oil Change Interval:

Every 10-15 hours of riding or annually, whichever comes first (refer to manual for specific usage scenarios)

Air Filter Cleaning Interval:

After every few rides or immediately after dusty conditions

Chain Lubrication Interval:

Every 5-10 hours of riding, or as needed based on conditions

Valve Clearance Check Interval:

Every 20-30 hours of riding (critical for performance and longevity)

Fluid Specifications

Brake Fluid Type:

DOT 4 or DOT 5.1 (check manual for specific recommendation)

Coolant Mixture Ratio:

50/50 distilled water and antifreeze

Known Issues

Common Wear Items:

Clutch plates, piston rings, valve guides, wheel bearings, steering head bearings, fork seals

Carburetor Issues:

Can be prone to clogging if fuel is not kept clean or if the bike sits for extended periods without fuel stabilizer

Electrical System Durability:

Wiring harnesses can be subject to vibration and stress; proper routing and securing are important.

📚 Vehicle History

Brand Heritage

Brand Origin:

Swedish, known for quality and performance in outdoor power equipment and motorcycles.

Model Evolution

Tc Lineup Context:

The TC line represents Husqvarna's commitment to competitive motocross and off-road racing, building on a legacy of innovation.

Production

Manufacturing Location:

Historically Sweden, with manufacturing often shifting or shared within European facilities in later years.

🏆 Awards & Recognition

Recognitions

Motorcycle Awards Context:

While specific awards for this exact model and year might not be widely publicized, Husqvarna's motocross and enduro models consistently receive positive reviews for performance and handling from specialized off-road publications.

Ratings

Performance Reviews:

Generally praised for strong engines, capable suspension, and agile handling characteristics for their class.

Certifications

Engine Certification:

Meets emissions standards applicable to off-road vehicles in its market of sale for the 2007 model year.