HUSQVARNA TE 400 Service Repair Manual 2001-2002

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🏷️ Basic Information Identification Make: Husqvarna Model: TE 400 Year: 2001-2002 Generation Model Generation: First Generation (pre-2004 redesign) Codes Engine Code: Likely based on a Rotax or similar platform, specific...

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Taper: Motorcycle

Distributeur:

UGS: 268014

Mots clés: 2001 2002 Husqvarna Motorcycle Motorcycles TE 400 TE Models

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

TE 400

Year:

2001-2002

Generation

Model Generation:

First Generation (pre-2004 redesign)

Codes

Engine Code:

Likely based on a Rotax or similar platform, specific codes not provided but typically alphanumeric (e.g., 5420)

👋 Introduction

Market Position

Vehicle Segment:

Dual-sport / Enduro motorcycle

Target Audience:

Off-road enthusiasts, dual-sport riders, technical maintenance users

Competitive Analysis

Key Competitors:

KTM EXC series, Yamaha WR series, Honda XR series, Suzuki DR-Z series

Key Features

Vehicle Philosophy:

Lightweight, agile off-road performance with street-legal capability

Manual Value Proposition:

Empowers owners to perform extensive maintenance and repairs, saving costs and ensuring optimal performance

📋 Manual Details

Coverage Areas

Model Years Covered:

2001, 2002

Regions Covered:

Global (technical specifications are generally universal)

Page Count

Estimated Page Count:

Hundreds (specific count not provided, typical for a comprehensive service manual)

Manual Type

Manual Type:

Service Repair Manual

Primary Purpose:

Repair, Maintenance, Rebuilding, Refurbishing, Restoration

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine Mechanics:

Complete overhaul, internal components, valve train, piston, crankshaft, connecting rod, lubrication system

Fuel System:

Carburetor(s) (likely Mikuni or Keihin), fuel pump, fuel lines, tank maintenance

Ignition System:

CDI unit, ignition coil, spark plug, wiring, timing procedures

Cooling System:

Radiator, fan, hoses, thermostat, coolant specifications, flushing procedures

Transmission Drivetrain:

Gearbox internals, clutch operation, shifting mechanism, chain and sprocket maintenance, lubrication

Suspension Front:

Fork disassembly, seal replacement, oil type and level, damping adjustments, steering head bearings

Suspension Rear:

Shock absorber servicing, linkage maintenance, bearing lubrication, spring pre-load adjustments

Brakes Front:

Caliper service, pad replacement, rotor inspection, hydraulic fluid type and bleeding, master cylinder

Brakes Rear:

Caliper service, pad replacement, rotor inspection, hydraulic fluid type and bleeding, master cylinder

Electrical System:

Wiring diagrams, lighting systems, battery maintenance, starter motor, charging system, fuses, relays

Chassis Frame:

Frame inspection, footpeg mounts, subframe, swingarm maintenance, bearing checks

Bodywork Plastics:

Fairing removal and installation, seat, fender components, fuel tank mounting

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustments, air filter cleaning, spark plug checks, lubrication points

Troubleshooting:

Diagnostic flowcharts, symptom-based problem solving, common issues and solutions

Engine Rebuild:

Complete engine disassembly, inspection, part replacement, torque specifications, reassembly procedures

Suspension Service:

Fork oil change and level setting, seal replacement, shock absorber rebuild (where applicable)

Brake System Overhaul:

Brake bleeding, pad and rotor replacement, caliper and master cylinder servicing

Electrical Diagnostics:

Fault finding for ignition, charging, and lighting systems using wiring diagrams

Carburetor Tuning:

Jetting changes, float height adjustment, idle speed and mixture control

Wheel And Tire Service:

Tire changes, spoke tensioning, bearing lubrication, wheel balancing (where applicable)

Torque Specifications:

Detailed torque values for all critical fasteners

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to complete engine and chassis rebuilds)

Diagnostic Capabilities:

Advanced diagnostic procedures for mechanical and electrical issues

Rebuild Procedures:

Detailed step-by-step instructions for major component rebuilds

📊 Manual Specifications

File Format

File Type:

Digital (PDF)

Searchability:

Likely text-searchable (standard for professionally produced PDFs)

Print Quality

Printability:

Printable pages for workshop use

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Quality:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder

Displacement:

Approximately 373 cc (exact specification may vary slightly by region/variant)

Bore X Stroke:

Typically around 84 mm x 68 mm (exact figures to be confirmed in manual)

Cooling System:

Liquid-cooled

Valve Train:

SOHC, 4 valves

Performance

Horsepower Estimate:

Likely in the range of 30-35 HP (subject to tuning and specific market regulations)

Torque Estimate:

Estimated 25-30 Nm (subject to tuning and specific market regulations)

Fuel System

Carburetor Model:

Likely Mikuni TM40 or similar 40mm flat slide carburetor

Fuel Type:

Unleaded gasoline

🔧 Transmission

Standard

Transmission Type:

6-speed manual

Optional

Optional Transmission:

N/A (Standard for this model)

Features

Clutch Type:

Wet multi-plate

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approximately 2200-2300 mm (typical for this class)

Width:

Approximately 850-900 mm (handlebar width)

Height:

Approximately 1250-1300 mm (seat height and handlebars)

Wheelbase:

Approximately 1470-1500 mm

Ground Clearance:

Typically over 300 mm

Weights

Dry Weight:

Approximately 120-130 kg

Wet Weight:

Approximately 135-145 kg (with fluids)

Fuel Tank Capacity:

Approximately 9-12 Liters (depending on variant)

Seat Height:

Approximately 950-970 mm

🛡️ Safety Features

Ratings

Safety Certification:

Meets street-legal requirements in applicable markets (e.g., DOT, ECE)

Active Features

Brakes:

Hydraulic disc brakes front and rear

Lighting:

Headlight, taillight, brake light, turn signals (street legal variants)

Passive Features

Frame Construction:

Chromoly steel frame for strength and impact resistance

Handguards:

Standard on many models for hand protection

💡 Technology Features

Infotainment

Infotainment System:

Basic instrumentation: speedometer, odometer, trip meter, engine warning light (no advanced infotainment)

Driver Assistance

Driver Assistance Features:

None (focus on rider control and mechanical systems)

Connectivity

Connectivity Options:

None (mechanical motorcycle)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 1500-3000 km or 6 months, refer to manual for exact intervals

Air Filter Cleaning:

Every 500-1000 km or as needed in dusty conditions

Spark Plug Replacement:

Every 3000-6000 km or as recommended

Valve Clearance Check:

Typically every 6000-10000 km

Fluid Specifications

Engine Oil Type:

High-quality 4-stroke motorcycle oil, SAE 10W-40 or 15W-50, meeting JASO MA or MA2 specification (verify in manual)

Engine Oil Capacity:

Approximately 1.5 - 1.8 Liters (with filter change, verify in manual)

Coolant Type:

Ethylene glycol-based antifreeze coolant mixture (50/50 with distilled water, verify in manual)

Brake Fluid Type:

DOT 4 hydraulic brake fluid (verify in manual)

Fork Oil Type:

Specific viscosity motorcycle fork oil, typically SAE 5W or 10W (verify in manual)

Known Issues

Common Wear Items:

Clutch plates, chain and sprockets, wheel bearings, steering head bearings, fork seals

Potential Issues:

Carburetor jetting sensitivity to altitude/temperature, occasional electrical connector corrosion, starter solenoid issues

📚 Vehicle History

Brand Heritage

Brand Origin:

Swedish, known for high-performance off-road motorcycles and power equipment

Off Road Legacy:

Long history in motocross and enduro racing

Model Evolution

Predecessor Models:

TE 410, TE 510 (sharing platform characteristics)

Successor Models:

Husqvarna TE 450 (later iterations)

Production

Manufacturing Location:

Likely Italy or Sweden during this period, under Italian ownership (Husqvarna was owned by Cagiva Group)

Production Period:

The TE 400 was part of a range of dual-sport and enduro bikes from Husqvarna in the early 2000s.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Not specifically documented for this model year, but Husqvarna consistently earned praise in off-road circles for performance.

Ratings

Performance Ratings:

Generally rated highly for off-road capability, suspension performance, and engine power delivery in its class.

Certifications

Emissions Certification:

Meets emissions standards for its respective model year and region.