Husqvarna TE250 TE450 TE510 2007 2008 Factory Service Repair Manual

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Taper: Motorcycle

Distributeur:

UGS: 102460

Mots clés: 2007 2008 Husqvarna Misc Motorcycle Motorcycles TE250 TE450 TE510

Variantes de produits

Description

This manual covers the TE Series motorcycles, specifically the TE250, TE450, and TE510 models produced in 2007 and 2008. These competition enduro motorcycles are renowned for their robust performance and off-road capabilities, building on a long heritage in motorcycle manufacturing, which originated in Sweden. Engineered for demanding terrain, these models feature liquid-cooled, 4-stroke engines with displacements of approximately 249.5 cc for the TE250, 449.5 cc for the TE450, and 501 cc for the TE510. Each is equipped with a 6-speed transmission and a wet multi-plate clutch, designed to provide reliable power delivery and control in competitive enduro riding scenarios. This comprehensive factory service repair manual provides detailed information essential for the maintenance and repair of your TE motorcycle. It encompasses a wide range of topics, including complete engine disassembly and assembly, fuel system adjustments, ignition system diagnostics, cooling system servicing, transmission and drivetrain maintenance, and detailed procedures for front and rear suspension and brake systems. Additionally, the manual covers electrical system troubleshooting, chassis and frame inspection, bodywork, and routine maintenance tasks such as oil changes and filter replacements. With step-by-step instructions, high-resolution diagrams, and precise technical specifications, this manual serves as an indispensable resource for owners and technicians to ensure the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

TE Series (TE250, TE450, TE510)

Model Variant:

TE250, TE450, TE510

Year:

2007, 2008

Codes

Manual Product Code:

Likely an internal or distributor code, not explicitly provided but essential for inventory

👋 Introduction

Market Position

Segment:

Competition Enduro/Off-Road Motorcycle

Target Audience:

Husqvarna owners, service technicians, and off-road enthusiasts seeking in-depth repair and maintenance information.

Competitive Analysis

Key Competitors:

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

Key Features

Features:

Official factory documentation, detailed diagrams, comprehensive troubleshooting, and clear step-by-step procedures.

Value Proposition

Value:

Enables owners to perform all maintenance and repairs, saving money and ensuring the longevity and optimal performance of their Husqvarna TE.

📋 Manual Details

Coverage Areas

Languages:

English (standard for factory manuals of this era and origin)

Page Count

Estimated Page Count:

Hundreds of pages (as stated in description, typical for full factory service manuals)

Manual Type

Type:

Factory Service Repair Manual

Format

Digital Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine disassembly, assembly, inspection, and repair procedures for all TE models.

Fuel System:

Carburetor (TE250, TE450, TE510) specifications, adjustment, troubleshooting, and overhaul.

Ignition System:

CDI ignition system components, timing, troubleshooting, and specifications.

Cooling System:

Radiator, fan, coolant, hoses, and water pump maintenance and repair.

Transmission And Drivetrain:

Clutch operation, gearbox disassembly, assembly, lubrication, and troubleshooting.

Suspension Front:

Fork (Marzocchi/Sachs) disassembly, oil changes, seal replacement, and adjustment procedures.

Suspension Rear:

Shock absorber (Sachs) servicing, linkage system maintenance, and bearing replacement.

Brakes Front:

Brake caliper, master cylinder, brake fluid, and disc specifications and service procedures.

Brakes Rear:

Rear brake caliper, master cylinder, brake fluid, and disc specifications and service procedures.

Electrical System:

Wiring diagrams, component testing, battery, lighting, and starter system diagnostics.

Chassis And Frame:

Frame inspection, swingarm maintenance, and wheel bearing service.

Bodywork And Plastics:

Fairing removal, seat mounting, and general body panel service.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug service, and air filter cleaning.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting for common issues.

Repair Procedures:

Step-by-step instructions for engine, transmission, suspension, and brake component repairs.

Overhaul Procedures:

Complete engine and component overhaul instructions, including tolerances and measurements.

Special Tool Requirements:

Identification of specific tools required for certain repair tasks.

Technical Depth

Depth Level:

Comprehensive: Covers everything from basic maintenance to full engine rebuilds and advanced diagnostics.

Diagnostic Capabilities:

Detailed diagnostic information for electrical and mechanical systems, including fault codes where applicable (though less common for carbureted models of this era).

Specifications And Tolerances:

Precise technical data, measurements, torques, and clearances for all components.

📊 Manual Specifications

File Format

Format:

Print Quality

Printable:

Yes, designed for printing full sections or the entire manual.

Image Quality:

High-resolution diagrams and illustrations

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type Te250:

Single-cylinder, 4-stroke, Liquid-cooled

Engine Type Te450:

Single-cylinder, 4-stroke, Liquid-cooled

Engine Type Te510:

Single-cylinder, 4-stroke, Liquid-cooled

Displacement

Displacement Te250:

249.5 cc (approx.)

Displacement Te450:

449.5 cc (approx.)

Displacement Te510:

501 cc (approx.)

Performance

Bore Stroke Te250:

Refer to manual for exact figures

Bore Stroke Te450:

Refer to manual for exact figures

Bore Stroke Te510:

Refer to manual for exact figures

Horsepower Te250:

Approx. 35-40 HP (estimated, refer to manual for exact dyno figures)

Horsepower Te450:

Approx. 45-50 HP (estimated, refer to manual for exact dyno figures)

Horsepower Te510:

Approx. 50-55 HP (estimated, refer to manual for exact dyno figures)

Torque Te250:

Refer to manual for exact figures

Torque Te450:

Refer to manual for exact figures

Torque Te510:

Refer to manual for exact figures

Fuel System

Carburetor Type:

Mikuni (likely VM series or similar for this era)

Carburetor Size:

Refer to manual (e.g., 38mm for TE450/TE510, smaller for TE250)

Fuel Type:

Unleaded Gasoline (91-98 RON recommended)

🔧 Transmission

Standard

Gearbox:

6-speed constant mesh

Features

Clutch Type:

Wet multi-plate

Final Drive:

Chain drive

Transmission Oil Type:

Refer to manual (typically SAE 10W/40 or 20W/50 motorcycle specific oil)

Transmission Oil Capacity:

Refer to manual (e.g., ~0.7-0.9 Liters)

📐 Dimensions

Exterior

Wheelbase:

Refer to manual for specific model variants (typically around 1470-1520 mm)

Weights

Dry Weight:

Refer to manual for specific model variants (typically around 110-120 kg)

Fuel Tank Capacity:

Refer to manual (typically around 8-9 Liters)

🛡️ Safety Features

Ratings

Safety Certification:

CE marked (typical for European manufactured bikes)

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Passive Features

Frame Construction:

Steel perimeter frame

💡 Technology Features

Infotainment

Infotainment System:

N/A (Minimalist off-road design)

Driver Assistance

Rider Aids:

N/A (Focus on rider skill and mechanical feedback)

Connectivity

Connectivity Features:

Engine Management

ECU Type:

Basic CDI unit (no advanced electronic engine management)

🔧 Maintenance

Service Intervals

Engine Oil Change:

Refer to manual (typically every 10-15 hours of riding or annually)

Air Filter Cleaning:

Refer to manual (frequently, especially in dusty conditions)

Spark Plug Inspection:

Refer to manual (e.g., every 20-30 hours)

Valve Clearance Check:

Refer to manual (e.g., every 40-60 hours)

Fluid Specifications

Engine Oil Grade:

Refer to manual (e.g., SAE 10W/40 or 20W/50 API SG or higher, JASO MA compliant)

Coolant Type:

Ethylene Glycol based coolant, mixed with distilled water (50/50 ratio)

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Clutch plates, chain and sprockets, fork seals, wheel bearings, coolant hoses.

Potential Problems:

Carburetor tuning sensitivity, occasional electrical gremlins, wear on kickstart mechanism if used excessively without proper engagement.

Part Numbers

Oil Filter Pn:

Refer to manual/parts fiche (e.g., Hiflofiltro HF152 or equivalent)

Air Filter Pn:

Refer to manual/parts fiche (e.g., Hiflofiltro HFA4605 or equivalent)

📚 Vehicle History

Brand Heritage

Brand Origin:

Swedish, with Italian manufacturing during this period.

Model Evolution

Previous Generations:

Husqvarna has a long history in off-road racing and enduro bikes dating back to the early 20th century.

Key Changes 2007 2008:

Updates to engine components, suspension settings, and chassis geometry typically occurred across model years. Specific details covered in the manual.

Production

Manufacturing Location:

Italy (during the period of ownership by Cagiva Group)