Category:
High-performance motocross/off-road motorcycles.
Target Audience:
Enthusiasts, mechanics, and owners of Husqvarna TC 250, 450, and 510 models from 2005-2006.
Segment:
Competes in the highly competitive 4-stroke off-road motorcycle segment against brands like KTM, Yamaha, Honda, and Suzuki.
Value Proposition:
Provides comprehensive, expert-level repair and maintenance information essential for keeping these specialized machines in optimal condition.
Manual Benefit:
Empowers owners and technicians to perform a wide range of services, from routine maintenance to complex engine rebuilds, saving time and money.
Vehicle Systems:
Engine, Chassis, Electrical System, Fuel System, Cooling System, Exhaust System, Transmission, Suspension, Brakes, Wheels, Tires, Bodywork, Troubleshooting
Estimated Pages:
Hundreds of pages (specific count not provided, but indicative of comprehensive content)
Type:
Service Repair Manual
Engine Mechanical:
Top-end overhaul (cylinder, piston, valves), Bottom-end overhaul (crankshaft, connecting rod, bearings), Timing system (camshaft, chain), Lubrication system, Cooling system, Fuel injection system components
Electrical System:
Ignition system, Lighting system, Battery and charging system, Starter system, Wiring diagrams, Sensor diagnostics
Chassis And Suspension:
Front fork disassembly and assembly, Rear shock absorber service, Swingarm and linkage maintenance, Steering head bearing service, Frame inspection
Braking System:
Brake caliper service, Master cylinder overhaul, Brake bleeding procedures, Pad and rotor replacement, Brake line inspection
Fuel And Exhaust:
Fuel pump inspection, Injector cleaning and testing, Exhaust system component inspection and replacement
Maintenance Tasks:
Oil changes, Filter replacements (air, oil), Chain adjustment and lubrication, Spark plug replacement, Valve clearance check and adjustment, Brake fluid flush, Coolant flush
Troubleshooting:
Diagnostic charts, Symptom-based troubleshooting, Fault code interpretation (if applicable)
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly
Rebuilding:
Comprehensive engine and gearbox rebuild procedures
Depth:
Detailed specifications, torque values, clearances, and assembly instructions for all major components.
Diagnostic Capabilities:
Covers diagnostic procedures for common malfunctions and electrical issues.
Searchable:
Likely searchable due to PDF format, allowing for quick information retrieval.
Quality:
High-resolution graphics and text, suitable for printing.
Binding:
Not Applicable (PDF format)
Paper:
Not Applicable (PDF format)
Type:
4-stroke, Single-cylinder (specific configurations vary by model variant)
Valve Train:
DOHC, 4 valves per cylinder
Displacement Tc250:
Approx. 250cc (specific exact displacement may vary slightly)
Displacement Tc450:
Approx. 450cc (specific exact displacement may vary slightly)
Displacement Tc510:
Approx. 510cc (specific exact displacement may vary slightly)
Horsepower Range:
Typically in the range of 40-60 HP, depending on the specific model and tuning.
Torque Characteristics:
Emphasis on strong mid-range and top-end power delivery, characteristic of motocross engines.
Induction:
Fuel Injection (specific system details would be in the manual)
Fuel Type:
Unleaded gasoline (Octane rating specified in manual)
Type:
5-speed manual transmission
Transmission Variants:
Not applicable, standard 5-speed manual for these models.
Clutch:
Hydraulically actuated wet multi-plate clutch.
Gear Ratios:
Specific gear ratios for each model and gear will be detailed in the manual.
Transmission Fluid:
Specific type and capacity (e.g., Motorex Gear Oil SAE 75W/90 or equivalent) detailed in manual.
Frame Type:
Chromoly steel perimeter frame.
Wheelbase:
Specifications vary by model and year, detailed in manual.
Dry Weight:
Varies by model (e.g., TC250 likely around 230-240 lbs, TC450/510 slightly more). Exact figures in manual.
Fuel Capacity:
Typically around 1.7-2.0 gallons. Exact figure in manual.
Safety Standards:
Designed for off-road competition and recreation. Not street legal in most configurations. Safety features are rider-centric.
Braking System Performance:
High-performance hydraulic disc brakes front and rear for effective stopping power.
Frame Integrity:
Robust chassis designed to withstand rigorous off-road use.
Ergonomics:
Designed for rider control and comfort during aggressive riding.
Infotainment System:
Not applicable. This is a pure-bred off-road motorcycle with no infotainment features.
Rider Aids:
No electronic rider aids (e.g., ABS, traction control) typically found on these models.
Connectivity:
No connectivity features. Focus is on mechanical performance and rider input.
Oil Change Interval:
Typically every 10-15 hours of riding, or as specified by the manual for normal/hard use.
Air Filter Cleaning:
Frequent cleaning recommended, often after every few rides, especially in dusty conditions.
Valve Adjustment Interval:
Typically every 25-50 hours of riding, or as recommended in the manual.
Chain And Sprockets:
Regular cleaning, lubrication, and tension adjustment are critical. Replacement interval depends on usage and maintenance.
Engine Oil:
Specific viscosity and API rating (e.g., SAE 10W/40, JASO MA) will be listed in the manual. Brands like Motorex are often recommended.
Coolant:
High-quality motorcycle coolant with antifreeze properties (e.g., ethylene glycol-based). Specific mixture ratio and type in manual.
Brake Fluid:
DOT 4 or DOT 5.1 specified for hydraulic brake systems. Ensure compatibility.
Common Wear Items:
Piston rings, valve stem seals, clutch plates, wheel bearings, fork seals, swingarm bearings are common wear items on high-performance off-road bikes.
Maintenance Criticality:
These models require diligent maintenance due to the high-stress nature of off-road riding. Neglect can lead to significant component damage.
Heritage:
Husqvarna Motorcycles has a long and storied history dating back to Sweden, with significant success in off-road racing disciplines.
Generation:
These models represent a period of development for Husqvarna's 4-stroke off-road lineup, following their acquisition by BMW.
Manufacturing Location:
Sweden/Italy (depending on the specific sourcing of components and assembly during this period).
