Husqvarna TE TC SM 250 400 450 510 2005 Service Repair Workshop Manual

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This manual covers the 2005 TE, TC, and SM series motorcycles, including models such as the TE 250, TE 400, TE 450, TE 510, TC 250, TC 400, TC 450,...

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Type: Motorcycle

Vendor:

Sku: 87568

Tags: 2005 34 Chainsaws Home and Garden Husqvarna Motorcycle Power Equipment SM 250 SM 400 SM 450 SM 510 TC 250 TC 400 TC 450 TC 510 TE 250 TE 400 TE 450 TE 510

Product variants

Description

This manual covers the 2005 TE, TC, and SM series motorcycles, including models such as the TE 250, TE 400, TE 450, TE 510, TC 250, TC 400, TC 450, TC 510, SM 250, SM 400, SM 450, and SM 510. These high-performance machines are renowned for their competitive edge in off-road racing and their adaptability for street-legal supermoto use. Built with a focus on power-to-weight ratio and agile handling, motorcycles from this era, with their Italian engineering and Swedish heritage, offered a potent combination for both demanding terrain and spirited riding. This comprehensive Service Repair Workshop Manual provides detailed guidance for owners and technicians. It covers a wide array of essential maintenance and repair procedures, including engine systems, transmission, clutch, chassis components, and electrical systems. You will find step-by-step instructions for disassembly, assembly, diagnostics, and tuning, alongside preventative maintenance schedules, troubleshooting guides for common issues, and clear wiring diagrams. The manual's depth ensures that both routine servicing and more complex repairs can be performed effectively, helping to maintain the optimal performance and longevity of your motorcycle.

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

TE TC SM

Year:

Codes

Platform Code:

Not Specified

👋 Introduction

Market Position

Segment:

High-performance off-road (Enduro/Motocross) and Supermoto motorcycles, known for their competitive edge and European heritage.

Competitive Analysis

Competitors 2005:

KTM EXC/SX, Yamaha WR/YZ, Honda CRF/CR, Suzuki RM-Z/RMX, Kawasaki KX/KLX.

Key Features

Vehicle Focus:

Designed for competitive off-road riding and street-legal supermoto conversions, emphasizing power-to-weight ratio and handling.

Manual Value Proposition

Diy Support:

Empowers DIY owners and independent mechanics to perform a wide range of maintenance and repair tasks, saving costs and enhancing vehicle longevity.

📋 Manual Details

Coverage Areas

Models Covered:

Husqvarna TE 250, TE 400, TE 450, TE 510, TC 250, TC 400, TC 450, TC 510, SM 250, SM 400, SM 450, SM 510

Page Count

Estimated Page Count:

Typically 400-800 pages for comprehensive service manuals of this era. Actual count not provided.

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English (Assumed, standard for technical manuals sold internationally)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine disassembly, assembly, lubrication, cooling, fuel delivery, ignition, exhaust, diagnostics, tuning.

Transmission Systems:

Clutch operation and maintenance, gearbox disassembly and assembly, gear shift mechanism, lubrication.

Chassis Systems:

Frame inspection and repair, suspension (forks, shock absorbers), steering, wheels, tires, brakes (hydraulic and mechanical), chain and sprockets.

Electrical Systems:

Wiring diagrams, battery, charging system (stator, rectifier/regulator), lighting (headlight, taillight, turn signals), ignition system components, starter motor, instrumentation, troubleshooting electrical faults.

Bodywork And Fixtures:

Body panel removal and installation, seat, fuel tank, fenders, fairings, exhaust system mounting.

Procedures Included

Preventative Maintenance:

Scheduled maintenance checks, oil changes, filter replacements, chain lubrication and adjustment, brake fluid replacement, spark plug inspection and replacement, air filter cleaning/replacement, valve clearance checks.

Troubleshooting:

Systematic diagnostic procedures for common problems, error code interpretation (if applicable), symptom-based troubleshooting guides.

Repair And Rebuild:

Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.

Technical Depth

Depth:

Comprehensive: Covers basic maintenance to complete engine and gearbox rebuilds, including detailed torque specifications and clearances.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable PDF if professionally scanned, otherwise image-based.

Print Quality

Printability:

Printable on any computer with a PDF reader and printer.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Illustrations

Illustration Quality:

Illustrated with clear, step-by-step instructions. Expect exploded views, diagrams, and photographic sequences.

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, single-cylinder (typically SOHC or DOHC depending on specific model variant)

Displacements Offered:

Approx. 250cc, 400cc, 450cc, 510cc (Specific bore and stroke vary by model)

Cooling System:

Liquid-cooled

Performance

Horsepower Range:

Estimated 40-60 HP depending on displacement and model (TE/TC vs. SM tuning).

Torque Range:

Not explicitly specified, but significant for off-road performance.

Fuel System

Fuel Delivery:

Carbureted (e.g., Keihin FCR series) for most 2005 models, although fuel injection may have been introduced on some late variants.

Ignition

Ignition System:

Digital CDI (Capacitor Discharge Ignition) with variable ignition timing.

Lubrication

Oil Type Recommendation:

High-quality synthetic motorcycle oil, SAE 10W-40 or 15W-50 (specific grade depends on ambient temperature and manufacturer recommendation). Check manual for exact API/JASO specs.

🔧 Transmission

Standard

Transmission Type:

6-speed manual sequential gearbox

Optional

Optional Gearboxes:

N/A for this model year.

Features

Clutch Type:

Hydraulic actuation, multi-plate wet clutch

Gear Ratios:

Specific gear ratios are detailed within the manual, varying by model and intended use (TE/TC/SM).

Maintenance

Transmission Oil Capacity:

Typically around 0.8 - 1.2 liters. Consult manual for exact capacity.

Transmission Oil Type:

Dedicated motorcycle transmission oil or high-quality engine oil meeting JASO MA/MA2 specifications. Check manual.

📐 Dimensions

Exterior

Wheelbase:

Varies by model (e.g., approx. 1470-1495 mm for TE/TC).

Weights

Dry Weight:

Varies by model, typically 105-120 kg.

Fuel Tank Capacity:

Typically 8-11 liters depending on the specific TE/TC/SM variant.

🛡️ Safety Features

Ratings

Safety Certification:

Not applicable in the same way as cars; compliance with relevant emissions and noise regulations for motorcycles.

Active Features

Braking System Front:

Hydraulic disc brake (e.g., Brembo or Grimeca calipers with large diameter discs for performance).

Braking System Rear:

Hydraulic disc brake (e.g., Brembo or Grimeca calipers).

Passive Features

Frame Construction:

Chromium-molybdenum steel trellis frame for strength and rigidity.

💡 Technology Features

Infotainment

Infotainment System:

Basic instrumentation: Speedometer, odometer, trip meter, neutral indicator, oil pressure light, high beam indicator.

Driver Assistance

Driver Assistance Features:

N/A (Motorcycle)

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10-15 hours of off-road use or 1000-2000 km for mixed use. Refer to manual for precise intervals.

Air Filter Cleaning:

Frequent cleaning or replacement recommended based on operating conditions, often every 5-10 hours.

Valve Clearance Check:

Typically every 50-100 hours of use. Crucial for engine performance and longevity.

Chain And Sprockets Inspection:

Regular inspection and lubrication every few rides, adjustment as needed.

Fluid Specifications

Coolant Type:

Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio). Specific coolant type and boiling point are detailed in the manual.

Brake Fluid Type:

DOT 4 or DOT 5.1 hydraulic brake fluid. Do not mix DOT fluid types.

Fork Oil Type And Weight:

Specific viscosity grade (e.g., SAE 5W, 7.5W, 10W) and type (e.g., Showa SS-01, Motul Factory Line) will be listed in the manual.

Known Issues

Common Wear Items:

Clutch plates, piston rings, valve guides/seals, wheel bearings, steering head bearings, fork seals, chain and sprockets.

Potential Electrical Issues:

Wiring harness chafing, rectifier/regulator failure (common in many bikes of this era), stator output degradation.

Engine Specific Concerns:

Some engines may have specific wear patterns or maintenance requirements that the manual will highlight. Overheating can lead to head gasket issues if not managed.

📚 Vehicle History

Brand Heritage

Brand Origin:

Husqvarna Motorcycles, founded in Sweden in 1903, is one of the oldest motorcycle manufacturers.

Model Evolution

2005 Generation:

Represents a significant era for Husqvarna's competitive off-road and supermoto offerings, often featuring Italian-developed engines and chassis.

Production

Manufacturing Location:

Primarily Italy during this period, under ownership of the Cagiva Group.

🏆 Awards & Recognition

Recognitions

Historical Performance:

Husqvarna models from this era were competitive in national and international Enduro and Supermoto racing. Specific awards for the 2005 models are not broadly documented but reflect a strong performance heritage.