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Introduction
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Market Position
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Segment:
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High-performance off-road motorcycles (enduro, motocross, supermoto) known for Italian engineering and racing pedigree.
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Competitive Analysis
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Competitors:
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KTM EXC/SX series, Yamaha YZ/WR series, Honda CRF series, Kawasaki KX/KLX series, Suzuki RM/DR series.
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Key Features
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Vehicle Appeal:
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Powerful engines, advanced chassis design, competitive pricing relative to performance, distinctive Italian styling, and a strong heritage in off-road racing.
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Manual Value Proposition:
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Provides essential, factory-accurate information for maintaining and repairing these specialized machines, ensuring optimal performance and longevity, and empowering owners to perform complex tasks.
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Manual Details
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Coverage Areas
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Models Covered:
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2008 Husqvarna TE 250, TE 450, TE 510, TC 250, TC 450, TC 510, TXC 250, TXC 450, TXC 510, SMR 450, SMR 510, SMR450 R
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Variants Covered:
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All engine displacements and specific model designations within the 2008 lineup.
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Page Count
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Estimated Pages:
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Varies by specific model and engine, but typically comprehensive. Expect several hundred pages.
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Manual Type
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Type:
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Workshop Service Repair Manual
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Language
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Language:
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English (presumed based on standard OEM manual distribution)
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Format
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Format:
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PDF Download
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Manual Coverage
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Systems Covered
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Engine:
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Detailed diagnosis, repair, and overhaul procedures for all engine variants (250cc, 450cc, 510cc), including top-end, bottom-end, cooling system, lubrication, and fuel injection.
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Transmission:
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Service and repair of the gearbox, clutch system (hydraulic), and related components.
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Electrical System:
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Wiring diagrams, component testing, troubleshooting for ignition, lighting, battery charging, and electronic control units (ECU).
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Chassis And Suspension:
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Front forks (rebuild, adjustments, fluid changes), rear shock absorber (rebuild, adjustments), swingarm, linkages, and bearings.
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Brakes:
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Front and rear brake system diagnosis, repair, caliper service, master cylinder service, bleeding procedures, and pad/rotor replacement.
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Fuel System:
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Fuel tank, fuel pump, injectors, fuel pressure regulator, and related lines.
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Exhaust System:
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Removal, installation, and inspection of exhaust components.
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Cooling System:
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Radiator, hoses, water pump, and coolant specifications.
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Bodywork And Plastics:
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Fairings, seat, fuel tank cover, and other cosmetic and protective components.
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Procedures Included
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Routine Maintenance:
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Oil changes, filter replacements, chain adjustment, lubrication points, and general inspection guidelines.
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Troubleshooting Guides:
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Systematic diagnostic procedures for common and uncommon issues, including fault codes and symptom-based solutions.
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Engine Rebuild:
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Complete instructions for engine disassembly, inspection, component replacement (pistons, rings, valves, bearings), and reassembly.
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Suspension Service:
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Detailed procedures for servicing front and rear suspension units, including oil level checks and replacements.
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Electrical Diagnostics:
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Step-by-step troubleshooting for electrical faults, utilizing wiring diagrams and test procedures.
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Brake System Maintenance:
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Bleeding, caliper overhaul, and component replacement.
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Torque Specifications:
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Precise torque values for all critical fasteners.
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Technical Depth
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Depth:
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Comprehensive OEM level detail, suitable for professional technicians and experienced home mechanics. Covers everything from basic maintenance to complete engine and component overhauls.
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Engine Specifications
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Primary Engine
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Engine Type:
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Four-stroke, liquid-cooled, DOHC (Double Overhead Camshaft)
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Engine Configurations:
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Single-cylinder available in 250cc, 450cc, and 510cc displacements.
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Bore X Stroke 250:
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Approx. 76 x 54.8 mm (verify specific model for precise figures)
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Bore X Stroke 450:
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Approx. 97 x 60.8 mm (verify specific model for precise figures)
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Bore X Stroke 510:
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Approx. 98 x 71.5 mm (verify specific model for precise figures)
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Performance
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Horsepower 250:
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Estimated 35-40 HP (at crankshaft, vary by tuning)
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Horsepower 450:
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Estimated 45-50 HP (at crankshaft, vary by tuning)
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Horsepower 510:
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Estimated 50-55+ HP (at crankshaft, vary by tuning)
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Torque Figures:
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Specific torque figures vary by displacement but are optimized for tractable power delivery across RPM range.
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Fuel System
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Fuel Delivery:
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Electronic Fuel Injection (EFI) - Mikuni or Keihin throttle body systems likely.
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Fuel Type:
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Unleaded gasoline, minimum octane rating 91 (RON+MON)/2.
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Ignition System:
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Digital CDI (Capacitor Discharge Ignition)
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Maintenance
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Service Intervals
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Oil Change Engine:
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Every 15-20 engine hours or annually, whichever comes first. Refer to manual for specific recommendations based on usage.
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Air Filter Cleaning:
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After every ride or as conditions dictate (e.g., dusty environments).
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Spark Plug Check:
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Every 30-40 engine hours.
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Valve Clearance Check:
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Every 60-80 engine hours, or as per manual recommendations.
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Fluid Specifications
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Engine Oil Type:
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Fully synthetic SAE 10W-50 motorcycle specific oil (e.g., Motorex Power Synt 4T 10W/50 or equivalent).
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Engine Oil Capacity 250:
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Approx. 1.4 - 1.5 Liters (check manual for precise fill level).
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Engine Oil Capacity 450/510:
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Approx. 1.5 - 1.6 Liters (check manual for precise fill level).
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Coolant Type:
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Permanent anti-freeze coolant (e.g., Motorex Coolant M5.0 or equivalent), mixture of 50% coolant and 50% distilled water.
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Clutch Fluid Type:
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DOT 4 hydraulic brake fluid.
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Fork Oil Type:
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Specific suspension fluid, e.g., SAE 5W or SAE 7.5W (refer to manual for precise viscosity and level).
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Known Issues
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Engine Reliability:
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Some models may experience issues with camshaft wear or valve train components if maintenance intervals are not strictly followed. Overheating can also be a concern if the cooling system is not properly maintained.
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Electrical Gremlins:
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Occasional electrical connection issues or sensor failures can occur, requiring careful inspection and cleaning.
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Suspension Seals:
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Fork and shock seals can wear over time, leading to leaks, especially under demanding off-road use.
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Clutch Actuation:
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Hydraulic clutch slave cylinder seals can sometimes fail, leading to clutch fluid leaks or poor clutch engagement.
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