Segment:
Competition Motocross/Off-Road
Competitors:
KTM EXC, Yamaha YZ-F, Honda CRF, Suzuki RM-Z, Kawasaki KX
Design Philosophy:
Performance-oriented, lightweight, powerful engine, advanced suspension for its era
Target User:
Motocross racers and aggressive off-road riders seeking peak performance
Manual Value Proposition:
Essential resource for maintaining and repairing a high-performance off-road motorcycle, enabling owners to perform complex tasks.
Primary Coverage:
Service, Maintenance, Repair, Troubleshooting
Secondary Coverage:
All Models, Engines, Trims, Transmissions
Estimated Pages:
Extensive (typical for workshop manuals of this era, likely 300+ pages)
Type:
Workshop Service Repair Manual
Engine Mechanical:
Complete engine overhaul, cylinder head, piston, crankshaft, valve train, lubrication system, cooling system
Fuel System:
Carburetor systems, fuel delivery, fuel tank, fuel lines
Ignition System:
Ignition timing, spark plugs, ignition coils, CDI unit
Transmission Drivetrain:
Clutch operation and adjustment, gearbox internal components, gear shift mechanism, final drive (chain and sprockets)
Suspension:
Front forks (USD - Upright/Inverted), rear shock absorber, linkage system, tuning and adjustment
Brakes:
Front and rear hydraulic brake systems, caliper service, master cylinder, brake fluid replacement, bleeding procedures
Electrical System:
Wiring diagrams, battery, lighting, starter system, charging system (alternator/stator)
Cooling System:
Radiator, hoses, coolant, thermostat, fan (if applicable)
Exhaust System:
Muffler, header pipe, heat shields
Chassis Frame:
Frame inspection, steering head bearings, swingarm, footpegs
Bodywork Trim:
Fairings, seat, fenders, tank shrouds, graphics removal/installation
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, chain adjustment, valve clearance checks
Troubleshooting:
Diagnostic charts for common problems, electrical faults, engine performance issues
Repair:
Step-by-step disassembly and reassembly instructions for all major components
Diagnostics:
Visual inspection guidelines, measurement specifications, fault finding strategies
Wiring Diagrams:
Detailed electrical schematics for easy fault tracing
Specifications Data:
Torque values, clearances, fluid capacities, measurements
Depth:
Comprehensive, covering from basic maintenance to complete engine and chassis rebuilds
Target Audience:
Professional technicians, experienced DIY mechanics
Type:
Four-stroke, single-cylinder
Displacement:
501cc (approximate, actual may vary slightly)
Bore X Stroke:
Information typically detailed in the manual
Compression Ratio:
Information typically detailed in the manual
Valve Train:
SOHC (Single Overhead Camshaft), 4 valves
Cooling System:
Liquid-cooled
Horsepower:
Estimated 50-55 HP (subject to tuning and specific model variants)
Torque:
Information typically detailed in the manual
Carburetor:
Mikuni VM38SS or similar (specific model dependent)
Fuel Type:
Unleaded gasoline (RON 95 or higher recommended)
Fuel Delivery:
Gravity feed from fuel tank to carburetor
Type:
5-speed manual transmission
Options:
N/A (Typically single transmission option for this model)
Clutch:
Wet, multi-plate, cable-actuated
Final Drive:
O-ring sealed chain drive
Gear Ratios:
Specific gear ratios detailed in the manual
Safety Standards:
Not applicable for off-road motorcycles in typical automotive safety rating contexts (e.g., NHTSA, Euro NCAP). Focus is on rider protection through design and proper use.
Braking System:
Hydraulic disc brakes front and rear
Chassis Design:
Robust frame providing stability and impact resistance
Bodywork:
Protective plastics and guards
Oil Change Engine:
Every 10-15 hours of riding or 6 months (typical for off-road use, consult manual for precise values)
Air Filter Cleaning:
After every few rides, or as needed based on conditions
Valve Clearance Check:
Every 30-40 hours of riding (critical for performance and longevity)
Chain Lubrication Adjustment:
Regularly, every 500-1000 km or after significant off-road use
Engine Oil:
API SG or higher, SAE 10W-40 or 15W-50 motorcycle specific oil (consult manual for exact viscosity and type)
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors, mixed 50/50 with distilled water
Brake Fluid:
DOT 4 hydraulic brake fluid
Fork Oil:
Specific viscosity and type as per manual (e.g., Showa SS-03 or equivalent)
Engine Performance:
Potential for carburetor jetting issues in varying altitudes/temperatures; regular valve clearance checks are crucial.
Suspension Wear:
Seals in forks and shock can wear over time, requiring periodic service.
Electrical Connections:
Off-road use can lead to dirt ingress in electrical connectors; regular cleaning and dielectric grease application is recommended.
Clutch Slippage:
Can occur with heavy use or worn clutch plates/springs; adjustment and inspection are key.
Manufacturer Origin:
Husqvarna Motorcycles, founded in Sweden in 1903, known for its long history in off-road and motocross racing.
Tc Series Development:
The TC series represents Husqvarna's dedicated line of motocross bikes, continually evolving in engine technology, suspension, and chassis design.
Manufacturing Location:
Husqvarna Motorcycles, typically Italy during this period under parent company ownership.
