This manual covers the TE 250, TE 450, TE 510, TC 250, TC 450, TC 510, SM 400 R, SM 450 R, and SM 510 R models from the 2005 model year. One of the world's oldest motorcycle manufacturers, has a strong heritage in off-road racing, which influences the design and performance of these versatile machines. These motorcycles are engineered for demanding off-road and supermoto applications, offering a blend of robust construction, reliable performance, and a rich lineage of racing success.
This comprehensive Service Repair Manual provides detailed information for the maintenance, repair, and overhaul of your motorcycle. It includes step-by-step instructions, diagnostic procedures, troubleshooting guides, technical specifications, wiring schematics, and assembly instructions for various components. With detailed illustrations, diagrams, and hundreds of photos, this manual is an invaluable resource for do-it-yourself enthusiasts and professional mechanics alike, ensuring the longevity and optimal performance of your vehicle.
Model:
TE 250, TE 450, TE 510, TC 250, TC 450, TC 510, SM 400 R, SM 450 R, SM 510 R
Vin Prefix Te250:
ZCGH800AC5V006000
Vin Prefix Te450:
ZCGH802BC5V006000
Vin Prefix Te510:
ZCGH803CA5V006000
Vin Prefix Tc250:
ZCGH800AA5V052000
Vin Prefix Tc450:
ZCGH802BA5V052000
Vin Prefix Tc510:
ZCGH803CD5V052000
Vin Prefix Sm400R:
ZCGH801AD5V006000
Vin Prefix Sm450R:
ZCGH802BD5V006000
Vin Prefix Sm510R:
ZCGH803CC5V006000
Vin Prefix Te250 Us Cdn:
ZCGTE250#5V006000
Vin Prefix Te450 Us Cdn:
ZCGTE450#5V006000
Vin Prefix Te510 Us Cdn:
ZCGTE510#5V006000
Vin Prefix Tc250 Us Cdn:
ZCGTC250#5V052000
Vin Prefix Tc450 Us Cdn:
ZCGTC450#5V052000
Vin Prefix Tc510 Us Cdn Alt:
ZCGTC510#5V052000
Vin Prefix Tc510 Us Cdn:
ZCGTC510#5V006000
Vin Prefix Sm450R Us Cdn:
ZCGSM450#5V006000
Vin Prefix Sm510R Us Cdn:
ZCGSM510#5V006000
Target Audience:
Do-it-yourself enthusiasts and professional mechanics seeking comprehensive repair information for Husqvarna motorcycles.
Value Proposition:
Provides an inexpensive way to maintain, repair, and restore Husqvarna motorcycles, saving on dealership service costs.
Completeness:
Complete tear down and rebuild procedures, detailed illustrations, diagrams, wiring schematics, and specifications.
Accessibility:
Instant download in PDF format, compatible with all major operating systems and devices.
Usability:
Searchable content for quick access to specific repair information and procedures.
Manual Scope:
Complete Service Repair for Husqvarna TE 250, TE 450, TE 510, TC 250, TC 450, TC 510, SM 400 R, SM 450 R, SM 510 R motorcycles
Region Notes:
Includes specific notes for USA/CDN-AUS models
Type:
Service Repair Manual
Engine:
Complete disassembly, overhauling, and re-assembly
Maintenance:
Scheduled maintenance, routine servicing
Troubleshooting:
Diagnostics and troubleshooting procedures
Settings Adjustments:
Settings and adjustments for various components
General Operations:
General operational procedures
Frame Suspensions Wheels:
Service and repair of frame, suspension systems, and wheels
Brakes:
Comprehensive brake system service and repair
Electrical System:
Wiring schematics and electrical system diagnostics/repair
Cooling System:
Engine cooling system service and maintenance
Clutch System:
Hydraulic control clutch service and repair
Repair Type:
Complete tear down and rebuild, refurbishment, restoration
Technical Guides:
Step-by-step instructions for all diagnostic and repair procedures
Assembly Kits:
KITS assembling instructions
Optional Parts:
Optional Parts List
Special Tools:
List of specific tools required for service
Depth:
Comprehensive, suitable for do-it-yourselfers and experienced mechanics
Visual Aids:
Detailed illustrations, diagrams, and hundreds of photos
Data Accuracy:
Torque specifications, part diagrams, and detailed specifications
Compatibility:
All Versions of Windows & Mac, Linux OS, iPhone, iPad, Android
Reader Requirement:
Adobe PDF Reader
Searchability:
Searchable text for easy navigation
Storage And Usage:
Save to hard drive, burn to CD-ROM, view on any computer, zoom, print
Quality Assurance:
100% Complete and Intact, no missing/corrupt pages/sections
Type:
Digital Download (PDF)
Physical Format:
Not Applicable (Digital)
Engine Type:
Single-cylinder, four-stroke (typical for these models)
Displacement Te250:
250cc (approximate)
Displacement Te450:
450cc (approximate)
Displacement Te510:
510cc (approximate)
Displacement Tc250:
250cc (approximate)
Displacement Tc450:
450cc (approximate)
Displacement Tc510:
510cc (approximate)
Displacement Sm400R:
400cc (approximate)
Displacement Sm450R:
450cc (approximate)
Displacement Sm510R:
510cc (approximate)
Fuel Delivery:
Carburetor (typical for 2005 models, though some later variants might have fuel injection)
Type:
6-speed manual transmission (common for these off-road and supermoto models)
Clutch:
Hydraulic clutch actuation
Model Variants:
Off-road (TE/TC) and Supermoto (SM R) configurations, resulting in varying dimensions and weight.
Dry Weight:
Variable by model, typically between 230-250 lbs (approximate, actual values require consultation of specific model data within the manual).
Braking System:
Hydraulic disc brakes front and rear (specific caliper and rotor sizes detailed in manual).
Frame Construction:
Chromoly steel frame (typical for these Husqvarna models, ensuring strength and rigidity).
Features:
Basic instrumentation: speedometer, odometer, trip meter, neutral indicator, and indicator lights. No advanced infotainment systems.
Oil Change:
Refer to specific mileage or operating hours recommendations within the manual, typically around 10-15 hours for severe off-road use.
Valve Adjustment:
Crucial for performance and longevity, interval specified in manual (e.g., 100-200 hours).
Engine Oil:
Manual will specify SAE viscosity grade (e.g., 10W-40 or 15W-50) and JASO MA standard. Capacity also detailed.
Coolant:
Type of antifreeze/coolant and mixture ratio for the cooling system.
Brake Fluid:
DOT 4 or DOT 5.1 recommended, as per manual specification.
Common Wear Items:
Clutch plates, fork seals, chain and sprockets, wheel bearings, and air filters are common wear items requiring regular inspection and replacement.
Electrical Connections:
Ensuring clean and secure electrical connections is important, especially in off-road environments where dirt and moisture can ingress.
Heritage:
Husqvarna Motorcycles is one of the oldest motorcycle manufacturers in the world, with a strong lineage in off-road and motocross racing.
Evolution 2005:
The 2005 models represent a significant period for Husqvarna, building on their established off-road prowess and introducing competitive supermoto variants.
Manufacturing Location:
Italy (historically, before later ownership changes).
Racing Heritage:
Husqvarna's history is rich with motocross and enduro racing success, contributing to the development and performance of their production models.
