2004 Husqvarna TE 250 / TE 450 / TC 250 / TC 450 / SM 400 / SM 450 R Owner's Manual

Technician-level documentation for Husqvarna motorcycles, covering engine, transmission, and electrical systems. Ref: HUSQVARNA_SERVICE_MANUAL_2004

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Husqvarna Models Covered & Key Technical Specifications

Models: TE 250, TE 450, TC 250, TC 450, SM 400 R, SM 450 R
Sub-models / Variants: 250, 400, 450, SMR, Enduro, Motocross, Supermotard, USA version
Build Years: 2004
Serial Numbers: 17-digit VIN located on steering head tube
Technical Data:

  • Engine type: Single cylinder, 4-stroke, liquid-cooled
  • Displacement (250): 249.5 cc (15.22 cu. in.)
  • Displacement (400): 399.53 cc (24.37 cu. in.)
  • Displacement (450): 449 cc (27.39 cu. in.)
  • Compression ratio (250): 12.5:1
  • Compression ratio (400-450): 12:1
  • Valve clearance (Intake): 0.15 mm (0.006 in.)
  • Valve clearance (Exhaust): 0.20 mm (0.008 in.)
  • Spark plug: NGK CR8EB
  • Spark plug gap: 0.7 mm (0.027 in.)
  • Transmission type: Constant mesh, 6-speed
  • Primary drive ratio (250): 3.667
  • Primary drive ratio (400-450): 3.148
  • Chain size: 5/8” x 1/4”
Technical Specifications
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Document Number / Seller:
26507 / Margaret Rodriguez
File Size:
5.77 MB
File Type:
PDF
Language:
English, French, German, Italian, Spanish
Pages:
305
Printable:
Yes
Category:
Motorbike
Last updated / verified
Nov 6, 2025

Husqvarna Manual Features & Content Preview

Husqvarna 2004 TE-TC-SM Service Manual Coverage

  • Covers 2004 Husqvarna TE 250, TE 450, TC 250, TC 450, SM 400 R, and SM 450 R motorcycle variants
  • Original OEM manufacturer publication, includes multi-language content across 305 pages
  • Contains detailed technical data, lubrication schedules, identification data, and electrical system information for the 2004 model year fleet
  • Delivered as a direct download the moment payment clears
  • Indexed PDF search covers every chapter and appendix
  • Full-text search finds any part number in seconds
  • Includes 10 detailed technical diagrams of controls, engine specifications, and VIN identification
  • This 2004 owner's manual documents essential setup and maintenance data required for Husqvarna race-tuned competition models

Operational and Maintenance Documentation

The 2004 Husqvarna TE-TC-SM workshop publication provides detailed operational guidelines for the model family, covering pre-ride inspection checklists, engine starting sequences for cold and warm conditions, and specific procedures for using the manual decompressor. The document details the electronic dash functions, including programming wheel circumference for accurate speed measurement and total mileage tracking. It also outlines essential safety procedures regarding the electric starting system, fuel cock operation, and side-stand usage.

Technical Specifications and Maintenance Data

This manual provides comprehensive technical reference values including engine bore, stroke, and displacement for the 250, 400, and 450 engine configurations. The lubrication section documents requirements for the dry-sump oil system and specific coolant, brake, and clutch fluid specifications. Torque settings, valve clearance limits, and sprocket/gear ratios are listed for each variant. Referenced technical data includes the intake valve clearance at 0.15 mm and exhaust valve clearance at 0.20 mm. The fuel tank capacity is documented at 7.7 liters, including the reserve.

Note: All service data shown here is for reference only — qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work. This manual provides a complete 305-page guide for the 2004 Husqvarna TE and TC enduro, motocross, and SM supermotard model lineup.

Manual FAQ, Purchase & Download Details

Can you preview which major vehicle systems are covered in the Husqvarna manual chapters? keyboard_arrow_down

Manual includes extensive coverage for primary systems such as the engine and transmission, alongside dedicated sections for electrical components, ignition systems, and periodic maintenance.

Which specification tables and technical data categories are included in the document? keyboard_arrow_down

Manual contains comprehensive specification tables that reference technical values, wear limits, and tightening torque requirements. These sections provide data categories for various components across all covered model years.

What kind of service-related data and lubricant information does this document provide? keyboard_arrow_down

Document contains a dedicated lubrication table and supplies section to reference necessary service fluids. It also includes comprehensive maintenance and adjustment tables, along with identification data for the engine and frame. Detailed information for USA and Australian model variants is additionally provided in the appendix.

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