2007 Husqvarna TE 250/450/510, TC 250/450/510, SM 400/450/510 R & SMR 450-R Workshop Manual (P/N 8000 A7735)

The Husqvarna workshop manual, P/N 8000 A7735, first edition dated July 2006, covers the 2007 TE 250/450/510, TC 250/450/510, SM 400/450/510 R, and SMR 450-R models.

Supplied as one 708-page PDF with English, Italian, French, German, and Spanish text.

• Engine repair: Engine removal, crankcase separation, cylinder-head overhaul, valve timing, crankshaft inspection, and model-specific transmission disassembly and reassembly.

• Fuel system: Keihin and Mikuni carburetor overhaul, float and accelerator-pump inspection, throttle-cable adjustment, and throttle-position sensor testing.

• Suspension: TE 250 Marzocchi fork overhaul, TE/SMR rear-shock repair, swingarm and linkage inspection, and model-specific suspension settings.

• Brakes and hydraulic clutch: Disc and pad inspection, front and rear brake bleeding, clutch-disc replacement, and clutch master-cylinder overhaul.

• Electrical diagnosis: Charging and electric starting system tests, ignition checks, wiring diagrams, and gear-position sensor inspection.

• Service references: Road and competition maintenance schedules, symptom/cause/remedy tables, torque charts, fluid capacities, engine specifications, and component wear limits.

Written for authorized Husqvarna workshop personnel, this manual assumes professional mechanical knowledge supported by workshop experience and the specified service tools.

Engine and Transmission Repair

The engine chapters cover valve-seat recutting, valve-guide replacement, cylinder/piston matching, connecting-rod checks, and oil-pump inspection. Bore, stroke, compression ratios, valve clearances, and spark plug specifications accompany the repair procedures.

Separate gearshaft assembly drawings distinguish the TC five-speed gearbox from the TE/SMR six-speed arrangement. Dedicated SMR 450-R clutch procedures identify tools 8000 A8190 and 8000 A8191 and address its specific drum, hub, and ball/pin arrangement.

The cylinder-head repair instructions flag the risk of bending a valve stem with a misaligned valve-spring compressor.

Carburetors and Engine Cooling

Carburetor coverage distinguishes the Mikuni TMR 38 for the SM 400 R from the Keihin FCR-MX 37 for the 250 models and FCR-MX 41 for the 450/510 models. Exploded views support separate inspection and adjustment procedures for these carburetor families.

The cooling-system layout identifies the water pump, dual radiators, and TE/SMR expansion tank. Related procedures cover coolant replacement, radiator and hose inspection, and water-pump removal and reassembly.

Suspension, Steering, and Brakes

Detailed fork-overhaul instructions apply to the TE 250's Marzocchi 45 mm USD fork, including oil-seal replacement, damper disassembly, and compression/rebound valve work. Rear-shock overhaul is documented for the TE/SMR Sachs unit; the TC's Öhlins shock is covered by setup and adjustment data.

The SMR 450-R section adds steering-head bushing selection and geometry adjustment. Its warning about unlisted bushing combinations explains how incorrect assembly can damage the steering components.

Separate front-brake bleeding procedures distinguish TE/TC from SMR systems. Chassis coverage extends to frame checks, wheel bearings, rim runout, spoke tension, and chain/sprocket wear.

Electrical Fault Finding and Regional Variants

Model-specific wiring diagrams distinguish TE/SMR, TC, and USA/Canada configurations. Charging-system diagrams and frame-harness routing drawings accompany connector and wire-color references and tests for the generator, regulator-rectifier, starter relay, and ignition coil.

Component locations and electrical test specifications help narrow down a starting or charging fault before parts are replaced. The digital-instrument section also covers model-code setup and instrument replacement.

The documentation separates standard street configurations from competition use in its maintenance schedules. Kit-installation sections cover kick and electric starting equipment, while regional notes include TC USA/Canada spark-arrester maintenance.

For workshop safety, secure the motorcycle during service and follow the manual's precautions for brakes and pressurized suspension components.

File Format and Readability

The total includes the front cover and publication page (two pages), the multilingual sections, and section dividers.

Written sections contain searchable PDF text; labels within wiring-diagram images are not searchable. There are no embedded PDF bookmarks. The contents pages and printed section codes provide page references.

Small wiring labels require zooming, and some fine wire codes remain pixelated and difficult to read at higher magnification.