2007 Husqvarna TE/TC/SM/SMR Series Workshop Manual (P/N 8000 A7735)

• Exact 2007 coverage: TE 250/450/510, TC 250/450/510, SM 400 R/450 R/510 R, and SMR 450-R, with separate model-specific starting VINs for USA/CDN and non-USA/CDN motorcycles. The 400 cc coverage is limited to the SM 400 R.
• Engine and drivetrain repair: Covers engine removal, cylinder-head and valve-train disassembly, piston and crankshaft inspection, crankcase splitting, oil-pump service, clutch work, gearbox teardown, and model-specific reassembly.
• Fuel and electrical diagnosis: Identifies the Keihin FCR-MX 37, Mikuni TMR 38, and Keihin FCR-MX 41 applications, with carburetor overhaul, TPS/GPS checks, charging and starting tests, ignition diagnosis, instrument setup, and electrical fault charts.
• Chassis, brake, and suspension work: Includes wheel and bearing service, steering and swingarm checks, model-specific brake bleeding, TE 250 Marzocchi fork overhaul, and Sachs rear-shock disassembly, inspection, bleeding, and recharging.
• Factory kit procedures: Details carburetor kits, turn signals, race-start hooks, TC electric-start conversions, the SM R kick-start kit (SMR 450-R excluded), and SMR 450-R steering-head bushings, hand guards, carbon parts, handlebar references, and fluid catch tank.
• Factory document and reference data: A 708-page PDF issued by MV Agusta Motor S.p.A., first edition dated July 2006, Part/Print No. 8000 A7735, with maintenance schedules, torque tables, capacities, clearances, wear limits, adjustment data, electrical test values, and special-tool numbers.

Husqvarna identifies this publication as workshop literature prepared for authorized service personnel. Its repair depth and reliance on special tools make it best suited to trained technicians with motorcycle engine, chassis, and electrical experience. The manual presents the material in English, Italian, French, German, and Spanish.

Model and VIN Coverage

The # character is reproduced from the manual at the VIN check-digit position.

Engine, Carburetor, and Electrical Repair Detail

The engine chapters document camshaft and water-pump removal, cylinder-head and valve work, timing-chain inspection, piston-to-cylinder and connecting-rod checks, crankshaft and counterbalancer service, and full crankcase and transmission assembly. The manual distinguishes the five-speed TC gearbox from the six-speed TE, SM R, and SMR 450-R transmissions, and it provides a separate clutch procedure for the SMR 450-R. Mikuni TMR 38 overhaul data is specific to the SM 400 R; 250 models use the Keihin FCR-MX 37, while the 450/510 applications use the FCR-MX 41.

Factory tool callouts include crankcase puller 1517 94702, flywheel extractor 8000 A1559, ignition checking tool 8000 A1512, front-fork seal tool 8000 91288, fork-cartridge retainer 8000 91289, and clutch-hub retaining wrench 8000 79015. The kit chapter also covers electric-start installation on the TC 250 and TC 450/510 using kits 8000 A6487 and 8000 A6488.

Named electrical references include the TE/SM R main wiring diagram and two configuration sheets: TC 250 with TE/SM R USA/CDN, and TC 450/510 plus SMR 450-R with TE/SM R USA/CDN. The chapter also supplies a charging-system schematic and generator and starter-motor test diagrams. Connector handling, harness routing, regulated-voltage and stator checks, CDI/coil diagnosis, and a system-level troubleshooting section support fault isolation rather than simple parts identification.

Maintenance Configurations, Suspension Scope, and Cautions

Separate maintenance tables distinguish full-power competition use from limited-power street configuration, including MX/enduro hour-based schedules and road mileage intervals. The dedicated internal fork chapter is specifically for the TE 250's 45 mm Marzocchi USD fork. The Sachs rear-shock overhaul covers the TE and supermoto applications, including the SMR 450-R under the manual's general applicability note; the TC's Öhlins shock is identified in the specifications but does not receive the same internal overhaul coverage. The USA/CDN appendix adds a market-specific non-road-use statement, warranty and noise-control material, and TC spark-arrester instructions, while the Australian note covers noise-control requirements.

On the TE and supermoto electrical layouts, starting the engine with both the battery and frame-mounted condenser removed can damage the voltage regulator. Substituting non-original compression shims in the rear shock can cause the shock to fail explosively. Brake bleeding, hot cooling-system work, and pressurized shock service should be performed only with the specified equipment and appropriate workshop training.