2004 Husqvarna TE 250/450, TC 250/450 & SM 450 R (2003–2004), SM 400 R, TE 510 & TE 510 Centennial Workshop Manual (P/N 8000 A2925)

This Husqvarna workshop manual, P/N 8000 A2925, is the March 2004 first edition published by MV Agusta Motorcycles for the 2003–2004 TE 250, TE 450, TC 250, TC 450, SMR 400, SM 450 R, TE 510, and TE 510 Centennial.

• Engine repair: Engine removal, cylinder-head and crankcase disassembly, crankshaft rebuilding, valve-seat work, camshaft inspection, and valve-timing setup.

• Transmission and clutch: Separate TC and TE/SMR gearbox assembly instructions, clutch inspection, hydraulic clutch master-cylinder overhaul, and system bleeding.

• Fuel and cooling: Mikuni TMR carburetor overhaul and jetting tables, water-pump disassembly, radiator inspection, coolant replacement, and hose checks.

• Suspension and wheels: Marzocchi USD fork and Sachs shock rebuilding, damping adjustments, swingarm linkage inspection, wheel-bearing replacement, and rim checks.

• Brakes: Disc and pad inspection, separate TE/TC and SMR front-brake bleeding procedures, rear-brake bleeding, and fluid replacement.

• Electrical troubleshooting: Starting, ignition, charging, and battery fault tables, component specifications, and removal instructions for the ignition coil, control unit, and voltage regulator.

Written for authorized Husqvarna workshop personnel, this manual assumes mechanical experience and familiarity with the specified tools and inspection equipment.

Engine, Gearbox and Carburetor Work

The engine-overhaul section provides piston-to-cylinder matching information, valve-guide wear limits, connecting-rod clearances, and selector-fork measurements. The hardened cylinder bore is not intended for conventional reboring.

Separate TC and TE/SMR transmission exploded views help identify the correct shaft and gear arrangement before reassembly. Gear-ratio and primary-drive tables distinguish the engine families.

The Cylinder Head Gasket Selection Chart links gasket selection to piston height.

Assembly drawings identify lubrication points and fastener requirements, supported by component-specific torque tables. The special-tool list includes crankcase puller 1517 94702 and flywheel extractor 8000 A1559.

Valve-disassembly cautions explain how an incorrectly aligned spring compressor can bend a valve stem.

Mikuni TMR carburetors: Application-specific tables distinguish TMR 36, TMR 38, and TMR 41 units. The overhaul material covers throttle-slide, float, needle-valve, and metering-needle inspection, with jetting and needle-position references.

Maintenance, Suspension and Brakes

The maintenance charts distinguish motocross and enduro service demands, while the SMR schedules separate competition and road use. Inspection, replacement, cleaning, lubrication, and overhaul requirements are identified by component.

Marzocchi's Fork Working cross-sections explain compression and rebound oil flow. The fork troubleshooting chart connects oil leakage, excessive stiffness, and unresponsive adjusters with possible causes; Sachs shock procedures extend to the reservoir, diaphragm, seals, and damper rod.

TE 510 Centennial-specific fork settings and rear brake-pad limits are identified in the relevant sections. Braking System and Hydraulic Clutch System layouts show the hydraulic assemblies and their connections.

Optional-parts lists cover suspension springs, gearing, and Enduro kits. Regional notes include USA/CDN spark-arrester inspection and cleaning.

Electrical Coverage and Cooling Layout

Electrical scope: Chapter M is listed as unfinished in the contents and is absent from this edition. Electrical coverage consists of specifications, troubleshooting tables, and component-removal instructions; wiring diagrams are not included.

The safety notices cover battery isolation on Version A models, which lack an engine start-stop switch and can crank unexpectedly during service. The condenser warning explains how cranking with the battery and condenser removed can damage the voltage regulator.

The Cooling System layout identifies the radiators, water pump, hose connections, and TE/SMR expansion-tank kit. Inspection guidance covers restricted airflow and deteriorated hoses.

Selected Valve, Fuel and Starter Data

These are a few examples from the manual's adjustment, capacity, and electrical specifications.

For the covered engines, cold valve clearance is 0.10–0.15 mm at the intake and 0.15–0.20 mm at the exhaust. The adjustment section also provides a shim-selection calculation.

The metric capacity table lists 10.5 liters of fuel, including reserve, for the TE 510 Centennial. Electrical specifications identify a 12 V, 450 W starter motor; the separate fault tables address starting and charging problems.

Searchable Text and PDF Contents

Text search and navigation: Written sections are searchable; some illustration labels are embedded in images. There are no embedded PDF bookmarks.

Supplied as one printable 533-page PDF with English, Italian, French, German, and Spanish text. The total already includes the two unnumbered opening pages, seven otherwise blank pages, and the manual's regional notes.