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

• Built for the 2003–2004 Husqvarna TE 250, 450, 510, TC 250, 450, SMR 400, 450, and TE 510 Centennial performance motorcycles
• Official MV Agusta Motorcycles publication P/N 8000 A2925, dated March 2004
• Contains 533 pages of engine, chassis, electrical, and Mikuni TMR carburetor specifications
• Includes 15 detailed periodic maintenance schedules tailored for competition and road usage
• Documents serial number ranges for correct model identification across 2003–2004 production cycles
• Serves as the primary factory reference for the launch build of the 510-series engine and early SMR configurations
• Details engine overhauling, hydraulic clutch bleeding, front fork rebuilds, valve clearance adjustments, and carburetor tuning
• Features wiring diagrams, troubleshooting charts, exploded views, torque wrench setting tables, routing schematics, and specific tools lists

Document Structure and Technical Details

This factory PDF publication delivers the hard data required to maintain and overhaul the 2003–2004 Husqvarna lineup. It kicks off with essential operational warnings and safety protocols—critical reading to prevent equipment damage or personal injury before turning a wrench. For instance, on "Version A" models lacking an engine start-stop switch, you must always disconnect the battery prior to service to prevent accidental engine engagement.

Mechanics should also be aware of a costly repair trap involving the ignition condenser on these electric-start configurations. If you remove the condenser after taking out the battery, any accidental engine cranking will instantly destroy the voltage regulator. To safely prevent this electrical damage, always push the starter button once immediately after battery removal to completely discharge the system.

From there, the documentation dives into 18 highly structured chapters. You get detailed teardown, inspection, and reassembly parameters for the engine, transmission, frame, and suspension. If you want to bypass expensive dealership visits, this guide provides the exact step-by-step instructions needed for complex tasks like bleeding the hydraulic clutch, overhauling the Marzocchi USD front forks, and completely rebuilding the bottom end.

The manual breaks down the electrical system and cooling circuits while mapping out optional parts configurations. You will find comprehensive maintenance charts inside. These schedules are split specifically for motocross and enduro demands, cross-referencing component service limits, replacement intervals, and factory torque specs. Having direct access to strict factory tolerances on your workbench ensures accurate component alignment and prevents stripped crankcase threads.

Specification Highlights

Technical data is straightforward and clearly laid out, utilizing detailed wiring diagrams, exploded views, troubleshooting charts, electrical schematics, and fluid capacity tables. For instance, the TE 250 engine displacement is listed at 249.5 cc, with intake valve clearances specified between 0.10 and 0.15 mm. If you are looking at the TE 510 Centennial, the tank capacity sits at 10.5 liters. Electrical diagnostic values are provided for the 12V-450W starting motor alongside comprehensive lighting specs for both TE and SMR variants.

The manual details six-speed gear ratios and primary transmission settings for the 250, 400, 450, and 510 engine families. Suspension data is equally deep. It provides reference values, factory-recommended clearances, and adjustment ranges for both the Marzocchi front forks and Sachs rear shocks.