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)
533 Pages • 20.78 MB • Instant, Printable PDF
Husqvarna Models Covered & Key Technical Specifications
Models: TE 250, TE 450, TC 250, TC 450, SMR 400, SM 450 R, TE 510, TE 510 Centennial
Sub-models / Variants: TE, TC, SM 400 R, SMR 400, SMR 450, Centennial
Model Years: 2003–2004
Serial Numbers: TC 250: ZCGH800AA3V050001 (2003) - ZCGH800AA4V050001 (2004), TC 450: ZCGH802BA3V050001 (2003) - ZCGH802BA4V050001 (2004), TE 250: ZCGH800AC3V000001 (2003) - ZCGH800AC4V000001 (2004), TE 450: ZCGH802BC3V000001 (2003) - ZCGH802BC4V000001 (2004), SMR 400: ZCGH801AD4V000001 (2004), SMR 450: ZCGH802BD3V000001 (2003) - ZCGH802BD4V000001 (2004), TE 510: ZCGH803CA4V000001 (2004), TE 510 Centennial: ZCGH803CB4V000001 (2004)
Technical Data:
- Engine: 4-stroke, single cylinder
- Displacement: 249.5 cc to 501.03 cc
- Compression ratio: 12:1 to 12.5:1
- Valvetrain: Double overhead camshaft, 4 valves
- Fuel system: Mikuni TMR carburetors with TPS and acceleration pump
- Cooling: Liquid-cooled with dual radiators
- Lubrication: Dry sump with two lobe pumps and cartridge filter
- Starting: Electric with automatic decompressor
Husqvarna Manual Features & Content Preview
- 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 fuel-injection specifications
- Includes 15 detailed 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
Document Structure and Technical Details
This factory 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. 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.
The manual also breaks down the electrical system and cooling circuits while mapping out optional parts configurations. You will find comprehensive periodic maintenance tables inside. These schedules are split specifically for motocross and enduro demands, cross-referencing component service limits, replacement intervals, and factory torque specs.
Specification Highlights
Technical data is straightforward and clearly laid out. 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.
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