2004 Husqvarna TE 250-450, TC 250-450, SM 450 R/ 2003-2004, SM 400, TE 510-TE 510 Centennial Workshop Manual

2004 Husqvarna TE, TC, SMR, and TE Centennial models with workshop manual procedures for maintenance and repair. Publication Part. N. 8000 A2925.

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Husqvarna 2004 Husqvarna TE 250-450, TC 250-450, SM 450 R/ 2003-2004, SM 400, TE 510-TE 510 Centennial Workshop Manual manual page preview - page 1 of 533

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Technical Safety Notice
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This official OEM document is intended for professional technicians and skilled operators. Performing service on mechanical equipment involves inherent risks. By purchasing, you acknowledge that RepairLoader provides original manufacturer data for informational purposes. Always prioritize safety: use correct tools, wear protective gear, and consult a certified professional if you are uncertain of any procedure.

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
Build 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
Technical Specifications
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Document Number / Seller:
28497 / Jerry Bell
File Size:
20.78 MB
File Type:
PDF
Language:
English, Italian, France, German, Spanish
Pages:
533
Printable:
Yes
Category:
Motorbike
Last updated / verified
Dec 7, 2025

Husqvarna Manual Features & Content Preview

2004 Husqvarna TE/TC/SM Workshop Manual Coverage

  • Built for 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, and electrical specifications
  • Indexed PDF search covers every chapter and appendix
  • Re-download the file any time, no expiration
  • Includes 15 detailed maintenance schedules tailored for competition and road usage
  • Documents serial number ranges for correct model identification across 2003–2004 production cycles
  • This specific document serves as the primary factory reference for the launch build of the 510-series engine and early SMR model configurations

Document Structure and Technical Scope

This 533-page Husqvarna TE/TC/SM workshop manual provides technical documentation for the maintenance and repair of the 2003–2004 Husqvarna performance motorcycle range. The manual begins with essential notices regarding safety and operational warnings, followed by a detailed general section covering engine, transmission, and chassis components. The documentation spans 18 distinct chapters, detailing the procedures for engine disassembly, overhaul, and re-assembly alongside frame, suspension, and brake service information.

Additional segments within this Husqvarna TE/TC/SM publication offer a structured look at the electrical system, cooling arrangements, and optional parts configuration. The document contains comprehensive periodic maintenance schedules, which are split to define intervals for both motocross and enduro usage requirements. These tables cross-reference specific component service needs, replacement schedules, and torque settings to assist in how factory workshop documentation is structured.

Specification Highlights

The 2004 Husqvarna TE 250 engine displacement is documented at 249.5 cc. Intake valve clearance is listed at 0.10–0.15 mm in the engine specification table. Fuel tank capacity for the 2004 TE 510 Centennial model is documented at 10.5 liters. The electrical system provides diagnostic details for the 12V-450W starting motor and various lighting specifications for the TE and SMR variants. Data tables detail the 6-speed gear ratios and primary transmission gear settings for the 250, 400, 450, and 510 engine families. Reference values for Marzocchi front forks and Sachs rear shocks are provided to define factory-recommended clearances and adjustment ranges.

Reference only — always consult a certified technician before performing service on this equipment.

An official 533-page Husqvarna OEM workshop manual covering the 2003–2004 TE, TC, and SMR series, documenting engine, chassis, electrical, and fuel-injection specifications for the specified production serial numbers.

Document Reference: Part. N. 8000 A2925 (03-2004)

Manual FAQ, Purchase & Download Details

What documentation is contained in the PDF regarding the ignition system, charging components, and switchgear? keyboard_arrow_down

Manual includes technical details for the electronic capacitive discharge ignition system, which features a digital controlled variable spark advance and specific spark plug requirements.

Is the manual an official document for the Husqvarna workshop program? keyboard_arrow_down

PDF is labeled as an official Workshop Manual with part number 8000 A2925, dated 03-2004. It serves as a comprehensive reference document intended for use by authorized Husqvarna service stations.

Are the engine, transmission, and cooling system sections included in the chapter coverage? keyboard_arrow_down

Document contains dedicated chapters for engine disassembly, overhauling, and re-assembly alongside sections for the liquid-cooled dual radiator system. It also covers the hydraulic control clutch system to support professional technical training.

Which technical data categories are referenced in the specification tables? keyboard_arrow_down

Specification tables list technical categories such as bore and stroke measurements, valve angles, and tightening torque wrench settings for the covered motorcycle models.

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