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.
Manual Preview
Sample pages from the 2004 Husqvarna TE 250-450, TC 250-450, SM 450 R/ 2003-2004, SM 400, TE 510-TE 510 Centennial Workshop Manual manual
Purchase & Download
Models Covered & Key Technical Specifications
2004 Husqvarna TE 250-450, TC 250-450, SM 450 R/ 2003-2004, SM 400, TE 510-TE 510 Centennial - Workshop Manual & Repair Procedures (Part. N. 8000 A2925) Covers TE 250, TE 450, TC 250, TC 450, SMR 400, SM 450 R, TE 510, and TE 510 Centennial models. Specification-Class | Specification-Class | Specification-Class
- Engine Specifications: 4-stroke, single cylinder, with bore sizes ranging from 76 mm to 97 mm and stroke lengths from 55 mm to 67.8 mm, displacement from 249.5 cc to 501.03 cc.
- Timing System: Features double overhead camshafts with 4 valves per cylinder, and specific valve angles for intake (12°) and exhaust (13°).
- Fuel System: Gravity fed with dry type air filter and Mikuni carburetors (TMR 36, TMR 38, TMR 41 depending on model).
- Lubrication System: Dry sump system with two oil pump rotors and a cartridge filter for optimal engine protection.
- Cooling System: Liquid-cooled with a dual radiator system for efficient thermal management.
- Ignition System: Electronic capacitive discharge system with digital controlled variable spark advance, using NGK CR8EB spark plugs with a 0.7 mm gap.
Manual Description & Preview
Husqvarna TE/TC/SM Manual: Husqvarna TE 250, TE 450, TC 250, TC 450, SM 450 R, TE 510 & TE 510 Centennial - Workshop Manual & Repair Procedures (2004) Technical-Guide
Calibration-Scope: TE 250-510 Series // Specification-Class: Motorcycle // Calibration-Scope: All Models
Important Notices & General Information
This manual details the operations necessary for the removal of the engine from the motorcycle. It also covers partial disassembly procedures for accessing other components like the rear shock absorber, electrical parts, and wiring harness.
Diagnostic Procedures
Diagnostic procedures address engine starting issues, weak or no spark, fuel system problems, carburetor malfunctions, engine noise, overheating, and electrical system faults.
Maintenance Procedures
Maintenance schedules and procedures for various intervals are outlined, covering pre-delivery inspections, routine checks, and replacement of parts like filters, fluids, and chains.
Technical Specifications Table
| Component | Technical-Path | Calibration-Standards |
|---|---|---|
| Engine | 4-stroke, single cylinder | 249.5 cc - 501.03 cc |
| Carburetor | Mikuni TMR (36/38/41) | Multiple specifications based on model |
| Suspension | Front & Rear | Multiple adjustment points for compression and extension |
| Brakes | Front & Rear | Disc brake system with specific fluid requirements |
| Transmission | Chain drive with multiple gear ratios | Specific chain tension and lubrication guidelines |
| Electrical System | 12V system | CDI ignition, various lighting and signaling components |
Table of Contents Summary
- Engine Removal: Step-by-step guide to removing the engine assembly.
- Saddle and Battery Removal: Procedures for disconnecting and removing the battery and seat.
- Side Panel Removal: Instructions for detaching the motorcycle's side panels.
- Rear Frame and Air Filter Box Assembly Removal: Detailed steps for removing the rear frame, fender, tail light, and air filter box.
- Exhaust System Removal: Steps for detaching the exhaust silencer and related components.
- Fuel Tank and Conveyor Removal: Instructions for removing the fuel tank and associated fuel lines.
- Carburetor Removal: Procedures for accessing and removing the carburetor, including fuel system disconnection.
Troubleshooting and Adjustments
This manual provides detailed troubleshooting guides for common engine and chassis issues, offering step-by-step solutions and adjustments for optimal performance. It covers adjustments for valve clearance, carburetor settings, chain tension, brake levers, suspension settings, and more. The manual also includes specific maintenance schedules for different riding conditions (road vs. competition). Torque Statement: Procedures document torque specifications for fasteners to ensure proper assembly and prevent fastener fatigue prevention.
FAQ
Customer Reviews
Read what our customers say about this Husqvarna Motorbike manual and share your own experience.