2006 Husqvarna TE 250 / TE 450 / TE 510 / TC 250 / TC 450 / TC 510 / SM 400 / SM 450 R / SMR 450 R Workshop Manual (P/N 8000 A5911)

• A 904-page PDF set in English, Italian, French, German, and Spanish: the 708-page Workshop Manual P/N 8000 A5911, 1st Edition (03-2006), plus the 196-page Spare Parts Catalog Part/Catalog No. 8000 A5912, Ed. 11-2006.
• Engine coverage follows removal from the motorcycle through internal inspection, repair, and final reassembly. The cylinder head, valve train, piston, crankshaft, oil pumps, clutch, transmission, and starter systems are all addressed.
• Fuel and electrical sections cover Mikuni and Keihin carburetor overhaul and adjustment, TPS and gear-shift position sensor checks, charging and starter diagnosis, electronic ignition testing, digital instrument setup, and configuration-specific wiring diagrams.
• Chassis procedures include steering-head and wheel inspection, TE 250 Marzocchi fork service, TE/SMR rear-shock overhaul, swingarm and linkage repair, suspension setup, chain service, and frame-alignment reference dimensions.
• Brake and hydraulic-clutch chapters provide model-specific pad and disc inspection, fluid replacement, bleeding, clutch master-cylinder overhaul, and operational checks for the TE, TC, SM/SMR, and SMR 450-R configurations.
• Parts-catalog content adds numbered exploded views, model and market applicability codes, OEM part numbers, color-version notes, initial serial numbers, and a numerical part-number index.

The workshop manual was expressly prepared for Husqvarna workshops and authorized personnel. It supplements personal experience and factory training, making the set appropriate for professional motorcycle technicians equipped for precision engine, suspension, brake, and electrical repair work.

Model and VIN Coverage

The Workshop Manual covers the 2006 TE 250, TE 450, TE 510, TC 250, TC 450, TC 510, SM 400 R, SM 450 R, SM 510 R, and SMR 450-R. The catalog is limited to the TC/TE 250-450-510 and SMR 400-450-510 families; it does not include the SMR 450-R. The # character below is reproduced exactly as printed in the OEM serial tables.

Configuration-Specific Repair Depth

The engine chapters cover the four-stroke, DOHC four-valve singles and distinguish the Keihin FCR-MX 37 used on 250 models, the Mikuni TMR 38 fitted to the SM 400 R, and the Keihin FCR-MX 41 used on the 450/510 range. They separate the TC five-speed transmission from the TE/SMR six-speed unit, identify the SMR counterbalancer, and provide different clutch procedures for the SMR 450-R. Kick-start, electric-start, and optional starter-kit configurations are handled separately. The pre-delivery checklist and maintenance schedules distinguish full-power competition use from limited-power, street-legal TE/SMR operation.

Cause-and-remedy charts address hard starting, poor engine performance, engine and driveline noise, clutch or gearbox faults, steering and suspension behavior, braking problems, and electrical failures.

The internal front-fork repair chapter is specifically for the TE 250 Marzocchi 45 USD fork. It covers fault isolation, oil and seal service, air bleeding, complete disassembly, damping-unit work, and compression/rebound adjustment. Larger Marzocchi forks used on the 400/450/510 models are identified, but no equivalent internal overhaul chapter is provided. Rear-shock overhaul is labeled for the Sachs-equipped TE/SMR models; the TC Öhlins unit is identified, but its internal overhaul falls outside that procedure's scope.

The SMR 450-R receives dedicated material for its separate clutch, carbon components, adjustable steering-head bushings, starting hook, handguards, handlebar, muffler, and fluid catch tank. Its steering chapter maps the supplied offset and angle bushing combinations.

Electrical Diagrams, Factory Tools, and Reference Data

Named references include the TE/SMR wiring diagram; the TC 250 and USA/CDN-market TE/SMR electrical diagram; and the TC 450/510, SMR 450-R, and USA/CDN-market TE/SMR diagram. Other examples are the generator test diagram, Marzocchi fork exploded and damping-flow views, and the cooling-system circuit view.

The catalog carries plates numbered 1 through 38, plus configuration-specific A/B variants and a numerical index. Separate drawings identify the carburetors, transmissions, fork and shock versions, front-brake layouts, and wiring harnesses.

Factory tool listings identify crankcase puller 1517 94702, flywheel extractor 8000 A1559, and ignition checking tool 8000 A1512. Further repair references specify clutch-hub retaining wrench 8000 79015, SMR 450-R clutch assembly wrench 8000 A8190, and fork cartridge retainer 8000 91289. Supporting data includes the cylinder-head gasket-selection chart and staged cross-pattern tightening sequence, plus torque tables, carburetor jetting, clearances, wear limits, fluid specifications and capacities, suspension settings, and electrical test values.

Manual-Specific Repair Cautions

During engine removal, the frame-mounted condenser must remain installed after battery removal; starting without it can burn the voltage regulator. The specified semiconductor test methods also matter because an incorrect check can seriously damage the ECU or regulator-rectifier.

Trained workshop practice is required around engine internals, brakes, pressurized suspension components, and electrical testing. The motorcycles lack a cooling fan and thermostat, so extended idling can overheat the engine; sustained full-throttle road operation can cause severe engine damage.