Husqvarna TE/TC/SM/SMR 2006 Workshop & Parts Manual Set (P/N 8000 A5911)

Use the workshop procedures alongside the catalog’s numbered exploded views to identify components and their OEM part numbers when planning a repair. Each publication has its own model-specific starting serial numbers, listed in the coverage box above.

SMR 450-R coverage: Repair material is included in the workshop manual; the parts catalog does not cover this configuration.

PDF Search, Chapter Bookmarks, and Diagram Detail

Search and diagram labels: Running text in both publications supports PDF text search. Embedded bookmarks open the workshop chapters and the beginning of the parts catalog; individual catalog plates are not separately bookmarked. Wiring diagrams contain image-based labels that are not text-searchable. Small wire-color codes and connector markings require zooming.

One printable, 904-page PDF contains both publications in English, Italian, French, German, and Spanish. Original covers, preliminary pages, indexes, and section divider pages are included in the publication totals above.

Engine Overhaul, Chassis Service, and Parts Identification

These selected content highlights summarize the main workshop areas. Further topics include muffler packing replacement and USA/CDN spark-arrester inspection.

• Engine repair: Step-by-step procedures for engine removal, cylinder-head and valve-train work, piston and crankshaft inspection, oil-pump service, and final reassembly.

• Clutch and transmission: Clutch replacement, gear-shaft and selector inspection, transmission reassembly, and separate procedures for the SMR 450-R clutch.

• Fuel and electrical systems: Mikuni and Keihin carburetor overhaul, TPS and gear-position sensor checks, charging and starter diagnosis, ignition testing, and configuration-specific wiring diagrams.

• Suspension and chassis: TE 250 Marzocchi fork service, TE/SMR rear-shock overhaul, swingarm and linkage repair, steering-head inspection, wheel service, and chain checks.

• Brakes and hydraulic clutch: Model-specific pad and disc inspection, fluid replacement, bleeding, clutch master-cylinder overhaul, and operational checks.

• Parts identification: Numbered exploded views, OEM part numbers, model and market applicability notes, color variants, 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.

Engine, Transmission, and Starting Configurations

The engine chapters address DOHC valve-train inspection, valve-seat work, cylinder and piston matching, crankshaft checks, and the SMR counterbalancer. The cylinder-head gasket-selection chart and staged cross-pattern tightening instructions support reassembly alongside component-specific torque tables, clearances, and wear limits.

TC and TE/SMR transmission assemblies are treated separately. Kick-start, electric-start, and optional starter-kit configurations have their own material, including installation instructions for the optional starting equipment.

Pre-delivery checks and maintenance schedules distinguish full-power competition operation from limited-power, street-legal TE/SMR use. Cause-and-remedy charts address hard starting, poor performance, engine and driveline noise, clutch and gearbox faults, chassis behavior, braking problems, and electrical failures.

Fuel, Cooling, and Electrical Diagnosis

Carburetor sections distinguish the Mikuni-equipped SM 400 R from the Keihin-equipped models, with overhaul illustrations, jetting data, float checks, and adjustment information.

Electrical references include the TE/SMR wiring diagram, the TC 250 and USA/CDN-market diagram, and the TC 450/510 and SMR 450-R diagram. A generator test diagram adds charging-system reference data. Digital instrument configuration, replacement, and wiring-harness routing are also covered.

The cooling-system circuit view identifies the pump, radiators, hoses, and expansion-tank arrangement. Related inspection material addresses restricted airflow, radiator damage, and deteriorated coolant hoses.

Suspension Limits and SMR 450-R Equipment

Front fork: The internal overhaul chapter is specifically for the TE 250 Marzocchi 45 USD fork. Exploded and damping-flow views accompany fault isolation, oil and seal service, air bleeding, damping-unit disassembly, and adjustment. Larger Marzocchi forks are identified, but equivalent internal overhaul instructions are not included.

Rear shock: Internal overhaul is labeled for Sachs-equipped TE/SMR models. The TC Öhlins unit is identified, but that procedure does not cover its internal overhaul. Chassis references also include frame-alignment dimensions and wheel-bearing inspection.

SMR 450-R: Dedicated material covers carbon components, adjustable steering-head bushings, the starting hook, handguards, handlebar, muffler, and fluid catch tank. Bushing-combination charts distinguish steering offset and angle settings.

Factory Tools, Parts Plates, and Repair Cautions

Factory tool references identify crankcase puller 1517 94702, flywheel extractor 8000 A1559, and ignition checking tool 8000 A1512. Clutch tools include retaining wrench 8000 79015 and SMR 450-R assembly wrench 8000 A8190; fork tooling includes cartridge retainer 8000 91289.

Catalog plates run from 1 through 38, with additional A/B variants. Separate illustrations distinguish carburetors, transmissions, fork and shock versions, front-brake layouts, and wiring harnesses. Applicability and color notes connect these drawings to the listed parts.

The engine-removal section warns that starting with the frame-mounted condenser removed can damage the voltage regulator. Electrical notes also identify the risk of ECU or regulator-rectifier damage from incorrect semiconductor testing.

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

A Preview of Valve and Charging-System Specifications

Valve-adjustment data specifies cold-engine clearances of 0.10–0.15 mm for the intake valves and 0.15–0.20 mm for the exhaust valves. The accompanying shim-selection information connects measured clearance to replacement-pad thickness.

For the TE/SMR battery-charging check, the regulated-voltage range is 12.5–14.5 V with the engine warm, running slightly above 3,000 rpm, and the battery charged. Related sections provide generator and regulator checks for investigating an out-of-range reading.