Husqvarna TE/TC/SM 2005 Service & Repair Manual (P/N 8000 A4443)

• Factory publication and format: A 605-page PDF, first edition dated November 2004, published by MV Agusta Motorcycles as P/N 8000 A4443. The page count includes Italian, English, French, German, and Spanish content.
• Model coverage: Covers the 2005 TE 250/450/510, TC 250/450/510, and SM 400 R/450 R/510 R—identified throughout the procedures as SMR—with title-page starting-VIN tables for standard and USA/CDN machines.
• Engine and transmission repair: Documents engine removal, complete disassembly and inspection, crankshaft and counterbalancer work, DOHC cylinder-head and valve service, piston/cylinder repair, clutch and oil-pump service, timing-system installation, and separate TE-SMR and TC gearbox reassembly.
• Fuel, cooling, and hydraulic systems: Includes Keihin and Mikuni carburetor overhaul and setting data, TPS checks, dual-radiator cooling-system inspection, and hydraulic-clutch master-cylinder overhaul, fluid replacement, and bleeding.
• Chassis and brake work: Details Marzocchi USD fork and Sachs rear-shock overhaul, swingarm/linkage and wheel service, steering adjustment, chain/sprocket inspection, brake-pad and disc checks, fluid replacement, and front/rear brake bleeding.
• Diagnostics and shop references: Provides model-specific wiring diagrams, charging/starter/CDI tests, component-location and harness-routing views, fault charts, maintenance schedules, torque tables, wear limits, fluid data, optional-kit instructions, and a factory special-tool list.

Husqvarna prepared this publication for its workshops and authorized personnel; the engine teardown, electrical testing, and pressurized-suspension work assume shop-level experience, precision measuring equipment, and the specified service tools.

VIN Coverage and Regional Differences

The general-market validity table gives a separate starting VIN for every covered model:

A second table supplies USA/CDN VIN patterns. The main chapters treat TE and TC as competition motorcycles and give SMR separate road-use and competition maintenance schedules. Chapter Z adds USA/CDN/Australia noise-control notices, a U.S. off-highway statement, and TE/SMR spark-arrester maintenance.

Carburetor, Gearbox, and Engine Rebuild Coverage

This is carbureted coverage, not fuel injection. The 250 uses a Keihin FCR-MX 37, SM 400 R uses a Mikuni TMR 38, and the 450/510 models use a Keihin FCR-MX 41; each is shown with an accelerator pump and TPS. The manual gives overhaul and setting data for both carburetor families. It also distinguishes the five-speed TC from the six-speed TE/SMR transmissions, TE electric-and-kick starting from TC/SMR electric starting, and the related optional kick-start equipment.

Engine repair includes crankcase splitting, crankshaft and counterbalancer removal, selector forks and drum, valve-seat recutting and valve-guide replacement, cam chain and tensioner, cylinder/piston/ring and connecting-rod inspection, clutch and dry-sump oil-pump work, and a cylinder-head-gasket selection chart for reassembly. The kit chapter covers guards, carburetor kits, passenger footrests, turn signals, a racing harness, the TC race-start hook, and optional kick-starter installation, with model and regional restrictions.

Suspension, Electrical, and Diagnostic Depth

The suspension section covers full disassembly and rebuild, not adjustment alone: Marzocchi fork-seal and damping-unit procedures, fork troubleshooting, Sachs shock disassembly and reassembly, and service for the swingarm, linkage, bearings, wheels, and chain drive. Brake coverage distinguishes TE/TC and SMR hardware and includes wear inspection, fluid replacement, and bleeding.

Named illustrations include the TE/SMR wiring diagram; the TC and USA/CDN TE/SMR wiring diagram; electrical-component location views; generator and starter-motor test diagrams; frame harness routing; and the cooling-circuit layout. Electrical repair coverage includes battery leakage, regulated output, stator and ignition-coil resistance, regulator/rectifier, starter relay and motor, gear-position and throttle-position sensor checks, connectors, fuses, lighting, and fault isolation.

Factory tool callouts include crankcase puller 1517 94702, flywheel extractor 8000 A1559, ignition checker 8000 A1512, clutch-hub wrench 8000 79015, and fork tools 8000 91288 and 8000 91289.

Model-Specific Repair Cautions and Scope

After battery removal, the manual warns that the condenser must remain on the frame; starting without it can damage the voltage regulator. In the Sachs shock, substituting other compression-shim blades can cause the damper to rupture in use. Pressurized suspension, brake, and engine work should be performed with the specified support and service tools and the factory safety notes.

The PDF includes an optional-parts list, not the separate illustrated spare-parts catalog, which the manual identifies as P/N 8000 A4444. Husqvarna also directs shops to applicable Service Bulletins for newer adjustment data or repair methods.