2008 Husqvarna TE / TC / TXC / SMR Factory Service Manual (P/N 8000 B0148)

• Manual identity and exact model coverage: A 470-page PDF containing the Husqvarna factory workshop manual, P/N 8000 B0148, 1st Edition dated February 2008, for the 2008 TE 250/450/510 I.E., TC 250/450/510, USA-only TXC 250/450/510, SMR 450/510 I.E., and SMR 450-R.
• Engine and drivetrain repair: Covers engine removal, cylinder-head and camshaft disassembly, valve and seat work, cylinder/piston inspection, crankshaft and connecting-rod overhaul, oil-pump service, gearbox and selector inspection, clutch repair, timing-system assembly, and complete engine reinstallation. Separate procedures address the TC 5-speed gearbox, TE/TXC/SMR 6-speed gearbox, SMR 450/510 counterbalancer, and the SMR 450-R slipper clutch.
• Fuel-system and electrical diagnosis: Breaks out the Mikuni D42 electronic-injection system used on TE/SMR models from the Keihin FCR-MX 37 carburetor on TC/TXC 250 and the FCR-MX 41 system on TC/TXC 450/510 and SMR 450-R. Coverage includes the 8000 A9634 diagnosis kit, TPS idle/feedback adjustment, fuel-pump and relay checks, carburetor overhaul, charging and starting tests, ignition checks, sensor testing, digital-instrument functions, and fault tracing.
• Suspension and chassis service: Provides separate Marzocchi USD fork overhaul procedures for TE/SMR and TC/TXC/SMR 450-R configurations, including cartridge and bottom-valve work, seal and bushing replacement, oil filling, air bleeding, preload, compression, and rebound setup. The rear-suspension section covers shock removal, internal overhaul, reservoir diaphragm service, reassembly, damping adjustment, swingarm bearings, and linkage inspection.
• Brakes, hydraulic clutch, cooling, and setup work: Details separate street and competition maintenance schedules, disc and pad inspection, front and rear brake bleeding, fluid replacement, hydraulic clutch master-cylinder overhaul and bleeding, cooling-system checks, valve and decompressor adjustment, chain alignment, steering-head adjustment, wheel service, exhaust packing, and final operational checks.
• Factory kit, diagram, tool, and specification content: Includes TE/SMR racing-kit cable conversion, TC electric-start installation, SMR kick-start installation, starting-hook and accessory-kit procedures, plus USA/CDN/AUS spark-arrester and canister information. Model-specific wiring diagrams, exploded and sectional views, torque tables, fluid-capacity data, wear limits, clearance specifications, suspension settings, and electrical test values are included.

Model and Configuration Coverage

The manual distinguishes the street-legal limited-power standard configuration for TE and SMR from full-power competition conversions. TC, TXC, and SMR 450-R are treated as competition models. It also separates the major hardware differences that matter during repair: Mikuni injection versus Keihin carburetion, fan-equipped TE/SMR cooling versus the competition cooling layout, 5-speed versus 6-speed transmissions, electric/kick-start combinations, and the SMR 450-R slipper-clutch assembly.

Validity is stated from the following vehicle identification numbers:

TE: 250 ZKHA200AA8V000001; 450 ZKHA202AA8V000001; 510 ZKHA203AA8V000001
TE USA: 250 ZKHECECA*8V100001; 450 ZKHECENB8V100001; 510 ZKHECEHB8V100001
TC: 250 ZKHA200AA8V050001; 450 ZKHA202AA8V050001; 510 ZKHA203AA8V050001
TXC USA: 250 ZKHTX250*8V000001; 450 ZKHTX450*8V000001; 510 ZKHTX510*8V000001
SMR: 450 ZKHA202AB8V000001; 510 ZKHA203AB8V000001; SMR 450-R: ZKHA222AB8V050001

Diagnostic References, Tools, and Scope

The electrical section is more than a single schematic. Particularly useful references include the TE/SMR wiring diagram, TC/TXC 250 wiring diagram, TC/TXC 450-510/SMR 450-R wiring diagram, TE/SMR ECU wiring diagram, generator and starter-motor test diagrams, and Marzocchi fork cartridge/bottom-valve section views. Connector identification, component-location drawings, harness routing, charging-system checks, ignition-coil tests, gear-position and carburetor TPS checks, and digital-instrument troubleshooting are included.

Special-tool references include crankcase puller 1517 94702, TC/TXC flywheel extractor 8000 A1559, TE/SMR flywheel extractor 8000 B0144, valve assembly/removal tool 8000 39521, clutch-hub retaining wrench 8000 79015, and diagnosis kit 8000 A9634. Procedure pages also identify SMR 450-R clutch tool 8000 A8190 and Marzocchi fork fixtures where required.

This is the workshop manual, not the separate spare-parts catalog P/N 8000 B0149. It does contain model-specific optional-parts lists and factory kit installation chapters. The injection section explains connection and basic use of the diagnosis kit, identifying air- and coolant-temperature inputs, atmospheric pressure, throttle position, the SMR tilt sensor, O2 feedback and heater, battery supply, gear position, injector pulse, and ignition-coil operation. It also covers TPS adjustment plus direct fuel-pump and relay checks; the kit's separate software User's Guide and Operation Manual are referenced rather than reproduced in this PDF.

Two repair traps are called out clearly. On TXC models, starting the engine with the condenser removed after battery service can damage the voltage regulator. In the Marzocchi fork chapters, clamping outside the designated areas can deform components and irreparably damage the fork.

Brake bleeding, pressurized rear-shock repair, fuel-system work, and major engine or suspension service require secure support, proper pressure release, and the specified factory procedures before disassembly begins.