Husqvarna TE/TC/TXC/SMR 250-510 Workshop Manual (2009) (P/N 8000 H0368)

First-edition Husqvarna workshop manual, P/N 8000 H0368, issued September 2008 for the 2009 TE 250/310/450/510, TC 250/450/510, USA-only TXC 250/450/510, and SMR 450/510.

Searchable PDF, Chapter Bookmarks and Diagram Detail

Text search and wiring detail: The main text is searchable, with embedded bookmarks for the major chapters. Some labels within diagram artwork are outside text search. Small wire and connector labels in the TE/SMR wiring diagrams remain partly blurred even when enlarged.

One printable, English-language 412-page PDF, including the original cover and copyright/edition page. These two preliminary pages are already included in the total.

Engine Overhaul, Fuel-System Diagnosis and Chassis Service

This selection of covered work highlights the main repair areas. Other topics include muffler packing replacement and headlamp adjustment.

• Engine repair: Step-by-step engine removal, disassembly and reassembly, cylinder-head and valve work, piston/crankshaft inspection, timing installation, and final adjustment.

• Drivetrain and lubrication: Gearbox and clutch overhaul, selector-fork and drum inspection, oil-pump service, and illustrated assembly and lubrication references.

• Fuel-system service: TE/SMR injection diagnosis and TPS-adjustment requirements; carburetor overhaul and tuning sections for TC 450/510 and TXC 250/450/510.

• Electrical troubleshooting: Charging, starter and ignition tests, GPS/TPS checks, digital-instrument service, connector identification, harness routing, and variant-specific wiring diagrams.

• Suspension repair: Marzocchi fork teardown and reassembly, Sachs rear-shock overhaul, damping adjustment, and swingarm and linkage inspection.

• Brakes, clutch and cooling: Brake bleeding, hydraulic-clutch master-cylinder repair and reverse bleeding, radiator and hose inspection, plus frame and wheel service.

• Workshop reference: Maintenance schedules, torque tables, clearances, wear limits, fluid specifications, diagnostic charts, exploded views, and OEM special-tool numbers.

Written for Husqvarna workshops and authorized service personnel, this manual assumes technical knowledge, workshop experience, and the specified tools and measuring equipment.

Road and Competition Configurations

The manual distinguishes standard, limited-power TE/SMR road configurations from full-power competition versions, with separate road and racing maintenance schedules.

Starting-system coverage follows the variants: TC kick start, TE/TXC electric and kick start, and SMR electric start with an optional kick-starter kit. The transmission chapters provide separate assembly sequences for TC and TE/TXC/SMR gearboxes.

Section O documents TE/SMR full-power conversion parts and ECU-mapping requirements. It identifies the converted configuration as intended for closed-circuit competition. The TE dual-mode switch section explains dry- and wet-ground map selection.

Kit installation chapters cover engine guards, SMR passenger footrests and kick starter, TE hand guards, TE/SMR turn signals, the TC/TXC race-start hook, and a racing license-plate holder.

Internal Engine Inspection and Assembly

Overhaul coverage extends to valve-seat recutting and guide replacement, camshaft and timing-chain inspection, cylinder-to-piston fitting, piston-ring and connecting-rod checks, crankshaft runout, and SMR counterbalancer work.

The cylinder-head gasket selection chart matches piston deck position to gasket thickness and part code. It provides a reference for selecting the gasket after work that affects the piston’s position relative to the cylinder.

Injection Diagnostics and Carburetor Overhaul

TE/SMR injection: The Mikuni D42 section explains connection of Diagnosis Software Kit 8000 A9634, current and stored fault checks, sensor and controlled-component checks, and fault-memory clearing. Fuel-pump and relay tests support troubleshooting alongside the diagnostic readings.

After throttle-body removal or replacement, the manual specifies the TPS idle and feedback adjustment commands. Detailed software operation relies on the diagnostic kit’s separate user and operation guides.

The diagnostic software, interface cable, separate kit guides, and ECU reprogramming kit 8000 H0237 are referenced service equipment and documentation; they are not included with this PDF.

Carburetor models: The detailed overhaul and adjustment sections identify TC 450/510 and TXC 250/450/510. They cover jets and passages, needle-valve sealing, throttle-slide movement, float height, accelerator-pump inspection, and model-specific baseline settings for the Keihin FCR-MX 37 and 41 carburetors.

Suspension, Hydraulic Controls and Electrical References

Separate TE/SMR and TC/TXC fork sections describe cartridge and valve work, seal and bushing replacement, oil filling, air bleeding, and damping-stack inspection. The SHIVER 50 Factory Works component section view illustrates the internal arrangement.

Sachs rear-shock coverage includes spring and reservoir service, piston-unit inspection, seal and diaphragm replacement, oil filling and bleeding, gas recharge, and damping adjustment. Fork and shock service involves spring load and stored pressure.

Brake procedures distinguish TE/TC/TXC and SMR front-system bleeding. The hydraulic-clutch chapter covers fluid discharge, master-cylinder overhaul, and reverse bleeding, and expressly prohibits brake fluid in the clutch circuit.

Electrical references include TE/SMR, TXC 250, and TC/TXC 450-510 wiring diagrams, the TE/SMR ECU schematic, and the starter-motor test chart. A separate lubrication-system diagram identifies the oil circuits and components.

The TXC battery-removal instructions warn that starting the engine with the condenser removed can damage the voltage regulator.

Special Tools and Service Updates

The tool list identifies crankcase puller 1517 94702, flywheel extractors 8000 A1559 and 8000 B0144, valve tool 8000 39521, assembly support 8A00 90662, and clutch-hub wrench 8000 79015.

As a first-edition publication, the manual directs technicians to consult applicable Husqvarna service bulletins for updated adjustment data and repair methods.

Preview of Valve-Clearance and Shim Data

For all covered models, the cold-engine valve-clearance check specifies 0.10–0.15 mm for intake valves and 0.15–0.20 mm for exhaust valves.

The adjustment section lists replacement shims from 1.60 to 2.60 mm in 0.05 mm increments. The reassembly chapter also provides the calculation for selecting a replacement shim from the measured clearance and existing shim thickness.