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

• 412-page PDF — official first-edition Husqvarna workshop manual, Part/Print No. 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.
• Covers engine removal and disassembly, cylinder-head and valve repair, piston/crankshaft inspection, gearbox and clutch overhaul, oil-pump service, timing installation, reassembly, and final adjustment.
• Separates TE/SMR Mikuni D42 electronic injection from TC/TXC Keihin FCR-MX 37 and 41 carburetors, with the applicable diagnosis, TPS setup, overhaul, and tuning procedures.
• Maps TE/SMR, TXC 250, and TC/TXC 450-510 electrical systems, including charging, starter, ignition and GPS/TPS checks, digital-instrument service, connector identification, and wire-harness routing.
• Details Marzocchi fork repair, Sachs rear-shock overhaul, swingarm and linkage inspection, brake bleeding, cooling-system inspection, hydraulic-clutch master-cylinder repair, and frame/wheel service.
• Provides exploded views, wiring and lubrication schematics, diagnostic charts, maintenance schedules, torque tables, clearances, wear limits, fluid specifications, and OEM special-tool numbers.

Model and Configuration Coverage

The manual distinguishes street-legal TE and SMR motorcycles in standard limited-power form from full-power competition configurations, with separate road and racing maintenance schedules. TC uses a five-speed gearbox; TE, TXC, and SMR use six-speed transmissions. Starting-system coverage follows the actual variants: TC kick start, TE/TXC electric and kick start, and SMR electric start with an optional kick-starter kit. Section O also documents TE/SMR full-power conversion parts and ECU-mapping requirements, plus the TE dual-mode switch for dry- and wet-ground maps.

The factory kit chapters add installation coverage for 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.

Printed VIN validity:
TE, world market: ZKHA200AA9V000001, ZKHA204AA9V000001, ZKHA202AA9V000001, ZKHA203AA9V000001
TE, USA: ZKHKBECF*9V100001, ZKHKBEDF*9V100001, ZKHKBEFF*9V100000, ZKHKBEHF*9V100000
TC 450/510: ZKHA202AA9V050001, ZKHA203AA9V050001; USA: ZKHTC450*9V100000, ZKHTC510*9V100000
TXC 250/450/510, USA only: ZKHTX250*9V000001, ZKHTX450*9V000001, ZKHTX510*9V000001
SMR 450/510: ZKHA202AB9V000001, ZKHA203AB9V000001

TC 250 is named in the title and service data, but the validity page does not print a separate TC 250 starting VIN.

Engine and Fuel-System Repair Depth

The engine section treats the four-stroke, DOHC, four-valve single-cylinder platform as a full overhaul rather than a maintenance-only unit. It covers valve-seat and guide work, camshaft and timing-chain inspection, cylinder-to-piston fitting, piston-ring and connecting-rod checks, crankshaft runout, oil-pump inspection, selector-fork and drum checks, separate five- and six-speed gearbox assembly, clutch inspection, and SMR counterbalancer work. A cylinder-head gasket selection chart matches piston deck position to the correct gasket code after top-end or crankshaft repair.

For TE/SMR, the PDF explains use of Diagnosis Software Kit 8000 A9634 to identify current and stored injection faults, check sensor values and controlled components, clear fault memory, and perform TPS idle/feedback adjustment after throttle-body work. Fuel-pump and relay checks are included. The working PC software, interface cable, and ECU reprogramming kit 8000 H0237 are separate referenced service tools; they are not supplied with the manual. TC/TXC sections instead cover Keihin carburetor cleaning and overhaul, jets and passages, needle valve, throttle slide, float system, accelerator pump, and model-specific baseline settings.

Chassis, Electrical, and Shop Reference

Separate TE/SMR and TC/TXC fork chapters cover cartridge and bottom-valve teardown, seal and bushing replacement, oil filling, air bleeding, damping-stack inspection, and reassembly. The Sachs rear-shock section addresses spring and reservoir service, piston-unit inspection, seal and diaphragm replacement, oil filling and bleeding, gas recharge, and damping adjustment. Brake chapters distinguish TE/TC/TXC and SMR front-system bleeding; the hydraulic clutch section covers fluid discharge, master-cylinder overhaul, and reverse bleeding.

Named visual references include the TE/SMR, TXC 250, and TC/TXC 450-510 wiring diagrams; the TE/SMR ECU wiring diagram; starter-motor test chart; SHIVER 50 Factory Works fork section view; cylinder-head gasket selection chart; and lubrication-system diagram. 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.

Two manual-specific cautions matter during repair work: the hydraulic clutch requires the specified mineral fluid rather than brake fluid, and the TXC condenser must remain installed after battery removal because running the engine without it can damage the voltage regulator. Fork and rear-shock repair also involves spring load and stored pressure. As a first-edition publication, the manual directs technicians to check applicable Husqvarna service bulletins for later adjustment data and repair-method updates.