Husqvarna TC 449 & TE/TXC/SMR 449/511 Workshop Manual (2011–2012)

Factory workshop manual for TC 449 I.E., TE 449/511 I.E., and TXC 449/511 I.E. MY11/MY12; SMR 449 I.E. MY11; and SMR 511 I.E. MY11/MY12. First edition 03-2012, Rev. 02.

PDF Search, Bookmarks and Diagram Detail

Search and schematic labels: Body text is searchable, with embedded bookmarks for chapters and individual procedures. Some wiring-diagram labels are not reliably searchable; small connector, pin, and wire-code labels require zooming.

One printable English PDF with 414 pages, including the cover, one revision-record page, and 15 blank or intentionally blank pages.

Engine Overhaul, Chassis Service and Electrical Diagnosis

The following selected coverage highlights outline the main workshop areas. Other included topics range from throttle-cable adjustment to model-specific exhaust-system removal.

• Engine and driveline repair: Step-by-step procedures cover engine removal, cylinder-head and valve-train service, piston/cylinder inspection, crankshaft and countershaft work, oil pumps, clutch repair, and gearbox/selector overhaul.

• Suspension and chassis: Kayaba and Marzocchi fork disassembly and overhaul, rear shock removal, swingarm and linkage service, steering adjustment, wheels, bearings, spokes, chain, and sprockets.

• Electrical diagnosis: Model-year-specific wiring diagrams, connector-location views, charging and starting tests, ignition troubleshooting, relay checks, and digital-dashboard setup.

• Fuel injection: Husqvarna Service Tool connection and diagnostic functions, current and stored malfunctions, sensor readings, mapping status, and fuel-pump inspection.

• Brakes and hydraulic clutch: Pad replacement, disc inspection, model-specific front and rear brake bleeding, clutch master-cylinder servicing, and hydraulic-clutch bleeding.

• Cooling system: Radiator removal, coolant replacement, cooling-circuit views, hose inspection, and radiator-condition assessment.

• Factory reference data: MY11/MY12 maintenance schedules, adjustment data, component torque tables, capacities, wear limits, electrical test specifications, special tools, and exploded assembly views.

Written for Husqvarna service centers and authorized personnel, this workshop manual suits trained technicians; Husqvarna treats it as a complement to operator training, not a substitute.

Engine, Transmission and Scheduled Service

Valve timing and internal inspection: The engine chapters document top-dead-center locking, camshaft and timing-chain service, valve-clearance adjustment using shims and half-balls, valve-seat and guide checks, and piston/cylinder measurement.

Crankshaft and countershaft procedures include bearing service and axial-clearance adjustment. Oil-pump, coolant-pump, starter/freewheel, clutch, and gearbox work extends through disassembly and reassembly, with separate TC and TE/TXC/SMR transmission layouts and selector-component inspection.

Special-tool references include TDC lock 8000H5009, flywheel puller/presser 8000H5011/8000H5013, and valve-service fixture components 8000H5015–8000H5019.

Maintenance and setup: Separate MY11 and MY12 tables distinguish competition/full-power use from street-legal/limited-power configurations. Adjustment sections cover suspension settings, fork oil levels, brake and clutch controls, chain service, steering clearance, and road/racing tire-pressure applications.

Wiring Diagrams and Electrical Fault Finding

Separate MY11 and MY12 drawings help technicians select the correct circuit before tracing a fault. Examples include the TC MY11/MY12 engine wiring diagram; TE/TXC/SMR MY11 plus SMR MY12 engine wiring diagram; TE/TXC MY12 engine wiring diagram; TE MY12 vehicle wiring diagram; and charging-system and solenoid-starter schematics.

Connector-position views accompany stator resistance and output tests, regulated-voltage checks, starter and relay tests, dashboard setup, and ignition troubleshooting. For a battery that will not hold charge, the troubleshooting section links the symptom to current-draw, generator, and regulator checks.

Disconnecting the battery cables while the engine is running can irreparably damage the voltage regulator.

Husqvarna Service Tool and Injection Diagnostics

The fuel-injection chapter identifies Husqvarna Service Tool P/N 8000 H3898, diagnosis module 8000H3902, bike-module cable 8000 H3899, and USB cable 8000 H3903.

Diagnostic coverage includes current and stored malfunctions, sensor and throttle-position readings, injector pulse width, lambda functions, mapping status, and over-rev hours. Fuel-pump testing is also covered. The tool’s separate User Guide and Operation Manual are referenced but are not reproduced in this PDF.

Fork Overhaul, Rear Suspension and Wheel Service

The fork chapter separates TC/TXC and TE Kayaba procedures from SMR Marzocchi service. It covers cartridge and bottom-valve work, seal replacement, oil filling, and fork troubleshooting.

Rear-suspension coverage includes shock removal, swingarm and linkage service, bearings, and chain-guide components; internal rear-shock rebuilding is not covered. Wheel service includes bearing replacement, axle and rim runout checks, spoke inspection, and sprocket-wear assessment.

Marzocchi tool references include R5051AC and R5081AA. Incorrect vise clamping can permanently damage fork parts; R5081AA is specified for holding the internal assembly, not rotating it.

Brake, Clutch and Cooling Service

Brake material separates SMR front-pad and bleeding procedures from TC/TE/TXC work and provides disc-thickness and runout limits. Hydraulic-clutch service includes master-cylinder seal replacement.

Cooling-system coverage includes radiator-fin assessment and hose-condition checks. USA/CDN notes provide spark-arrester maintenance instructions and a canister-kit component view.

Perform cooling work only after the engine has cooled, support the motorcycle securely, and isolate the electrical system as directed before repair.

A Preview of Engine Clearances and Charging Checks

For the covered engines, the piston/cylinder inspection section specifies a piston installation clearance of 0.06–0.08 mm. Crankshaft inspection includes an axial-clearance range of 0.30–0.50 mm, alongside the related measurement and adjustment procedures.

The charging-system section specifies regulated battery voltage of 14.0–14.5 V with the engine warmed up, running slightly above 3,000 rpm, and the battery charged.