2011–2012 Husqvarna TC/TE/TXC/SMR 449/511 OEM Workshop Manual (Ed. 03–2012)

• Exact factory coverage: TC 449 I.E. MY11/MY12; TE 449 and 511 I.E. MY11/MY12; TXC 449 and 511 I.E. MY11/MY12; SMR 449 I.E. MY11; and SMR 511 I.E. MY11/MY12. This is the 414-page PDF, first edition 03-2012, Rev. 02.
• Internal engine and driveline repair includes engine removal, cylinder-head and valve-train work, camshaft and timing service, piston/cylinder inspection, crankshaft and countershaft work, oil and coolant pumps, clutch service, and gearbox/selector overhaul.
• Model-specific chassis setup covers the TC/TE/TXC Kayaba fork and SMR Marzocchi fork, fork disassembly and overhaul, rear shock removal, swingarm and linkage service, steering adjustment, wheels, bearings, spokes, chain, and sprockets.
• Electrical and fuel-injection diagnosis provides model-year-specific engine and vehicle wiring diagrams, connector-location views, charging/starting/ignition tests, relay and dashboard checks, Husqvarna Service Tool coverage, and fuel-pump inspection.
• Brake, hydraulic-clutch, and cooling work includes pad and disc inspection, front and rear brake bleeding, clutch master-cylinder servicing and bleeding, radiator and hose service, and cooling-system overhaul.
• Factory reference data includes MY11/MY12 maintenance schedules, model-specific adjustment data, component torque tables, capacities, wear and inspection 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.

VIN Coverage From the Factory Table

The manual states coverage from the following serial numbers onward. TXC is listed only by U.S. VIN; # is printed in those patterns.

*Factory print note: the title and section headers identify SMR 449, but the two corresponding entries in the VIN table read “SMR 499.” The VIN patterns above reproduce the table values while retaining the model designation used throughout the manual.

Engine, Transmission, and Scheduled Service

The engine section reaches well beyond routine maintenance. It documents top-dead-center locking; valve-clearance, camshaft, timing-chain, cylinder-head, and valve work; piston/cylinder measurement; crankshaft, countershaft, and bearing service; oil-pump, starter/freewheel, and clutch repair; and gearbox/selector disassembly and reassembly. It distinguishes the 5-speed TC from the 6-speed TE, TXC, and SMR configuration. Cold valve-clearance specifications are separated for TC versus TE/TXC/SMR.

Separate MY11 and MY12 maintenance tables distinguish competition/full-power use from street-legal/limited-power configurations. Setup data covers model- and year-specific suspension settings, fork oil levels, brake and clutch controls, chain service, steering clearance, road/racing tire-pressure applications, and tightening data.

Electrical Schematics and Injection Diagnostics

MY11 and MY12 electrical configurations are not treated as interchangeable. Named drawings 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, stator resistance and output tests, regulated-voltage checks, starter and relay tests, dashboard setup, and ignition troubleshooting support electrical repair.

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. It covers current and stored malfunctions, sensor and throttle-position readings, injector pulse, lambda functions, mapping status, over-rev hours, and fuel-pump testing. The tool's separate User Guide and Operation Manual are referenced but are not reproduced in this PDF.

Suspension, Chassis, and Repair Cautions

Front-suspension material covers the 48 mm Kayaba fork on TC/TE/TXC and the 50 mm Marzocchi fork on SMR, including cartridge and bottom-valve work, seal replacement, oil filling, and troubleshooting. The rear chapter covers shock removal, swingarm and linkage service, bearings, and chain-guide components; it does not provide an internal shock rebuild. Brake bleeding, hydraulic-clutch service, cooling-system overhaul, wheel-bearing replacement, runout checks, and USA/CDN spark-arrester and canister information round out the repair scope.

Special-tool references include TDC lock 8000H5009, flywheel puller/presser 8000H5011/8000H5013, the valve-service fixture components 8000H5015-8000H5019, and Marzocchi tools R5051AC/R5081AA. The manual warns that disconnecting the battery cables while the engine is running can irreparably damage the regulator. It also cautions that incorrect vise clamping can permanently damage fork parts and that R5081AA must hold, not rotate, the internal assembly. Perform cooling work only after the engine has cooled, support the motorcycle securely, and isolate the electrical system as directed before repair.