Husqvarna TC 450 Instruction manual

Workshop Manual
TE 310-450-510/2010-I.E.,
TC 450/2010,
TXC 450-510/2010 (only USA),
SMR 450-510 2010-I.E.
Part. N. 8000 H1344 (10-2009)

To the best knowledge of HUSQVARNA MOTORCYCLES S.R.L. - Varese, Inc. the material contained herein is accurate as of the
date this pubblication was approved for printing. Cagiva Motor S.p.a. - Varese, Inc. reserves the right to change specications, equip-
ment, or designs at any time without notice and without incurring obligation. Illustrations in this manual are merely for demonstration
purposes and could not exactly match the detail described.No part of this manual can de reproduced without permission in writing of
the copyright holder. 1st Edition (10-2009)

a.1Part. N. 8000 H1344 (10-2009)
FOREWORD, SUMMARY
1st Edition (10-2009)
Printed in Italy
Print No. N° 8000 H1344
VALIDITY (from vehicle identication number)
Copyright by
HUSQVARNA MOTORCYCLES S.R.L.
BMW Group
Servizio Assistenza Tecnica
Via Nino Bixio, 8
21024 Biandronno
(Varese) - Italy
tel. ++39 0332 75.61.11
fax ++39 0332 756 558
www.husqvarna-motorcycles.com
Workshop Manual
TE 310-450-510/2010-I.E.,
TC 450/2010,
TXC 450-510/2010 (only USA),
SMR 450-510/2010-I.E.
TE 310: ZKHA204AAAV000001
TE 450: ZKHA202AAAV000001
TE 510: ZKHA203AAAV000001
TE 310 (USA): ZKHKBEDF*AV100001
TE 450 (USA): ZKHKBEFF*AV100000
TE 510 (USA): ZKHKBEHF*AV100000
TC 450: ZKHA202AAAV050001
TC 450 (USA): ZKHTC450*AV100000
TXC 450 (USA): ZKHTX450*AV000001
TXC 510 (USA): ZKHTX510*AV000001
SMR 450: ZKHA202ABAV000001
SMR 510: ZKHA203ABAV000001
1. Vehicle identication number

a.2 Part. N. 8000 H1344 (10-2009)
FOREWORD, SUMMARY
Foreword
This publication intended for HUSQVARNA Workshops has been prepared for the
purpose of helping the authorized personnel in the maintenance and repair work of the
motorcycles herewith dealt with. The perfect knowledge of the technical data contained
herein is essential for a more complete professional training of the operator.
The paragraphs have been completed with schematic illustrations evidencing the subject
concerned, in order to enable a more immediate understanding.
This manual contains information with particular meanings:
Accident prevention rules for the operator and for the personnel working near by.
Possibility of damaging the vehicle and/or its components.
Additional information concerning the operation under way.
Useful suggestions
HUSQVARNA suggests, in order to prevent troubles and in order to have an excellent
nal result, to generically comply with the following instructions:
– in case of repair work, weigh the impressions of the Customer who complains about
the improper operation of the motorcycle, and formulate proper clearing questions
about the symptoms of the trouble.
– detect clearly the cause of the trouble. This manual gives the theoretical bases which
however shall be integrated by the personal experience and by the attendance to
training courses periodically organized by HUSQVARNA.
– rationally plan the repair work in order to prevent dead time as for instance procure-
ment of spare parts, tool preparation, etc.
– reach the component to be repaired and perform only the required operations.
In this connection, it will be useful to consult the disassembly sequence contained in
this manual.
General instructions for repair work
1 Always replace the seal rings and split pins with new components.
2 When loosening or tightening nuts or bolts, always start from the bigger ones or from
the center. Lock at the prescribed torque wrench setting following a crossed run.
3 Always earmark the components or positions which could be mistaken one for another
at the time of assembly.
4 UseoriginalHUSQVARNAspare parts and the lubricants of the recommended brands.
5 Use special tools, where specied.
6 Consult the Service Bulletins as they may contain up-dated adjustment data and
repair methodologies.

a.3Part. N. 8000 H1344 (10-2009)
FOREWORD, SUMMARY
Summary
Chapter Section
Foreword, summary...................................................... a
Important notices.......................................................... b
General ........................................................................ A
Maintenance ................................................................ B
Troubles and remedies................................................. C
Settings and adjustments ............................................ D
General operations ...................................................... E
Engine disassembly...................................................... F
Engine overhauling ...................................................... G
Engine re-assembly ..................................................... H
Front suspension ......................................................... I
Rear suspension ......................................................... J
Brakes .......................................................................... L
Electric system ............................................................ M
Engine cooling system.................................................. N
"KITS" assembling instructions..................................... O
Hydraulic control clutch .............................................. P
Optional Parts List........................................................ Q
Fuel injection system.................................................... S
Lubrication system........................................................ T
Specic tools ............................................................... W
Torque wrench settings................................................. X
Frame, wheels ............................................................ Y
Notes for USA/CDN-AUS models................................. Z
NOTES
1) Where not otherwise specied, data and instructions refer to all models.

a.4 Part. N. 8000 H1344 (10-2009)
FOREWORD, SUMMARY

b.1Part. N. 8000 H1344 (10-2009)
IMPORTANT NOTICES
Section b

b.2 Part. N. 8000 H1344 (10-2009)
IMPORTANT NOTICES
1) The TC and TXC models are guaranteed COMPETITION motorcycles ex-
empt from functional defects, the suggested maintenance table for competition
use is shown on chapter B.
2) TE and SMR are STREET LEGAL motorcycles (with LIMITED POWER EN-
GINE); they are guaranteed exempt from functional defects and covered with
legalguarantee,iftheSTANDARDCONFIGURATIONismaintainedandthesug-
gested maintenance table, shown on chapter B, is observed. If TE and SMR are
transformedinCOMPETITIONMOTORCYCLES(withFULLPOWERENGINE),
the suggested maintenance table for competition use is shown on chapter B.
IMPORTANT
The reference for recognition of the guarantee will be the MOTORCYCLE CON-
FIGURATION, as shown below:
A)STANDARDMOTORCYCLE,STREETLEGAL:withLIMITEDPOWERENGINE
B)COMPETITIONMOTORCYCLE,RACINGUSE:withFULLPOWERENGINE
TC-TXC
TE
SMR

b.3Part. N. 8000 H1344 (10-2009)
IMPORTANT NOTICES
* This motorcycles was not designed for long trips with the engine
always at maximum rpm as can occur whilst travelling on roads
or highways. Long trips at full throttle can cause severe damage
to the engine.
*Thismotorcyclesis setupforcompetitionuseandthereforeguar-
antees maximum performance with the rider alone. It is thereby
not recommended to use the vehicle on circuits or off-road with
a passenger.
* ALWAYS keep in mind that these motorcycles have been de-
signed strictly for competition use, that is, for conditions of usage
very different from those presented on the road.
* In order to maintain the vehicle’s “Guarantee of Functionality”,
the client must follow the maintenance program indicated in the
chapter B by carrying out maintenance checks at authorized
HUSQVARNA dealers. The cost for substituting parts and for the
labour necessary in order to respect the maintenance plan, is
charged to the client. The guarantee is EXTINGUISHED in the
case where the motorcycle is rented.
Notes
Referencestothe “left”or “right”of themotorcyclearein thesense
of a person facing forwards.
Z: number of teeth
A: Austria
AUS: Australia
B: Belgium
BR: Brazil
CDN: Canada
CH: Switzerland
D: Germany
E: Spain
F: France
FIN: Finland
GB: Great Britain
I: Italy
J: Japan
USA: United States of America
Where not specied, alla the data and the instructions are referred
to any and all the Countries.

b.4 Part. N. 8000 H1344 (10-2009)
IMPORTANT NOTICES