Husqvarna TE 250 Instruction manual

Workshop Manual
TE 250-450-510/2008-I.E.,
TC 250-450-510/2008,
TXC 250-450-510/2008 (only USA),
SMR 450-510 2008-I.E.
SMR 450-R/2008
Part. N. 8000 B0148 (02-2008)

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 specifications,
equipment, 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 (02-2008)

a.1Part. N. 8000 B0148 (02-2008)
FOREWORD, SUMMARY
1st Edition (02-2008)
Printed in Italy
Print No. N° 8000 B0148
VALIDITY (from vehicle identification 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 250-450-510/2008-I.E.,
TC 250-450-510/2008,
TXC 250-450-510/2008 (only USA),
SMR 450-510/2008-I.E.
SMR 450-R/2008
TE 250: ZKHA200AA8V000001
TE 450: ZKHA202AA8V000001
TE 510: ZKHA203AA8V000001
TE 250 (USA): ZKHECECA*8V100001
TE 450 (USA): ZKHECENB8V100001
TE 510 (USA): ZKHECEHB8V100001
TC 250: ZKHA200AA8V050001
TC 450: ZKHA202AA8V050001
TC 510: ZKHA203AA8V050001
TXC 250 (USA): ZKHTX250*8V000001
TXC 450 (USA): ZKHTX450*8V000001
TXC 510 (USA): ZKHTX510*8V000001
SMR 450: ZKHA202AB8V000001
SMR 510: ZKHA203AB8V000001
SMR 450-R: ZKHA222AB8V050001
1. Vehicle identification number
1

a.2 Part. N. 8000 B0148 (02-2008)
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 final
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 procurement
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 Use original HUSQVARNA spare parts and the lubricants of the recommended brands.
5 Use special tools, where specified.
6 Consult the Service Bulletins as they may contain up-dated adjustment data and repair
methodologies.

a.3Part. N. 8000 B0148 (02-2008)
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
SMR 450-R ................................................................... R
Fuel injection system .................................................... S
Specific tools................................................................. W
Torque wrench settings ................................................. X
Frame, wheels ............................................................. Y
Notes for USA/CDN-AUS models ................................. Z
NOTES
1) Where not otherwise specified, data and instructions refer to all models.
2) Where not otherwise specified, data and instructions of SMR models are referred to the SMR 450-R model too.

a.4 Part. N. 8000 B0148 (02-2008)
FOREWORD, SUMMARY

b.1Part. N. 8000 B0148 (02-2008)
IMPORTANT NOTICES
Section b

b.2 Part. N. 8000 B0148 (02-2008)
IMPORTANT NOTICES
1)TheTC,TXCandSMR450-R modelsareguaranteedCOMPETITION motorcycles
exempt from functional defects, the suggested maintenance table for competition
use is shown on chapter B.
2)TE andSMR are STREET LEGALmotorcycles(withLIMITEDPOWERENGINE);
they are guaranteed exempt from functional defects and covered with legal
guarantee, if the STANDARD CONFIGURATION is maintained and the suggested
maintenance table, shown on chapter B, is observed. If TE and SMR are
transformed in COMPETITION MOTORCYCLES (with FULL POWER ENGINE),
the suggested maintenance table for competition use is shown on chapter B.
IMPORTANT
The reference for recognition of the guarantee will be the MOTORCYCLE
CONFIGURATION, as shown below:
A)STANDARDMOTORCYCLE,STREET LEGAL: withLIMITEDPOWERENGINE
B) COMPETITION MOTORCYCLE, RACING USE: with FULL POWER ENGINE
TC-TXC
TE
SMR
SMR 450-R

b.3Part. N. 8000 B0148 (02-2008)
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.
* This motorcycles is setup for competition use and therefore guar-
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
References to the “left” or “right” of the motorcycle are in the sense
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 specified, alla the data and the instructions are re-
ferred to any and all the Countries.

b.4 Part. N. 8000 B0148 (02-2008)
IMPORTANT NOTICES