2009 HUSQVARNA TE TC TXC SMR 250 310 450 510 Service Manual

Workshop Manual TE 250-310-450-510/2009-I.E., TC 250-450-510/2009, TXC 250-450-510/2009 (only USA) , SMR 450-510 2009-I.E. Part. N. 8000 H0368 (09-2008)

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 (09-2008)

a.1 Part. N. 8000 H0368 (09-2008) FOREWORD, SUMMARY 1 st Edition (09-2008) Printed in Italy Print No. N° 8000 H0368 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 250-310-450-510/2009-I.E., TC 250-450-510/2009, TXC 250-450-510/2009 (only USA) , SMR 450-510/2009-I.E. TE 250: ZKHA200AA9V000001 TE 310: ZKHA204AA9V000001 TE 450: ZKHA202AA9V000001 TE 510: ZKHA203AA9V000001 TE 250 (USA): ZKHKBECF*9V100001 TE 310 (USA): ZKHKBEDF*9V100001 TE 450 (USA): ZKHKBEFF*9V100000 TE 510 (USA): ZKHKBEHF*9V100000 TC 450: ZKHA202AA9V050001 TC 510: ZKHA203AA9V050001 TC 450 (USA): ZKHTC450*9V100000 TC 510 (USA): ZKHTC510*9V100000 TXC 250 (USA): ZKHTX250*9V000001 TXC 450 (USA): ZKHTX450*9V000001 TXC 510 (USA): ZKHTX510*9V000001 SMR 450: ZKHA202AB9V000001 SMR 510: ZKHA203AB9V000001 1. Vehicle identification number

a.2 Part. N. 8000 H0368 (09-2008) 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.3 Part. N. 8000 H0368 (09-2008) 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 Fuel injection system .................................................... S Lubrication system ........................................................ T 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.

2009 HUSQVARNA TE TC TXC SMR 250 310 450 510 Service Manual

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