2010 Husqvarna TE450 Service & Repair 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 speciﬁcations, 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.1 Part. N. 8000 H1344 (10-2009) FOREWORD, SUMMARY 1 st Edition (10-2009) Printed in Italy Print No. N° 8000 H1344 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 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 identiﬁcation 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 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 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 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 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 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.

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

b.1 Part. 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 exempt 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 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 CON- FIGURATION, as shown below: A) STANDARD MOTORCYCLE, STREET LEGAL: with LIMITED POWER ENGINE B) COMPETITION MOTORCYCLE, RACING USE: with FULL POWER ENGINE TC-TXC TE SMR

b.3 Part. 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. * 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 designed 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 referred to any and all the Countries.

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

2010 Husqvarna TE450 Service & Repair Manual

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