🏷️ Basic Information Identification Make: Husqvarna Model: TC250, TE250, TC450, TE450, SM400, SM450 R Year: 2004 Type: Workshop Service Repair Manual Codes Product Code Identifier: HUSQVARNA_TC_TE_SM_2004_WRSM_PDF 👋 Introduction Market Position Target Audience: Husqvarna motorcycle owners, independent repair shops, and DIY enthusiasts performing maintenance and repairs on 2004 models. Competitive Analysis Value Proposition: Provides comprehensive, model-specific repair data, empowering users to maintain and repair their Husqvarna motorcycles effectively and cost-efficiently. Key Features Instant Download: Immediate access to critical repair information post-purchase. All 2004 Models: Covers the full range of Husqvarna's 2004 off-road and supermoto offerings. Detailed Procedures: Step-by-step instructions for every repair, ensuring accuracy and reducing guesswork. 📋 Manual Details Coverage Areas Manual Coverage: All 2004 Model Variants (TC250, TE250, TC450, TE450, SM400, SM450 R) Page Count Estimated Page Count: Likely 300-600 pages (typical for comprehensive workshop manuals) Manual Type Type: Workshop Repair Manual / Service Manual Language Language: English Format Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, inspection, reassembly, valve adjustment, piston/cylinder, crankshaft, timing. Engine Electrical: Ignition system, CDI unit, spark plug, wiring diagrams, starter system. Fuel System: Carburetor (Mikuni/Keihin type specific to models), fuel pump, fuel tank, fuel lines, fuel filter. Cooling System: Radiator, coolant, hoses, water pump, thermostat. Transmission Drivetrain: Gearbox (clutch, gears, shafts), final drive, chain, sprockets, lubrication. Suspension: Front forks (damping, seals, oil), rear shock absorber (preload, damping), linkages, bearings. Brakes: Hydraulic brake systems (front and rear calipers, master cylinders, lines, pads, discs), bleeding procedure. Electrical System: Lighting, horn, battery, charging system, handlebar controls, troubleshooting. Chassis Frame: Frame inspection, headstock bearings, swingarm, rear axle. Bodywork Plastics: Fender removal/installation, seat, fuel tank cover, side panels, graphics. Procedures Included Routine Maintenance: Oil changes, filter replacement, chain adjustment, spark plug checks, air filter cleaning/replacement. Troubleshooting: Diagnostic procedures for common performance issues, starting problems, electrical faults. Component Overhaul: Detailed instructions for dismantling, inspecting, repairing, and reassembling major components. Wiring Diagrams: Complete electrical schematics for all models covered. Torque Specifications: Precise torque values for all critical fasteners. Adjustment Procedures: Carburetor, clutch, throttle, brake lever, suspension settings. Special Tool Requirements: Identification and use of any specialized tools needed for specific repairs. Technical Depth Depth: Comprehensive: From basic maintenance to complete engine and gearbox rebuilds. Diagnostic Capabilities: Detailed troubleshooting guides for identifying and resolving mechanical and electrical issues. Illustrations Diagrams: Richly illustrated with exploded views, step-by-step diagrams, and clear line drawings. 📊 Manual Specifications File Format Format Details: PDF. Allows for easy searching, printing, and digital viewing on multiple devices. Compatible with PC & Mac (Windows 95 to Windows 11, macOS). Print Quality Quality: High-resolution digital PDF, ensuring clarity of text, diagrams, and images. Binding Type Binding: Not applicable (Digital Download) Paper Type Paper: Not applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder (typical for these models) Displacement Tc250 Te250: Approximately 250cc Displacement Tc450 Te450 Sm450R: Approximately 450cc Displacement Sm400: Approximately 400cc Performance Horsepower Range: Varies by model and specific tune, but typically in the 40-55 HP range for 450cc models. Torque Range: Varies by model and specific tune, but significant low-end and mid-range torque expected for off-road applications. Fuel System Carburetor Type: Likely Mikuni TM series or Keihin FCR series, with specific model and size variations. Ignition System: Digital CDI (Capacitor Discharge Ignition) with variable ignition timing. 🔧 Transmission Standard Gearbox Type: Constant mesh, sequential, 5-speed or 6-speed (model dependent, 6-speed common for off-road). Supermoto models might feature different gearing. Optional Optional Gearbox: Not applicable for factory spec. Features Clutch Type: Hydraulically operated, multi-plate wet clutch. Final Drive: O-ring sealed chain, 520 pitch typical. 📐 Dimensions Exterior Seat Height: High, typical for dirt bikes (e.g., 950-1000mm range, model dependent). Ground Clearance: Significant ground clearance for off-road use. Weights Dry Weight: Lightweight, typically around 100-120 kg depending on model and specific components. 🛡️ Safety Features Ratings Safety Certification: Not typically rated by formal crash test agencies like NHTSA/Euro NCAP as these are off-road/competition motorcycles. Active Features Braking System: Powerful hydraulic disc brakes front and rear, often Brembo or Grimeca components. Passive Features Frame Construction: Robust chromoly steel or aluminum frame providing structural integrity. 💡 Technology Features Infotainment Infotainment System: Not applicable (Basic motorcycle technology for its era). Driver Assistance Driver Assistance Features: Not applicable (Focus on rider control and machine feedback). Connectivity Connectivity Features: Not applicable. Lighting Lighting System: Halogen headlight, LED taillight/brake light (for street-legal SM models). 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10-20 hours of riding, or as specified in the manual for street use. Air Filter Cleaning: Recommended after every few rides or in dusty conditions. Valve Clearance Check: Typically every 50-100 hours of riding, or based on performance symptoms. Fluid Specifications Engine Oil Type: High-quality synthetic or semi-synthetic motorcycle engine oil (e.g., SAE 10W-40 or 10W-50, JASO MA rated). Specific viscosity and API rating to...