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Husqvarna TC250 TC450 TC510 Complete Workshop Repair Manual 2007 2008 PDF Download
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Basic Information Identification Make: Husqvarna Model: TC250, TC450, TC510 Model Variants: Motocross Generation Generation: First Generation (post-BMW acquisition, before KTM acquisition) Codes Platform Code: Not readily available, but likely shared...
Tipo: Motorcycles
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SKU: 59146
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| Basic Information | |
| Identification | |
| Make: | Husqvarna |
| Model: | TC250, TC450, TC510 |
| Model Variants: | Motocross |
| Generation | |
| Generation: | First Generation (post-BMW acquisition, before KTM acquisition) |
| Codes | |
| Platform Code: | Not readily available, but likely shared chassis/engine architecture across these displacements |
| Introduction | |
| Market Position | |
| Market Segment: | Performance Off-Road Motorcycles (Motocross) |
| Competitive Analysis | |
| Competitors: | KTM (SX series), Yamaha (YZ series), Honda (CRF series), Kawasaki (KX series), Suzuki (RM series). |
| Key Features | |
| Vehicle Strengths: | Husqvarnas of this era, under BMW ownership, were known for their strong engines and capable chassis, often offering a different feel and aesthetic compared to Japanese rivals. The TC series was positioned as a direct competitor in the premium motocross segment. |
| Manual Purpose | |
| Manual Value Proposition: | Essential for owners and technicians to maintain, diagnose, and repair the TC250, TC450, and TC510 models. Provides the detailed information required for proper servicing, ensuring optimal performance and longevity. |
| Manual Details | |
| Coverage Areas | |
| Regions Covered: | Global, as Husqvarna is an international brand. Specific regional variations are unlikely to be a focus in this type of manual. |
| Page Count | |
| Page Count: | Estimating 300-500 pages based on typical complete workshop manuals for multi-model coverage. |
| Manual Type | |
| Manual Type: | Complete Workshop Repair Manual / Service Manual |
| Language | |
| Language: | Likely English, with potential for other languages depending on the original source of the PDF. Product description implies English. |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine Systems: | Engine overhaul, top-end rebuild, piston/ring replacement, valve adjustment, lubrication system, cooling system (if applicable), ignition system, fuel delivery system (carburetor/fuel injection), starting system. |
| Drivetrain Systems: | Clutch operation and adjustment, transmission internal inspection and repair, gear shift mechanism, final drive (chain and sprockets). |
| Chassis Systems: | Frame inspection and repair, suspension (forks and rear shock) service, steering head bearing service, wheel bearing replacement, brake system overhaul (hydraulic clutch and brake components, caliper and master cylinder rebuilds), electrical system (wiring diagrams, component testing, lighting, ignition coil, stator). |
| Procedures Included | |
| Maintenance Procedures: | Routine oil changes, filter replacements (oil, air), chain adjustment, brake pad replacement, spark plug inspection/replacement, valve clearance checks. |
| Repair Procedures: | Complete engine rebuild, transmission disassembly and reassembly, suspension fork seal replacement, rear shock servicing, electrical troubleshooting, carburetor/injector cleaning and rebuilding. |
| Troubleshooting Guides: | Diagnostic charts for common problems, symptom-based troubleshooting, electrical fault finding. |
| Technical Depth | |
| Technical Depth: | Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls. Includes detailed torque specifications, clearances, and diagnostic procedures. |
| Manual Specifications | |
| File Format | |
| File Format: | |
| Print Quality | |
| Print Quality: | Typically high resolution for clarity of diagrams and text in downloadable PDFs. Users can print at their desired quality. |
| Binding Type | |
| Binding Type: | N/A (Digital Download) |
| Paper Type | |
| Paper Type: | N/A (Digital Download) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Four-stroke, single-cylinder, DOHC (Dual Overhead Camshaft) |
| Bore Stroke Tc250: | 250cc variant: Specific figures vary, but typically around 76mm x 55mm. |
| Bore Stroke Tc450: | 450cc variant: Specific figures vary, but typically around 95mm x 63.4mm. |
| Bore Stroke Tc510: | 510cc variant: Specific figures vary, but typically around 97mm x 71mm. |
| Performance | |
| Horsepower Tc250: | Estimated 40-45 HP (stock) |
| Horsepower Tc450: | Estimated 48-53 HP (stock) |
| Horsepower Tc510: | Estimated 50-55 HP (stock) |
| Torque Tc450: | Estimated 35-40 lb-ft (stock) |
| Fuel System | |
| Fuel Delivery System: | Likely Mikuni carburetors for 2007/2008 models, though specific EFI models might exist or have been introduced later. The manual would detail carburetor tuning and maintenance. |
| Cooling System | |
| Cooling Type: | Liquid-cooled |
| Lubrication System | |
| Oil Capacity: | Typically around 0.8 - 1.2 liters, specific to model. Manual will detail exact capacity and type. |
| Ignition System | |
| Ignition Type: | Digital CDI (Capacitor Discharge Ignition) |
| Transmission | |
| Standard | |
| Transmission Type: | 5-speed manual |
| Optional | |
| Optional Transmissions: | None for this model year/variant. |
| Features | |
| Clutch Type: | Hydraulically actuated wet multi-plate clutch |
| Transmission Fluid Spec: | Manual will specify SAE 10W/40 or 20W/50 motorcycle-specific engine oil or dedicated transmission fluid. Common brands like Motul, Castrol, Yamalube would be referenced for compatibility. |
| Dimensions | |
| Exterior | |
| Wheelbase: | Varies by model, typically around 58-60 inches (1470-1525 mm). |
| Seat Height: | Varies by model, typically around 37-38 inches (940-965 mm). |
| Weights | |
| Dry Weight Tc250: | Approx. 230-240 lbs (104-109 kg) |
| Dry Weight Tc450: | Approx. 240-250 lbs (109-113 kg) |
| Dry Weight Tc510: | Approx. 245-255 lbs (111-116 kg) |
| Fuel Capacity: | Typically around 1.5-2.0 gallons (5.7-7.5 liters). |
| Safety Features | |
| Ratings | |
| Safety Ratings: | N/A for off-road motorcycles in the same way as street vehicles. Focus is on structural integrity and component safety. |
| Active Features | |
| Braking System: | Hydraulic disc brakes front and rear. Specific caliper and rotor sizes will be detailed in the manual. |
| Passive Features | |
| Frame Construction: | Chromoly steel or aluminum frame, designed for strength and rigidity in off-road conditions. |
| Suspension Safety: | High-performance, adjustable suspension (WP or Marzocchi forks, Sachs or Ohlins rear shock) for stable handling and absorbing impacts. Manual will cover proper adjustment and maintenance. |
| Technology Features | |
| Infotainment | |
| Infotainment System: | N/A - This is a motocross bike. Features are focused on performance and rider control, not comfort or entertainment. |
| Driver Assistance | |
| Rider Aids: | None (no ABS, traction control etc. on these models). |
| Connectivity | |
| Connectivity Features: | N/A |
| Electrical Components | |
| Lighting: | Headlight and taillight (often basic for off-road use, may require a separate battery or be AC powered). |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Every 5-10 hours of riding, or as specified in the manual for optimal performance. |
| Air Filter Cleaning: | After every few rides, or more frequently in dusty conditions. Manual will detail cleaning and oiling procedures. |
| Valve Adjustment Interval: | Typically every 20-40 hours of riding, depending on riding style and initial wear. Crucial for maintaining performance. |
| Fluid Specifications | |
| Engine Oil Type: | High-quality synthetic 4-stroke motorcycle oil, SAE 10W/40 or 20W/50. Specific API classification (e.g., SG, SH, SJ) will be detailed. Brands like Motul 7100, Castrol Power 1 are common choices. |
| Coolant Type: | Pre-mixed or concentrated motorcycle-specific coolant (ethylene glycol based) with corrosion inhibitors. Manual will specify the required ratio if concentrated. |
| Brake Fluid Type: | DOT 4 hydraulic brake fluid. |
| Known Issues | |
| Common Wear Items: | Clutch plates, piston rings, valve guides, chain and sprockets, wheel bearings, fork seals, brake pads. |
| Potential Problems: | Valve seat wear (especially on hard-driven engines), occasional electrical connector issues, carburetor jetting sensitivities to altitude/temperature. Manual provides diagnostic steps. |
| Vehicle History | |
| Brand Heritage | |
| Brand Origin: | Swedish, founded in 1689. Husqvarna Motorcycles division has a long and storied history in off-road racing, particularly motocross and enduro. |
| Model Evolution | |
| 2007 2008 Era: | These years fall under the period when Husqvarna was owned by BMW Motorrad (from 2007 to 2013). This era saw significant investment and development, with bikes often featuring premium components and a focus on performance. The TC models represented Husqvarna's dedicated motocross offerings. |
| Production | |
| Manufacturing Location: | Primarily Italy during the BMW ownership period. |
| Awards & Recognition | |
| Recognitions | |
| Motocross Achievements: | Husqvarna has a strong racing pedigree. While specific awards for the 2007/2008 TC models might not be widely publicized, the brand's heritage in off-road racing speaks to their performance capabilities. |
| Ratings | |
| Review Scores: | Contemporary reviews would have praised their strong engines and competent chassis, positioning them as serious contenders against Japanese and European rivals. Specific magazine scores are not provided here but would be found in historical reviews. |
| Certifications | |
| Emissions Certification: | Not applicable for closed-course competition motorcycles in most markets. |