This manual covers the 2004 TE/TC 250, TC 450, and SM400 motorcycles. These high-performance, four-stroke machines are renowned for their robust engines, competitive performance, and specialized capabilities, catering to both off-road enthusiasts and supermoto riders. With a heritage rooted in Swedish engineering and a reputation for durability, these motorcycles represent a significant era in motocross and enduro technology. They are designed for demanding use, offering a powerful and engaging riding experience. This comprehensive repair workshop manual provides full and complete repair and workshop procedures for the specified motorcycle series. It details essential maintenance, troubleshooting, and repair processes across all major systems, including the engine, fuel, ignition, transmission, suspension, brakes, and electrical components. The manual is an indispensable resource for owners and technicians, offering factory-level information from basic checks and routine maintenance to complete engine overhauls and component replacements, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: Husqvarna Model: TE/TC 250, TC 450, SM400 Year: 2004 Vehicle Type: Motorcycle Engine Type: 4-Stroke 👋 Introduction Market Position Segment: High-performance off-road and supermoto motorcycles Competitive Analysis Competitors 2004: KTM EXC/SX, Yamaha YZ/WR, Honda CR/CRF, Suzuki RM/DRZ, Kawasaki KX/KLX Key Features Husky Reputation: Known for robust engines, competitive performance, and specialized off-road capabilities Manual Value: Essential for owners and mechanics to maintain and repair these specialized machines Document Type: Factory-level repair information 📋 Manual Details Coverage Areas Primary Coverage: Full and complete repair and workshop procedures Model Coverage Note: Covers 2004 models and onwards within the specified series Page Count Estimated Pages: Varies by specific model/engine, typically 300-500+ pages for comprehensive manuals Manual Type Type: Repair Workshop Manual Language Language: English (assumed based on product description) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, tuning, and troubleshooting (including top-end, bottom-end, lubrication, cooling) Fuel System: Carburetor service, fuel pump, fuel lines, fuel tank maintenance and repair Ignition System: Ignition coil, stator, CDI unit, spark plug diagnosis and replacement Transmission Drivetrain: Clutch operation, gearbox disassembly/assembly, gear selection, chain/sprocket maintenance Suspension: Front fork service (seals, oil, springs), rear shock absorber maintenance and adjustment Brakes: Hydraulic brake system overhaul (master cylinders, calipers, lines), bleeding procedures, pad replacement Electrical System: Wiring diagrams, battery service, lighting, starter motor, charging system troubleshooting Chassis Frame: Frame inspection, steering head bearing service, swingarm maintenance Bodywork Trim: Fairing removal/installation, seat, fenders, and other trim components Procedures Included Routine Maintenance: Oil changes, filter replacement, chain adjustment, spark plug checks, air filter cleaning/replacement Troubleshooting: Diagnostic procedures for common starting, running, and electrical issues Repair Overhaul: Detailed step-by-step instructions for complete engine, transmission, and component rebuilds Component Replacement: Instructions for replacing parts like brake pads, clutch plates, bearings, seals, and cables Diagnostics: Fault finding charts and diagnostic flowcharts for various systems Technical Depth Depth: Comprehensive (A-Z repair, from basic checks to complete engine rebuilds) 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF, allowing for quick information retrieval Print Quality Quality: Professional quality, suitable for printing sections or the entire manual Binding Type Binding: N/A (Digital PDF download) Paper Type Paper: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Engine Family: Husqvarna 4-stroke single cylinder Te Tc 250 Displacement: Approximately 250cc (specific bore/stroke may vary) Tc 450 Displacement: Approximately 450cc (specific bore/stroke may vary) Sm400 Displacement: Approximately 400cc (specific bore/stroke may vary) Cooling System: Liquid-cooled Valve Train: SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) depending on specific model variant Performance Power Output Approx: 250cc: ~30-35 HP, 400/450cc: ~40-45 HP (estimates, actual may vary) Torque Spec: Not specified in product info, requires manual lookup Fuel System Carburetor Type: Mikuni or Keihin flat-slide carburetors common (e.g., VM34, VM36, MX series) Fuel Type: Unleaded gasoline Ignition System Ignition Type: Digital CDI (Capacitor Discharge Ignition) Lubrication Oil Type Recommendation: High-quality motorcycle-specific 4-stroke engine oil (e.g., SAE 10W-40, consult manual for exact specs) 🔧 Transmission Standard Type: Manual Gear Count: Typically 5 or 6 speed Clutch Type: Wet multi-plate Features Primary Drive: Gear drive Final Drive: Chain drive Transmission Oil Spec: Dedicated transmission oil or engine oil depending on design (consult manual) 📐 Dimensions Exterior Wheelbase Approx: Varies by model (e.g., 57-58 inches) Seat Height Approx: Varies by model (e.g., 36-38 inches) Weights Dry Weight Approx: Varies by model (e.g., 230-260 lbs) Fuel Capacity Approx: Varies by model (e.g., 2.0-3.0 gallons) 🛡️ Safety Features Ratings Safety Certification: Designed for off-road competition or street legality (SM models) - meets applicable standards Active Features Brakes: Hydraulic disc brakes (front and rear) Tires: Off-road knobby tires (TE/TC) or street-legal tires (SM) Passive Features Frame Construction: Steel perimeter frame (typical for Husqvarna) Handlebar: Fat bar or standard diameter handlebars with handguards (often standard) 💡 Technology Features Infotainment Features: N/A (Performance-oriented off-road/supermoto motorcycles focus on mechanical function) Driver Assistance Features: N/A Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every...