The TC250, TC450, and TC510 models from the 2007 and 2008 production years represent a significant chapter in the esteemed heritage of off-road competition motorcycles. These machines, known for their robust Swedish engineering and performance-oriented design, were built to excel in the demanding world of motocross and off-road riding. They offer a blend of raw power, agile handling, and durability, making them a formidable choice for riders seeking a competitive edge. The long-standing commitment to off-road excellence is evident in every aspect of these versatile motorcycles, designed to deliver an exhilarating and reliable riding experience. This workshop repair service manual provides comprehensive guidance for the TC250, TC450, and TC510 models covering the 2007 and 2008 model years. The manual details all essential maintenance procedures, from routine oil changes and filter replacements to complex engine overhauls and suspension servicing. It includes in-depth troubleshooting steps, technical specifications, wiring diagrams, and information on special tools required for repairs. This resource is an indispensable tool for owners, mechanics, and technicians aiming to maintain, diagnose, and repair these high-performance off-road motorcycles, ensuring they operate at peak efficiency and longevity. 🏷️ Basic Information Identification Make: Husqvarna Model: TC250, TC450, TC510 Year: 2007, 2008 Codes Manual Product Name: Husqvarna TC250 TC450 TC510 2007 2008 Service Repair Manual 👋 Introduction Market Position Segment: Competition Motocross/Off-road Motorcycle Target Audience: Husqvarna owners, mechanics, service technicians specializing in off-road motorcycles. Competitive Analysis Competitors: KTM EXC/MXC series, Yamaha YZFs, Honda CRF, Suzuki RMZ, Kawasaki KXF Key Features Brand Focus: Husqvarna's heritage in off-road racing and durable Swedish engineering. Manual Utility: Essential for maintaining peak performance, diagnosing issues, and executing repairs on these specialized off-road machines. 📋 Manual Details Coverage Areas Languages: English Regions Covered: Global (Specifications may vary by region) Page Count Estimated Page Count: 300-500 (typical for comprehensive service manuals of this era) Manual Type Manual Type: Workshop Repair Service Manual Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, including disassembly, assembly, component testing, and specifications for TC250, TC450, TC510 variants. Fuel System: Carburetor (Mikuni VM34/VM38 likely) or fuel injection system (if applicable for the year/model), fuel pump, fuel filter, lines, and pressure testing. Ignition System: CDI unit, ignition coils, spark plugs, timing specifications, troubleshooting ignition faults. Cooling System: Radiator, water pump, thermostat, coolant hoses, fan operation, flush and fill procedures. Transmission: Clutch operation and adjustment, gearbox inspection, lubrication, gear selection mechanism, shift drum and forks. Suspension: Front forks (e.g., Marzocchi, WP) disassembly, rebuild, oil type and level, spring rates, damping adjustments. Rear shock absorber service, linkage maintenance, bearing lubrication. Brakes: Hydraulic brake system (front and rear), caliper service, master cylinder overhaul, brake line replacement, pad and rotor specifications, bleeding procedures. Electrical System: Wiring diagrams for all circuits, battery maintenance, charging system (stator, rectifier/regulator), starter motor, lighting, switches, fuses, and troubleshooting electrical gremlins. Chassis Frame: Frame inspection, headstock bearings, swingarm pivot bearings, wheel hub bearings, alignment checks. Bodywork: Plastic body panel removal and installation, seat, fuel tank mounting, graphics. Procedures Included Preventive Maintenance: Detailed schedules for oil changes, filter replacements (air, oil), chain adjustment and lubrication, spark plug replacement, valve clearance checks, and general inspection points. Troubleshooting: Systematic diagnostic flowcharts and procedures for identifying common mechanical and electrical faults, covering starting issues, poor performance, strange noises, and system failures. Repair Rebuild: Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair or replacement of worn parts, and reassembly for all major systems. Technical Specifications: Torque specifications for all fasteners, engine timing, valve clearances, fluid capacities, gear ratios, electrical component resistance values, and wear limits. Special Tools: Identification of specific tools required for certain procedures, such as flywheel pullers, bearing presses, specialized wrenches, and measurement instruments. Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic user maintenance to complete engine rebuilds, electrical system diagnostics, and chassis component overhauls. Diagnostic Capability: Advanced diagnostic procedures for identifying root causes of performance issues, electrical faults, and mechanical failures using specified measurement techniques. Component Level Detail: Detailed diagrams and instructions for individual component servicing, including pistons, rings, valves, crankshafts, bearings, seals, and electronic components. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF, allowing for quick keyword-based navigation. Print Quality Printability: Designed for printing, with clear diagrams and legible text. Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type Tc250: Liquid-cooled, 4-stroke, Single-cylinder (likely a variant of the TE250 engine) Engine Type Tc450: Liquid-cooled, 4-stroke, Single-cylinder (likely a variant of the TE450 engine) Engine Type Tc510: Liquid-cooled, 4-stroke, Single-cylinder (likely a variant of the TE510 engine) Bore Stroke Tc250: Specifics vary, but generally around 76mm x 55mm (check manual for exact) Bore Stroke Tc450: Specifics vary, but generally around 97mm x 60.8mm (check manual for exact) Bore Stroke Tc510: Specifics vary, but generally around...