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HUSQVARNA TC 250 450 510 Digital Workshop Repair Manual 2007-2008

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🏷️ Basic Information Identification Make: Husqvarna Model: TC 250, TC 450, TC 510 Product Type: Digital Workshop Repair Manual Codes Model Years Covered: 2007, 2008 👋 Introduction Market Position Target User: Owners of Husqvarna TC 250, TC 450, TC 510 motorcycles from 2007-2008 seeking in-depth repair and maintenance guidance. Competitive Analysis Value Proposition: Provides factory-level technical information to empower owners and independent shops to perform complex repairs and maintenance accurately, reducing reliance on expensive dealership services. Key Features Content Breadth: Covers the full spectrum of servicing, from routine checks to complete engine overhauls. Diagnostic Focus: Emphasis on systematic troubleshooting and diagnostic procedures. 📋 Manual Details Coverage Areas Primary Focus: Mechanical, electrical, and body repair for TC 250, TC 450, TC 510 models Geographic Applicability: Global (based on common service procedures, may vary by regional specification) Page Count Estimated Pages: Extensive (typically 500+ pages for comprehensive manuals of this era) Manual Type Type: Workshop Repair Manual Language Language: English (typically) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, tuning, diagnostics, troubleshooting for all specified displacements. Fuel System: Carburetor (if applicable) or Fuel Injection system service, cleaning, adjustment, component testing, diagnostics. Ignition System: Spark plug, coil, ECU, and sensor testing and replacement procedures. Transmission: Clutch service, gearbox inspection, maintenance, and overhaul for the specific models. Cooling System: Radiator, hoses, thermostat, water pump service and leak testing. Exhaust System: Exhaust pipe, muffler, and catalytic converter (if applicable) inspection and replacement. Suspension: Front fork (telescopic), rear shock absorber, linkage service, adjustments, and component replacement. Brakes: Hydraulic brake system (front and rear), caliper, master cylinder, brake lines, rotor, and pad service and bleeding procedures. Wheels And Tires: Wheel bearing service, tire installation and balancing, spoke tensioning (if applicable). Steering: Handlebar, steering stem, and steering bearing inspection and service. Electrical System: Wiring diagrams, battery, lighting system, starter motor, charging system, fuses, and relays. Bodywork: Fairings, seat, fuel tank, fenders, and plastic component removal, installation, and repair. Procedures Included Maintenance: Scheduled maintenance tasks, fluid changes, filter replacements, chain adjustment, general inspection checklists. Troubleshooting: Diagnostic flowcharts, common problems and their solutions, error code interpretation (if applicable). Repair: Step-by-step instructions for component removal, repair, and reinstallation for all major systems. Rebuild: Detailed procedures for engine and major component rebuilds. Diagnostics: Guidance on diagnosing electrical and mechanical faults. Technical Depth Level: Comprehensive workshop level, suitable for professional mechanics and advanced DIY enthusiasts. Detail Level: Includes torque specifications, tolerances, special tool requirements, and detailed diagrams. Illustrations: Richly illustrated with clear line drawings and exploded views. 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text within the PDF, allowing quick access to information. Print Quality Quality: High resolution for clear viewing and printing of diagrams and text. Binding Type Binding: Not applicable (Digital Download) Paper Type Paper: Not applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, liquid-cooled (typical for these models) Bore X Stroke: Varies by model (e.g., TC 250: ~76 x 54.8 mm; TC 450: ~97 x 60.8 mm; TC 510: ~98 x 71.8 mm - refer to manual for exact specifications) Displacement: 250cc, 450cc, 510cc Performance Horsepower: Varies by model and tune (e.g., TC 250 ~35-40 HP, TC 450 ~45-50 HP, TC 510 ~50-55 HP - refer to manual for precise figures) Torque: Varies by model and tune (refer to manual for precise figures) Fuel System Fuel Delivery: Carburetor (likely Keihin FCR variants) or Electronic Fuel Injection (EFI) depending on specific sub-model and market. Fuel Type: Unleaded gasoline (Octane rating specified in manual) Valve Train Type: DOHC (Double Overhead Camshaft), 4 valves per cylinder Lubrication System: Wet sump, with separate oil for gearbox/clutch (common in Husqvarnas of this era). Engine Oil Capacity: Varies by model (e.g., ~1.1-1.5 liters - consult manual for exact figure and oil separation) 🔧 Transmission Standard Transmission Type: 6-speed sequential manual transmission Optional Transmission Options: None (standard for competition motorcycles) Features Clutch Type: Wet multi-plate clutch (often hydraulically actuated) Gear Ratios Ratios: Specific gear ratios for each model and gear are detailed in the manual. Gearbox Oil Specification: Dedicated gearbox oil (e.g., SAE 75W/90 or similar API GL-4 specification - consult manual) 📐 Dimensions Exterior Length: Varies by model (refer to manual for exact specifications) Width: Varies by model (refer to manual for exact specifications) Height: Varies by model (refer to manual for exact specifications) Weights Dry Weight: Varies by model (e.g., TC 250 ~105 kg, TC 450 ~110 kg, TC 510 ~112 kg - refer to manual for exact figures) Wet Weight: Varies by model and fluids (refer to manual for exact figures) Fuel Capacity Tank Capacity: Typically around 7-8 liters for these models (consult manual for precise figure) 🛡️ Safety Features Ratings Safety Ratings: Not applicable to off-road competition motorcycles in terms of traditional automotive crash ratings. Active Features Braking System: High-performance...
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HUSQVARNA TC 250 450 510 Digital Workshop Repair Manual 2007-2008
🏷️ Basic Information
Identification
Make:
Husqvarna
Model:
TC 250, TC 450, TC 510
Product Type:
Digital Workshop Repair Manual
Codes
Model Years Covered:
2007, 2008
👋 Introduction
Market Position
Target User:
Owners of Husqvarna TC 250, TC 450, TC 510 motorcycles from 2007-2008 seeking in-depth repair and maintenance guidance.
Competitive Analysis
Value Proposition:
Provides factory-level technical information to empower owners and independent shops to perform complex repairs and maintenance accurately, reducing reliance on expensive dealership services.
Key Features
Content Breadth:
Covers the full spectrum of servicing, from routine checks to complete engine overhauls.
Diagnostic Focus:
Emphasis on systematic troubleshooting and diagnostic procedures.
📋 Manual Details
Coverage Areas
Primary Focus:
Mechanical, electrical, and body repair for TC 250, TC 450, TC 510 models
Geographic Applicability:
Global (based on common service procedures, may vary by regional specification)
Page Count
Estimated Pages:
Extensive (typically 500+ pages for comprehensive manuals of this era)
Manual Type
Type:
Workshop Repair Manual
Language
Language:
English (typically)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, assembly, tuning, diagnostics, troubleshooting for all specified displacements.
Fuel System:
Carburetor (if applicable) or Fuel Injection system service, cleaning, adjustment, component testing, diagnostics.
Ignition System:
Spark plug, coil, ECU, and sensor testing and replacement procedures.
Transmission:
Clutch service, gearbox inspection, maintenance, and overhaul for the specific models.
Cooling System:
Radiator, hoses, thermostat, water pump service and leak testing.
Exhaust System:
Exhaust pipe, muffler, and catalytic converter (if applicable) inspection and replacement.
Suspension:
Front fork (telescopic), rear shock absorber, linkage service, adjustments, and component replacement.
Brakes:
Hydraulic brake system (front and rear), caliper, master cylinder, brake lines, rotor, and pad service and bleeding procedures.
Wheels And Tires:
Wheel bearing service, tire installation and balancing, spoke tensioning (if applicable).
Steering:
Handlebar, steering stem, and steering bearing inspection and service.
Electrical System:
Wiring diagrams, battery, lighting system, starter motor, charging system, fuses, and relays.
Bodywork:
Fairings, seat, fuel tank, fenders, and plastic component removal, installation, and repair.
Procedures Included
Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, chain adjustment, general inspection checklists.
Troubleshooting:
Diagnostic flowcharts, common problems and their solutions, error code interpretation (if applicable).
Repair:
Step-by-step instructions for component removal, repair, and reinstallation for all major systems.
Rebuild:
Detailed procedures for engine and major component rebuilds.
Diagnostics:
Guidance on diagnosing electrical and mechanical faults.
Technical Depth
Level:
Comprehensive workshop level, suitable for professional mechanics and advanced DIY enthusiasts.
Detail Level:
Includes torque specifications, tolerances, special tool requirements, and detailed diagrams.
Illustrations:
Richly illustrated with clear line drawings and exploded views.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely searchable text within the PDF, allowing quick access to information.
Print Quality
Quality:
High resolution for clear viewing and printing of diagrams and text.
Binding Type
Binding:
Not applicable (Digital Download)
Paper Type
Paper:
Not applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, 4-stroke, liquid-cooled (typical for these models)
Bore X Stroke:
Varies by model (e.g., TC 250: ~76 x 54.8 mm; TC 450: ~97 x 60.8 mm; TC 510: ~98 x 71.8 mm - refer to manual for exact specifications)
Displacement:
250cc, 450cc, 510cc
Performance
Horsepower:
Varies by model and tune (e.g., TC 250 ~35-40 HP, TC 450 ~45-50 HP, TC 510 ~50-55 HP - refer to manual for precise figures)
Torque:
Varies by model and tune (refer to manual for precise figures)
Fuel System
Fuel Delivery:
Carburetor (likely Keihin FCR variants) or Electronic Fuel Injection (EFI) depending on specific sub-model and market.
Fuel Type:
Unleaded gasoline (Octane rating specified in manual)
Valve Train
Type:
DOHC (Double Overhead Camshaft), 4 valves per cylinder
Lubrication
System:
Wet sump, with separate oil for gearbox/clutch (common in Husqvarnas of this era).
Engine Oil
Capacity:
Varies by model (e.g., ~1.1-1.5 liters - consult manual for exact figure and oil separation)
🔧 Transmission
Standard
Transmission Type:
6-speed sequential manual transmission
Optional
Transmission Options:
None (standard for competition motorcycles)
Features
Clutch Type:
Wet multi-plate clutch (often hydraulically actuated)
Gear Ratios
Ratios:
Specific gear ratios for each model and gear are detailed in the manual.
Gearbox Oil
Specification:
Dedicated gearbox oil (e.g., SAE 75W/90 or similar API GL-4 specification - consult manual)
📐 Dimensions
Exterior
Length:
Varies by model (refer to manual for exact specifications)
Width:
Varies by model (refer to manual for exact specifications)
Height:
Varies by model (refer to manual for exact specifications)
Weights
Dry Weight:
Varies by model (e.g., TC 250 ~105 kg, TC 450 ~110 kg, TC 510 ~112 kg - refer to manual for exact figures)
Wet Weight:
Varies by model and fluids (refer to manual for exact figures)
Fuel Capacity
Tank Capacity:
Typically around 7-8 liters for these models (consult manual for precise figure)
🛡️ Safety Features
Ratings
Safety Ratings:
Not applicable to off-road competition motorcycles in terms of traditional automotive crash ratings.
Active Features
Braking System:
High-performance hydraulic disc brakes front and rear, designed for off-road use.
Suspension Performance:
Advanced adjustable suspension systems (e.g., Kayaba or Marzocchi forks, Sachs or Öhlins rear shocks) for optimal control and stability.
Passive Features
Frame Construction:
Robust steel or aluminum alloy frame designed for durability and handling.
Handguards:
Standard on most models for hand protection.
💡 Technology Features
Infotainment
Infotainment System:
None (basic motocross/off-road bike, typically no integrated infotainment features).
Driver Assistance
Assistance Features:
None (designed for pure off-road riding, no rider aids like ABS or traction control common on street bikes).
Connectivity
Connectivity Features:
None (basic electronics for ignition, lighting, and instrumentation only).
Instrumentation
Dashboard:
Digital or analog instrument cluster with speedometer, odometer, trip meter, and indicator lights (refer to manual for specific display functions).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 15-20 hours of riding or annually (refer to manual for exact specification and conditions).
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (after every few rides).
Chain Lubrication:
Recommended after every ride or as needed, depending on conditions.
Valve Clearance Check:
Typically every 50-100 hours of riding (refer to manual for specific interval and procedure).
Fluid Specifications
Engine Oil Grade:
Refer to manual for recommended oil viscosity (e.g., 10W-40 or 15W-50) and specific motorcycle oil formulation.
Coolant Type:
Ethylene glycol-based antifreeze and distilled water mixture (typically 50/50 ratio - consult manual).
Brake Fluid Type:
DOT 4 hydraulic brake fluid (consult manual for specific type and DOT rating).
Known Issues
Common Wear Items:
Clutch plates, brake pads, wheel bearings, swingarm/linkage bearings, fork seals, piston rings, and valve guides are common wear items on performance off-road motorcycles.
Electrical Gremlins:
Older wiring harnesses can develop issues with corrosion or loose connections, particularly in off-road environments. Manual will cover troubleshooting these.
📚 Vehicle History
Brand Heritage
Brand Origin:
Husqvarna Motorcycles, a Swedish brand with a long history dating back to 1903, known for its off-road prowess.
Model Evolution
Model Lineage:
The TC (Cross-Country) line has been a cornerstone of Husqvarna's motocross and enduro offerings, evolving significantly with engine sizes and chassis updates throughout the years.
Production
Manufacturing Era:
2007-2008 models represent a specific generation of Husqvarna's off-road motorcycles, often developed under BMW ownership (which acquired Husqvarna in 2007). These bikes were known for their Italian design influence and competitive performance.
🏆 Awards & Recognition
Recognitions
Model Awards:
Husqvarna models from this era were generally well-regarded in off-road and motocross publications for their performance and handling, though specific awards would be model year and region-dependent. The manual provides the expertise to maintain that performance.
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