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...
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.
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.