HUSQVARNA TE 250 450 510 Digital Workshop Repair Manual 2007-2008
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🏷️ Basic Information Identification Make: Husqvarna Model: TE 250, TE 450, TE 510 Model Variant: Dual-Sport / Enduro Product Name: HUSQVARNA TE 250 450 510 Digital Workshop Repair Manual 2007-2008 PDF Download Codes Manual Product Code: Not specified in provided information 👋 Introduction Market Position Target User: Enthusiasts, DIY mechanics, professional technicians seeking comprehensive documentation. Value Proposition: Significant cost savings on service and repairs compared to dealership labor, empowerment of owner to perform maintenance and repairs. Competitive Analysis Alternatives: Factory service manuals (often more expensive and harder to find), generic repair guides (less specific), online forums (unverified information). Key Features Accuracy: Covers same information as professional technicians. Visuals: High quality photos, illustrations, and diagrams for clarity. Delivery: Instant PDF download for immediate access. 📋 Manual Details Coverage Areas Model Years Covered: 2007, 2008 Engine Variants Covered: 250cc, 450cc, 510cc (specific engine configurations may vary, manual should detail these) Regions Covered: Global (assumed, typical for workshop manuals) Page Count Estimated Page Count: Not specified, but described as 'highly detailed' and 'everything you will ever need' Manual Type Type: Digital Workshop Repair Manual Purpose: Repair, maintenance, rebuilding, refurbishment, restoration Language Language: English (inferred from description) Format Delivery Method: PDF Download 📖 Manual Coverage Systems Covered Engine: Full engine overhaul, top-end components, bottom-end components, lubrication system, cooling system, fuel injection system, ignition system, exhaust system, emission control systems. Transmission: Clutch system (operation, adjustment, replacement), gearbox (disassembly, inspection, assembly, gear selection), final drive, chain and sprockets. Chassis And Body: Frame, sub-frame, swingarm, suspension (front forks, rear shock absorber - disassembly, servicing, tuning), steering system, wheels, bearings, body panels, seating, luggage systems (if applicable). Brakes: Front and rear brake systems (hydraulic circuits, master cylinders, calipers, brake pads, rotors), bleeding procedures, fluid specifications. Electrical: Battery, charging system (stator, rectifier/regulator), starting system (starter motor, solenoid), lighting system (headlight, taillight, indicators), instrument cluster, wiring diagrams, troubleshooting electrical faults, sensor identification and testing. Fuel System: Fuel tank, fuel pump, fuel filter, fuel lines, fuel injection system (injectors, throttle body, ECU mapping considerations). Cooling System: Radiator, coolant hoses, water pump, thermostat, coolant specifications and capacity. Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, chain adjustment, spark plug checks, air filter cleaning/replacement), pre-ride inspections, winter storage procedures. Repair And Rebuild: Complete engine disassembly and reassembly, gearbox overhaul, suspension servicing, brake system repairs, electrical component replacement, chassis component repairs. Diagnostics And Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, fault code identification (if applicable), wiring diagram interpretation for fault finding. Technical Adjustments: Valve clearance adjustment, carburetor synchronization (if applicable, though likely FI), idle speed adjustment, clutch lever free play adjustment. Special Tools: Identification and usage of specialized tools required for specific repair and maintenance tasks. Technical Depth Depth: Comprehensive (A-Z coverage, professional technician level) Detail Level: High (includes high quality photos, illustrations, and diagrams) 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Likely searchable text within PDF, enhancing usability. Print Quality Quality: High quality (as stated in product description) Usability: Printable for physical use, avoiding wear and tear on digital format. Binding Type Type: N/A (Digital format) Paper Type Type: N/A (Digital format) Computer Requirements Operating Systems: Microsoft Windows 95, 98, 98SE, 2000, NT, ME, XP, Vista, Windows 7. Compatible with all Mac computers. ⚙️ Engine Specifications Primary Engine Engine Family: Husqvarna TE Series (likely single-cylinder, liquid-cooled, 4-stroke, DOHC) Bore Stroke 250: Varies by specific model year, refer to manual for exact specifications. Bore Stroke 450: Varies by specific model year, refer to manual for exact specifications. Bore Stroke 510: Varies by specific model year, refer to manual for exact specifications. Performance Horsepower 250: Approx. 27-35 HP (varies by specific model year and tuning, manual will provide exact figures) Horsepower 450: Approx. 40-48 HP (varies by specific model year and tuning, manual will provide exact figures) Horsepower 510: Approx. 45-55 HP (varies by specific model year and tuning, manual will provide exact figures) Torque 250: Refer to manual for exact specifications. Torque 450: Refer to manual for exact specifications. Torque 510: Refer to manual for exact specifications. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - specific injector type and ECU control will be detailed in the manual. Ignition Type: Electronic Ignition (CDI or similar ECU-controlled system) Engine Internals Cylinder Count: 1 Valve Train: DOHC (Double Overhead Camshaft) 🔧 Transmission Standard Type: 6-speed constant mesh manual transmission Optional Type: N/A (typically standard for this class of motorcycle) Features Clutch Type: Wet, multi-plate clutch (hydraulic actuation common) Gear Ratios Ratios: Specific gear ratios for each model variant will be detailed in the manual. Fluid Specifications Transmission Oil Type: Refer to manual for specific viscosity and API rating (typically SAE 10W-40 or 15W-50 motorcycle specific oil). 📐 Dimensions Exterior Length: Refer to manual for exact specifications. Varies by model and year. Width: Refer to manual for exact specifications. Varies...
Complete engine disassembly and reassembly, gearbox overhaul, suspension servicing, brake system repairs, electrical component replacement, chassis component repairs.
Diagnostics And Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault code identification (if applicable), wiring diagram interpretation for fault finding.
Technical Adjustments:
Valve clearance adjustment, carburetor synchronization (if applicable, though likely FI), idle speed adjustment, clutch lever free play adjustment.
Special Tools:
Identification and usage of specialized tools required for specific repair and maintenance tasks.
Technical Depth
Depth:
Comprehensive (A-Z coverage, professional technician level)
Detail Level:
High (includes high quality photos, illustrations, and diagrams)
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Likely searchable text within PDF, enhancing usability.
Print Quality
Quality:
High quality (as stated in product description)
Usability:
Printable for physical use, avoiding wear and tear on digital format.
Binding Type
Type:
N/A (Digital format)
Paper Type
Type:
N/A (Digital format)
Computer Requirements
Operating Systems:
Microsoft Windows 95, 98, 98SE, 2000, NT, ME, XP, Vista, Windows 7. Compatible with all Mac computers.
⚙️ Engine Specifications
Primary Engine
Engine Family:
Husqvarna TE Series (likely single-cylinder, liquid-cooled, 4-stroke, DOHC)
Bore Stroke 250:
Varies by specific model year, refer to manual for exact specifications.
Bore Stroke 450:
Varies by specific model year, refer to manual for exact specifications.
Bore Stroke 510:
Varies by specific model year, refer to manual for exact specifications.
Performance
Horsepower 250:
Approx. 27-35 HP (varies by specific model year and tuning, manual will provide exact figures)
Horsepower 450:
Approx. 40-48 HP (varies by specific model year and tuning, manual will provide exact figures)
Horsepower 510:
Approx. 45-55 HP (varies by specific model year and tuning, manual will provide exact figures)
Torque 250:
Refer to manual for exact specifications.
Torque 450:
Refer to manual for exact specifications.
Torque 510:
Refer to manual for exact specifications.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - specific injector type and ECU control will be detailed in the manual.
Ignition Type:
Electronic Ignition (CDI or similar ECU-controlled system)
Engine Internals
Cylinder Count:
1
Valve Train:
DOHC (Double Overhead Camshaft)
🔧 Transmission
Standard
Type:
6-speed constant mesh manual transmission
Optional
Type:
N/A (typically standard for this class of motorcycle)
Specific gear ratios for each model variant will be detailed in the manual.
Fluid Specifications
Transmission Oil Type:
Refer to manual for specific viscosity and API rating (typically SAE 10W-40 or 15W-50 motorcycle specific oil).
📐 Dimensions
Exterior
Length:
Refer to manual for exact specifications. Varies by model and year.
Width:
Refer to manual for exact specifications. Varies by model and year.
Height:
Refer to manual for exact specifications. Varies by model and year.
Weights
Dry Weight 250:
Approx. 230-250 lbs (104-113 kg), refer to manual for exact specification.
Dry Weight 450:
Approx. 235-255 lbs (106-115 kg), refer to manual for exact specification.
Dry Weight 510:
Approx. 240-260 lbs (109-118 kg), refer to manual for exact specification.
Fuel Tank Capacity:
Typically 2.5-3.5 gallons (9.5-13 liters), refer to manual for exact specification.
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (motorcycle specific safety is generally not rated by government agencies in the same way as cars)
Active Features
Braking System:
Hydraulic disc brakes front and rear, ABS typically not standard on this model/era, but check manual for specific trims.
Passive Features
Lighting:
Headlight, taillight, brake light, turn signals (depending on street-legal designation).
Chassis Design:
Robust frame designed for off-road use, providing structural integrity.
💡 Technology Features
Infotainment
System:
Basic digital instrument cluster displaying speed, RPM, odometer, trip meter, and indicator lights. No advanced infotainment features typical of cars.
Driver Assistance
Features:
N/A (motorcycle; ABS may be optional on some later models, but unlikely for this era's dual-sports).
Connectivity
Features:
N/A
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 15-30 operating hours or annually, consult manual for precise intervals based on riding conditions.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions. Check manual for specific interval (e.g., every 5-10 operating hours).
Spark Plug Inspection:
Refer to manual, typically every 50-100 operating hours.
Valve Clearance Check:
Refer to manual, typically every 100-200 operating hours.
Chain And Sprocket Maintenance:
Regular cleaning, lubrication, and tension adjustment recommended at frequent intervals (e.g., every 500-1000 km or as needed).
Fluid Specifications
Engine Oil Specification:
Refer to manual for specific viscosity (e.g., SAE 10W-40, SAE 15W-50) and JASO MA/MA2 rating for wet clutches. API SG or higher.
Coolant Specification:
Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Refer to manual for exact type and capacity.
Brake Fluid Specification:
DOT 4 brake fluid (refer to manual for specific manufacturer recommendations).
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, fork seals, chain and sprockets, spark plugs, air filters.
Potential Engine Issues:
Valve seat wear, piston ring wear, timing chain tensioner issues (depending on specific engine design). Manual will detail inspection and service procedures.
Electrical Component Reliability:
Early EFI systems can sometimes have sensor issues or regulator/rectifier problems. Manual will aid in diagnosing these.
📚 Vehicle History
Brand Heritage
Brand Origin:
Husqvarna Motorcycles is one of the oldest motorcycle manufacturers, founded in Sweden in 1689, with a long history in off-road and enduro racing.
Model Evolution
Te Series Development:
The TE series has a long lineage of dual-sport and enduro motorcycles, evolving with technological advancements in engines, suspension, and chassis design.
Production
Manufacturing Location:
Likely manufactured in Italy during this period, as Husqvarna was part of the Cagiva group.
🏆 Awards & Recognition
Recognitions
Model Specific Awards:
Information not provided, but Husqvarna motorcycles are generally well-regarded in the off-road and enduro community for performance and handling.