Husqvarna TE 400 TE-TC-SMR 400-570 Motorcycle Complete Workshop Service Repair Manual 2001 2002
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🏷️ Basic Information Identification Make: Husqvarna Model: TE 400 Model Variant: TE-TC-SMR 400-570 Model Years Covered: 2001, 2002 Codes Engine Code Range: 400cc to 570cc 👋 Introduction Market Position Positioning: Essential resource for Husqvarna off-road enthusiasts and mechanics, enabling DIY repairs and maintenance. Competitive Analysis Value Proposition: Provides significant cost savings over dealership service, empowers owners with repair knowledge, and ensures optimal vehicle performance. Key Features Ease Of Use: Step-by-step instructions with accompanying pictures for clarity. Accessibility: Downloadable to PC, Mac, tablets, and smartphones, with Adobe Reader compatibility. Delivery: Instant email delivery upon payment confirmation. Coverage: Extensive A-Z coverage of all service and repair procedures. 📋 Manual Details Coverage Areas Primary Coverage: Complete Workshop Service and Repair Model And Engine Variants: All Models, Engines, Trim, and Transmission Types Page Count Estimated Page Count: Not Specified (Comprehensive Coverage A-Z) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Complete Engine Overhaul, Tuning, Troubleshooting, Component Specifics Transmission: Gearbox Servicing, Repair, Troubleshooting, Clutch Operation Fuel System: Carburetor/Fuel Injection Servicing, Fuel Pump, Lines, Tank Maintenance Ignition System: Ignition Timing, Coil, Spark Plug, CDI Unit Diagnostics and Replacement Cooling System: Radiator, Fan, Coolant Lines, Thermostat Maintenance and Repair Electrical System: Wiring Diagrams, Lighting, Starting System, Charging System, Battery Service Suspension System: Front Fork Servicing (Seals, Oil, Valving), Rear Shock Absorber Maintenance, Linkage Care Braking System: Brake Pad Replacement, Bleeding Procedures, Caliper Maintenance, Master Cylinder Overhaul Exhaust System: Exhaust Pipe and Silencer Maintenance, Gasket Replacement Frame And Bodywork: Chassis Inspection, Fairing Removal/Installation, Seat Maintenance Wheels And Tires: Tire Mounting/Dismounting, Wheel Bearing Service, Spoke Adjustment Procedures Included Maintenance: Routine Checks, Lubrication Schedules, Filter Replacements, Chain Adjustment Repair: Component Replacement, Reassembly, Troubleshooting Common Faults Troubleshooting: Diagnostic Guides for Mechanical and Electrical Issues Diagnostics: Step-by-step diagnostic procedures for various systems Rebuilds: Engine and Transmission Rebuild Procedures Technical Depth Depth: Comprehensive: From basic maintenance to complete engine and gearbox rebuilds, including advanced diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable Text Content Print Quality Quality: High Quality, Printable Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-Cylinder, Four-Stroke (typical for these models) Displacement Range: 400cc - 570cc (covers TE 400 and larger variants like TE 510/570) Cooling Method: Liquid-Cooled (typical) Valve Train: DOHC (Double Overhead Camshaft), typically 4 valves Performance Power Output Range: Estimated 35-50+ HP (varies significantly by exact model and tuning) Torque Curve Characteristics: Designed for strong low-to-mid range torque for off-road traction Fuel System Fuel Delivery: Carburetor (e.g., Mikuni) or Electronic Fuel Injection (EFI) depending on specific model variant Carburetor Size Typical: 36-41mm (e.g., Mikuni TM36, TM40) Maintenance Notes Spark Plug Type: NGK (specific part number varies, e.g., CR9EK) Valve Clearance Adjustment: Requires specific feeler gauges and torque settings detailed in manual 🔧 Transmission Standard Type: 6-Speed Manual Optional Optional Types: N/A (Standard for TE/TC models) Features Clutch Type: Wet Multi-Plate Clutch Gear Ratios: Specific ratios provided for each gear within the manual Transmission Fluid Type: Motorcycle-specific transmission oil (e.g., SAE 75W/90 or 10W/40, check manual for exact spec) Maintenance Fluid Capacity: Approx. 0.7 - 1.0 Liters (verify in manual) 📐 Dimensions Exterior Type: Enduro/Motocross Motorcycle Weights Dry Weight Approx: 110-125 kg (approximate, varies by model and year) 🛡️ Safety Features Ratings Safety Standard: Motorcycle safety standards Active Features Braking System: Hydraulic Disc Brakes (Front and Rear) Suspension Features: Long-travel suspension for off-road terrain absorption Passive Features Frame Construction: Strong perimeter or trellis frame design 💡 Technology Features Infotainment Infotainment System: N/A (Designed for performance, not infotainment) Driver Assistance Assistance Features: N/A (Focus on rider control and machine capability) Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 50-100 hours or annually (refer to manual for specific mileage/time recommendation) Air Filter Cleaning: Frequent cleaning recommended, especially in dusty conditions (e.g., every few rides) Chain Lubrication Adjustment: Every 300-500 km or as needed Valve Check Interval: Every 100-200 hours or annually Fluid Specifications Engine Oil Type: High-quality motorcycle specific 4-stroke engine oil (e.g., Motul 5100 10W-40 or 15W-50, check manual for exact API/JASO spec) Coolant Type: Ethylene glycol-based antifreeze mixture (typically 50/50 with distilled water) Fork Oil Type: Specific fork oil viscosity (e.g., SAE 5W or 10W, volume as per manual) Known Issues Common Wear Items: Clutch plates, piston rings, fork seals, chain and sprockets due to high-performance off-road use. Electrical Connectors: Potential for corrosion in connectors due to off-road environment (manual provides wiring diagrams for troubleshooting). 📚 Vehicle History Brand Heritage Heritage: Husqvarna Motorcycles, established in Sweden, known for off-road prowess and innovation. Model Evolution Evolution: The TE (Tout-Terrain) and TC (Tout-Terrain Competition) lines are Husqvarna's dedicated off-road motorcycles, with the 400cc and 570cc models representing significant displacements for competition and trail riding. Production Manufacturing Location: Italy (under...
Component Replacement, Reassembly, Troubleshooting Common Faults
Troubleshooting:
Diagnostic Guides for Mechanical and Electrical Issues
Diagnostics:
Step-by-step diagnostic procedures for various systems
Rebuilds:
Engine and Transmission Rebuild Procedures
Technical Depth
Depth:
Comprehensive: From basic maintenance to complete engine and gearbox rebuilds, including advanced diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable Text Content
Print Quality
Quality:
High Quality, Printable
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-Cylinder, Four-Stroke (typical for these models)
Displacement Range:
400cc - 570cc (covers TE 400 and larger variants like TE 510/570)
Cooling Method:
Liquid-Cooled (typical)
Valve Train:
DOHC (Double Overhead Camshaft), typically 4 valves
Performance
Power Output Range:
Estimated 35-50+ HP (varies significantly by exact model and tuning)
Torque Curve Characteristics:
Designed for strong low-to-mid range torque for off-road traction
Fuel System
Fuel Delivery:
Carburetor (e.g., Mikuni) or Electronic Fuel Injection (EFI) depending on specific model variant
Carburetor Size Typical:
36-41mm (e.g., Mikuni TM36, TM40)
Maintenance Notes
Spark Plug Type:
NGK (specific part number varies, e.g., CR9EK)
Valve Clearance Adjustment:
Requires specific feeler gauges and torque settings detailed in manual
🔧 Transmission
Standard
Type:
6-Speed Manual
Optional
Optional Types:
N/A (Standard for TE/TC models)
Features
Clutch Type:
Wet Multi-Plate Clutch
Gear Ratios:
Specific ratios provided for each gear within the manual
Transmission Fluid Type:
Motorcycle-specific transmission oil (e.g., SAE 75W/90 or 10W/40, check manual for exact spec)
Maintenance
Fluid Capacity:
Approx. 0.7 - 1.0 Liters (verify in manual)
📐 Dimensions
Exterior
Type:
Enduro/Motocross Motorcycle
Weights
Dry Weight Approx:
110-125 kg (approximate, varies by model and year)
🛡️ Safety Features
Ratings
Safety Standard:
Motorcycle safety standards
Active Features
Braking System:
Hydraulic Disc Brakes (Front and Rear)
Suspension Features:
Long-travel suspension for off-road terrain absorption
Passive Features
Frame Construction:
Strong perimeter or trellis frame design
💡 Technology Features
Infotainment
Infotainment System:
N/A (Designed for performance, not infotainment)
Driver Assistance
Assistance Features:
N/A (Focus on rider control and machine capability)
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 50-100 hours or annually (refer to manual for specific mileage/time recommendation)
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (e.g., every few rides)
Chain Lubrication Adjustment:
Every 300-500 km or as needed
Valve Check Interval:
Every 100-200 hours or annually
Fluid Specifications
Engine Oil Type:
High-quality motorcycle specific 4-stroke engine oil (e.g., Motul 5100 10W-40 or 15W-50, check manual for exact API/JASO spec)
Coolant Type:
Ethylene glycol-based antifreeze mixture (typically 50/50 with distilled water)
Fork Oil Type:
Specific fork oil viscosity (e.g., SAE 5W or 10W, volume as per manual)
Known Issues
Common Wear Items:
Clutch plates, piston rings, fork seals, chain and sprockets due to high-performance off-road use.
Electrical Connectors:
Potential for corrosion in connectors due to off-road environment (manual provides wiring diagrams for troubleshooting).
📚 Vehicle History
Brand Heritage
Heritage:
Husqvarna Motorcycles, established in Sweden, known for off-road prowess and innovation.
Model Evolution
Evolution:
The TE (Tout-Terrain) and TC (Tout-Terrain Competition) lines are Husqvarna's dedicated off-road motorcycles, with the 400cc and 570cc models representing significant displacements for competition and trail riding.
Production
Manufacturing Location:
Italy (under Cagiva Group ownership during this period)
🏆 Awards & Recognition
Recognitions
Brand Recognition:
Husqvarna is a highly respected brand in off-road motorcycling, known for its performance and durability.
Ratings
Customer Satisfaction:
Generally high for models of this era, particularly among dedicated off-road riders.
Certifications
Emission Standards:
Meets applicable emission standards for the model year and region.
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