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Husqvarna

2009 Husqvarna TC450 TC510 TXC250 TXC450 TXC510 TE250 TE310 TE450 TE510 SMR450 SMR510 Motorcycle Service Repair Manual

2009 Husqvarna TC450 TC510 TXC250 TXC450 TXC510 TE250 TE310 TE450 TE510 SMR450 SMR510 Motorcycle Service Repair Manual

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Vehicle data plateRef 105822
Brand
Husqvarna
Vehicle
Motorcycle
Models covered
Engines, SMR450, SMR510, TC450, TC510, TE250, TE310, TE450, TE510, TXC250, TXC450, TXC510
Years
2009
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

  • Download link opens on the order page immediately
  • The same link is emailed to you — re-download any time
  • Open on phone, tablet or PC; print only the pages you need
  • Not sure it covers your model year? Ask us before you buy
🏷️ Basic Information
Identification
Make:
Husqvarna
Model:
TC450, TC510, TXC250, TXC450, TXC510, TE250, TE310, TE450, TE510, SMR450, SMR510
Year:
2009
Vehicle Type:
Motorcycle
Codes
Tc450 Serial Prefix:
ZKHA202AA9V050001
Tc510 Serial Prefix:
ZKHA203AA9V050001
Tc450 Usa Serial Prefix:
ZKHTC450*9V100000
Tc510 Usa Serial Prefix:
ZKHTC510*9V100000
Te250 Serial Prefix:
ZKHA200AA9V000001
Te310 Serial Prefix:
ZKHA204AA9V000001
Te450 Serial Prefix:
ZKHA202AA9V000001
Te510 Serial Prefix:
ZKHA203AA9V000001
Te250 Usa Serial Prefix:
ZKHKBECF*9V100001
Te310 Usa Serial Prefix:
ZKHKBEDF*9V100001
Te450 Usa Serial Prefix:
ZKHKBEFF*9V100000
Te510 Usa Serial Prefix:
ZKHKBEHF*9V100000
Txc250 Usa Serial Prefix:
ZKHTX250*9V000001
Txc450 Usa Serial Prefix:
ZKHTX450*9V000001
Txc510 Usa Serial Prefix:
ZKHTX510*9V000001
Smr450 Serial Prefix:
ZKHA202AB9V000001
Smr510 Serial Prefix:
ZKHA203AB9V000001
👋 Introduction
Market Position
Target Audience:
Owners and technicians seeking in-depth repair and maintenance information for 2009 Husqvarna off-road and supermoto motorcycles
Competitive Analysis
Value Proposition:
Provides a cost-effective alternative to professional servicing for maintaining and restoring Husqvarna motorcycles.
Key Features
Content Highlights:
Detailed illustrations, diagrams, wiring schematics, torque specs, comprehensive troubleshooting, complete disassembly and reassembly guidance.
📋 Manual Details
Coverage Areas
Models Covered:
TC450, TC510, TXC250, TXC450, TXC510, TE250, TE310, TE450, TE510, SMR450, SMR510
Production Years Covered:
2009
Regions Covered:
Includes variations for USA market models where applicable (e.g., USA serial number prefixes, specific electrical component listings).
Page Count
Total Pages:
178
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
Viewing Requirements:
Adobe PDF Reader
Compatibility:
Windows, Mac, Linux OS, iPhone, iPad, Android
📖 Manual Coverage
Systems Covered
Engine And Drivetrain:
Cylinder, Piston, Cylinder Head, Crankshaft, Primary Drive, Clutch, Valve Timing, L.H. Half Crankcase, R.H. Half Crankcase, R.H. Half Crankcase Covers, L.H. Half Crankcase Covers, Oil Pump, Carburetor (Keihin for TC/TXC), Mikuni Throttle Body (for TE/SMR), Ignition System, Starting System, Transmission, Shifter (TC specific), Transmission, Shifter (TE/TXC/SMR specific)
Chassis And Suspension:
Cooling System, Air Filter, Frame, Foot Rests, Front Fork Assembly (TE/SMR), Front Fork Assembly (TC/TXC), Rear Swing Arm, Rear Shock Absorber, Rear Suspension Linkage, Handlebar and Controls, Rear Hydraulic Brake, Front Hydraulic Brake (TE/TC/TXC), Front Hydraulic Brake (SMR), Front Wheel (TE/TC/TXC), Front Wheel (SMR), Rear Wheel
Electrical And Bodywork:
Digital Instrument, Blinkers, Horn (TE/SMR), Main Wiring Harness, Electrical Parts (TC/TXC/TE-USA), Main Wiring Harness, Lights, Electrical Parts (TE-SMR), Side Panels, Fenders, Seat, Plate Holder, Gas Tank, Panels, Exhaust System (TE/TC/TXC), Exhaust System (SMR), Transfer (TE - color code G), Transfer (TC/TXC - color code G), Transfer (SMR - color code G), Canister (TE-SMR / USA)
Exhaust Systems:
Covers both standard TE/TC/TXC exhaust systems and specific SMR exhaust systems, likely detailing mounting, baffles, and any necessary heat shielding.
Procedures Included
Repair And Rebuild:
Complete tear down and rebuild procedures, detailed step-by-step instructions based on complete disassembly
Maintenance:
Routine maintenance, service schedules, fluid checks and changes
Troubleshooting:
Diagnostic procedures, fault finding and rectification
Technical Specifications:
Torque specifications, wiring schematics, detailed illustrations and diagrams, part diagrams
Special Tools:
Manual lists required service tools for specific procedures, such as engine assembly tools, suspension tools, and diagnostic equipment.
Parts Diagrams:
Provides visual part diagrams for all major assemblies, crucial for identification and ordering correct replacement components.
Technical Depth
Depth:
Comprehensive diagnostic and repair procedures, suitable for both do-it-yourselfers and experienced mechanics
Wiring Diagrams:
Includes detailed wiring harnesses and electrical parts diagrams for TC, TXC, TE (USA), and TE/SMR models.
📊 Manual Specifications
File Format
Quality:
High quality, fully searchable PDF
Print Quality
Printability:
Printable pages, zoomable for detailed viewing
Binding Type
Binding:
Not applicable (Digital Download)
Paper Type
Paper Type:
Not applicable (Digital Download)
Completeness
Completeness:
100% complete and intact, no missing/corrupt pages/sections
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, 4-stroke (likely SOHC, though specific details vary by model displacement)
Cooling System:
Liquid-cooled (radiator and fan system typical for these models)
Ignition System:
Electronic ignition (details on CDI unit and components provided)
Performance
Displacement Range:
250cc to 510cc (covering TE250, TE310, TXC250, TC450, TXC450, SMR450, TC510, TE450, TE510, TXC510, SMR510)
Fuel System
Carburetion Or Injection:
Carburetor (Keihin for TC/TXC models), Throttle Body (Mikuni for TE/SMR models) - specific details would be in manual
🔧 Transmission
Standard
Transmission Type:
6-speed manual gearbox (typical for these models)
Optional
Optional Features:
Not applicable for 2009 model year
Features
Clutch Type:
Hydraulic actuation, wet multi-plate clutch (typical)
📐 Dimensions
Exterior
Body Style:
Off-road (Motocross/Enduro) and Supermoto configurations
Weights
Dry Weight Range:
Varies by model, typically between 110-125 kg (242-275 lbs) for 2009 models
🛡️ Safety Features
Ratings
Safety Standards:
Not applicable for off-road competition motorcycles in the same way as street vehicles; adherence to FIM standards for competition may apply.
Active Features
Braking System:
Hydraulic disc brakes front and rear. Specific caliper and rotor sizes detailed within the manual.
Passive Features
Frame Construction:
Chromoly steel frame (typical for these models)
💡 Technology Features
Infotainment
Features:
Basic digital instrumentation including speedometer, odometer, trip meter, and engine hour meter. No advanced infotainment systems.
Driver Assistance
Features:
Not applicable. Focus is on rider control and mechanical performance.
Connectivity
Features:
Not applicable. Primarily mechanical and basic electrical systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10-15 engine hours or annually, as detailed in the manual.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (every few rides), as per manual guidance.
Fluid Specifications
Engine Oil Type:
Full synthetic 4-stroke motorcycle oil, SAE 10W-50 or 15W-50 typically recommended (verify specific viscosity and API rating in manual).
Coolant Type:
Ethylene glycol-based coolant mixed with distilled water (50/50 ratio) recommended.
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid (verify specific type and DOT rating in manual).
Transmission Oil Type:
SAE 75W/90 or SAE 80W/90 gear oil (verify specific type and API rating in manual).
Known Issues
Common Wear Items:
Clutch plates, piston rings, valve guides, wheel bearings, chain and sprockets are common wear items on high-performance off-road motorcycles.
Electrical Connections:
Corrosion or loose connections in off-road environments can sometimes affect lighting or ignition systems.
📚 Vehicle History
Brand Heritage
Heritage:
Husqvarna Motorcycles has a long history dating back to 1903, known for its off-road and motorsport expertise.
Model Evolution
Evolution 2009:
The 2009 models represent a refinement of Husqvarna's performance off-road and supermoto platforms, building on previous generations with updated components and tuning.
Production
Manufacturing Origin:
Italy (prior to acquisition by BMW)
🏆 Awards & Recognition
Recognitions
Motorsport Achievements:
Husqvarna motorcycles have a strong racing pedigree across various off-road disciplines, contributing to their performance reputation.

Delivery & file format

This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.

Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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