Segment:
High-performance off-road and dual-sport motorcycle segment.
Target Audience:
Husqvarna TE510 owners, technicians, and enthusiasts seeking detailed repair and maintenance information.
Competitors 2004:
KTM EXC series, Yamaha WR series, Honda CRF-X series, Suzuki DR-Z series, Kawasaki KLX series.
Manual Advantage:
Provides comprehensive technical data for DIY servicing, repairs, and overhauls, enabling cost-effective maintenance.
Content Quality:
Detailed step-by-step instructions, specifications, and illustrations for accurate repairs.
Primary Coverage:
Workshop Service and Repair for all 2004 Husqvarna TE510 models
Geographic Scope:
Assumed to cover models sold globally, documentation language is English.
Page Count:
Not specified, described as comprehensive.
Manual Type:
Workshop Repair Manual / Service Manual
Format:
PDF (Portable Document Format)
Engine:
Detailed diagnosis, overhaul, and repair of the engine and its sub-systems (e.g., ignition, fuel, lubrication, cooling, exhaust).
Transmission:
Inspection, repair, and adjustment of the gearbox, clutch, and associated components.
Chassis:
Frame, suspension (front forks and rear shock absorber), steering system, wheels, and tires.
Brakes:
Hydraulic brake system (front and rear discs), including master cylinders, calipers, lines, and bleeding procedures.
Electrical System:
Wiring diagrams, battery, lighting system, starting system, charging system (alternator/stator), and ignition system.
Fuel System:
Carburetor (likely Mikuni or Keihin), fuel pump, fuel lines, and tank.
Cooling System:
Liquid cooling system (if applicable), radiator, coolant pump, and hoses.
Bodywork And Trim:
Fairings, seat, fenders, handlebars, and related fittings.
Scheduled Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication points, and general inspections.
Troubleshooting:
Diagnostic procedures for common and uncommon problems across all systems.
Repair And Overhaul:
Step-by-step instructions for disassembly, cleaning, inspection, repair, and reassembly of all major components.
Adjustments:
Carburetor tuning, valve clearance adjustments, chain tension, and brake lever settings.
Wiring Diagnostics:
Interpreting wiring diagrams for electrical fault finding.
Suspension Setup:
Adjusting front fork and rear shock absorber settings for various riding conditions.
Depth Level:
Comprehensive, covering basic maintenance to complete engine and gearbox rebuilds, including electrical troubleshooting.
Diagrams And Illustrations:
Includes exploded views, assembly drawings, wiring diagrams, and photographic illustrations for clarity.
Engine Type:
Four-stroke, single-cylinder
Displacement:
Approximately 501 cc (exact figure may vary slightly by sub-model, but TE510 indicates this displacement class).
Bore X Stroke:
Specifications would be detailed in the manual, typically around 97mm x 67.8mm for this era.
Cooling System:
Liquid-cooled
Valvetrain:
SOHC (Single Overhead Camshaft), 4 valves
Horsepower:
Estimated 45-50 HP (Varies by tuning and exhaust).
Torque:
Specifications would be detailed in the manual, typically in the range of 45-50 Nm.
Fuel Delivery:
Carburetor (Likely Mikuni VM series or Keihin FCR, size typically 38-41mm)
Fuel Type:
Unleaded Gasoline (Octane rating as specified in manual)
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Transmission Type:
6-speed constant mesh
Optional Gearbox:
N/A for this model and year.
Clutch Type:
Wet, multi-plate, hydraulically operated
Final Drive:
O-ring sealed chain
Gear Ratios:
Specific ratios are detailed within the manual.
Transmission Oil Type:
Motorcycle-specific transmission oil or a high-quality 10W-40 or 10W-50 engine oil, as per manual recommendation.
Transmission Oil Capacity:
Typically around 1.0-1.2 liters, specific capacity detailed in manual.
Length:
Refer to manual for exact dimensions.
Width:
Refer to manual for exact dimensions.
Height:
Refer to manual for exact dimensions.
Dry Weight:
Approximately 118-125 kg (unspecified in product info, typical for model).
Wet Weight:
Approximately 130-138 kg (with fluids, unconfirmed).
Fuel Tank Capacity:
Approximately 8-10 liters (specific capacity in manual).
Safety Certification:
CE, EPA emissions compliance (depending on market).
Braking System:
Hydraulic disc brakes front and rear for strong stopping power.
Suspension Design:
Long-travel suspension (Marzocchi front forks, Sachs rear shock) providing control over rough terrain.
Lighting:
Headlight, tail light, brake light, turn signals for visibility.
Ergonomics:
Designed for off-road control and rider comfort during extended use.
Infotainment System:
N/A for this model; focus is on performance and off-road capability.
Assistance Features:
N/A; basic functions like lighting and indicators.
Connectivity Options:
N/A.
Dashboard Features:
Analog speedometer, tachometer, odometer, trip meter, and indicator lights.
Oil Change Interval:
Approximately every 1,500-3,000 km or 6-12 months, or as per manual's specific recommendation based on usage.
Air Filter Cleaning:
Regular inspection and cleaning, frequency dependent on riding conditions (e.g., every 500-1000 km or after dusty rides).
Valve Clearance Check:
Typically every 6,000-10,000 km, detailed procedure in manual.
Engine Oil Type:
High-quality synthetic or semi-synthetic motorcycle oil, SAE 10W-40 or 10W-50 recommended, meeting API SG/SH/SJ or JASO MA standards. Exact viscosity and specifications in manual.
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors, mixed 50/50 with distilled water. Refer to manual for specific ratios and additive requirements.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Carburetor Tuning:
Can be sensitive to altitude and temperature changes, requiring periodic adjustment.
Electrical Connections:
Older bikes may experience corrosion or loose connections, requiring regular inspection and cleaning.
Suspension Seals:
Fork seals and rear shock seals can wear over time, especially with off-road use, leading to leaks.
Brand Origin:
Husqvarna Motorcycles, founded in Sweden in 1903, a pioneer in motorcycle manufacturing.
Te Series Legacy:
The TE series represents Husqvarna's lineage of versatile off-road and dual-sport motorcycles, built for endurance and performance.
2004 Model Context:
The 2004 TE510 was part of a period where Husqvarna was refining its engine and chassis technologies, often featuring Italian-developed components following ownership changes.
Manufacturing Location:
Typically Italy during this period.
