The TE610, produced for the 1995 and 1996 model years, represents a robust dual-sport motorcycle engineered for versatility. As part of the esteemed 'TE' enduro line, this Second Generation model offers capable off-road performance combined with road legality, making it ideal for trail riding, adventure touring, and light commuting. Its design emphasizes durability and a strong connection to a rich heritage, one of the oldest motorcycle manufacturers globally. This model features a liquid-cooled, four-stroke, single-cylinder engine with a displacement of 576 cc, delivering approximately 40-45 horsepower and 45-50 Nm of torque. The motorcycle is equipped with a 6-speed manual transmission, wet multi-plate clutch, and hydraulic disc brakes front and rear, supported by long-travel suspension for superior terrain management.
This comprehensive factory service manual provides detailed guidance for the maintenance, repair, and servicing of your TE610. Covering a wide array of systems, including the engine, fuel system, ignition, cooling, transmission, suspension, brakes, and electrical systems, this manual is an indispensable resource. It includes procedures for routine maintenance tasks, troubleshooting guides, component disassembly and reassembly, diagnostic steps, and adjustments, along with information on special tools. Whether you are performing basic upkeep or in-depth repairs, this manual equips owners and technicians with the necessary technical specifications and procedures to ensure the optimal performance and longevity of the vehicle.
    
    
    
    
    
    
    
    
        
            Engine Code Generic:
        
        
            TE610-specific
        
     
    
    
        
            Generation Identifier:
        
        
            Second Generation TE610
        
     
 
    
    
    
        
            Vehicle Segment:
        
        
            Dual-Sport / Enduro Motorcycle
        
     
    
    
        
            Competitors 1995 1996:
        
        
            KTM EXC series, Yamaha WR series, Honda XR series, Suzuki DR series
        
     
    
    
        
            Motorcycle Purpose:
        
        
            Versatile off-road capability with road legality, suitable for trail riding, adventure touring, and light commuting.
        
     
 
    
    
    
        
            Primary Coverage:
        
        
            Service, Repair, Workshop
        
     
    
    
        
            Estimated Page Count:
        
        
            300-500
        
     
    
    
        
            Manual Type:
        
        
            Factory Service Manual / Workshop Manual
        
     
    
    
    
    
 
    
    
    
        
            Engine Service And Overhaul:
        
        
            Yes
        
     
    
        
            Fuel System And Carburetion:
        
        
            Yes
        
     
    
    
    
        
            Transmission And Clutch:
        
        
            Yes
        
     
    
        
            Suspension Systems Front And Rear:
        
        
            Yes
        
     
    
        
            Brake System Front And Rear:
        
        
            Yes
        
     
    
        
            Electrical System And Wiring Diagrams:
        
        
            Yes
        
     
    
    
        
            Wheel And Tire Service:
        
        
            Yes
        
     
    
    
    
        
            Routine Maintenance Tasks:
        
        
            Yes
        
     
    
        
            Troubleshooting Guides:
        
        
            Yes
        
     
    
        
            Component Disassembly And Reassembly:
        
        
            Yes
        
     
    
        
            Diagnostic Procedures:
        
        
            Yes
        
     
    
        
            Adjustment Procedures:
        
        
            Yes
        
     
    
        
            Special Tool Identification And Use:
        
        
            Yes
        
     
    
    
        
            Depth Of Coverage:
        
        
            Comprehensive: From basic maintenance to full engine rebuilds and electrical system diagnostics.
        
     
 
    
    
    
    
        
            Searchable Text:
        
        
            Likely, depending on the original scan quality.
        
     
    
    
        
            Print Quality Recommendation:
        
        
            High resolution recommended for clarity of diagrams and text.
        
     
    
    
        
            Binding For Digital Format:
        
        
            N/A (Digital Download)
        
     
    
    
        
            Paper Type For Print:
        
        
            Standard A4 or Letter paper suitable for printing.
        
     
 
    
    
    
        
            Engine Type:
        
        
            Four-stroke, single-cylinder
        
     
    
        
            Displacement:
        
        
            576 cc (35.1 cu in)
        
     
    
        
            Bore X Stroke:
        
        
            Approx. 92 mm x 84 mm (3.62 in x 3.31 in)
        
     
    
        
            Compression Ratio:
        
        
            Typically around 9.5:1 to 10.0:1
        
     
    
        
            Cooling System:
        
        
            Liquid-cooled
        
     
    
        
            Valve Train:
        
        
            SOHC, 4 valves
        
     
    
    
        
            Horsepower Estimate:
        
        
            Approximately 40-45 hp (at crankshaft)
        
     
    
        
            Torque Estimate:
        
        
            Approximately 45-50 Nm (33-37 lb-ft) (at crankshaft)
        
     
    
    
        
            Carburetor Type:
        
        
            Mikuni VM or TMR series, single
        
     
    
        
            Carburetor Size Estimate:
        
        
            38 mm or 40 mm
        
     
 
    
    
    
        
            Transmission Type:
        
        
            Constant mesh, 6-speed manual
        
     
    
    
        
            Optional Transmissions:
        
        
            N/A
        
     
    
    
        
            Clutch Type:
        
        
            Wet, multi-plate
        
     
    
        
            Final Drive:
        
        
            O-ring sealed chain
        
     
 
    
    
    
        
            Overall Length:
        
        
            Varies, typically around 2200 mm (86.6 in)
        
     
    
        
            Overall Width:
        
        
            Varies, typically around 850 mm (33.5 in)
        
     
    
        
            Overall Height:
        
        
            Varies, typically around 1250 mm (49.2 in)
        
     
    
        
            Wheelbase:
        
        
            Approx. 1470 mm (57.9 in)
        
     
    
        
            Ground Clearance:
        
        
            Approx. 300 mm (11.8 in)
        
     
    
    
        
            Dry Weight:
        
        
            Approx. 130 kg (287 lbs)
        
     
    
        
            Wet Weight Estimate:
        
        
            Approx. 145 kg (320 lbs)
        
     
 
    
    
    
        
            Safety Ratings:
        
        
            N/A (Motorcycles typically not rated by NHTSA/Euro NCAP)
        
     
    
    
        
            Braking System:
        
        
            Hydraulic disc brakes, front and rear
        
     
    
        
            Suspension Stability:
        
        
            Long-travel suspension for off-road terrain management
        
     
    
    
        
            Lighting:
        
        
            Headlight, tail light, brake light, turn signals (where applicable for road legality)
        
     
 
    
    
    
        
            Infotainment System:
        
        
            Basic analog instrumentation (speedometer, odometer, tachometer if equipped).
        
     
    
    
        
            ABS Or Traction Control:
        
        
            No electronic rider aids.
        
     
    
    
        
            Connectivity Features:
        
        
            N/A
        
     
 
    
    
    
        
            Oil Change Interval:
        
        
            Every 3,000 km (1,860 miles) or 6 months, whichever comes first (typical recommendation).
        
     
    
        
            Air Filter Cleaning:
        
        
            Every 1,000 km (620 miles) or as needed based on conditions.
        
     
    
        
            Spark Plug Replacement:
        
        
            Every 6,000 km (3,730 miles) or annually.
        
     
    
        
            Valve Clearance Check:
        
        
            Every 6,000 km (3,730 miles).
        
     
    
    
        
            Engine Oil Type:
        
        
            SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil.
        
     
    
        
            Engine Oil Capacity:
        
        
            Approx. 1.8 - 2.0 liters (1.9 - 2.1 US qt) with filter change.
        
     
    
        
            Coolant Type:
        
        
            Ethylene glycol based antifreeze mixed with distilled water (50/50 ratio).
        
     
    
        
            Brake Fluid Type:
        
        
            DOT 4 hydraulic brake fluid.
        
     
    
    
        
            Carburetor Tuning:
        
        
            Can be sensitive to altitude and temperature; requires periodic adjustment.
        
     
    
        
            Electrical Connections:
        
        
            Older models may experience corrosion or loose connections, particularly in off-road environments.
        
     
    
        
            Suspension Seals:
        
        
            Fork seals and shock seals can wear over time, especially with heavy off-road use.
        
     
    
        
            Clutch Adjustment:
        
        
            Clutch cable and operation may require periodic adjustment for optimal feel.
        
     
 
    
    
    
        
            Husqvarna Legacy:
        
        
            Husqvarna is one of the oldest motorcycle manufacturers, founded in Sweden in 1689, with a long history in off-road racing and innovation.
        
     
    
    
        
            Te610 Positioning:
        
        
            Part of Husqvarna's 'TE' (Tout Terrain) enduro line, designed for versatility.
        
     
    
        
            1990S Husqvarna:
        
        
            1990s marked a period of continued development in their four-stroke enduro and motocross offerings.
        
     
    
    
        
            Manufacturing Location:
        
        
            Italy (under Cagiva ownership during this period)
        
     
 
    
    
    
        
            Industry Awards:
        
        
            While specific awards for the 1995-1996 TE610 are not widely documented, Husqvarna motorcycles of this era were generally well-regarded within the off-road community for their performance and durability.