Segment:
Competition Motocross/Enduro
Target Audience:
Husqvarna TC510 owners, mechanics, and enthusiasts.
Competitors 2007 2008:
KTM EXC series, Yamaha YZ-F series, Honda CRF series, Suzuki RM-Z series, Kawasaki KX-F series.
Vehicle Appeal:
Known for its powerful engine, agile handling, and Italian heritage.
Manual Value Proposition:
Enables DIY maintenance and repairs, reducing service costs and downtime.
Primary Coverage:
Workshop Service and Repair
Scope:
Complete Official Factory Service Manual
Estimated Pages:
Hundreds (Printable in entirety or by section)
Type:
Service Repair Manual
Format:
Downloadable Digital Format (PDF recommended for printability)
File Type:
PDF (Portable Document Format)
Quality:
High-resolution scans for clear text and diagrams.
Binding:
N/A (Digital Download)
Paper:
N/A (Digital Download)
Engine Mechanical:
Complete overhaul, disassembly, inspection, and reassembly of all engine components.
Engine Electrical:
Ignition system, starting system, charging system, fuel injection system diagnostics.
Fuel System:
Fuel pump, injectors, fuel pressure regulator, throttle body, carburetor (if applicable), fuel tank, lines.
Transmission:
Clutch operation, gear shifting mechanisms, gearbox disassembly and assembly, lubrication.
Suspension:
Front forks (rebuild, oil changes, settings), rear shock absorber (rebuild, settings), linkage systems.
Brakes:
Hydraulic system, brake caliper maintenance and rebuild, brake pad replacement, master cylinder service, bleeding procedures.
Cooling System:
Radiator, hoses, water pump, thermostat, coolant specifications, bleeding procedures.
Electrical System:
Wiring diagrams, component testing, battery, lighting, switches, relays, fuses.
Chassis And Frame:
Frame inspection, steering head bearing service, swingarm, footpegs.
Bodywork And Trim:
Fairings, seat, fenders, graphics, removal and installation procedures.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication points, air filter cleaning/replacement.
Troubleshooting:
Diagnostic charts for common problems, fault finding based on symptoms.
Major Repairs:
Engine rebuild, transmission overhaul, suspension fork rebuild, brake system repairs.
Component Disassembly Reassembly:
Step-by-step instructions for every major component.
Technical Specifications:
Torque values, clearances, fluid capacities, electrical specifications.
Wiring Diagrams:
Detailed electrical schematics for all systems.
Depth:
Comprehensive (from basic maintenance to full engine and chassis rebuilds).
Diagnostic Capabilities:
Advanced diagnostic procedures for electrical and mechanical systems.
Engine Type:
4-Stroke Single Cylinder
Displacement:
501 cc (approximate, exact may vary slightly by specific sub-model or region)
Bore X Stroke:
Information available within the manual.
Cooling System:
Liquid-cooled
Horsepower:
Information available within the manual (typically in the high 40s to low 50s HP range for this class).
Torque:
Information available within the manual.
Fuel Delivery:
Electronic Fuel Injection (EFI) or Carburetor depending on exact specification and market; manual will specify.
Ignition System:
Digital CDI
Valve Train:
DOHC (Double Overhead Camshaft)
Starting System:
Kickstart
Length:
Information available within the manual.
Width:
Information available within the manual.
Height:
Information available within the manual.
Dry Weight:
Information available within the manual (typically around 100-110 kg).
Wet Weight:
Information available within the manual.
Front Travel:
Information available within the manual (typically 280-300mm).
Rear Travel:
Information available within the manual (typically 290-310mm).
Wheelbase:
Information available within the manual.
Engine Oil Change:
Typically every 10-15 hours of riding or annually, but precise intervals are in the manual.
Air Filter Cleaning:
Frequent cleaning recommended based on riding conditions (e.g., every few rides in dusty environments).
Valve Clearance Check:
Typically every 30-40 hours of riding; manual will specify precise interval and procedure.
Spark Plug Replacement:
Varies, but typically checked at oil changes and replaced as needed.
Engine Oil Type:
Specific motorcycle-grade 4-stroke oil (e.g., SAE 10W-50 or 15W-50, JASO MA/MA2 rated). Manual will confirm viscosity and specifications.
Engine Oil Capacity:
Information available within the manual.
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid (manual will specify).
Transmission Oil:
Often shared with engine oil, but manual will specify if separate or specific type required.
Typical Wear Items:
Clutch plates, piston rings, valve guides, wheel bearings, steering head bearings, brake pads, chain and sprockets.
Engine Related:
Potential for valve guide wear and cam chain tensioner issues if not properly maintained. Manual addresses inspection and replacement.
Suspension Related:
Regular fork seal replacement and fork oil changes are critical for optimal performance.
Heritage:
Husqvarna Motorcycles, established in Sweden in 1903, has a long and storied history in motorsport, particularly in motocross and enduro.
Tc510 Lineage:
The TC line represents Husqvarna's competition motocross models. The 510cc class signifies a powerful engine, often favored for its torque and broad powerband.
2007 2008 Updates:
Specific technical updates for these model years will be detailed within the service manual, often including engine tuning, suspension refinements, and chassis tweaks.
Manufacturing Origin:
Italy (during the period of BMW ownership, though origins are Swedish).
