Category:
Dual-sport / Enduro motorcycle
Target User:
Owners, technicians, and enthusiasts seeking to maintain, repair, or understand the Husqvarna TE510.
Segment:
Competed in the highly contested 500cc-class enduro segment against manufacturers like KTM, Yamaha, Honda, and Suzuki.
Key Selling Points Of Model:
Known for its potent single-cylinder engine, capable off-road suspension, and Italian heritage.
Manual Value:
Provides the authoritative, factory-backed repair procedures necessary for accurate and efficient maintenance and repair, ensuring optimal performance and longevity.
Manual Usability:
Searchable PDF format allows quick access to specific information, and the ability to print specific sections or the entire manual enhances workshop convenience.
Engine:
Detailed information on the TE510's single-cylinder, four-stroke engine, including disassembly, inspection, assembly, timing, lubrication, cooling, and emissions control.
Transmission:
Comprehensive coverage of the gearbox, clutch (including operation, maintenance, and repair), shifting mechanisms, and related components.
Fuel System:
Includes details on the fuel tank, fuel pump, fuel filter, fuel lines, and carburetor (or fuel injection system if applicable for the specific variant) adjustments and servicing.
Ignition System:
Information on the ignition coil, spark plug, CDI unit, and troubleshooting ignition-related issues.
Electrical System:
Coverage of the battery, charging system (stator, regulator/rectifier), lighting, starter motor, wiring diagrams, and troubleshooting electrical faults.
Suspension:
Detailed procedures for front fork (e.g., Marzocchi Shiver) and rear shock absorber (e.g., Sachs) maintenance, adjustments, seal replacement, and fluid changes.
Brakes:
In-depth information on front and rear brake systems, including hydraulic circuits, master cylinders, calipers, brake pads, rotors, fluid replacement, bleeding, and troubleshooting.
Chassis And Frame:
Procedures for frame inspection, steering head bearing maintenance, swingarm service, and wheel bearing replacement.
Bodywork And Trim:
Guidance on removing and installing fenders, seat, fuel tank cover, side panels, and other plastic body components.
Cooling System:
Details on radiator maintenance, coolant specifications, hose inspection, and fan operation (if equipped).
Exhaust System:
Information on exhaust pipe, muffler, and heat shield maintenance.
Routine Maintenance:
Covers essential periodic maintenance tasks such as oil changes, filter replacements, spark plug checks, chain adjustment, and valve clearance checks.
Troubleshooting:
Includes diagnostic flowcharts and symptom-based troubleshooting guides for common mechanical and electrical problems.
Component Overhaul:
Detailed step-by-step instructions for complete disassembly, cleaning, inspection, measurement, and reassembly of major engine and chassis components.
Repair And Replacement:
Guidance on replacing worn or damaged parts, including seals, bearings, gaskets, cables, and electrical connectors.
Adjustments:
Specific instructions for adjusting clutch, throttle, brakes, suspension settings, and carburetor/fuel injection parameters.
Specifications And Tolerances:
Provides critical torque values, clearances, fluid capacities, and wear limits for all major components.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine rebuilds and advanced diagnostics, suitable for both novice and experienced mechanics.
Engine Type:
Single-cylinder, four-stroke
Engine Displacement:
Approximately 477cc (specific variant dependent, often referred to as 510cc in marketing)
Bore X Stroke:
Specifications typically found within the manual, crucial for engine rebuilds.
Cooling System:
Liquid-cooled
Valve Train:
SOHC (Single Overhead Camshaft) with 4 valves (typical configuration for this era and class)
Compression Ratio:
Specifications found within the manual, vital for engine diagnostics.
Horsepower:
Typically in the range of 45-55 hp (exact figures vary by model year and market specifications).
Torque:
Specific torque figures will be detailed in the manual, crucial for performance tuning.
Carburetor Type:
Likely Keihin FCR or similar high-performance carburetor for this era, with specific model number in manual.
Fuel Grade Recommendation:
Premium unleaded gasoline (specific octane rating in manual).
Engine Oil Type:
API SG, SH, SJ or higher, JASO MA certified motorcycle oil recommended. Viscosity typically 10W-40 or 15W-50 depending on temperature. Exact specifications and capacities in manual.
Infotainment System:
N/A (This is a dedicated off-road/enduro motorcycle, not equipped with typical automotive infotainment systems.)
Rider Assistance:
N/A (Focus is on rider control and mechanical systems. No electronic rider aids like ABS or traction control typically found on this model.)
Connectivity Features:
N/A (No Bluetooth, Wi-Fi, or smartphone integration on this model.)
Dashboard Features:
Basic digital or analog instrumentation including speedometer, odometer, trip meter, and indicator lights (e.g., neutral, turn signals, high beam).
Oil Change Interval:
Typically every 1,000 - 2,000 km or annually, depending on usage severity. Specific recommendations in manual.
Air Filter Cleaning Interval:
Frequent cleaning recommended, especially in dusty conditions. Check every few rides, clean every 500-1000 km or as needed.
Valve Clearance Check Interval:
Typically around 5,000 - 10,000 km or annually. Crucial for engine health and performance.
Chain Lubrication Adjustment Interval:
Lubricate every 300-500 km or after riding in wet conditions. Adjust slack as needed, typically every 500-1000 km or as per manual.
Brake Fluid Type:
DOT 4 recommended for hydraulic brake systems.
Coolant Type:
Ethylene glycol-based coolant (50/50 mix with distilled water) for freeze and corrosion protection. Specific type in manual.
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, swingarm bearings, brake pads, and chain/sprockets are typical wear items requiring periodic inspection and replacement.
Engine Performance Degradation:
Can be related to carburetor jetting, spark plug condition, valve clearance, or fuel quality. Manual provides diagnostic steps.
Suspension Leaks:
Fork seal and rear shock seal leaks are common in off-road use due to harsh conditions. Manual details seal replacement procedures.
Brand Origin:
Husqvarna Motorcycles, a Swedish brand with a long and storied history in off-road and motocross racing, founded in 1689 initially as a firearms manufacturer.
Te Series Legacy:
The TE series represents Husqvarna's commitment to the enduro racing and trail riding segment, building on decades of off-road expertise.
2007 2008 Updates:
While specific major revisions for these exact years are not universally documented without consulting Husqvarna's internal bulletins, this period saw continued refinement of their single-cylinder platform, often including updates to suspension, fueling, and engine mapping.
Manufacturing Location:
Historically produced in Sweden and later in Italy following acquisitions.
