Positioning:
Targeted at owners and technicians of the Husqvarna TE510 dual-sport/enduro motorcycle, providing the authoritative documentation for its maintenance and repair.
Value Proposition:
Offers comprehensive technical data and procedures often missing or incomplete in general owner's manuals, empowering users to perform complex tasks.
Features:
Detailed step-by-step repair instructions, diagnostic flowcharts, comprehensive troubleshooting guides, clear diagrams and illustrations.
Primary Coverage:
Comprehensive service, repair, and maintenance for Husqvarna TE510 (2007-2008).
Secondary Coverage:
Troubleshooting, diagnostics, electrical system schematics, component overhauls.
Estimated Pages:
Estimated 300-500 pages (typical for this level of detail).
Type:
Service Repair Workshop Manual
Format:
Digital (likely PDF), potentially printable.
Engine:
Complete engine disassembly, assembly, tuning, component inspection (piston, rings, valves, camshafts, crankshaft, cylinder head, cylinder bore).
Fuel System:
Carburetor (Mikuni VM34-136 or similar), fuel pump, fuel lines, fuel tank inspection and cleaning.
Ignition System:
CDI ignition, stator, spark plug specifications, troubleshooting ignition faults.
Cooling System:
Radiator, coolant hoses, water pump inspection and replacement, coolant specifications.
Transmission Drivetrain:
Gearbox disassembly/assembly, clutch operation and adjustment, chain and sprocket inspection and replacement, gear ratios.
Suspension:
Front forks (Marzocchi Shiver USD or similar), rear shock absorber, linkage system, suspension adjustments, seal replacement.
Brakes:
Hydraulic front and rear brake systems, caliper inspection and rebuild, master cylinder service, brake fluid specifications, bleeding procedures.
Electrical System:
Wiring diagrams, battery maintenance, lighting system, starter motor, fuses, troubleshooting electrical circuits.
Frame Chassis:
Frame inspection, steering head bearings, swingarm bushings, wheel bearings, axle specifications.
Bodywork Plastics:
Fairing removal/installation, seat, fuel tank, fenders.
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, lubrication points, valve clearance checks.
Repair:
Component-level repairs, complete engine rebuilds, suspension rebuilds, brake system overhauls.
Troubleshooting:
Diagnosis of common performance issues, starting problems, electrical faults, suspension behavior.
Diagnostics:
Step-by-step diagnostic procedures for various systems, fault code interpretation (if applicable).
Specifications:
Torque specifications for all fasteners, clearances, fluid capacities, tolerances.
Depth:
In-depth, professional-level coverage suitable for experienced mechanics and serious DIY enthusiasts. Includes detailed diagrams and step-by-step instructions.
Type:
4-stroke, single-cylinder
Displacement:
Approximately 498cc (actual displacement may vary slightly based on bore/stroke specifications for the year).
Bore X Stroke:
Typically around 97mm x 80.5mm (confirm specific data in manual).
Cooling System:
Liquid-cooled
Valve Train:
SOHC, 4 valves
Horsepower:
Estimated 40-45 HP at peak RPM (actual figures vary).
Torque:
Estimated 40-45 Nm at peak RPM (actual figures vary).
Carburetor Type:
Mikuni VM34-136 or similar
Fuel Type:
Unleaded gasoline
Engine Oil Type:
SAE 10W-40 motorcycle specific oil (check manual for exact API/JASO rating).
Oil Capacity:
Approximately 1.7 - 1.9 liters (including filter, check manual for exact capacity).
Length:
Refer to manual for precise dimensions; typically around 2200mm.
Width:
Refer to manual for precise dimensions; typically around 800mm.
Height:
Refer to manual for precise dimensions; typically around 1250mm.
Dry Weight:
Approximately 110-115 kg (dry).
Wet Weight:
Approximately 120-125 kg (wet, with fluids).
Fuel Tank Capacity:
Approximately 7.5 - 8.5 liters.
Front Wheel Size:
21 inches
Rear Wheel Size:
18 inches
Front Tire Size:
80/100-21 (common off-road sizing, check manual for specific recommendations).
Rear Tire Size:
110/100-18 or 120/90-18 (common off-road sizing, check manual for specific recommendations).
Bolt Pattern:
N/A (spoke wheels with axle mounting).
Crash Test Ratings:
N/A (Motorcycles are not typically subject to standardized automotive crash testing like cars).
Braking System:
Hydraulic disc brakes (front and rear) with braided steel lines for enhanced performance and feel.
Lighting:
Headlight, taillight/brake light, turn signals (depending on dual-sport homologation).
Frame Construction:
Steel perimeter frame designed for rigidity and impact resistance.
Oil Change Interval:
Typically every 2,000-3,000 km or annually, whichever comes first (check manual for specific recommendation).
Air Filter Cleaning:
Frequent cleaning/replacement recommended, especially after dusty riding conditions.
Valve Clearance Check:
Typically every 4,000-6,000 km (critical for engine performance and longevity).
Chain Lubrication Adjustment:
Regularly (every 500-1000 km) and after washing or wet riding.
Coolant Type:
Ethylene glycol based coolant, typically a 50/50 mix with distilled water. (Refer to manual for specific type and concentration).
Brake Fluid Type:
DOT 4 or DOT 5.1 brake fluid (confirm specific requirement in manual).
Common Problems:
Potential for carburetor jetting issues (requiring adjustment for altitude/conditions), wear on suspension bushings, and regular chain/sprocket maintenance.
Preventative Measures:
Regular cleaning, proper lubrication, adherence to maintenance schedule, and quality parts are key to longevity.
Heritage:
Husqvarna is one of the oldest motorcycle manufacturers in the world, with a strong legacy in off-road and motocross racing.
Te510 Lineage:
The TE510 is part of Husqvarna's long-standing line of versatile enduro and dual-sport motorcycles, known for their performance and off-road capability.
Manufacturing Location:
Typically manufactured in Italy during this period.
Production Period:
The TE510 model was produced for many years, with the 2007-2008 generation representing a specific iteration of the design.
