Segment:
Dual-sport / Supermoto motorcycle segment.
Target Audience:
Owners and technicians performing maintenance and repairs on the Husqvarna TE610E and SM610 models.
Competitors 1998:
KTM EXC series, Honda XR series, Yamaha WR series, Suzuki DR-Z series.
Offroad Capability:
TE610E: Designed for off-road use with long-travel suspension and rugged construction.
Supermoto Conversion:
SM610: Supermoto variant featuring smaller wheels, street tires, and upgraded suspension for on-road performance.
Engine Design:
Robust single-cylinder, four-stroke engine known for its torque and durability.
Engine Mechanical:
Full overhaul and repair procedures for the engine, including disassembly, inspection, reassembly, and tuning.
Fuel System:
Carburetor adjustment, cleaning, rebuilding, and fuel pump (if applicable) service.
Ignition System:
Spark plug specifications, ignition timing, coil testing, and CDI unit diagnosis.
Cooling System:
Radiator, coolant, fan operation, and thermostat testing (relevant for TE models).
Transmission Gearbox:
Clutch operation, gear selection, lubrication, and internal transmission component servicing.
Chassis Frame:
Frame inspection, swingarm removal and installation, and steering head bearing maintenance.
Suspension Front:
Fork oil change, seal replacement, spring inspection, and damper adjustment for the TE and SM models.
Suspension Rear:
Monoshock absorber service, linkage lubrication, and rear spring adjustment.
Brakes Front:
Brake pad replacement, caliper service, master cylinder rebuilding, and hydraulic fluid flush.
Brakes Rear:
Brake drum/disc service, caliper/drum cylinder maintenance, and hydraulic fluid flush.
Electrical System:
Wiring diagrams, battery maintenance, lighting system, starter motor, and charging system diagnosis.
Bodywork Panels:
Fairing removal and installation, seat, fuel tank, and fender maintenance.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug checks, and tire pressure checks.
Troubleshooting:
Diagnostic flowcharts and common problem identification for various systems.
Engine Rebuild:
Detailed instructions for complete engine teardown, parts inspection, and reassembly.
Suspension Service:
Step-by-step guides for fork and shock absorber servicing.
Brake System Overhaul:
Complete instructions for servicing the hydraulic brake system components.
Electrical Diagnostics:
Fault finding for charging system, ignition, lighting, and starting circuits.
Depth:
Comprehensive, covering routine maintenance to full engine and chassis rebuilds.
Illustrations:
Highly illustrated with clear diagrams and exploded views.
Special Tools:
Lists required special tools for specific repair procedures.
Type:
Four-stroke, liquid-cooled, single-cylinder
Displacement:
576 cc (35.1 cu in)
Bore X Stroke:
93 mm x 83 mm (3.66 in x 3.27 in)
Valve Train:
SOHC, 4 valves
Compression Ratio:
Approximately 10.5:1 (spec may vary slightly)
Horsepower Approx:
Approx. 40-45 hp @ 6500 rpm (varies by market and tuning)
Torque Approx:
Approx. 45 Nm (33 lb-ft) @ 5500 rpm (varies by market and tuning)
Carburetor:
Dell'Orto PHM 40 (or similar 40mm flat slide carburetor)
Fuel Capacity:
Approx. 12 liters (3.2 US gallons) for TE610E, potentially different for SM610
Oil Type:
API SG/SH or JASO MA, SAE 10W-40 motorcycle oil recommended
Oil Capacity W Filter:
Approx. 1.6 - 1.8 liters (specific value in manual)
Wheelbase:
Approx. 1460 mm (57.5 in) for TE610E, potentially shorter for SM610
Seat Height:
High, typical for enduro/supermoto bikes (exact specification in manual)
Ground Clearance:
Significant for TE610E, reduced for SM610 (specifics in manual)
Dry Weight:
Approx. 125-135 kg (275-298 lbs) depending on model and equipment.
Safety Standards:
Designed to meet relevant motorcycle safety standards of the era.
Braking System:
Hydraulic disc brakes front and rear (dual caliper front on some SM variants).
Lighting:
Headlight, taillight, brake light, and turn signals (standard on SM, optional/basic on TE).
Frame Construction:
Steel trellis or semi-double cradle frame for rigidity and impact absorption.
Oil Change Interval:
Every 3,000 - 5,000 km or 6 months (refer to manual for exact mileage and conditions).
Air Filter Cleaning:
Every 1,000 - 2,000 km or as needed based on riding conditions.
Chain Maintenance:
Lubricate and adjust chain every 500 km.
Spark Plug Check:
Every 4,000 - 6,000 km.
Engine Oil Viscosity:
10W-40
Coolant Type:
Ethylene glycol-based antifreeze/coolant mixture (50/50 ratio)
Common Wear Items:
Clutch plates, fork seals, steering head bearings, wheel bearings, and chain/sprockets.
Potential Electrical Quirks:
Wiring harness integrity and connector corrosion can sometimes cause intermittent issues.
Carburetor Tuning:
Carburetor may require periodic adjustment for optimal performance due to altitude or temperature changes.
