Husqvarna TC510 2007 2008 Service Repair Workshop Manual

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Taper: Motorcycle

Distributeur:

UGS: 101400

Mots clés: 2007 2008 Husqvarna Misc Motorcycle Motorcycles TC510

Variantes de produits

Description

The TC510, produced for the 2007 and 2008 model years, is a high-performance off-road motorcycle designed for motocross and competitive riding. This machine emphasizes power, handling, and durability, featuring a liquid-cooled, four-stroke, single-cylinder engine with a displacement of approximately 508 cc, delivering an estimated 50-55 horsepower. Its robust construction and advanced suspension systems, including upside-down telescopic front forks and a monoshock rear setup, are engineered to excel in demanding off-road conditions. With a focus on performance and rider control, the TC510 is positioned as a competitive option for motocross riders and serious off-road enthusiasts. This comprehensive Service Repair Workshop Manual provides detailed instructions and specifications for the TC510 (2007-2008). It covers all essential aspects of maintenance, diagnosis, and repair, including in-depth procedures for the engine, fuel system, ignition, cooling, transmission, clutch, suspension, brakes, wheels, tires, and electrical system. The manual includes preventative maintenance schedules, troubleshooting guides, component replacement instructions, and technical data such as torque specifications and clearances. This resource is designed to assist owners, mechanics, and technicians in effectively maintaining, troubleshooting, and repairing the vehicle to ensure optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

TC510

Year:

2007, 2008

Vehicle Type:

Off-road Motorcycle / Motocross

Codes

Product Code:

HUS-TC510-0708-SM

👋 Introduction

Market Position

Positioning:

High-performance motocross machine aimed at competitive riders and serious enthusiasts.

Competitive Analysis

Key Competitors:

KTM EXC series, Yamaha YZ-F series, Honda CRF series, Suzuki RM-Z series, Kawasaki KX-F series.

Key Features

Performance Focus:

Emphasis on power, handling, and durability for off-road racing conditions.

Target User:

Motocross riders, off-road racers, and experienced mechanics requiring detailed service information.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

Digital (likely PDF, assuming common availability for this type of product)

Page Count

Page Count:

Estimated 200-350 pages (typical for comprehensive motorcycle service manuals of this era)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, tuning, diagnostics, and overhaul of the 510cc single-cylinder engine.

Fuel System:

Carburetor (Mikuni), fuel pump, fuel tank, fuel lines, and associated components inspection and repair.

Ignition System:

CDI ignition, spark plug, ignition coil, and troubleshooting.

Cooling System:

Radiator, hoses, coolant, cooling fan (if applicable), and temperature sensor.

Transmission Clutch:

Clutch assembly (plates, springs, actuation), gearbox, shift mechanism, and transmission oil.

Suspension Front:

Upside-down telescopic forks (e.g., Marzocchi or Paioli), internals, seals, oil levels, and adjustments.

Suspension Rear:

Monoshock rear suspension, shock absorber, linkage system, bearings, seals, and adjustment.

Brakes Front:

Brake caliper, master cylinder, brake lines, brake disc, and pad replacement/service.

Brakes Rear:

Rear brake caliper, master cylinder, brake lines, brake disc, and pad replacement/service.

Wheels Tires:

Wheel bearings, spoke tension, tire fitting, and recommended tire pressures.

Electrical System:

Wiring diagrams, battery, lighting (headlight, taillight, indicators if street legal), switches, and fuses.

Frame Chassis:

Frame inspection, swingarm, steering head bearings, and general chassis components.

Bodywork:

Plastic body panels, seat, fuel tank mounting, and fairings.

Procedures Included

Preventative Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustment, and lubrication.

Troubleshooting:

Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides.

Repair Overhaul:

Step-by-step instructions for complete disassembly and reassembly of major vehicle components.

Component Replacement:

Detailed guidance on replacing specific parts like pistons, valves, bearings, seals, and cables.

Carburetor Tuning:

Jetting, float height adjustments, idle speed, and air-fuel mixture settings.

Suspension Adjustment:

Setting sag, compression, and rebound damping for optimal performance.

Electrical Diagnostics:

Using wiring diagrams to diagnose electrical faults, testing components.

Technical Depth

Depth Level:

Comprehensive (covers routine maintenance to full engine and gearbox rebuilds).

Torque Specifications:

Detailed torque values for critical fasteners throughout the motorcycle.

Clearances Tolerances:

Specific measurements for valve clearances, piston-to-cylinder wall, bearing play, etc.

Wiring Diagrams:

Full electrical system schematics with component identification.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable if digitally generated from a clean source, allowing quick access to specific information.

Print Quality

Print Readability:

Designed for clear printing with legible text and diagrams.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder

Displacement:

508 cc (approximate)

Bore X Stroke:

95 mm x 72 mm (typical for this engine, confirm with manual for exact spec)

Cooling System:

Liquid-cooled

Valve Train:

SOHC (Single Overhead Camshaft), 4 valves

Performance

Horsepower:

Estimated 50-55 HP (subject to specific tuning and model year variations)

Torque:

Estimated 45-50 Nm (subject to specific tuning and model year variations)

Fuel System

Carburetor:

Mikuni VM38SS or similar (confirm specific size and model)

Fuel Delivery:

Carburetor with mechanical fuel pump

🔧 Transmission

Standard

Transmission Type:

Constant-mesh, 6-speed sequential gearbox

Optional

Optional Gearboxes:

N/A (Motorcycles typically have a single, fixed transmission configuration)

Features

Clutch Type:

Wet multi-plate clutch

Transmission Oil Type:

JASO MA certified 10W-40 or 15W-50 motorcycle oil (confirm specific grade and capacity in manual)

📐 Dimensions

Exterior

Wheelbase:

Approx. 1480-1500 mm (148-150 cm)

Seat Height:

Approx. 950-970 mm (95-97 cm)

Ground Clearance:

Approx. 300-320 mm (30-32 cm)

Weights

Dry Weight:

Approx. 110-115 kg

Fuel Tank Capacity:

Approx. 8-9 Liters

Wheels Tires

Front Wheel Size:

21 x 1.60 inches

Rear Wheel Size:

18 x 2.15 inches (or 19 x 2.15 inches, common variations exist)

Front Tire Size:

80/100-21 (e.g., Dunlop D752, Michelin S12)

Rear Tire Size:

100/90-18 or 110/90-19 (e.g., Dunlop D752, Michelin S12)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Off-road vehicles are not typically subjected to automotive crash safety ratings)

Active Features

Braking System:

Hydraulic disc brakes front and rear for reliable stopping power.

Suspension Control:

Adjustable suspension components for rider control and terrain adaptation.

Passive Features

Frame Construction:

Robust steel or alloy frame designed for off-road impact resistance.

Ergonomics:

Designed for rider maneuverability and control in challenging conditions.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Pure performance off-road motorcycle, no infotainment features).

Driver Assistance

Driver Assistance Features:

N/A (No electronic rider aids like ABS or traction control on this model).

Connectivity

Connectivity Features:

N/A (No connectivity features).

Engine Management

ECU Features:

Basic CDI ignition control unit for spark timing; no advanced electronic fuel injection or complex engine mapping.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 10-15 hours of riding or annually, whichever comes first (verify with manual for precise intervals).

Air Filter Cleaning:

Clean after every few rides, especially in dusty conditions.

Chain Lubrication Adjustment:

Lubricate every 500-800 km (300-500 miles) or as needed, adjust tension regularly.

Spark Plug Inspection:

Inspect every 20-30 hours of riding.

Fluid Specifications

Engine Oil:

SAE 10W-40 or 15W-50, API SG/SH/SJ, JASO MA compliant motorcycle oil (confirm specific recommendations).

Coolant:

Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio) for a freezing point of -37°C (-34°F).

Fork Oil:

Specific fork oil viscosity (e.g., Kayaba Fork Oil 01, Motorex Fork Oil SAE 5W) and level (verify exact type and quantity in manual).

Brake Fluid:

DOT 4 Hydraulic Brake Fluid (confirm specific type).

Known Issues

Common Wear Items:

Clutch plates, brake pads, wheel bearings, steering head bearings, fork seals, and piston rings are common wear items due to the nature of motocross riding.

Engine Specifics:

Regular valve clearance checks and adjustments are crucial for engine longevity and performance in these high-revving engines. Carburetor jetting may need adjustment for altitude or temperature changes.

Suspension Notes:

Fork seal leaks are a relatively common issue in aggressive off-road use; timely replacement is important to prevent internal damage.

📚 Vehicle History

Brand Heritage

Heritage:

Husqvarna is one of the oldest motorcycle manufacturers, with a rich history in off-road and motocross racing.

Model Evolution

Tc Series Evolution:

The TC line represents Husqvarna's commitment to motocross, with continuous updates in engine technology, chassis design, and suspension for enhanced performance.

Production

Manufacturing Origin:

Husqvarna Motorcycles were originally from Sweden, but by this era, ownership had shifted and production was often based in Italy.

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

While specific awards for the 2007/2008 TC510 are not prominently documented, Husqvarna models of this era were generally well-regarded in off-road enthusiast circles for their power and handling capabilities.

Ratings

Performance Reviews:

Contemporary reviews often highlighted its strong engine performance and capable suspension for its class.