Husqvarna TE449 TE511 2011 Service Repair Manual

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UGS: 92521

Mots clés: 2011 Husqvarna Misc Motorcycle Motorcycles TE449 TE511

Variantes de produits

Description

This manual covers the 2011 competition enduro motorcycles. These robust machines are engineered for off-road performance, offering agility and power for enthusiasts and competitive riders. Known for their advanced suspension systems, including upside-down front forks and a progressive linkage rear shock, and reliable liquid-cooled, four-stroke engines with electronic fuel injection, these models represent dedication to off-road excellence. The TE series is designed for challenging terrain and demanding riding conditions, providing a thrilling experience for those who venture off the beaten path. This comprehensive Service Repair Manual in English provides detailed guidance for maintaining and repairing your TE449/TE511. It covers all essential systems, including complete engine overhauls, fuel injection, transmission, electrical systems, chassis, suspension, brakes, and bodywork. The manual includes step-by-step instructions for scheduled maintenance, troubleshooting common issues, complete disassembly and assembly procedures, and advanced diagnostic techniques. With detailed torque specifications, critical measurements, and clear wiring diagrams, this resource is an invaluable tool for owners and technicians aiming to keep these motorcycles in optimal working condition.

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

TE449 / TE511

Year:

Codes

Model Codes:

TE449, TE511

👋 Introduction

Market Position

Segment:

Competition Enduro Motorcycle

Target Audience:

Enthusiasts, owners seeking to perform their own maintenance and repairs, professional mechanics.

Competitive Analysis

Competitors:

KTM EXC, Yamaha WR, Honda CRF, Suzuki RM-Z, Kawasaki KX models of the same era.

Key Features

Design Philosophy:

Designed for off-road performance, agility, and robustness.

Manual Benefit:

Provides the essential technical knowledge to maintain and repair the Husqvarna TE449/TE511 effectively.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Manual

Language:

English

Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, including cylinder head, piston, crankshaft, connecting rod, valve train, lubrication system, cooling system.

Fuel System:

Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank, fuel lines.

Transmission:

Gearbox assembly, clutch operation, shift mechanism, transmission fluid specifications and service.

Electrical System:

Wiring diagrams, starter system, ignition system, lighting, battery, charging system, sensors, ECU.

Chassis And Suspension:

Frame, front forks (upside-down telescopic hydraulic), rear shock absorber (monoshock), linkage system, swingarm.

Brakes:

Front and rear brake systems, hydraulic lines, calipers, master cylinders, brake fluid specifications, rotor and pad replacement.

Wheels And Tires:

Wheel bearing service, tire pressure recommendations, wheel and tire specifications.

Bodywork And Plastics:

Fairings, seat, fuel tank cover, fenders, removal and installation procedures.

Procedures Included

Maintenance:

Scheduled maintenance checks, oil changes, filter replacements, chain adjustment and lubrication, spark plug replacement, air filter cleaning/replacement.

Troubleshooting:

Diagnostic procedures for common problems, fault finding charts, error code explanations.

Repair:

Detailed step-by-step repair instructions for all major components and systems.

Disassembly And Assembly:

Complete procedures for dismantling and reassembling all major motorcycle components.

Suspension Tuning:

Basic adjustments for compression, rebound, and preload on front forks and rear shock. Advanced tuning may require specialized knowledge or parts.

Wheel Truing And Spoke Maintenance:

Information on checking spoke tension and basic wheel truing procedures.

Radiator And Cooling System Maintenance:

Flushing, coolant replacement, hose inspection and replacement.

Carburetor Tuning Or Efi Adjustment:

Adjustment procedures for EFI system parameters if applicable, or troubleshooting for fuel delivery issues.

Exhaust System Service:

Removal, inspection, and reinstallation of exhaust components.

Technical Depth

Diagnostics:

Advanced diagnostic procedures, including use of specialized tools and interpretation of sensor data.

Rebuilds:

Comprehensive instructions for engine and transmission rebuilds.

Specifications:

Torque specifications, clearances, tolerances, and critical measurements for all parts.

Special Tools:

Identification and usage of specific tools required for certain procedures (e.g., flywheel puller, clutch holding tool).

Wiring Diagrams Interpretation:

Detailed, color-coded wiring diagrams with component identification for accurate electrical troubleshooting.

📊 Manual Specifications

File Format

File Format:

Searchability:

Searchable text for quick information retrieval.

Printability:

Printable pages for physical referencing.

Resolution:

High-resolution images and diagrams.

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

Page Count

Estimated Page Count:

Likely 300-500 pages (typical for a comprehensive service manual of this era).

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder, liquid-cooled, DOHC

Te449 Displacement:

449.5 cc

Te511 Displacement:

478 cc (often referred to as 510cc class)

Bore X Stroke Te449:

98 mm x 59.6 mm

Bore X Stroke Te511:

100 mm x 60.9 mm

Performance

Horsepower Approximate Te449:

50-55 HP (approximate, varies with tuning)

Horsepower Approximate Te511:

52-58 HP (approximate, varies with tuning)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) - Keihin throttle body

Ignition System:

Digital CDI ignition

Maintenance

Oil Type Recommendation:

High-performance motorcycle-specific 4-stroke oil (e.g., JASO MA/MA2 compliant, SAE 10W-40 or 15W-50 depending on climate, as specified in manual).

Oil Capacity Approximate:

Approx. 1.1 - 1.3 Liters (check manual for exact capacity with filter change).

Spark Plug Type Recommendation:

NGK CR9EB or equivalent (refer to manual for exact spec).

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Optional

Optional Gear Ratios:

N/A (standardized)

Features

Clutch Type:

Wet multi-plate clutch, hydraulically operated

Transmission Fluid Type:

Refer to manual; often the same as engine oil for wet clutch systems, but specific viscosity and JASO rating are critical.

📐 Dimensions

Exterior

Frame Type:

Steel perimeter frame

Front Suspension Type:

Marzocchi 48mm Upside-Down (USD) Telescopic Hydraulic Fork

Rear Suspension Type:

Progressive linkage with Sachs monoshock absorber

Front Brake Type:

Hydraulic disc, Brembo caliper

Rear Brake Type:

Hydraulic disc, Brembo caliper

Front Wheel Size:

21 inch

Rear Wheel Size:

18 inch

Weights

Dry Weight Approximate Te449:

Approx. 116 kg (256 lbs)

Dry Weight Approximate Te511:

Approx. 117 kg (258 lbs)

🛡️ Safety Features

Ratings

Safety Classification:

Off-road motorcycle, designed for closed-course competition and off-road use. Not street legal in most jurisdictions without modification.

Active Features

Braking System:

Powerful hydraulic disc brakes front and rear for reliable stopping power in off-road conditions.

Passive Features

Ergonomics:

Designed for rider control and stability during aggressive off-road riding.

💡 Technology Features

Infotainment

Infotainment Features:

Basic; typically features a digital multi-function display for speed, odometer, trip meter, and engine hour meter.

Driver Assistance

Driver Assistance Systems:

None. Primarily focused on mechanical performance and rider control.

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10-15 hours of riding or annually, whichever comes first (refer to manual for precise interval).

Air Filter Cleaning:

Frequent cleaning is recommended, especially in dusty conditions (e.g., every 5-10 hours of riding).

Chain Lubrication Adjustment:

Regularly, ideally every 500-1000 km or as needed based on slack.

Valve Clearance Check:

Typically at 6,000-10,000 km or as specified in the manual for major service intervals.

Fluid Specifications

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid

Coolant Type:

Ethylene glycol-based coolant, 50% mixture with distilled water (specific type/color may be recommended in manual).

Known Issues

Common Wear Items:

Clutch plates, piston rings, valve guides, fork seals, wheel bearings, chain and sprockets.

Electrical Connectors:

Corrosion or loose connections can sometimes cause intermittent electrical issues, particularly in off-road environments. Regular inspection and dielectric grease are advised.

📚 Vehicle History

Brand Heritage

Brand Origin:

Husqvarna Motorcycles is one of the oldest motorcycle manufacturers, originating from Sweden, now part of the KTM Group.

Model Evolution

Te Series:

The TE (Tuareg Enduro) series represents Husqvarna's long-standing commitment to off-road competition and trail riding, evolving from 2-stroke to advanced 4-stroke technology.

Production

Manufacturing Location:

Likely manufactured in Italy during this period, reflecting Husqvarna's ownership structure at the time.

🏆 Awards & Recognition

Recognitions

Off Road Capability:

Husqvarna's TE models are generally well-regarded for their off-road prowess and competition-bred performance, often earning praise in comparative tests within the enduro segment.

Ratings

Engine Durability Perception:

Generally considered robust for a performance-oriented dirt bike, but requires diligent maintenance as per manufacturer recommendations.