|
Manual Coverage
|
|
Systems Covered
|
|
Engine:
|
Comprehensive coverage including disassembly, assembly, diagnostics, and specifications for the TE449 and TE511 engines.
|
|
Fuel System:
|
Detailed procedures for fuel injection system, fuel pump, injectors, and associated components.
|
|
Ignition System:
|
Information on ignition coils, spark plugs, and troubleshooting ignition-related issues.
|
|
Cooling System:
|
Maintenance and repair of the radiator, coolant hoses, water pump, and fan assembly.
|
|
Exhaust System:
|
Repair and inspection of exhaust pipes, mufflers, and catalytic converters (if applicable).
|
|
Transmission:
|
Complete overhaul, maintenance, and troubleshooting for the gearbox and clutch mechanisms.
|
|
Chassis Frame:
|
Inspection, maintenance, and repair of the frame, subframe, and associated mounting points.
|
|
Suspension Front:
|
Detailed procedures for fork service, including seal replacement, oil changes, and spring adjustments.
|
|
Suspension Rear:
|
Maintenance and repair of the rear shock absorber, linkage, and swingarm assembly.
|
|
Brakes Front:
|
Brake caliper service, disc replacement, brake line maintenance, and bleeding procedures.
|
|
Brakes Rear:
|
Rear brake caliper service, disc replacement, and related maintenance procedures.
|
|
Wheels Tires:
|
Wheel bearing replacement, tire mounting, and balancing information.
|
|
Steering:
|
Handlebar, triple clamp, and steering head bearing maintenance and adjustment.
|
|
Electrical System:
|
Wiring diagrams, battery maintenance, lighting system, starter motor, and troubleshooting electrical faults.
|
|
Bodywork Fairings:
|
Removal, installation, and repair of plastic body panels, seat, and fuel tank.
|
|
Lubrication System:
|
Oil change procedures, filter replacement, and lubrication points.
|
|
Procedures Included
|
|
Maintenance:
|
Scheduled maintenance tasks, including fluid changes, filter replacements, and inspections.
|
|
Troubleshooting:
|
Diagnostic flowcharts and step-by-step guides for identifying and resolving common and uncommon problems.
|
|
Repair:
|
Detailed instructions for disassembling, repairing, and reassembling all major vehicle components.
|
|
Overhaul:
|
Complete rebuild procedures for the engine, transmission, and other critical systems.
|
|
Specifications Torque Values:
|
Accurate torque specifications for all fasteners and critical bolts.
|
|
Clearances Tolerances:
|
Essential service clearances and tolerances for engine components and other moving parts.
|
|
Wiring Diagrams:
|
Comprehensive electrical wiring diagrams for easy diagnosis and repair.
|
|
Part Number Identification:
|
Identification of essential part numbers for ordering replacements.
|
|
Technical Depth
|
|
Depth:
|
Factory-level technical depth, suitable for professional mechanics and advanced DIY enthusiasts.
|
|
Diagnostic Capabilities:
|
Includes diagnostic procedures for identifying mechanical and electrical faults.
|
|
Rebuild Procedures:
|
Detailed rebuild instructions for engine, gearbox, and suspension components.
|
|
Engine Specifications
|
|
Primary Engine
|
|
Engine Type:
|
Four-stroke, single-cylinder (for both TE449 and TE511, with displacement differences)
|
|
Displacement Te449:
|
Approximately 449cc (exact figure may vary slightly by source)
|
|
Displacement Te511:
|
Approximately 510cc (exact figure may vary slightly by source)
|
|
Bore X Stroke Te449:
|
Detailed in manual (typically around 97mm x 60.8mm for TE449-based engines, specific to 2011 generation)
|
|
Bore X Stroke Te511:
|
Detailed in manual (typically around 98mm x 70.1mm for TE511-based engines, specific to 2011 generation)
|
|
Valve Train:
|
DOHC, 4 valves per cylinder (typical for this era and model)
|
|
Cooling:
|
Liquid-cooled
|
|
Performance
|
|
Horsepower Te449:
|
Estimated 50-55 HP (varies by specific tuning and exhaust)
|
|
Horsepower Te511:
|
Estimated 55-60 HP (varies by specific tuning and exhaust)
|
|
Torque Te449:
|
Estimated 40-45 Nm
|
|
Torque Te511:
|
Estimated 45-50 Nm
|
|
Fuel System
|
|
Fuel Delivery:
|
Electronic Fuel Injection (EFI) - Mikuni system common for this era
|
|
Fuel Type:
|
Unleaded gasoline (minimum 91 octane recommended)
|
|
Fuel Tank Capacity:
|
Approx. 8.5 liters (2.2 gallons)
|
|
Maintenance
|
|
Service Intervals
|
|
Oil Change Interval:
|
Refer to manual; typically every 15-20 hours of riding or annually.
|
|
Air Filter Cleaning:
|
Regular cleaning/replacement recommended based on riding conditions (e.g., every 5-10 hours).
|
|
Spark Plug Inspection:
|
Inspect every 15-20 hours, replace as needed.
|
|
Valve Clearance Check:
|
Typically at longer intervals, e.g., every 100-150 hours; detailed in manual.
|
|
Fluid Specifications
|
|
Engine Oil Type:
|
Refer to manual; typically a high-quality synthetic motorcycle oil, e.g., SAE 10W-50 or 15W-50.
|
|
Engine Oil Capacity:
|
Refer to manual for exact capacity with and without filter change.
|
|
Coolant Type:
|
Ethylene glycol-based coolant with corrosion inhibitors.
|
|
Fork Oil Type:
|
Refer to manual; specific weight and viscosity oil, e.g., WP Suspension Fluid or Motorex Fork Oil.
|
|
Brake Fluid Type:
|
DOT 4 hydraulic brake fluid.
|
|
Known Issues
|
|
Common Wear Items:
|
Clutch plates, spark plugs, air filters, fork seals, and chain/sprockets are common wear items in off-road bikes.
|
|
Electrical Gremlins:
|
Some older European bikes can occasionally suffer from electrical gremlins; the manual's wiring diagrams are essential.
|
|
Suspension Maintenance:
|
Regular suspension servicing is critical for maintaining optimal performance and preventing premature wear of seals and bushings.
|
