Segment:
Competition Motocross / Off-Road Performance
Target Audience:
Husqvarna TC510 owners, mechanics, and enthusiasts performing maintenance and repairs
Comparable Models:
KTM EXC/SX series, Yamaha YZ-F series, Honda CRF series, Suzuki RM-Z series, Kawasaki KX-F series of the same era.
Product Benefit 1:
Provides detailed, step-by-step instructions for all maintenance and repair tasks.
Product Benefit 2:
Includes crucial technical specifications, torque values, and clearances for accurate work.
Product Benefit 3:
Essential for troubleshooting and diagnosing performance issues.
Product Benefit 4:
Digital PDF format offers easy searchability and portability.
Product Benefit 5:
Facilitates cost savings by enabling DIY maintenance and repairs.
Engine Mechanical:
Complete engine disassembly, assembly, inspection, and repair (pistons, rings, crankshaft, camshaft, valves, timing, lubrication, cooling)
Engine Electrical:
Ignition system, starting system, charging system, fuel injection system, sensors, ECU troubleshooting, wiring diagrams
Fuel System:
Fuel pump, injectors, fuel pressure regulator, fuel tank, fuel lines, carburetor (if applicable for specific markets/variants, though FI is typical for this era)
Cooling System:
Radiator, water pump, thermostat, hoses, coolant specifications, bleeding procedures
Exhaust System:
Exhaust pipes, muffler, catalytic converter (if equipped), mounting and inspection
Transmission:
Clutch operation, gearbox disassembly and assembly, gear inspection, lubrication, shifting mechanism
Drivetrain:
Chain drive system, sprockets, adjustment, lubrication
Suspension:
Front forks (rebuild, adjustment, fluid levels), rear shock absorber (rebuild, adjustment, linkage service)
Brakes:
Hydraulic brake system, master cylinders, calipers, brake pads, rotors, brake lines, bleeding procedures, fluid specifications
Wheels And Tires:
Tire pressure, inspection, replacement, wheel bearings, spoke tension (for applicable models)
Steering:
Handlebar, steering stem, bearings, lubrication, adjustment
Electrical System:
Battery, lighting system (headlight, taillight, indicators), horn, wiring harnesses, fuses, relays
Bodywork And Frame:
Frame inspection, plastic body panels, seat, fuel tank mounting, fenders
Troubleshooting:
Diagnostic procedures for common and uncommon issues across all systems
Preventative Maintenance:
Scheduled maintenance tasks, inspections, lubrication points, wear item replacement
Routine Service:
Oil changes, filter replacements, chain adjustments, brake fluid flushes, coolant changes
Engine Overhaul:
Complete engine rebuild instructions, including torque specifications and clearances
Suspension Service:
Fork seal replacement, fork oil changes, shock absorber servicing
Brake System Repair:
Brake pad replacement, caliper servicing, hydraulic system bleeding
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams and test procedures
Fuel System Cleaning:
Injector cleaning, fuel filter replacement
Wheel Bearing Replacement:
Proper removal and installation of wheel bearings
Carburetor Adjustment Or Efi Tuning:
Details on fuel mixture adjustments or EFI system parameters
Depth Level:
Comprehensive - covers from basic maintenance to full engine and component rebuilds
Diagnostic Capability:
Advanced diagnostic procedures, including troubleshooting guides and fault code interpretation (if applicable for EFI models)
Repair Scope:
Full disassembly and reassembly of all major mechanical and electrical components
Special Tools:
Identification and use of specialized tools required for specific repair procedures
Engine Type:
Single-cylinder, Four-stroke
Displacement:
Approximately 501cc (specific bore and stroke details within manual)
Bore X Stroke:
Refer to manual for exact specifications
Cooling System:
Liquid-cooled
Valve Train:
SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft), confirmed by manual
Compression Ratio:
Refer to manual for exact specifications
Horsepower:
Estimated 50-60 HP (specific output within manual)
Torque:
Estimated 45-55 Nm (specific output within manual)
Induction:
Electronic Fuel Injection (EFI) - Keihin or Mikuni (specific system to be confirmed by manual)
Fuel Type:
Unleaded Gasoline (minimum octane rating specified in manual)
Oil Type:
High-quality motorcycle engine oil (specific viscosity and API rating provided in manual, e.g., SAE 10W-40, JASO MA)
Oil Change Interval:
Typically every 10-20 engine hours or per manual recommendation, depending on riding conditions.
Air Filter Cleaning:
Frequent cleaning/replacement, often every few hours of riding, especially in dusty conditions.
Chain Lubrication Adjustment:
Regular inspection and lubrication, adjustment as needed.
Spark Plug Inspection Replacement:
Refer to manual for specific mileage or hour intervals.
Valve Clearance Check:
Typically every 50-100 engine hours, critical for performance. Specific interval in manual.
Engine Oil Viscosity:
SAE 10W-40 (common, but confirm with manual)
Engine Oil Standard:
JASO MA or MA2 (for wet clutch compatibility), API SG or higher (confirm with manual)
Coolant Type:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water (confirm specific type in manual)
Brake Fluid Type:
DOT 4 hydraulic brake fluid (confirm with manual)
Fork Oil Type Viscosity:
Specific fork oil type and viscosity (e.g., Showa SS-04 or equivalent) provided in manual.
Common Wear Item:
Clutch plates, brake pads, chain and sprockets are high-wear items in off-road riding.
Engine Component Longevity:
Proper maintenance is crucial for piston, ring, and valve longevity, especially with hard use.
Suspension Seals:
Fork seal leaks can occur, requiring regular inspection and timely replacement.
Fueling Issues:
EFI systems can be sensitive to fuel quality; ensure clean fuel and proper filter maintenance.
Manufacturer Origin:
Husqvarna Motorcycles, originally Swedish, by the time of these models, it was under Italian ownership (Cagiva Group).
Off Road Legacy:
Husqvarna has a long and storied history in off-road racing, dating back to the early 20th century, with numerous championship titles.
Tc Series Development:
The TC line represents Husqvarna's dedicated motocross competition models, evolving significantly with engine technology, suspension, and chassis design throughout the 2000s.
2007 Updates:
Likely received updates in engine tuning, suspension components, and chassis geometry from previous years. Specific details in manual.
2008 Updates:
Continued refinement of the 2007 platform, potentially including minor engine improvements, suspension tweaks, or aesthetic changes. Specific details in manual.
Manufacturing Location:
Italy (under Cagiva Group ownership)
