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HUSQVARNA TE 520 CENTENNIAL Workshop Repair Manual Download All 2004-2005 ModelS COVERED PDF

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🏷️ Basic Information Identification Make: Husqvarna Model: TE 520 Centennial Type: Dual-Sport Motorcycle Generation Model Years: 2004-2005 Codes Chassis Code Common: Likely shared with standard TE 520 variants of the...
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HUSQVARNA TE 520 CENTENNIAL Workshop Repair Manual Download All 2004-2005 ModelS COVERED PDF
🏷️ Basic Information
Identification
Make:
Husqvarna
Model:
TE 520 Centennial
Type:
Dual-Sport Motorcycle
Generation
Model Years:
2004-2005
Codes
Chassis Code Common:
Likely shared with standard TE 520 variants of the era, specific Centennial identifier not readily available without VIN lookup.
👋 Introduction
Market Position
Segment:
High-performance, European-designed dual-sport/enduro motorcycle, often favored for off-road prowess and distinctive styling.
Competitive Analysis
Competitors:
Competed against models from KTM (e.g., EXC series), Husaberg, Yamaha (WR series), Honda (CRF-X series), Suzuki (DR-Z series), and Kawasaki (KLX series) in the premium off-road and dual-sport segment.
Key Features
Centennial Edition:
The 'Centennial' designation likely signifies a special edition model, potentially with unique graphics, components, or celebratory badging, marking a significant anniversary for Husqvarna.
Off Road Bias:
Strong off-road capabilities with features like long-travel suspension, durable construction, and powerful engine characteristics, while also being street-legal for dual-sport use.
📋 Manual Details
Coverage Areas
General:
Comprehensive workshop repair and service for Husqvarna TE 520 Centennial models.
Page Count
Estimated Pages:
Extensive, likely exceeding 300 pages based on typical workshop manuals for this class of motorcycle.
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF (Downloadable)
📖 Manual Coverage
Systems Covered
Engine:
Engine overhaul, disassembly, assembly, tuning, lubrication system, cooling system, fuel system, ignition system, exhaust system.
Transmission:
Clutch, gearbox, shifting mechanism, maintenance, repair, specifications.
Chassis:
Frame, suspension (front forks and rear shock absorber), steering system, wheel bearings, swingarm.
Brakes:
Hydraulic brake systems (front and rear calipers, master cylinders, brake lines, brake fluid specifications).
Electrical:
Wiring diagrams, lighting system, charging system (stator, regulator/rectifier), battery, starter motor, ignition system components.
Bodywork:
Body panels, seat, fuel tank, fenders, fairings, instrumentation.
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, spark plug inspection/replacement, air filter cleaning/replacement.
Troubleshooting:
Diagnostic procedures, common problems and their solutions, electrical fault finding.
Component Rebuild:
Engine, carburetor/fuel injection, suspension components, brake calipers, gearbox.
Adjustments:
Carburetor/throttle body synchronization and adjustment, clutch and throttle cable free play, suspension sag.
Safety Checks:
Brake system checks, tire pressure and condition, steering head bearing adjustment.
Technical Depth
Level:
In-depth, professional-level repair and diagnostic information for both DIY enthusiasts and professional mechanics.
Detail Level:
Step-by-step instructions with clear diagrams, illustrations, and specifications for accurate disassembly, reassembly, and adjustment.
Diagnostic Capability:
Enables diagnosis of mechanical and electrical issues, including component testing and fault code interpretation (if applicable).
📊 Manual Specifications
File Format
Compatibility:
Compatible with PC and Mac operating systems (Windows 95, 98, 2000, NT, XP, Vista, 7, 8, etc.).
Searchability:
Likely includes searchable text within the PDF for quick access to specific information.
Print Quality
Resolution:
High-quality, suitable for printing individual pages or the entire manual.
Binding Type
Physical Format:
N/A (Digital Download)
Paper Type
Physical Format:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Type:
Four-stroke, single-cylinder
Displacement:
Approximately 501 cc (specific bore and stroke may vary slightly by year/version).
Cooling System:
Liquid-cooled
Valvetrain:
SOHC (Single Overhead Camshaft), 4 valves
Performance
Horsepower:
Estimated 45-50 HP (at crankshaft, dependent on tuning and specific model variant).
Torque:
Torque figures typically in the range of 40-45 Nm (29-33 lb-ft) at lower RPMs, providing strong low-end grunt for off-road riding.
Fuel System
Carburetor:
Likely a large-bore Mikuni or Keihin flat-slide carburetor (e.g., Mikuni TM40 or TM42).
Fuel Type:
Unleaded gasoline (minimum 91 octane recommended).
Lubrication System
Type:
Wet sump
🔧 Transmission
Standard
Type:
6-speed constant mesh sequential gearbox
Optional
Type:
N/A
Features
Clutch:
Hydraulically actuated wet multi-plate clutch
Final Drive:
O-ring chain drive
Fluid Specifications
Transmission Oil:
Likely SAE 10W-40 or 10W-50 motorcycle-specific transmission oil (refer to manual for exact grade and API rating).
📐 Dimensions
Exterior
Wheelbase:
Approximately 1470-1500 mm (57.9-59.1 inches).
Seat Height:
Around 950-970 mm (37.4-38.2 inches).
Weights
Dry Weight:
Approximately 115-125 kg (253-275 lbs).
Wet Weight:
Approximately 130-140 kg (287-309 lbs) with fluids.
Tires
Front Tire Size:
Typically 90/90-21
Rear Tire Size:
Typically 120/90-18 or 140/80-18
Fuel Capacity
Tank Size:
Approximately 9-11 liters (2.4-2.9 US gallons).
🛡️ Safety Features
Ratings
Crash Test Data:
N/A for motorcycles in the traditional automotive sense. Safety is primarily through rider skill and protective gear.
Active Features
Braking System:
Disc brakes front and rear, designed for effective stopping power in varied conditions.
Suspension:
High-quality, adjustable suspension (e.g., Marzocchi USD forks, Sachs or Ohlins rear shock) provides stability and control.
Passive Features
Lighting:
Headlight, taillight, and brake lights for visibility on public roads.
Protective Equipment Recommendation:
Manual strongly emphasizes the use of full protective gear (helmet, goggles, gloves, boots, body armor) for safe operation.
💡 Technology Features
Infotainment
System:
N/A (basic instrumentation only - speedometer, odometer, engine hour meter, indicator lights).
Driver Assistance
Features:
N/A
Connectivity
Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 10-15 hours of riding or annually, whichever comes first. Refer to manual for specific mileage/time interval.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (every few rides or as needed).
Spark Plug Inspection:
Inspect every 10-20 hours of riding. Replace if fouled or worn.
Valve Clearance Check:
Recommended every 20-30 hours of riding or annually.
Fluid Specifications
Engine Oil Capacity:
Approximately 1.0 - 1.2 liters (refer to manual for precise capacity).
Coolant Type:
Ethylene glycol based antifreeze mixture (50/50 with distilled water recommended).
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid.
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, chain and sprockets, fork seals, and spark plugs are common wear items on high-performance off-road motorcycles.
Carburetor Tuning:
Can require periodic re-jetting or adjustment due to altitude changes or modifications.
Electrical Connections:
Ensuring all electrical connections are clean and secure is vital for reliable operation.
📚 Vehicle History
Brand Heritage
Origin:
Husqvarna Motorcycles is one of the oldest motorcycle manufacturers in the world, founded in Sweden in 1903.
Specialty:
Renowned for its off-road racing heritage, particularly in motocross, enduro, and desert racing.
Model Evolution
Te Series:
The TE series represents Husqvarna's dedication to the enduro and dual-sport market, evolving from their motocross platforms with features for street legality and extended range.
Production
Manufacturing Location:
During this period, Husqvarna was owned by the Cagiva Group and manufactured in Italy.
🏆 Awards & Recognition
Recognitions
Model Specific:
While specific awards for the 'Centennial' edition are not widely documented, Husqvarna motorcycles of this era consistently received praise in the enthusiast press for their performance and off-road capability.
Ratings
Brand Performance:
Husqvarna is consistently rated highly by off-road and dual-sport riders for its robust engineering and competitive performance.
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