Positioning:
A highly detailed and comprehensive service manual aimed at DIY enthusiasts and professional technicians for the 2004 Husqvarna TE510 dual-sport motorcycle.
Comparison:
Positions itself as the same manual used by professional mechanics, offering superior detail and usability over generic repair guides.
Features:
Instant PDF download, illustrated step-by-step instructions, comprehensive system coverage, diagnostic support, and factory maintenance information.
Coverage:
Comprehensive service, repair, and maintenance for the 2004 Husqvarna TE510.
Page Count:
Not explicitly stated, but implied to be extensive given the detailed coverage.
Manual Type:
Service Repair Workshop Manual
Engine:
Engine overhaul, rebuilding, performance, firing orders, engine component breakdowns.
Transmission:
Transmission removal and installation, in-car servicing, detailed specifications.
Brakes:
Brake servicing procedures, complete torque specifications for brake components.
Electrical:
Complete wiring diagrams, vacuum diagrams.
Suspension:
Suspension procedures and specifications.
Drivetrain:
Chain removal and tightening, U-joint and CV-joint repair procedures.
Cooling System:
Air conditioning repair and capacities, although this might be more general than specific to the TE510's typical off-road configuration.
Chassis:
Front end alignment procedures and specifications.
Maintenance:
Factory maintenance schedules and charts, preventative maintenance.
Troubleshooting:
Troubleshooting and diagnostics, computer diagnostic trouble tree charts, driving concerns.
Repair:
Step-by-step repair procedures for all covered systems.
Diagnostics:
Computer diagnostic codes, detailed diagnostics for performance issues.
Rebuilding:
Engine overhaul and rebuilding procedures.
Timing Belt:
Timing belt replacement and repair procedures.
Belts:
Serpentine belt routings and diagrams.
Depth:
Detailed technical specifications on every model covered, complete torque specifications, factory maintenance schedules.
Illustrations:
Hundreds of illustrations, zoomable illustrations, detailed component explosions, exploded views.
Format Details:
PDF, may require unzipping (WinZip/WinRAR), compatible with all PDF readers, printable, searchable text implied.
Quality:
Very best quality, can be printed from any computer/printer.
Binding:
Digital download only, no physical copy, CD, or DVD.
Paper:
Not applicable (digital format).
Type:
Likely a single-cylinder, liquid-cooled, 4-stroke engine (typical for TE510 models of this era).
Displacement:
Specific displacement for the 2004 TE510 would be around 500cc (e.g., 501cc).
Horsepower:
Estimated 45-50 HP, depending on specific tuning and model variants.
Torque:
Estimated 40-45 Nm.
Induction:
Likely carburetor-fed (e.g., Keihin or Mikuni) for this model year, although some later models introduced fuel injection.
Fuel Type:
Unleaded gasoline (octane rating as specified in the manual, likely 95 RON).
Oil Type:
Motorcycle-specific synthetic or semi-synthetic engine oil, likely SAE 10W-40 or 15W-50, meeting JASO MA standards.
Oil Capacity:
Approximately 1.0 - 1.2 liters, exact capacity to be confirmed in the manual.
System:
Digital CDI (Capacitor Discharge Ignition).
System:
Liquid-cooled with a radiator and fan.
Type:
6-speed constant mesh manual transmission.
Options:
Not applicable for this model.
Clutch:
Wet multi-plate clutch, hydraulic actuation.
Gear Ratios:
Specific gear ratios are detailed within the manual for each gear.
Transmission Oil:
Dedicated transmission oil or the same engine oil as specified for the engine lubrication, depending on internal design. Capacity typically around 0.5 - 0.7 liters.
Length:
Variable by specific configuration, but typical for an enduro motorcycle.
Width:
Variable by specific configuration.
Height:
Variable by specific configuration.
Dry Weight:
Approximately 110-115 kg.
Wet Weight:
Approximately 120-125 kg (with fluids).
Gvwr:
Not typically specified for off-road motorcycles in the same way as cars.
Crash Test Results:
Not applicable (motorcycle).
Braking System:
Hydraulic disc brakes front and rear, likely with braided steel lines.
Lighting:
Headlight, taillight, brake light, turn signals (depending on road legality configuration).
Frame:
Chromoly steel perimeter frame.
Ergonomics:
Designed for off-road riding with emphasis on rider control and maneuverability.
Features:
Minimal; typically features a basic analog or digital instrument cluster showing speed, RPM, odometer, and basic indicator lights. No advanced infotainment systems.
Features:
None; designed as a performance-oriented dual-sport motorcycle, not equipped with electronic rider aids beyond basic engine management.
Features:
Not applicable.
Oil Change:
Typically every 1,500-3,000 km or annually, as per manual. Clutch and transmission oil may have separate intervals or be combined with engine oil service.
Air Filter:
Frequent cleaning/replacement recommended, especially in dusty conditions (e.g., every 500-1,000 km or after each significant off-road ride).
Spark Plug:
Inspection and gap check every 3,000-5,000 km, replacement as needed. Specific plug type is crucial.
Chain And Sprockets:
Regular cleaning, lubrication (every 500-800 km), and tension adjustment. Replacement based on wear indicators.
Coolant:
Mixture of distilled water and ethylene glycol-based antifreeze (50/50 ratio), meeting specific motorcycle coolant standards.
Brake Fluid:
DOT 4 or DOT 5.1 brake fluid, depending on manufacturer specification.
Common Problems:
Potential issues can include carburetor tuning, electrical connectors in exposed areas, and wear on off-road specific components like suspension seals and chain/sprockets, especially with heavy use.
Maintenance Tips:
Regular washing and lubrication, thorough pre-ride checks, and adherence to the factory maintenance schedule are critical for longevity.
Heritage:
Husqvarna Motorcycles is one of the oldest motorcycle manufacturers in the world, with roots in Sweden dating back to 1903. Known for its off-road and enduro racing heritage.
Evolution:
The TE series (T for Terra/Enduro, E for Enduro) has a long lineage within Husqvarna, evolving through various engine displacements and chassis designs to meet enduro racing standards and dual-sport requirements.
Production Era:
The TE510 was a staple in Husqvarna's dual-sport lineup during the early to mid-2000s.
