Husqvarna TE510 2007 2008 Service Repair Manual

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Type: Motorcycle

Vendor:

Sku: 100352

Tags: 2007 2008 Husqvarna Misc Motorcycle Motorcycles TE510

Product variants

Description

The TE510 is a performance-oriented dual-sport motorcycle designed for the demanding enduro segment. Produced for the 2007 and 2008 model years, this machine combines a rich heritage in off-road racing with modern technology, including electronic fuel injection. Its single-cylinder, liquid-cooled engine, approximately 498cc, delivers potent power suited for challenging terrain, complemented by a robust chassis and high-performance adjustable suspension. Built with a focus on off-road capability while maintaining street legality, the TE510 offers a thrilling riding experience for enthusiasts seeking adventure on varied landscapes. This comprehensive Service and Repair Manual provides detailed information essential for the maintenance, diagnosis, and repair of your TE510. It covers a wide array of systems, including engine mechanicals, fuel injection, transmission, suspension, brakes, and the electrical system. Within its pages, you will find routine maintenance procedures, in-depth engine rebuild instructions, systematic troubleshooting guides, and specific component overhaul procedures. The manual is designed to empower owners and technicians alike, offering clear explanations, exploded views, torque specifications, and diagnostic capabilities to ensure the optimal performance and longevity of your motorcycle.

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

TE510

Year:

2007, 2008

Codes

Chassis Codes:

Likely chassis codes specific to these model years, though not explicitly provided in product info.

👋 Introduction

Market Position

Segment:

Dual-sport / Enduro motorcycle segment.

Target Audience:

Owners and technicians performing maintenance, repairs, and diagnostics on the Husqvarna TE510 for off-road and dual-sport use.

Competitive Analysis

Competitors 2007 2008:

KTM EXC series, Yamaha WR series, Honda CRF-X, Suzuki DR-Z, Kawasaki KLX.

Key Features Vehicle

Design Philosophy:

Performance-oriented dual-sport motorcycle focused on off-road capability with street legality.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive service and repair information for Husqvarna TE510 models from 2007 and 2008.

Page Count

Estimated Pages:

Typically between 250-400 pages for a complete service manual of this nature, though exact count not specified.

Manual Type

Type:

Service and Repair Manual

Language

Language:

Likely English, standard for most international service manuals, though confirmation is usually on the product itself.

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed breakdown of engine components, including cylinder head, pistons, crankshaft, lubrication system, cooling system.

Engine Management:

Fuel injection system (EFI), ignition system, emissions control systems, sensor diagnostics.

Transmission:

Clutch operation, gear shifting mechanisms, gearbox disassembly and reassembly, lubrication.

Suspension:

Front fork (e.g., Marzocchi, WP depending on specific configuration) service, rear shock absorber service, linkage maintenance.

Brakes:

Front and rear brake system maintenance, caliper service, master cylinder overhaul, hydraulic lines, brake fluid specifications.

Electrical System:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, lighting system, switchgear.

Fuel System:

Fuel pump, fuel filter, injectors, throttle body, fuel tank maintenance.

Cooling System:

Radiator, hoses, coolant specifications, water pump service.

Exhaust System:

Exhaust pipe and muffler maintenance, gasket replacement.

Chassis And Bodywork:

Frame inspection, body panel removal and installation, seat, handlebars, footpegs.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning/replacement, spark plug replacement.

Engine Rebuild:

Detailed instructions for engine disassembly, inspection, repair, and reassembly, including torque specifications.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, including fault codes and symptom analysis.

Component Overhaul:

Specific procedures for overhauling components like carburetors (if applicable, though EFI is more likely), fuel injectors, brake calipers, suspension units.

Electrical Diagnostics:

Testing of electrical components, troubleshooting starting and charging issues, diagnosing sensor faults.

Technical Depth

Diagnostic Capability:

Advanced diagnostic capabilities, including wiring diagrams, component testing procedures, and fault code interpretation.

Repair Scope:

Covers everything from basic adjustments and fluid changes to complete engine and transmission rebuilds.

Information Detail:

Includes detailed exploded views, torque specifications, clearances, and service limits for all major components.

📊 Manual Specifications

File Format

File Type:

Searchability:

Typically searchable text within the PDF for quick information retrieval.

Printability:

Printable pages, allowing users to create physical copies of specific sections or the entire manual.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity, essential for understanding complex procedures.

Binding Type

Binding:

Not applicable to PDF format. For a physical manual, typical binding would be spiral-bound or perfect-bound for ease of use.

Paper Type

Paper:

Not applicable to PDF format. For a physical manual, expect durable, semi-gloss paper suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke

Displacement:

Approximately 498cc (specific bore and stroke would be detailed in the manual).

Cooling System:

Liquid-cooled

Performance

Horsepower Estimate:

Likely in the range of 45-55 HP, depending on specific tuning and exhaust.

Torque Estimate:

Torque figures would be specific, typically suited for off-road grunt.

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), likely with a Keihin or similar throttle body.

Fuel Type:

Unleaded gasoline

Ignition

Ignition System:

Digital CDI with electronic advance

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Optional

Optional Transmission:

N/A for this model

Features

Clutch Type:

Wet multi-plate clutch, hydraulically operated

📐 Dimensions

Exterior

Length:

Specific dimensions would be found in the manual, typical for an enduro bike.

Width:

Specific dimensions would be found in the manual.

Height:

Specific dimensions would be found in the manual.

Weights

Dry Weight:

Likely in the range of 110-120 kg (dry).

Wet Weight:

Wet weight would include fluids.

🛡️ Safety Features

Ratings

Safety Certifications:

Designed for off-road use, road legality may vary by region and require specific modifications/approvals.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Suspension Performance:

High-performance adjustable suspension (e.g., upside-down forks, monoshock rear) for off-road control.

Passive Features

Chassis Structure:

Robust steel or aluminum frame designed for durability and handling.

💡 Technology Features

Infotainment

Infotainment System:

Minimalist dashboard focused on essential information: speed, odometer, trip meter, neutral indicator, high-beam, turn signals, engine warning light. No advanced infotainment features.

Driver Assistance

N/A (ABS was not common or standard on off-road/enduro bikes of this era).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10-15 hours of off-road riding or annually, but specific recommendation in manual.

Air Filter Cleaning:

Frequent cleaning, often every few rides or after dusty conditions.

Chain Maintenance:

Lubrication and tension check every 300-500 km or after riding in wet conditions.

Fluid Specifications

Engine Oil Type:

Likely a high-quality synthetic motorcycle oil, e.g., Motorex or similar, with specific viscosity (e.g., 10W-50 or 15W-50).

Coolant Type:

Ethylene glycol-based coolant mixed with distilled water.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Transmission Oil Type:

Separate transmission oil, often same viscosity as engine oil but specific motorcycle-grade is crucial.

Known Issues

Common Wear Items:

Clutch plates, wheel bearings, steering head bearings, chain and sprockets, spark plugs, air filter, valve clearances.

Potential Electrical Gremlins:

As with many off-road bikes of this era, electrical connections and grounding points can be a source of intermittent issues; the manual will guide diagnostics.

Efi System Checks:

Regular checks of fuel filter and injector cleanliness are important for optimal performance.

📚 Vehicle History

Brand Heritage

Husqvarna Legacy:

Husqvarna has a long and storied history in motorcycle racing, particularly in off-road disciplines like motocross and enduro, dating back to the early 20th century.

Model Evolution

Te510 Lineage:

The TE series represents Husqvarna's commitment to the enduro market, evolving over the years with technological advancements like fuel injection.

Production

Manufacturing Location:

Typically manufactured in Italy during this period under the MV Agusta Group ownership.

🏆 Awards & Recognition

Recognitions

Motorcycle Press Reviews:

Reviews from motorcycle publications of the time would highlight its performance in enduro events and its potent off-road capabilities, with mixed reviews on street manners and reliability compared to Japanese counterparts.

Ratings

Industry Ratings:

Would typically receive strong ratings for engine performance and suspension in off-road contexts.