Segment:
Off-road, Enduro, Dual-Sport motorcycle segment.
Target Audience:
Husqvarna TE 510 owners seeking to perform maintenance, repairs, and overhauls themselves or understand the workings of their motorcycle.
Competitors Era:
KTM EXC series, Yamaha WR series, Honda CRF-X, Suzuki DR-Z, Kawasaki KX models of the same period.
Ease Of Use:
Exploded views, diagrams, and step-by-step instructions are highlighted for simplifying repair procedures.
Resource Value:
Provides all necessary technical information for servicing, teardowns, repairs, and adjustments.
Accessibility:
Instant PDF download for immediate access across various computing platforms.
Covered Years:
2004, 2005
Covered Models:
All TE 510 models
Estimated Page Count:
Varies based on specific model year, but comprehensive coverage suggests 300-600 pages typical for this type of manual.
Manual Type:
Workshop Service Repair Manual
Format:
PDF (Portable Document Format)
Delivery Method:
Instant Download
Compatibility:
PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, 7, 8, etc.)
Engine Mechanical:
Engine disassembly, assembly, cylinder head, piston, crankshaft, camshaft, valve train, timing.
Fuel System:
Carburetor(s) adjustment, cleaning, and overhaul; fuel tank, fuel lines, fuel pump (if applicable).
Ignition System:
Spark plug specifications, ignition timing, coil, CDI unit, wiring diagrams.
Cooling System:
Radiator, cooling fan, coolant specifications, thermostat, hoses.
Transmission:
Gearbox disassembly, assembly, inspection, maintenance, lubricant specifications, clutch operation.
Drivetrain:
Chain and sprockets inspection and adjustment, rear hub.
Suspension Front:
Fork seals, oil levels, damping adjustments, internal components, triple clamps.
Suspension Rear:
Shock absorber, linkage system, swingarm, bearings, adjustments.
Brakes Front:
Brake caliper, master cylinder, brake pads, brake lines, rotor, bleeding procedures.
Brakes Rear:
Brake caliper, master cylinder, brake pads, brake lines, rotor, bleeding procedures.
Wheels And Tires:
Tire pressure, wheel bearing inspection, spoke tension, wheel removal/installation.
Electrical System:
Battery, lighting, wiring harnesses, fuses, starter motor, charging system.
Chassis And Bodywork:
Frame inspection, fuel tank, seat, fenders, handlebars, footpegs, exhaust system.
Preventative Maintenance:
Regular service checks, lubrication points, cleaning procedures, fluid changes.
Troubleshooting:
Diagnostic flowcharts, common problem identification, solutions for starting issues, performance problems, electrical faults.
Disassembly And Assembly:
Detailed step-by-step instructions for component removal and installation.
Rebuilds And Overhauls:
Complete engine rebuild, carburetor overhaul, suspension component refurbishment.
Adjustments:
Carburetor idle and mixture, valve clearance, chain tension, suspension settings.
Torque Specifications:
Precise torque values for all critical fasteners and components.
Depth:
Comprehensive (suitable for DIY enthusiasts and professional mechanics).
Detail Level:
Step-by-step instructions, exploded views, diagrams, illustrations, troubleshooting guides.
Engine Type:
Single-cylinder, 4-stroke
Displacement:
Approximately 478cc to 500cc (specific to TE 510)
Bore X Stroke:
Details will be in the manual, typical for this displacement range.
Horsepower Estimate:
Likely in the range of 40-50 HP, depending on tuning and model year specifics.
Torque Estimate:
Details will be provided in the manual.
Fuel Delivery:
Carburetor (likely Keihin or Mikuni, specific model in manual)
Fuel Type:
Unleaded gasoline
Oil Type Recommendation:
High-quality synthetic or semi-synthetic motorcycle engine oil (e.g., SAE 10W-40 or 15W-50, specific grade in manual).
Valve Actuation:
DOHC (Double Overhead Camshaft), 4 valves
Oil Change Interval:
Typically every 10-15 hours of riding or annually. Specific recommendation in manual.
Air Filter Cleaning:
As needed, depending on riding conditions; recommend checking and cleaning before/after each major ride.
Valve Clearance Check:
Recommended every 30-50 hours of riding. Precise interval in manual.
Fork Oil Type:
Specific suspension fluid (e.g., 5W or 7.5W), exact type and quantity in manual.
Brake Fluid Type:
DOT 4 brake fluid.
Common Wear Items:
Clutch plates, chain and sprockets, fork seals, wheel bearings, exhaust packing (depending on usage).
Potential Electrical Issues:
Wiring harness integrity and connector corrosion can be common in off-road environments, manual will cover diagnostics.
Filter Part Numbers:
Manual will provide specific part numbers for oil filters, air filters, and other consumables.
