🏷️ Basic Information

Make:

Husqvarna

Model:

SM 610S

Model Variant:

Supermoto

Production Years Covered:

1999, 2000, 2001, 2002

👋 Introduction

Motorcycle Segment:

Supermoto / Dual-Sport

Target Audience:

Enthusiasts, mechanics, and owners looking for in-depth repair and maintenance information for their Husqvarna SM 610S.

Competitors Of Time:

KTM 640 LC4, Aprilia SXV 550 (later models), various Japanese dual-sport and supermoto conversions.

Engine Type:

Single-cylinder, four-stroke, liquid-cooled

Suspension Type:

Upside-down telescopic front forks, monoshock rear suspension with adjustable linkage.

Braking System:

High-performance disc brakes front and rear.

Intended Use:

On-road performance riding, spirited commuting, light off-road capability.

📋 Manual Details

Systems Covered:

Engine, Transmission, Chassis, Suspension, Brakes, Electrical System, Fuel System, Cooling System, Lubrication System, Exhaust System, Wheels and Tires, Bodywork

Estimated Page Count:

200-300

Manual Type:

Workshop Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of engine components (cylinder, piston, crankshaft, connecting rod, valves, camshaft, timing system).

Fuel System:

Carburetor overhaul, adjustment, and troubleshooting; fuel pump inspection; fuel tank maintenance.

Cooling System:

Radiator inspection and repair, coolant flow, thermostat operation, water pump maintenance.

Lubrication System:

Oil pump operation, oil filter replacement, oil circuit diagnosis.

Transmission Gearbox:

Gearbox disassembly, inspection, repair, and reassembly; clutch operation and adjustment; shift mechanism.

Suspension Front:

Front fork disassembly, service, and adjustment (damping, spring preload); steering head bearing service.

Suspension Rear:

Rear shock absorber service and adjustment; swingarm bearing service; linkage maintenance.

Brake System Front:

Brake caliper service, pad replacement, hydraulic line inspection, master cylinder overhaul, rotor inspection.

Brake System Rear:

Rear brake caliper service, pad replacement, hydraulic line inspection, master cylinder overhaul, rotor inspection.

Electrical System Ignition:

Ignition coil testing, spark plug specifications, CDI unit troubleshooting.

Electrical System Lighting:

Headlight, taillight, and turn signal bulb replacement and wiring checks.

Electrical System Charging:

Stator, regulator/rectifier testing, battery maintenance and charging.

Routine Maintenance:

Oil and filter change procedures, spark plug inspection/replacement, air filter cleaning/replacement, chain adjustment and lubrication, brake fluid replacement, coolant replacement.

Troubleshooting:

Diagnostic procedures for common starting issues, engine performance problems, electrical faults, and braking issues.

Engine Overhaul:

Detailed steps for cylinder head removal/installation, piston and ring replacement, valve adjustments, crankshaft and bearing inspection.

Suspension Service:

Front fork oil change and seal replacement, rear shock absorber service, linkage lubrication.

Brake System Repair:

Brake pad replacement, caliper bleeding, line replacement, master cylinder rebuild.

Electrical Diagnostics:

Wiring diagrams, component testing procedures for ignition, charging, and lighting systems.

Clutch Service:

Clutch cable adjustment, clutch plate inspection and replacement.

Wheel And Tire Service:

Wheel bearing replacement, tire mounting and balancing, spoke tensioning.

Depth Level:

Comprehensive: Covers routine maintenance, minor repairs, major overhauls, and advanced troubleshooting.

Diagnostic Information:

Includes specifications for key measurements, tolerances, electrical resistance, and voltage readings for troubleshooting.

Torque Specifications:

Provides detailed torque values for critical fasteners across all systems.

Special Tools:

Identifies specialized tools required for specific repair procedures.

📊 Manual Specifications

File Type:

PDF

Searchable:

Yes (typically, depending on PDF creation)

Printability:

High-resolution graphics and text, suitable for printing individual pages or the entire manual.

Binding:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Code General:

Likely based on Husqvarna's established LC4 platform, specific engine code may vary

Engine Displacement:

Approximately 600cc (often around 576cc for this era)

Bore X Stroke:

Typical for this displacement range (e.g., 92.0 mm x 87.0 mm, subject to confirmation from manual).

Compression Ratio:

Typically around 10.0:1 to 11.5:1 (subject to confirmation).

Valve Train:

SOHC (Single Overhead Camshaft), 4 valves per cylinder.

Horsepower Peak:

Estimated 45-55 HP at the crank (subject to specific tuning and market).

Torque Peak:

Estimated 50-60 Nm (subject to specific tuning and market).

Carburetor Type:

Mikuni VM Series (e.g., VM38 or similar, subject to specific model year/market).

Fuel Type:

Unleaded gasoline, minimum octane rating 91 (RON+MON)/2.

Fuel Tank Capacity:

Approximately 10-12 liters.

🔧 Transmission

Transmission Type:

Constant mesh, 6-speed sequential

Transmission Options:

N/A (Standard 6-speed transmission)

Clutch Type:

Wet, multi-plate, cable-actuated

Gear Ratios:

Specific ratios would be detailed in the manual, essential for performance tuning and diagnostics.

Final Drive:

Chain drive, 520 pitch (typical).

Transmission Oil Type:

Motorcycle-specific 4-stroke engine oil (e.g., SAE 10W-40 or 20W-50, refer to manual for exact specification).

📐 Dimensions

Overall Length:

Approx. 2200 mm (subject to variation).

Overall Width:

Approx. 850 mm (excluding mirrors, subject to variation).

Seat Height:

Approx. 900-920 mm (high for supermoto configuration).

Dry Weight:

Approx. 140-150 kg (subject to variation based on equipment).

Wet Weight:

Approx. 155-165 kg (with all fluids, subject to variation).

Maximum Load Capacity:

Typically around 150-200 kg for rider and luggage.

🛡️ Safety Features

Safety Certifications:

Designed to meet European ECE regulations for motorcycles of its era. Specific crash test data not typically public for this type of motorcycle.

Braking System Type:

Hydraulic disc brakes front and rear.

Tires:

Street-biased dual-sport or supermoto tires for optimal grip on pavement.

Lighting:

Headlight, taillight, brake light, turn signals.

Chassis Design:

Robust frame designed for agility and stability.

💡 Technology Features

Dashboard:

Analog speedometer and tachometer, with basic indicator lights (oil pressure, turn signals, high beam).

ABS:

N/A (Anti-lock Braking System not typically offered on this model).

Bluetooth Usb:

N/A (No built-in connectivity features).

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 km or annually. Refer to manual for specific mileage based on usage.

Spark Plug Check:

Every 5,000-8,000 km.

Valve Clearance Check:

Every 10,000-15,000 km (critical for 4-valve SOHC engines).

Chain Maintenance:

Lubricate and adjust chain every 500-1000 km, or after washing/wet riding.

Engine Oil Type:

High-quality motorcycle 4-stroke engine oil, SAE 10W-40 or 20W-50, API SG or higher. Always consult manual for exact grade.

Coolant Type:

Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio). Specific coolant recommendations in manual.

Brake Fluid Type:

DOT 4 or DOT 5.1, depending on system requirements. Manual will specify.

Fork Oil Type:

Specific viscosity fork oil (e.g., SAE 10W or 15W). Manual will provide exact type and level.

Common Wear Items:

Clutch plates, valve stem seals, fork seals, chain and sprockets, brake pads.

Electrical Gremlins:

Potential for aging wiring harness issues, stator or regulator/rectifier failure, common in motorcycles of this era. Manual assists in diagnosis.

Carburetor Tuning:

May require periodic cleaning and adjustment, especially if the bike sits for extended periods. Manual provides detailed tuning guides.

Cooling System Leaks:

Hose degradation or radiator leaks can occur over time. Manual aids in inspection and replacement.

📚 Vehicle History

Brand Origin:

Husqvarna Motorcycles is one of the oldest motorcycle manufacturers, originating in Sweden in 1689 (initially for weapons manufacturing) and producing motorcycles since 1903.

Sm Series Development:

The SM 610S represents Husqvarna's commitment to the growing supermoto market, building on their off-road expertise and adapting it for street performance.

Predecessor Models:

Earlier Husqvarna models in the 600cc class and their enduro/motocross siblings.

Manufacturing Location:

Italy (at the time of ownership by Cagiva Group).

Key Production Years:

Model line active throughout the late 1990s and early 2000s, with updates and variations.

🏆 Awards & Recognition

Period Reviews:

While specific 'awards' are rare for individual workshop manuals, the manual's value is recognized by its ability to facilitate proper maintenance and repair, extending the life and performance of the SM 610S. Reviews of the motorcycle itself often praised its agility and performance for its class.

Manual Utility Rating:

High - Essential resource for owners and technicians.