Market Segment:
High-performance dual-sport/enduro motorcycle.
Target Audience:
Enthusiasts seeking off-road capability with street-legal features, targeting riders who demand reliability and performance in demanding conditions.
Competitors:
KTM EXC series, Yamaha WR series, Honda CRF-X series, Suzuki DR-Z series, Kawasaki KLX series of the same era.
Unique Selling Points:
Swedish heritage of Husqvarna, often characterized by robust engines and agile handling tailored for off-road. Known for performance and distinct styling.
Systems Covered:
Engine, fuel system, ignition system, cooling system, lubrication, exhaust system, transmission, clutch, chassis, suspension (front and rear), wheels, tires, brakes (front and rear), electrical system (lighting, starting, charging, ignition), controls, bodywork, troubleshooting, maintenance, diagnostics.
Estimated Page Count:
Hundreds of pages (as stated in product description, likely 300-600 pages for a complete factory manual).
Manual Type:
Workshop Service Repair Manual
Language:
English (highly probable for a factory manual of this era and origin).
Format:
Downloadable (Digital PDF)
Engine Systems:
Detailed disassembly, assembly, inspection, and repair of the 4-stroke engine, including cylinder head, valves, camshafts, piston, connecting rod, crankshaft, and all related components. Covers timing chain, oil pump, and internal lubrication.
Fuel And Ignition:
Covers carburetor settings and overhaul (likely Mikuni or Keihin), fuel pump, fuel filter, ignition system components (CDI, spark plug, coil), and timing.
Transmission And Clutch:
Detailed procedures for transmission disassembly, inspection, and reassembly. Covers gear selection mechanism, clutch operation (hydraulic or cable), clutch plates, and associated components.
Suspension And Steering:
Front telescopic forks (including internal components, oil levels, and adjustments) and rear monoshock suspension. Covers linkage, bearings, and adjustments. Steering system inspection and maintenance.
Brakes:
Front and rear hydraulic disc brake systems, including caliper overhaul, master cylinder service, brake fluid replacement, bleeding procedures, and pad/rotor inspection.
Electrical System:
Wiring diagrams, troubleshooting guides for headlights, taillights, brake lights, turn signals, horn, starting system (starter motor, battery), charging system (alternator, regulator/rectifier), and all switches and sensors.
Maintenance Procedures:
Regular maintenance tasks such as oil changes, filter replacements (oil, air, fuel), spark plug replacement, chain adjustment and lubrication, brake bleeding, coolant flush, and general inspection.
Troubleshooting Guides:
Systematic diagnostic procedures for common problems, including starting issues, engine performance problems, electrical faults, and braking system malfunctions.
Repair Procedures:
Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation of virtually every part of the motorcycle.
Diagnostic Charts:
Fault diagnosis charts based on symptoms, helping technicians pinpoint the root cause of mechanical or electrical issues.
Depth Of Coverage:
Comprehensive factory-level detail, suitable for professional mechanics and experienced DIY enthusiasts. Includes torque specifications, clearances, tolerances, and specialized tool requirements.
Engine Type:
4-stroke, Single Cylinder
Displacement:
495 cc (approximate, specific bore/stroke within manual)
Bore X Stroke:
Details within manual, typical for this displacement.
Cooling System:
Liquid-cooled
Valve Train:
DOHC, 4 valves (typical configuration)
Horsepower:
Estimated 50-55 HP (factory stock, specific figures in manual)
Torque:
Details within manual, indicative of strong low-to-mid range power.
Fuel Delivery:
Carburetor (likely Mikuni TM40 or similar, specifics in manual)
Fuel Type:
Unleaded Gasoline (91+ octane recommended)
Length:
Details in manual, typical for dual-sport.
Width:
Details in manual, typical for dual-sport.
Height:
Details in manual, typical for dual-sport.
Dry Weight:
Approx. 240-250 lbs (109-113 kg), specific figure in manual.
Fuel Tank Capacity:
Approx. 2.2-2.6 Gallons (8.5-10 Liters), specific figure in manual.
Safety Ratings:
N/A (Motorcycles are not typically rated by standard automotive safety organizations like NHTSA/IIHS).
Braking System:
Hydraulic disc brakes front and rear, engineered for effective stopping power.
Lighting:
Headlight, taillight, brake light, and potentially turn signals for street legality.
Frame Construction:
Robust steel or aluminum frame designed for off-road abuse and stable on-road handling.
Engine Oil Change:
Every 3,000 km or 6 months (typical for this type of bike, refer to manual for exact specification).
Air Filter Cleaning:
Frequent cleaning recommended, especially after dusty rides (intervals in manual).
Chain Lubrication Adjustment:
Regular checks and lubrication are crucial for longevity (intervals in manual).
Engine Oil Type:
SAE 10W-40 or 15W-50, JASO MA certified motorcycle oil (verify specific grade in manual).
Fork Oil Type:
Specific fork oil viscosity and quantity detailed in the manual (e.g., SAE 5W or 10W).
Brake Fluid Type:
DOT 4 or DOT 5.1 (verify specific requirement in manual).
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, fork seals, and rear shock linkage bearings are common wear items on high-mileage or heavily used enduro bikes.
Potential Problems:
Overheating if cooling system is neglected, potential carburetor jetting issues in varying altitudes, wear in the decompression mechanism (if equipped).
Brand Origin:
Husqvarna Motorcycles is one of the world's oldest motorcycle manufacturers, founded in Sweden in 1903.
Te510 Lineage:
The TE series represents Husqvarna's commitment to the enduro and dual-sport market, evolving through various engine sizes and chassis designs over the years.
Production Period:
2007-2008 (specific model years covered by this manual).
Manufacturing Location:
Italy (at the time of this model, under Italian ownership).
