Husqvarna TE449 TE511 2011 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Husqvarna Model: TE449 / TE511 Year: 2011 Codes Model Codes: TE449, TE511 👋 Introduction Market Position Segment: Dual-sport / Enduro motorcycle segment. Target Audience: Enthusiasts, professional mechanics, and owners seeking detailed maintenance and repair information. Competitive Analysis Competitors: KTM EXC, Yamaha WR, Honda CRF-X, Suzuki DR-Z. Key Features Unique Selling Points: Husqvarna's Italian heritage, performance-oriented dual-sport design, focus on off-road capability with street legality. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Workshop Page Count Estimated Pages: 300+ Manual Type Type: Service Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Full disassembly, inspection, repair, and reassembly of engine components (pistons, rings, valves, camshafts, crankshaft, connecting rods, cylinder head, cylinder block). Fuel System: Fuel injection system diagnostics, cleaning, component testing (injectors, fuel pump, pressure regulator), fuel tank service. Ignition System: Ignition coil testing, spark plug specifications, ECU diagnostics. Cooling System: Radiator service, coolant types and capacities, water pump inspection, hose replacement, thermostat testing. Exhaust System: Exhaust pipe and muffler inspection, gasket replacement. Transmission Drivetrain: Gearbox inspection, clutch service, lubrication requirements, chain and sprocket maintenance. Suspension: Front and rear suspension fork service, shock absorber maintenance, linkage inspection, bearing replacement. Brakes: Brake pad replacement, caliper service, master cylinder overhaul, brake fluid specifications and bleeding procedures, rotor inspection. Electrical System: Wiring diagrams, component testing (battery, starter motor, alternator/stator, lights, sensors), fuses and relays, ECU identification. Chassis Frame: Frame inspection, steering head bearing service, swingarm maintenance. Bodywork: Fairing removal and installation, seat service, fuel tank removal and installation. Wheels Tires: Tire pressure recommendations, wheel bearing service, spoke tensioning. Procedures Included Routine Maintenance: Oil change intervals, filter replacement (oil, air), chain lubrication and adjustment, spark plug replacement, valve clearance checks. Troubleshooting: Diagnostic charts for common problems, symptom-based troubleshooting guides for engine, electrical, and drivetrain issues. Component Repair: Detailed step-by-step instructions for rebuilding major components like engines, transmissions, and suspension units. Torque Specifications: Comprehensive list of all critical torque values for fasteners and bolts throughout the motorcycle. Wiring Diagrams: Full color, detailed wiring schematics for all electrical systems. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to full engine rebuilds and advanced diagnostics. Diagnostic Capability: Includes guidance on interpreting fault codes and diagnosing electrical issues. Special Tools: Lists and descriptions of specialized tools required for specific repair procedures. 📊 Manual Specifications File Format Format Details: Digital PDF, typically searchable and printable. High-resolution for clarity. Print Quality Quality: N/A (digital format), but designed for clear viewing of diagrams and text. Binding Type Type: N/A (digital format) Paper Type Type: N/A (digital format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, DOHC Displacement Te449: 449.4 cc Displacement Te511: 477.5 cc Bore X Stroke Te449: 97 mm x 60.8 mm Bore X Stroke Te511: 97 mm x 64 mm Compression Ratio: Approximately 12.8:1 (varies slightly by model) Performance Horsepower Estimate: Approx. 50-55 HP (at crank, specific dyno data varies) Torque Estimate: Approx. 30-35 lb-ft (at crank, specific dyno data varies) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Keihin or Mikuni EFI system Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/2 Fuel Tank Capacity: Approximately 8.5 liters (2.25 gallons) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Optional Optional Gearbox: N/A (standard 6-speed) Features Clutch Type: Wet multi-plate clutch, hydraulically operated Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length Approx: 2200 mm (86.6 inches) Width Approx: 820 mm (32.3 inches) Height Approx: 1250 mm (49.2 inches) Seat Height: Approx. 960 mm (37.8 inches) Weights Dry Weight Approx Te449: 110 kg (242.5 lbs) Dry Weight Approx Te511: 112 kg (246.9 lbs) Wet Weight Approx: 125 kg (275.6 lbs) (estimated, with fluids) Wheelbase: Approx. 1475 mm (58.1 inches) 🛡️ Safety Features Ratings Safety Certification: Meets DOT and EPA emissions standards for street legality. Active Features Braking System: Hydraulic disc brakes front and rear. Brembo calipers commonly used. Lighting: Halogen headlight, LED taillight, turn signals (as per road legality). Passive Features Frame Construction: Chromoly steel trellis frame for rigidity and impact absorption. 💡 Technology Features Infotainment Display Type: Digital LCD instrument cluster. Displays speed, RPM, odometer, trip meters, clock, and basic indicator lights. Driver Assistance ABS: N/A (Anti-lock Braking System typically not equipped on off-road focused models of this era). Connectivity Bluetooth Usb: N/A 🔧 Maintenance Service Intervals Engine Oil Change: Every 15 hours of operation or annually, whichever comes first. (Refer to manual for specific conditions) Oil Filter Replacement: With every oil change. Air Filter Cleaning: Every 10 hours of operation or as needed in dusty conditions. Valve Clearance Check: Every 30 hours of operation. Fluid Specifications Engine Oil Type: SAE 10W-50, JASO MA/MA2 certified synthetic motorcycle oil (e.g., Motorex Power Synt 4T 10W/50). Engine Oil Capacity: Approximately 1.1 liters (1.16 US qt) without filter change, 1.2 liters (1.27 US qt) with...
Diagnostic charts for common problems, symptom-based troubleshooting guides for engine, electrical, and drivetrain issues.
Component Repair:
Detailed step-by-step instructions for rebuilding major components like engines, transmissions, and suspension units.
Torque Specifications:
Comprehensive list of all critical torque values for fasteners and bolts throughout the motorcycle.
Wiring Diagrams:
Full color, detailed wiring schematics for all electrical systems.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to full engine rebuilds and advanced diagnostics.
Diagnostic Capability:
Includes guidance on interpreting fault codes and diagnosing electrical issues.
Special Tools:
Lists and descriptions of specialized tools required for specific repair procedures.
📊 Manual Specifications
File Format
Format Details:
Digital PDF, typically searchable and printable. High-resolution for clarity.
Print Quality
Quality:
N/A (digital format), but designed for clear viewing of diagrams and text.
Binding Type
Type:
N/A (digital format)
Paper Type
Type:
N/A (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, DOHC
Displacement Te449:
449.4 cc
Displacement Te511:
477.5 cc
Bore X Stroke Te449:
97 mm x 60.8 mm
Bore X Stroke Te511:
97 mm x 64 mm
Compression Ratio:
Approximately 12.8:1 (varies slightly by model)
Performance
Horsepower Estimate:
Approx. 50-55 HP (at crank, specific dyno data varies)
Torque Estimate:
Approx. 30-35 lb-ft (at crank, specific dyno data varies)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - Keihin or Mikuni EFI system
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2
Fuel Tank Capacity:
Approximately 8.5 liters (2.25 gallons)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Optional
Optional Gearbox:
N/A (standard 6-speed)
Features
Clutch Type:
Wet multi-plate clutch, hydraulically operated
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length Approx:
2200 mm (86.6 inches)
Width Approx:
820 mm (32.3 inches)
Height Approx:
1250 mm (49.2 inches)
Seat Height:
Approx. 960 mm (37.8 inches)
Weights
Dry Weight Approx Te449:
110 kg (242.5 lbs)
Dry Weight Approx Te511:
112 kg (246.9 lbs)
Wet Weight Approx:
125 kg (275.6 lbs) (estimated, with fluids)
Wheelbase:
Approx. 1475 mm (58.1 inches)
🛡️ Safety Features
Ratings
Safety Certification:
Meets DOT and EPA emissions standards for street legality.
Active Features
Braking System:
Hydraulic disc brakes front and rear. Brembo calipers commonly used.
Lighting:
Halogen headlight, LED taillight, turn signals (as per road legality).
Passive Features
Frame Construction:
Chromoly steel trellis frame for rigidity and impact absorption.
💡 Technology Features
Infotainment
Display Type:
Digital LCD instrument cluster. Displays speed, RPM, odometer, trip meters, clock, and basic indicator lights.
Driver Assistance
ABS:
N/A (Anti-lock Braking System typically not equipped on off-road focused models of this era).
Connectivity
Bluetooth Usb:
N/A
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 15 hours of operation or annually, whichever comes first. (Refer to manual for specific conditions)
Oil Filter Replacement:
With every oil change.
Air Filter Cleaning:
Every 10 hours of operation or as needed in dusty conditions.
Valve Clearance Check:
Every 30 hours of operation.
Fluid Specifications
Engine Oil Type:
SAE 10W-50, JASO MA/MA2 certified synthetic motorcycle oil (e.g., Motorex Power Synt 4T 10W/50).
Engine Oil Capacity:
Approximately 1.1 liters (1.16 US qt) without filter change, 1.2 liters (1.27 US qt) with filter change. (Confirm with manual)
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, mixed 50/50 with distilled water. (e.g., Engine Ice, Motorex Coolant M3.0).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Clutch Fluid Type:
DOT 4 hydraulic clutch fluid (if hydraulic clutch system is separate).
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, chain and sprockets, brake pads/rotors, exhaust packing.
Potential Failures:
Some early models may have experienced issues with the EFI system or certain electrical components. Regular maintenance is key.
📚 Vehicle History
Brand Heritage
Origin:
Husqvarna Motorcycles is one of the oldest motorcycle manufacturers in the world, founded in Sweden in 1903.
Ownership History:
Acquired by BMW Motorrad in 2007, later sold to Pierer Mobility AG (KTM parent company) in 2013.
Model Evolution
Development:
The TE series represents Husqvarna's modern era of liquid-cooled, fuel-injected off-road and dual-sport machines, often sharing components and design philosophy with KTM.
Production
Manufacturing Location:
Italy (under BMW ownership at the time of this model's production)
🏆 Awards & Recognition
Recognitions
Industry Awards:
Husqvarna models of this era often received praise in motorcycle publications for their performance and off-road capability, though specific awards for the 2011 TE449/TE511 are not widely documented.
Ratings
Reliability Ratings:
Generally considered reliable with proper maintenance. Owner feedback often highlights the strong engine performance but can also point to the need for meticulous upkeep.
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