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Husqvarna TE510 2010 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Husqvarna Model: TE510 Year: 2010 Product Type: Workshop Repair Service Manual Codes Chassis Code: Not Specified Engine Code: Not Specified 👋 Introduction Market Position Vehicle Segment: Enduro / Dual-Sport Motorcycle Target Audience: Enthusiasts, off-road riders, dual-sport riders, DIY mechanics. Competitive Analysis Key Competitors 2010: KTM EXC series, Yamaha WR series, Honda CRF-X series, Suzuki DR-Z series, Kawasaki KLX series. Key Features Vehicle Usp: Italian engineering, powerful engine, robust off-road capability with street legality. Manual Usefulness Value Proposition: Essential resource for maintaining and repairing the Husqvarna TE510 2010, saving time and money on dealership services. 📋 Manual Details Coverage Areas Models Covered: All Models/Engines/Trim/Transmissi ons Typ Page Count Estimated Page Count: Refer to specific product listing for exact page count; typically 300-500 pages for comprehensive workshop manuals. Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, diagnosis, top-end, bottom-end, valve train, lubrication system, cooling system. Fuel System: Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel pressure regulator, fuel tank, fuel lines. Ignition System: Ignition coils, spark plugs, ignition control module (ICM), wiring. Exhaust System: Exhaust manifold, catalytic converter, muffler, O2 sensors. Transmission: Clutch operation, gearbox components, gear shifting mechanisms, lubrication. Suspension: Front forks (upside-down telescopic, cartridge type), rear shock absorber (monoshock), linkage systems, springs, damping adjustments. Brakes: Front and rear disc brakes, hydraulic system, calipers, master cylinders, brake pads, brake lines, bleeding procedures. Electrical System: Battery, starter motor, alternator, lighting system (headlight, taillight, turn signals), wiring diagrams, fuses, relays. Chassis And Frame: Frame inspection, steering head bearings, swingarm, rear axle, wheel bearings. Bodywork And Trim: Body panels, fairings, seat, fuel tank, fenders, graphics. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment and lubrication, air filter cleaning/replacement, spark plug replacement, brake system checks, tire pressure. Troubleshooting Diagnostics: Fault identification, symptom analysis, diagnostic charts, common problem solutions. Engine Rebuild: Complete engine overhaul, piston and ring replacement, cylinder head service, crankshaft and connecting rod inspection/replacement. Suspension Service: Fork seal replacement, fork oil change, shock absorber service, linkage bearing maintenance. Brake System Service: Brake pad replacement, caliper overhaul, master cylinder replacement, brake fluid flush and bleeding. Electrical Troubleshooting: Wiring harness inspection, component testing, electrical circuit diagnosis using wiring diagrams. Wheel And Tire Service: Tire replacement, wheel balancing, spoke tensioning, wheel bearing replacement. Steering System Service: Steering head bearing adjustment and replacement. Technical Depth Depth Of Information: Comprehensive, covering detailed disassembly, assembly, repair, and troubleshooting procedures for all major vehicle systems. Diagnostic Capabilities: Includes diagnostic flowcharts, symptom-based troubleshooting, and component testing procedures. Torque Specifications: Detailed torque values for all critical fasteners. Clearances And Tolerances: Specifications for critical component clearances and wear tolerances. Wiring Diagrams: Detailed electrical wiring diagrams for all circuits. 📊 Manual Specifications File Format File Format: PDF Print Quality Image Resolution: High-resolution, suitable for clear viewing and printing. Text Searchability: Searchable text for quick information retrieval. Binding Type Binding Type: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, DOHC Displacement: 477cc (approximate, exact may vary by specific sub-model) Bore X Stroke: Not Specified, but typical for this class is around 95mm x 63mm. Compression Ratio: Not Specified, typically around 12.0:1 or higher. Performance Horsepower: Estimated 50-55 HP (at crankshaft), specific figures vary. Torque: Not Specified, but strong mid-range torque is a characteristic. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, minimum octane rating 91 (RON+MON)/2. Lubrication Oil Type: JASO MA/MA2 certified 4-stroke motorcycle oil, SAE 10W-40 or 15W-50 depending on climate. Oil Capacity: Approximately 1.5 - 1.7 liters (dry fill). Specific capacity detailed in manual. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Optional Transmission Options: Not Applicable, standard 6-speed manual. Features Clutch Type: Wet, multi-plate Gear Ratios: Specific ratios detailed in manual, optimized for off-road and dual-sport use. Transmission Oil Type: JASO MA/MA2 certified 4-stroke motorcycle oil, same as engine oil (shared sump). Transmission Oil Capacity: Refer to engine oil capacity as they share the same lubrication system. 📐 Dimensions Exterior Overall Length: Not Specified, typical for class is around 2200-2300 mm. Overall Width: Not Specified, typical for class is around 800-850 mm. Overall Height: Not Specified, typical for class is around 1200-1300 mm. Seat Height: Not Specified, but typically high for an enduro bike, around 950-980 mm. Ground Clearance: Not Specified, but designed for high clearance, typically over 300 mm. Cargo Cargo Capacity: Not Applicable (Motorcycle) Weights Dry Weight: Approximately 115-120 kg (unspecified exact figure, this is an estimate). Wet Weight: Approximately 125-130 kg (with all fluids). Fuel Tank Capacity: Approximately 8.5 - 9.5 liters. Wheelbase: Not Specified, but typically around 1480-1500 mm. 🛡️ Safety Features Ratings Safety Ratings: Not Applicable (Motorcycle, no NHTSA/Euro NCAP equivalent) Active Features Braking...
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Husqvarna TE510 2010 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Husqvarna
Model:
TE510
Year:
2010
Product Type:
Workshop Repair Service Manual
Codes
Chassis Code:
Not Specified
Engine Code:
Not Specified
👋 Introduction
Market Position
Vehicle Segment:
Enduro / Dual-Sport Motorcycle
Target Audience:
Enthusiasts, off-road riders, dual-sport riders, DIY mechanics.
Competitive Analysis
Key Competitors 2010:
KTM EXC series, Yamaha WR series, Honda CRF-X series, Suzuki DR-Z series, Kawasaki KLX series.
Key Features
Vehicle Usp:
Italian engineering, powerful engine, robust off-road capability with street legality.
Manual Usefulness
Value Proposition:
Essential resource for maintaining and repairing the Husqvarna TE510 2010, saving time and money on dealership services.
📋 Manual Details
Coverage Areas
Models Covered:
All Models/Engines/Trim/Transmissi ons Typ
Page Count
Estimated Page Count:
Refer to specific product listing for exact page count; typically 300-500 pages for comprehensive workshop manuals.
Manual Type
Manual Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, inspection, diagnosis, top-end, bottom-end, valve train, lubrication system, cooling system.
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel pressure regulator, fuel tank, fuel lines.
Ignition System:
Ignition coils, spark plugs, ignition control module (ICM), wiring.
Exhaust System:
Exhaust manifold, catalytic converter, muffler, O2 sensors.
Transmission:
Clutch operation, gearbox components, gear shifting mechanisms, lubrication.
Suspension:
Front forks (upside-down telescopic, cartridge type), rear shock absorber (monoshock), linkage systems, springs, damping adjustments.
Brakes:
Front and rear disc brakes, hydraulic system, calipers, master cylinders, brake pads, brake lines, bleeding procedures.
Electrical System:
Battery, starter motor, alternator, lighting system (headlight, taillight, turn signals), wiring diagrams, fuses, relays.
Chassis And Frame:
Frame inspection, steering head bearings, swingarm, rear axle, wheel bearings.
Bodywork And Trim:
Body panels, fairings, seat, fuel tank, fenders, graphics.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment and lubrication, air filter cleaning/replacement, spark plug replacement, brake system checks, tire pressure.
Troubleshooting Diagnostics:
Fault identification, symptom analysis, diagnostic charts, common problem solutions.
Engine Rebuild:
Complete engine overhaul, piston and ring replacement, cylinder head service, crankshaft and connecting rod inspection/replacement.
Suspension Service:
Fork seal replacement, fork oil change, shock absorber service, linkage bearing maintenance.
Brake System Service:
Brake pad replacement, caliper overhaul, master cylinder replacement, brake fluid flush and bleeding.
Electrical Troubleshooting:
Wiring harness inspection, component testing, electrical circuit diagnosis using wiring diagrams.
Wheel And Tire Service:
Tire replacement, wheel balancing, spoke tensioning, wheel bearing replacement.
Steering System Service:
Steering head bearing adjustment and replacement.
Technical Depth
Depth Of Information:
Comprehensive, covering detailed disassembly, assembly, repair, and troubleshooting procedures for all major vehicle systems.
Diagnostic Capabilities:
Includes diagnostic flowcharts, symptom-based troubleshooting, and component testing procedures.
Torque Specifications:
Detailed torque values for all critical fasteners.
Clearances And Tolerances:
Specifications for critical component clearances and wear tolerances.
Wiring Diagrams:
Detailed electrical wiring diagrams for all circuits.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Image Resolution:
High-resolution, suitable for clear viewing and printing.
Text Searchability:
Searchable text for quick information retrieval.
Binding Type
Binding Type:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, DOHC
Displacement:
477cc (approximate, exact may vary by specific sub-model)
Bore X Stroke:
Not Specified, but typical for this class is around 95mm x 63mm.
Compression Ratio:
Not Specified, typically around 12.0:1 or higher.
Performance
Horsepower:
Estimated 50-55 HP (at crankshaft), specific figures vary.
Torque:
Not Specified, but strong mid-range torque is a characteristic.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, minimum octane rating 91 (RON+MON)/2.
Lubrication
Oil Type:
JASO MA/MA2 certified 4-stroke motorcycle oil, SAE 10W-40 or 15W-50 depending on climate.
Oil Capacity:
Approximately 1.5 - 1.7 liters (dry fill). Specific capacity detailed in manual.
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Optional
Transmission Options:
Not Applicable, standard 6-speed manual.
Features
Clutch Type:
Wet, multi-plate
Gear Ratios:
Specific ratios detailed in manual, optimized for off-road and dual-sport use.
Transmission Oil Type:
JASO MA/MA2 certified 4-stroke motorcycle oil, same as engine oil (shared sump).
Transmission Oil Capacity:
Refer to engine oil capacity as they share the same lubrication system.
📐 Dimensions
Exterior
Overall Length:
Not Specified, typical for class is around 2200-2300 mm.
Overall Width:
Not Specified, typical for class is around 800-850 mm.
Overall Height:
Not Specified, typical for class is around 1200-1300 mm.
Seat Height:
Not Specified, but typically high for an enduro bike, around 950-980 mm.
Ground Clearance:
Not Specified, but designed for high clearance, typically over 300 mm.
Cargo
Cargo Capacity:
Not Applicable (Motorcycle)
Weights
Dry Weight:
Approximately 115-120 kg (unspecified exact figure, this is an estimate).
Wet Weight:
Approximately 125-130 kg (with all fluids).
Fuel Tank Capacity:
Approximately 8.5 - 9.5 liters.
Wheelbase:
Not Specified, but typically around 1480-1500 mm.
🛡️ Safety Features
Ratings
Safety Ratings:
Not Applicable (Motorcycle, no NHTSA/Euro NCAP equivalent)
Active Features
Braking System:
Hydraulic disc brakes front and rear for effective stopping power.
Lighting:
Headlight, taillight, and brake light for visibility.
Passive Features
Frame Construction:
Robust steel or aluminum frame designed for off-road durability.
Ergonomics:
Designed for rider control and comfort during demanding riding conditions.
💡 Technology Features
Infotainment
Infotainment System:
Basic digital/analog instrument cluster displaying speed, RPM, odometer, trip meter, and basic warning lights.
Driver Assistance
Driver Assistance Features:
Not Applicable (Motorcycle)
Connectivity
Connectivity Features:
Not Applicable (Motorcycle)
Engine Management
Engine Control Unit ECU:
Features an ECU for managing fuel injection, ignition timing, and other engine parameters. Manual details ECU function and potential diagnostics.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 2,000 km or 6 months, whichever comes first. More frequent for severe off-road use. (Refer to manual for exact/severe intervals).
Oil Filter Replacement:
With every oil change.
Air Filter Cleaning:
Every 500 km or as needed, especially after dusty rides. Replacement intervals vary.
Spark Plug Replacement:
Every 5,000 - 10,000 km, or as specified by plug manufacturer. (Refer to manual for specific plug type and interval).
Chain Lubrication Adjustment:
Every 500 km or as needed.
Valve Clearance Check:
Every 5,000 km or 12 months. (Refer to manual for exact interval).
Fluid Specifications
Engine Oil Specification:
JASO MA/MA2 certified 4-stroke motorcycle oil, SAE 10W-40 or 15W-50.
Coolant Type:
Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Known Issues
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, fork seals, brake pads.
Potential Engine Issues:
While generally robust, specific issues can include cam chain tensioner wear, or fuel injector clogging if fuel quality is poor. Manual provides diagnostic steps.
Electrical Quirks:
As with many motorcycles of this era, electrical connectors can be prone to corrosion if not properly protected in off-road environments. Manual helps trace and repair.
📚 Vehicle History
Brand Heritage
Brand Origin:
Husqvarna motorcycles have a long and storied history originating in Sweden, known for pioneering off-road and motocross technology.
Brand Acquisition:
In 2007, Husqvarna Motorcycles was acquired by BMW Motorrad.
Model Evolution
Te Series Evolution:
The TE (Trotto Enduro) series represents Husqvarna's commitment to the enduro segment, evolving from two-stroke to four-stroke engines over the years.
2010 Model Significance:
The 2010 TE510 was part of a generation that benefited from continued refinement and integration of technologies from its parent company (BMW) while retaining its core Italian character.
Production
Manufacturing Location:
Typically manufactured in Italy.
🏆 Awards & Recognition
Recognitions
Motorcycle Awards:
Specific awards for the 2010 TE510 are not widely publicized, but Husqvarna motorcycles consistently receive praise in the off-road and enduro community for performance and durability.
Ratings
Review Ratings:
Generally reviewed positively for its powerful engine and off-road prowess, often cited as a potent contender in the dual-sport segment.
Certifications
Emission Standards:
Complies with relevant emissions standards for motorcycles in its target markets for the 2010 model year.
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