This manual covers the TC510, a performance-oriented competition motocross motorcycle produced for the 2007-2008 model years. Renowned for its powerful single-cylinder engine and advanced suspension systems, the TC510 was engineered to meet the demands of motocross racers and aggressive off-road riders. Its design philosophy emphasizes lightweight construction and potent performance, making it a competitive option within its segment. As a product of a brand with a rich heritage in off-road sports dating back to 1903, the TC510 embodies a commitment to durability and rider-focused engineering. This comprehensive workshop service repair manual provides essential information for the maintenance, troubleshooting, and repair of the TC510. It details procedures for all major systems, including the engine, fuel, ignition, transmission, suspension, brakes, and electrical components. With step-by-step instructions, diagnostic charts, and detailed technical specifications such as torque values and fluid capacities, this manual serves as an indispensable resource for professional technicians and experienced DIY mechanics. Its extensive coverage ensures that owners and service personnel can effectively maintain and restore the TC510 to optimal working condition. 🏷️ Basic Information Identification Make: Husqvarna Model: TC510 Generation Production Years: 2007-2008 Codes Engine Family Code: ES-TC510 👋 Introduction Market Position Segment: Competition Motocross/Off-Road Competitors: KTM EXC, Yamaha YZ-F, Honda CRF, Suzuki RM-Z, Kawasaki KX Key Features Design Philosophy: Performance-oriented, lightweight, powerful engine, advanced suspension for its era Target User: Motocross racers and aggressive off-road riders seeking peak performance Manual Value Proposition: Essential resource for maintaining and repairing a high-performance off-road motorcycle, enabling owners to perform complex tasks. 📋 Manual Details Coverage Areas Primary Coverage: Service, Maintenance, Repair, Troubleshooting Secondary Coverage: All Models, Engines, Trims, Transmissions Page Count Estimated Pages: Extensive (typical for workshop manuals of this era, likely 300+ pages) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, cylinder head, piston, crankshaft, valve train, lubrication system, cooling system Fuel System: Carburetor systems, fuel delivery, fuel tank, fuel lines Ignition System: Ignition timing, spark plugs, ignition coils, CDI unit Transmission Drivetrain: Clutch operation and adjustment, gearbox internal components, gear shift mechanism, final drive (chain and sprockets) Suspension: Front forks (USD - Upright/Inverted), rear shock absorber, linkage system, tuning and adjustment Brakes: Front and rear hydraulic brake systems, caliper service, master cylinder, brake fluid replacement, bleeding procedures Electrical System: Wiring diagrams, battery, lighting, starter system, charging system (alternator/stator) Cooling System: Radiator, hoses, coolant, thermostat, fan (if applicable) Exhaust System: Muffler, header pipe, heat shields Chassis Frame: Frame inspection, steering head bearings, swingarm, footpegs Bodywork Trim: Fairings, seat, fenders, tank shrouds, graphics removal/installation Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, chain adjustment, valve clearance checks Troubleshooting: Diagnostic charts for common problems, electrical faults, engine performance issues Repair: Step-by-step disassembly and reassembly instructions for all major components Diagnostics: Visual inspection guidelines, measurement specifications, fault finding strategies Wiring Diagrams: Detailed electrical schematics for easy fault tracing Specifications Data: Torque values, clearances, fluid capacities, measurements Technical Depth Depth: Comprehensive, covering from basic maintenance to complete engine and chassis rebuilds Target Audience: Professional technicians, experienced DIY mechanics 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for easy content retrieval Print Quality Quality: High resolution for clear diagrams and text Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: Four-stroke, single-cylinder Displacement: 501cc (approximate, actual may vary slightly) Bore X Stroke: Information typically detailed in the manual Compression Ratio: Information typically detailed in the manual Valve Train: SOHC (Single Overhead Camshaft), 4 valves Cooling System: Liquid-cooled Performance Horsepower: Estimated 50-55 HP (subject to tuning and specific model variants) Torque: Information typically detailed in the manual Fuel System Carburetor: Mikuni VM38SS or similar (specific model dependent) Fuel Type: Unleaded gasoline (RON 95 or higher recommended) Fuel Delivery: Gravity feed from fuel tank to carburetor 🔧 Transmission Standard Type: 5-speed manual transmission Optional Options: N/A (Typically single transmission option for this model) Features Clutch: Wet, multi-plate, cable-actuated Final Drive: O-ring sealed chain drive Gear Ratios: Specific gear ratios detailed in the manual 📐 Dimensions Exterior Wheelbase: Approximately 1480 mm (58.3 inches) - subject to model variant Seat Height: Approximately 950 mm (37.4 inches) - subject to model variant Weights Dry Weight: Approximately 105 kg (231.5 lbs) - subject to model variant Fuel Tank Capacity: Approximately 7.5 liters (2 gallons) - subject to model variant 🛡️ Safety Features Ratings Safety Standards: Not applicable for off-road motorcycles in typical automotive safety rating contexts (e.g., NHTSA, Euro NCAP). Focus is on rider protection through design and proper use. Active Features Braking System: Hydraulic disc brakes front and rear Passive Features Chassis Design: Robust frame providing stability and impact resistance Bodywork: Protective plastics and guards 💡 Technology Features Infotainment Features: N/A (Basic motocross bike, no infotainment features) Driver Assistance Features:...