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2011 TE 630
Husqvarna 2011 TE 630 Manuals
Manuals and User Guides for Husqvarna 2011 TE 630. We have
1
Husqvarna 2011 TE 630 manual available for free PDF download: Workshop Manual
Husqvarna 2011 TE 630 Workshop Manual (455 pages)
TE 630 / 2011 I.E. SMS 630 / 2011 I.E.
Brand:
Husqvarna
| Category:
Motorcycle
| Size: 31.52 MB
Table of Contents
Table of Contents
5
Foreword, Table of Contents
3
Workshop Manual
3
Table of Contents
5
Important Notices
7
General Information
9
Table of Contents
10
Cooling
11
Drive and Transmission
11
Engine
11
Fuel System
11
Ignition System
11
Lubrication
11
Part. N. 8000 H2051 (02-2010) a
11
Timing System
11
Brakes
12
Chassis
12
Suspension
12
Wheels
12
Electrical Components Location
13
Tyres
13
Overall Dimensions - Weight
14
Capacities
16
Maintenance
17
Troubleshooting
21
Settings and Adjustments
27
Table of Contents
28
Tank Removal
30
Valve Clearance Adjustment
33
Enrichener Lever Play Adjustment
34
Throttle Cable Adjustment
34
Engine Oil Level Check
35
Idle Adjustment
35
Engine Oil Replacement, Oil Filter Replacement
36
Mesh Filters Cleaning
37
Coolant Level Check
39
Coolant Replacement
40
Clutch Disassembly
41
Clutch Plate Replacement
41
Hydraulic Clutch Lever Adjustment and Fluid Level Check
42
Front Brake Lever Adjustment and Fluid Level Check
43
Rear Brake Pedal Adjustment
44
Rear Brake Pedal Free Play Adjustment
44
Air Filter Check
45
Rear Brake Fluid Level Check
45
Air Filter Cleaning
46
Chain Adjustment
47
Chain Lubrication
48
Lubricating an O-Ring Chain
48
Washing a Chain Without O-Rings
48
Suspension
49
Shock Absorber Spring Preload Adjustment
51
MARZOCCHI Front Fork Adjustment
53
Fork Oil Level
54
MARZOCCHI Front Fork Springs
55
Steering Bearing Clearance Adjustment
56
Supply Hose Check
57
Exhaust System Check
58
General Procedures
59
Table of Contents
60
Foreword
61
Saddle Removal
62
Side Panel Removal
62
Battery Removal
63
Exhaust System Removal
64
Air Box Removal
68
Throttle Body Removal
70
Removing the Rear Chassis Complete with Mudguard
72
Fuel Tank Removal
75
Fuel Tank Disassembly (Scoops and Fuel Pump)
78
Expansion Tank Removal
80
Removing Utilities (Solenoid Starter, Relays, Fuses, Flasher)
81
Electronic Control Unit Removal
82
Ignition Coil Removal
82
Voltage Regulator Removal
82
Electric Cooling Fan Removal
83
Front Mudguard Removal
83
Horn Removal
83
Digital Dashboard Removal
86
Headlamp Fairing Removal
87
Ignition Switch Removal
88
Thermal Expansion Valve Removal
89
Engine Removal
90
Secondary Drive Chain Removal
90
Radiator Removal
95
Engine Disassembly
97
Table of Contents
98
Layout of Engine Components
99
Camshaft Removal
100
Cylinder Head Cover Removal
100
Water Pump Body Removal
104
Water Pump Disassembly
104
Cylinder Head Removal
105
Valve Removal
108
Cylinder Removal
110
Flywheel Removal
111
Piston Removal
111
Clutch Cover Removal
114
Oil Filters Removal
115
Clutch Disassembly
116
Clutch Actuator Removal
119
Starter Motor Flange Removal
120
Starter Motor Removal
120
Gearbox Drive Shaft Removal
121
Gear Sensor Removal
123
Crankcase, Crankshaft and Countershaft Disassembly
124
Left Crankcase Seal Replacement
127
Countershaft Removal
128
Gearbox Disassembly
128
Crankshaft Removal
129
Crankshaft Components Removal
130
Crankcase Bearings Removal
131
Right Crankcase Crankshaft Seal Removal
131
Oil Pump Disassembly
132
Stator Removal
132
Engine Overhaul
133
Cleaning Parts
134
Clearances
134
Cylinder Head
134
Valve Seat Refacing
135
Valve Guide
137
Valve Guide Replacement
137
Valve
138
Valve Spring
138
Valve Installation
139
Rocker Arm Inspection
140
Camshaft
141
Timing Chain and Gears
142
Timing Chain Tensioners
142
Cylinder
143
Piston
143
Cylinder to Piston Clearance
144
Piston Pin
145
Piston Ring to Cylinder Clearance
146
Piston Rings
146
Piston Ring to Groove Clearance
147
Balancing Countershaft
148
Big End Radial Clearance
148
Crankshaft
149
Crankshaft Straightness
149
Small End Bushing Replacement
149
Clutch
150
Clutch Spring
151
Friction Plate to Clutch Housing Clearance
151
Selector Drum
153
Shifter Forks and Gears
153
Selector Drum to Shifter Fork Pins Clearance
154
Oil Pump Disassembly
155
Engine Reassembly
157
Table of Contents
158
General
159
Assembly and Lubrication Instructions (CRANK- ALTERNATOR- LUBRICATION- LEFT CRANKCASE HALF)
160
Tightening Torque Figures
161
Assembly and Lubrication Instructions (CLUTCH - KICK START- LUBRICATION- RIGHT CRANKCASE HALF)
162
Gearbox - Gear Shift Control
162
Tightening Torque Figures
163
Assembly and Lubrication Instructions (HEAD - CYLINDER - PISTON - TIMING SYSTEM - WATER PUMP - SPARK PLUG)
164
Tightening Torque Figures
167
Input Shaft
170
Output Shaft
170
Crankcase Assembly
173
Gear Sensor Installation
179
Gear Shift Control Assembly
180
Countershaft Weight/Gear Installation
183
Crankshaft Gears Installation
183
Clutch Assembly
186
Piston and Cylinder Installation
189
Piston Ring Installation
189
Cylinder Head Gasket Selection Table
191
Cylinder Head Installation
192
Water Pump Installation
194
Timing Chain Tensioner Installation
195
Camshaft Installation
196
Cylinder Head Cover and Spark Plug Installation
198
Flywheel and Flywheel Cover Installation
199
Oil Pump and Filter Cartridge Assembly
202
Sprocket Installation
202
Right Crankcase Assembly
203
Clutch Actuator Installation
204
Front Suspension
205
Rear Suspension
314
Rear Suspension
315
Lubrication Points (Grease)
316
Rear Shock Absorber
316
Rear Suspension
316
Rear Shock Absorber Removal
318
Disassembling, Servicing and Assembling the Rear Shock Absorber
319
Shock Absorber Inspection
320
Piston Assembly Inspections
323
Seal Replacement
323
Checking the Setting
324
Floating Piston Removal
327
Reservoir Replacement
327
Shock Absorber Assembly
328
Shock Absorber Damping Adjustment
332
Disassembling and Servicing the Swinging Arm
333
Servicing the Rear Suspension Drop Drag Link
335
Servicing the Swinging Arm Shaft
335
Chain Roller, Chain Guide, Chain Slider
336
Brakes
338
Brakes
339
Braking System
340
Brake Disc
341
Pads Cleaning
342
Bleeding the Front Braking System (TE)
344
Bleeding the Front Braking System (SMS)
345
Bleeding the Rear Braking System
347
Electrical System
352
Table of Contents
354
Colour Coding Key
356
Key to Wiring Diagram
356
Wiring Diagram
356
Charging System
361
Wiring Diagram
361
Charging System Inspections
362
Current Loss at the Battery
362
Regulated Voltage
362
Generator Inspection
363
Colour Coding Key
364
Generator No-Load Performance
364
Voltage Regulator/Rectifier Inspection
364
Wiring Diagram
364
Starting System
365
Wiring Diagram
365
Starting System Inspection
366
Starter Motor Maintenance
367
Starter Motor Test Curves
367
Solenoid Starter Inspection
368
Solenoid Starter Wiring Diagram
368
Electronic Ignition System
369
Checking Ignition Coil Windings Resistance
371
Electronic Control Unit (ECU)
372
Spark Plug
373
Gear Position Sensor Inspection (GPS: Gear Position Sensor)
374
Battery
375
Battery Charger
375
Headlight Adjustment
377
Headlamp Bulbs Replacement
378
Number Plate Bulb Replacement
380
Tail Light Replacement
380
Rear Turning Indicator Removal
381
Turning Indicator Bulb Replacement
381
Front Turning Indicator Removal
382
Number Plate Light Removal
383
Number Plate Holder Removal
384
Rear Mudguard Removal
384
Colour Coding Key
385
Left-Hand Switch
385
Colour Coding Key
386
Right-Hand Switch
386
Fuses
387
Semiconductor Parts
387
Connectors
388
Couplers
388
Charging System
393
Electronic Ignition System
393
Starting System
393
Troubleshooting
393
Wiring
394
Cable Routing and Electrical Parts Installation Instructions
395
Coil Position and Connector Connection
395
Position of Utilities
395
Electronic Control Unit Position
396
Securing the Engine / Chassis / Battery Ground Cables
396
Securing the Starter Motor/Solenoid Starter Cable
396
Voltage Regulator Position
396
Electric Fan Connection
397
Injector Connection
397
MAQS Connector Connection
397
Engine Water Temperature Connector
397
Lambda Sensor Position and Connector
398
Wiring Connection to Voltage Regulator
397
Ignition Switch and Left-Hand Switch Connection
398
Right-Hand Switch Connection
398
Ignition and Gear Sensor Cable Connection
399
Rear Stop Connection
399
Securing the Handlebar Wiring Harness
399
Cable Routing
400
Headlamp, Front Turning Indicators, STOP Light Connection
400
Routing of Steering Head Tube Wiring
400
Securing the Dashboard Bracket Connectors
400
Securing the Gear Sensor, Lambda Sensor, Stop Micro Switch Cables
401
Securing the Wiring Harness to the Mudguard
401
Securing the Wiring Harness to the Rear Chassis
401
Important
402
Engine Cooling
404
Hydraulically Controlled Clutch
410
Hydraulic Clutch System
412
Draining Clutch Fluid
413
Clutch Master Cylinder Servicing
414
Bleeding the Clutch System
415
Optional Components
418
Fuel Injection System
422
Special Tools
430
Tightening Torque Figures
432
Chassis and Wheels
442
Chassis
444
Lubrication Points (Lubricant)
445
Front Wheel
446
Rear Wheel
449
Wheel Servicing
451
Wheel Axle Warpage
451
Axle Runout over 100 MM
451
Wheel Spokes
452
Wheel Rim Warpage
452
Rear Chain Sprocket, Secondary Drive Sprocket and Chain
453
Tightening Torque Figures
453
Checking Chain and Sprockets for Wear
454
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