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Husqvarna Manuals
Motorcycle
2010 TXC-510
Workshop manual
Husqvarna 2010 TXC-510 Workshop Manual
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Contents
Table of Contents
Bookmarks
Table of Contents
Table of Contents
Workshop Manual
Important Notices
General
General
Cooling
Engine
Fuel Feeding
Ignition
Lubrication
Timing System
Transmission
Brakes
Frame
Suspensions
Tires
Wheels
Weights
Capacities
Maintenance
Troubles and Remedies
Settings and Adjustments
Settings and Adjustments
Adjustment of Starter Decompression Device
Throttle Cable Adjustment
Carburettor Adjustment (TC, TXC)
Idle Adjustment (TC, TXC, SMR 450-R)
Idle Adjustment (TE, SMR)
Clutch Discs Replacement (TC-TE-TXC-SMR)
Adjustment of the Control Lever and Check of the Clutch Fluid Level
Adjustment of Front Brake Control Lever and Fluid Level Control (TE-TC- TXC-SMR)
Rear Brake Pedal Position Adjustment
Checking the Rear Brake Fluid Level
Rear Brake Idle Stroke Adjustment
Checking the Engine Oil Level
Engine Oil Replacement and Bag Filters-Cartridge Filter Cleaning or Replacement
Coolant Level Check
Replacement of Coolant
Air Filter Check (TC-TXC)
Air Filter Check (TE-SMR)
Secondary Transmission Chain Adjustment
Adjusting the Suspensions According to Particular Track Conditions
Adjusting the Shock Absorber
Adjusting the Shock Absorber Spring Preload
Shock Absorber Hydraulic Brake Adjustment
Shock Absorber Springs
Adjusting the Front Fork
Front Fork Springs
Lock Adjustment
Steering Bearings Play Adjustment
Handlebar Position and Height Change (TE, TC, TXC, SMR)
Checking the Fuel Hose
Replacing the Muffler Deadening Material (TC-TE-TXC)
Replacing the Muffler Deadening Material (SMR)
Checking the Exhaust System
General Operations
General Operations
Foreword
Removal of Engine from Motorcycle
Removal of Saddle and Battery
Removal of Side Panels
Removal of Rear Frame with Fender (TE- SMR: with Tail Light) and Air Filter Box Assy
Removal of Exhaust System
Removal of Fuel Tank, Conveyors and Spoiler
Removal of Cooling Fan (TE-SMR), Radiators and Coolant Expansion Tank (TE-SMR)
Removal of Electronic Power Unit C.D.I., Electronic Coil, Voltage Regulator and Clutch Hose
Removal of Secondary Drive Chain
Engine Disassembly
Engine Disassembly
Camshaft Disassembly
Cylinder Head Cover Disassembly
Water Pump Body Disassembly
Cylinder Head Disassembly
Valve Disassembly
Cylinder Disassembly
Piston Disassembly
Flywheel Disassembly
Kick Start Pedal Disassembly (TC-TE-TXC)
Clutch Disassembly (TC, TE, TXC; SMR 450-510)
Transmission Cover Disassembly
Kick Start Components Disassembly (TC-TE-TXC)
Electric Starting System Disassembly (TE, TXC; SMR 450-510)
Oil Pump Disassembly
Gear Control Pedal and Gear Shifter Disassembly
Primary Transmission Driving Gear Disassembly
Crankcase Disassembly
Gearbox Disassembly
Crankshaft and Counter Balancing Shaft Disassembly (SMR 450-510)
Engine Overhauling
Assemblies
Cleaning of Components
Cylinder Head
Recutting the Valve Seats
Replacement of Valve Guides
Valve Guides
Valve
Valve Spring
Installation of Valves
Inspection of Rocker Arm
Starter Decompressor
Camshaft
Camchain Tensioner
Camshaft Chain and Gearing
Cylinder
Piston
Cylinder-Piston Fitting
Gudgeon Pin
Piston Rings
Piston Rings/Cylinder Clearance
Piston Ring/Piston Rings Groove Clearance
Connecting Rod Big End Side Clearance
Crankshaft
Connecting Rod Small End Bush Replacement
Clutch Housing-Friction Disc Clearance
Clutch Spring
Clutch Unit
Gear Selector Fork and Gearing
Oil Pump
Carburettor Overhauling (TC-TXC)
Selector Drum
Keihin" Carburettor Adjustment (TC-TXC)
Carburettor Checking
Engine Reassembly
Engine Reassembly
General Directions
Instructions for Assembly and Lubrication
Reassembly of Counter Balancing Shaft Driving Gear (SMR 450-510)
Reassembly of Transmission (TE-TXC-SMR)
Reassembly of Crankcase
Reassembly of Gearshift Mechanism, Electric Starting System and Oil Pump
Reassembly of Kick Start Components (TE-TC-TXC)
Reassembly of Clutch (TE-TXC-TC; SMR 450-510)
Reassembly of Timing System Drive Gear and Chain
Reassembly of Flywheel
Reassembly of Transmission Cover
Reassembly of Cylinder Head Cover, Spark Plug, Lubrication Hose
Reassembly of Gear Shift Position Sensor
Reassembly of Flywhel Cover
Reassembly of the Engine Oil Filters and Drain Plug
Engine and Motorcycle Reassembly
Cylinder Head Gasket Selection Chart
Table of Contents
Removing the Front Fork
Front Suspension
Front Suspension (te 310 EU-SMR)
Instructions for Use of Ø50USD Fork (te 310 EU-SMR)
Components of the Fork
General Rules for a Proper Overhauling
Instructions for Clamping in the Vice
Problems - Possible Causes - Solutions
General Maintenance Operations
Cleaning the Dust Seal
Bleeding the Air
Draining the Oil
Braking down the Pumping Element and the Bottom Valve
Braking down the Fork Leg - Slider and Removing the Oil Seals
Overhauling and Modifying the Cartridge and Bottom Valve Setting
Cartridge Overhauling (Rebound Braking)
Bottom Valve Overhauling (Compression Braking)
Re- Assembling the Fork Leg - Slider and Oil Seals
Re- Assembling the Pumping Element Unit and the Bottom Valve
Filling with Oil
Fitting the FORK Back on Themotorcycle
Adjustments
Rebound Adjustment
Compression Adjustment
Front Suspension (TC 450 - TXC 450-510)
(Models TC 450 - TXC 450-510)
Front Suspension (te 310 USA/AUS- te 450-510)
(Models te 310 USA/AUS- te 450-510)
Rear Suspension
Rear Suspension
Checking the Shock Absorber
Disassembly, Overhauling and Reassembly of the Rear Shock Absorber
Removing the Reservoir Plug and the Valve
Checks on the Piston Unit
Replacing the Gasket
Checking the Adjustment
Reservoir Replacement
Disassembling the Air/Oil Diaphragm of the Reservoir
Reassembling the Shock Absorber
Shock Absorber Damping Adjustment
Overhauling the Rear Swing Arm Axle
Overhauling the Rocking Lever and the Rear Suspension Tie Rod
Chain Tension Rollers, Chain Driving Roller, Chain Guide, Chain Runner
Brakes
Brakes
Cable Colour Coding (TE, SMR)
Cable Colour Coding (TC 450, TXC 450-510)
Electrical Components Location (Te-Smr)
Electrical Components Location (Tc-Txc)
Charging System (Te-Smr)
Battery Current Leakage
Charging System Checks
Generator Stator Coil Resistance Check
Regulated Voltage
Electric Starting System (Te-Smr)
Electric Starting System (Txc)
Starter Motor Check
Starter Motor Disassembly
Starter System Checks
Electric Start Remote Control Switch Check (TE-SMR-TXC)
Starter Motor Maintenance
Starter Motor Test Diagram
Electronic Ignition System (Tc-Txc)
Electronic Ignition System (Te-Smr)
Electronic Power Unit Wiring Diagram (Ecu) (Te-Smr)
Voltage Regulator (TE-SMR-TXC)
Voltage Regulator-Rectifier Wiring Diagram
Spark Plug
Gear Shift Position Sensor Check (GPS)
Battery Recharge
Headlamp Adjustment
Headlamp, Tail Lamp (Te-Smr)
Rear Tail Light Bulb Replacement
Replacing the Licence Plate Light Lamp
Handlebar Commutators
Connectors
Couplings
Notes
Battery
Fuses
Semiconductors Parts
Digital Instrument, Warning Lights (Te-Smr)
Instrument Replacement
Locating Operating Troubles
Wire Harness TC-TXC
Wire Harness TE-SMR
Cable Runway and Assembling Instructions for the 'Te/Smr' Electric Parts
Important Recommendation
Engine Cooling System
Hydraulic Control Clutch
Optional Parts List
Fuel Injection System
Fuel Injection System
Operating Instructions for the "DIAGNOSIS SOFTWARE KIT" on the Fuel Injection
Fuel Pump Check
Relay Check
Lubrication System
Specific Tools
Torque Wrench Settings
Frame
Front Wheel
Removing the Front Wheel
Reassembling the Front Wheel
Rear Wheel
Wheels Overhauling
Wheel Spokes
Rims Warpage
Notes for USA/CDN-AUS Models
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See also:
Owner's Manual
Workshop Manual
TE 310-450-510/2010-I.E.,
TC 450/2010,
TXC 450-510/2010
,
(only USA)
SMR 450-510 2010-I.E.
Part. N. 8000 H1344 (10-2009)
Table of
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Chapters
Table of Contents
5
General
12
Settings and Adjustments
36
General Operations
72
Engine Disassembly
98
Engine Overhauling
123
Engine Reassembly
150
Table of Contents
194
Rear Suspension
241
Brakes
271
Table of Contents
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Summarization of Contents
IMPORTANT NOTICES
Model-Specific Notices and Warranty
Information regarding model configurations, warranty terms, and usage guidelines.
Motorcycle Usage and Guarantee Notes
Details on motorcycle design limitations, usage conditions, and guarantee terms.
GENERAL
Engine and Transmission Specifications
Technical data for engine parameters and transmission gear ratios.
Chassis, Suspension, and Brakes Specifications
Details on frame, suspension, brake system, wheels, and tires.
Electrical Components Location and Overview
Identifies key electrical system components and provides an overview.
MAINTENANCE
Pre-Delivery Inspection Checklist
List of checks and operations for pre-delivery.
Periodic Maintenance Schedule
Schedule of maintenance tasks based on usage intervals for different models.
TROUBLES AND REMEDIES
Engine Troubleshooting
Identifies common engine problems, causes, and remedies.
Frame, Wheels, Suspension, and Electrical Issues
Troubleshooting guide for frame, wheels, suspension, and electrical system problems.
SETTINGS AND ADJUSTMENTS
Engine Adjustments
Procedures for carburetor and throttle adjustments.
Suspension Adjustments
Guide for adjusting front and rear suspension based on track conditions.
Handlebar and Steering Adjustments
Procedures for adjusting steering bearings and handlebar position/height.
ENGINE DISASSEMBLY
Cylinder Head and Valve Train Disassembly
Steps for removing and disassembling the cylinder head and valve train.
Crankcase and Transmission Disassembly
Procedures for disassembling the crankcase and transmission components.
ENGINE OVERHAULING
Cylinder Head and Valve Overhauling
Steps for checking and overhauling the cylinder head and valves.
Piston, Rings, and Cylinder Checks
Procedures for checking piston, rings, and cylinder for wear.
Clutch Unit Overhauling
Instructions for checking and overhauling clutch components.
ENGINE REASSEMBLY
General Reassembly Instructions
General guidelines and precautions for engine reassembly.
Crankshaft and Counterbalancing Shaft Reassembly
Steps for reassembling the crankshaft and counterbalancing shaft.
Transmission and Clutch Reassembly
Instructions for reassembling the transmission and clutch components.
Cylinder Head and Piston Reassembly
Procedures for assembling the piston and cylinder, and reassembling the cylinder head.
FRONT SUSPENSION
Front Fork Removal and Disassembly
Step-by-step guide for removing and disassembling the front fork.
Front Suspension Overhauling and Adjustments
Procedures for overhauling fork components and adjusting damping settings.
Front Suspension Reassembly
Steps for reassembling the front fork slider and components.
REAR SUSPENSION
Rear Shock Absorber Overhauling
Procedures for overhauling the rear shock absorber spring and components.
Rear Swing Arm Disassembly and Overhauling
Instructions for disassembling and overhauling the rear swing arm.
BRAKES
Disc Brake Checks and Pad Replacement
Guide for checking brake disc condition and replacing brake pads.
Brake System Bleeding
Procedures for bleeding the front and rear brake systems.
ELECTRIC SYSTEM, DIGITAL INSTRUMENT
Electrical Components Location and Diagrams
Identifies electrical components and provides wiring diagrams for TE-SMR and TC-TXC.
Charging System Checks
Procedures for checking battery and generator performance.
Ignition System and Starter System Checks
Troubleshooting for ignition and starter systems.
Digital Instrument and Warning Lights
Explains digital instrument functions, warning lights, and setting procedures.
ENGINE COOLING SYSTEM
Cooling Fluid Level Check
Procedure for checking and maintaining the engine's cooling fluid level.
Engine Cooling System Overhauling
Steps for overhauling the engine cooling system, including radiator and hoses.
“KIT” ASSEMBLING INSTRUCTIONS
Specific Kit Assembly Procedures
Instructions for assembling various optional kits like engine guards and hand guards.
Full Power Version Components Assembly
Instructions for assembling components to enable the full power version.
HYDRAULIC CONTROL CLUTCH
Hydraulic Clutch System Fluid Service
Procedures for discharging, overhauling, and bleeding the hydraulic clutch system.
OPTIONAL PARTS LIST
Optional Parts List (TE)
List of optional parts available for TE models with part numbers and models.
Optional Parts List (SMR)
List of optional parts available for SMR models with part numbers and models.
SPECIFIC TOOLS
Special Tools Catalog
Catalog of specialized tools required for maintenance and repair.
TORQUE WRENCH SETTINGS
Engine Component Tightening Torques
Torque specifications for engine nuts and bolts.
Chassis Component Tightening Torques
Torque specifications for chassis nuts and bolts.
FRAME AND WHEELS
Front Wheel Service
Procedures for removing, reassembling, and checking the front wheel.
Rear Wheel Service
Steps for removing, reassembling, and checking the rear wheel.
Wheel Spokes and Rim Checks
Instructions for checking wheel spoke tension and rim alignment.
Chain, Sprocket, and Pinion Wear Check
Guide for checking the wear of the drive chain, pinion, and sprocket.
NOTES FOR USA/CDN- AUS MODELS
Motorcycle Usage and Warranty Disclaimer
Legal disclaimer regarding motorcycle acceptance and warranty terms.
Spark Arrester Maintenance and Cleanout
Instructions for maintaining and cleaning the spark arrester for specific models.
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