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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)

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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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