2010r 310-510.pdf

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)

To the best knowledge of HUSQVARNA MOTORCYCLES S.R.L. - Varese, Inc. the material contained herein is accurate as of the

date this pubblication was approved for printing. Cagiva Motor S.p.a. - Varese, Inc. reserves the right to change speciications, equip-

ment, or designs at any time without notice and without incurring obligation. Illustrations in this manual are merely for demonstration

purposes and could not exactly match the detail described.No part of this manual can de reproduced without permission in writing of

the copyright holder.

1st Edition (10-2009)

FOREWORD, SUMMARY

Workshop Manual

TE 310-450-510/2010-I.E.,

TC 450/2010,

TXC 450-510/2010 (only USA) ,

SMR 450-510/2010-I.E.

HUSQVARNA MOTORCYCLES S.R.L.

BMW Group

Servizio Assistenza Tecnica

Via Nino Bixio, 8

21024 Biandronno

(Varese) - Italy

tel. ++39 0332 75.61.11

fax ++39 0332 756 558

www.husqvarna-motorcycles.com

1 st Edition (10-2009)

Printed in Italy

Print No. N° 8000 H1344

VALIDITY (from vehicle identiication number)

TE 310: ZKHA204AAAV000001

TE 450: ZKHA202AAAV000001

TE 510: ZKHA203AAAV000001

TE 310 (USA): ZKHKBEDF*AV100001

TE 450 (USA): ZKHKBEFF*AV100000

TE 510 (USA): ZKHKBEHF*AV100000

TC 450: ZKHA202AAAV050001

TC 450 (USA): ZKHTC450*AV100000

TXC 450 (USA): ZKHTX450*AV000001

TXC 510 (USA): ZKHTX510*AV000001

SMR 450: ZKHA202ABAV000001

SMR 510: ZKHA203ABAV000001

1. Vehicle identiication number

Part. N. 8000 H1344 (10-2009)

a.1

FOREWORD, SUMMARY

Foreword

This publication intended for HUSQVARNA Workshops has been prepared for the

purpose of helping the authorized personnel in the maintenance and repair work of the

motorcycles herewith dealt with. The perfect knowledge of the technical data contained

herein is essential for a more complete professional training of the operator.

The paragraphs have been completed with schematic illustrations evidencing the subject

concerned, in order to enable a more immediate understanding.

This manual contains information with particular meanings:

Accident prevention rules for the operator and for the personnel working near by.

Possibility of damaging the vehicle and/or its components.

Additional information concerning the operation under way.

Useful suggestions

HUSQVARNA suggests, in order to prevent troubles and in order to have an excellent

inal result, to generically comply with the following instructions:

– in case of repair work, weigh the impressions of the Customer who complains about

the improper operation of the motorcycle, and formulate proper clearing questions

about the symptoms of the trouble.

– detect clearly the cause of the trouble. This manual gives the theoretical bases which

however shall be integrated by the personal experience and by the attendance to

training courses periodically organized by HUSQVARNA .

– rationally plan the repair work in order to prevent dead time as for instance procure-

ment of spare parts, tool preparation, etc.

– reach the component to be repaired and perform only the required operations.

In this connection, it will be useful to consult the disassembly sequence contained in

this manual.

General instructions for repair work

1 Always replace the seal rings and split pins with new components.

2 When loosening or tightening nuts or bolts, always start from the bigger ones or from

the center. Lock at the prescribed torque wrench setting following a crossed run.

3 Always earmark the components or positions which could be mistaken one for another

at the time of assembly.

4 Use original HUSQVARNA spare parts and the lubricants of the recommended brands.

5 Use special tools, where speciied.

6 Consult the Service Bulletins as they may contain up-dated adjustment data and

repair methodologies.

a.2

Part. N. 8000 H1344 (10-2009)

FOREWORD, SUMMARY

Summary

Chapter Section

Foreword, summary...................................................... a

Important notices .......................................................... b

General ........................................................................

Maintenance ................................................................

Troubles and remedies.................................................

Settings and adjustments ............................................

General operations ......................................................

Engine disassembly......................................................

Engine overhauling ......................................................

Engine re-assembly .....................................................

Front suspension .........................................................

Rear suspension .........................................................

Brakes ..........................................................................

Electric system ............................................................

Engine cooling system..................................................

"KITS" assembling instructions.....................................

Hydraulic control clutch ..............................................

Optional Parts List ........................................................

Fuel injection system ....................................................

Lubrication system........................................................

Speciic tools ...............................................................

Torque wrench settings.................................................

Frame, wheels ............................................................

Notes for USA/CDN-AUS models.................................

NOTES

1) Where not otherwise speciied, data and instructions refer to all models.

Part. N. 8000 H1344 (10-2009)

a.3

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