Husqvarna TE511 Off-Road Motorcycle Manuals

Manuals and User Guides for Husqvarna TE511 Off-Road Motorcycle. We have 1 Husqvarna TE511 Off-Road Motorcycle manual available for free PDF download: Workshop Manual

Husqvarna TE511 Workshop Manual (385 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 28.69 MB

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
- Engine
  11
- Fuel System
  11
- Ignition System
  11
- Lubrication
  11
- Timing System
  11
- Chassis
  12
- Suspension
  12
- Brakes
  13
- Tyres
  13
- Wheels
  13
- Electrical Components Location
  14
- Supplies
  15
- Overall Dimensions - Weight
  16
- Maintenance
  19
- Troubleshooting
  25
- Settings and Adjustments
  31
Settings and Adjustments

32
Table of Contents

60
- Saddle Removal
  61
- Side Panel Removal
  61
- Front Mudguard Removal
  63
- Number Plate Holder Removal (te - SMR)
  63
- Rear Mudguard Removal
  64
- Battery Removal
  65
- Tank Removal
  65
- Cock Removal
  69
- Fuel Pump Removal
  69
- Throttle Body Removal
  70
- Exhaust System Removal (SMR)
  73
- Exhaust System Removal (te - TXC)
  74
- Exhaust System Removal (TC)
  77
- Rear Chassis Removal
  79
- Rear Tank Removal
  81
- Solenoid Starter Removal
  81
- CDI Electronic Control Unit Removal
  82
- Voltage Regulator Removal
  82
- Coil Removal and Spark Plug Check
  83
- Clutch Hose Removal
  85
- Electric Cooling Fan Removal (te - TXC - SMR)
  86
- Horn Removal (te - SMR)
  86
- Air Filter Box Removal
  87
- Engine Guard Removal
  89
- Gear Shift Pedal Removal
  89
- Chain Slider Removal
  90
- Engine Removal
  93
- Radiator Removal
  97
- Adjustments - Engine
  99
- Engine Disassembly/Reassembly
  107
Table of Contents

108
- Oil Filter Cover on Crankcase
  
  113
  - Engine Oil Filter Disassembly
    114
  - Engine Oil Filter Assembly
    115
- Oil Filters Replacement
  
  113
  - Oil Filter Disassembly
    113
  - Oil Filter Assembly
    113
- Spark Plug Recess Ignition Coil
  
  116
  - Spark Plug Recess Ignition Coil Disassembly
    116
  - Spark Plug Recess Ignition Coil Assembly
    116
- Spark Plug Recess
  
  117
  - Spark Plug Recess Disassembly
    117
  - Spark Plug Recess Assembly
    117
- Spark Plug
  
  118
  - Spark Plug Disassembly
    118
  - Spark Plug Assembly
    118
- Oil Pressure Adjustment Valve Replacement
  
  119
  - Oil Pressure Adjustment Valve Disassembly
    119
  - Oil Pressure Adjustment Valve Assembly
    119
- Cylinder Head Cover
  
  120
  - Removing Cylinder Head Cover
    120
  - Fitting Cylinder Head Cover
    120
- Engine Positioning at Ignition TDC
  
  121
  - Securing Crankshaft at TDC
    121
- Camshaft Disassembly
  
  122
- Camshaft Assembly
  
  122
  - Bearing Mount Disassembly
    122
  - Camshaft Check
    122
  - Bearing Mount Assembly
    123
  - Bearing Mount Fitting
    123
- Engine Left Crankcase
  
  124
  - Engine Left Crankcase Cover Disassembly
    124
  - Engine Left Crankcase Cover Assembly
    124
- Alternator Replacement
  
  125
  - Flywheel Disassembly
    125
  - Stator Disassembly
    126
  - Freewheel Disassembly
    126
  - Freewheel Assembly
    126
  - Stator Assembly
    127
  - Flywheel Assembly
    127
- Crankcase Left Cover Replacement
  
  128
  - Stator Disassembly
    128
  - Stator Assembly
    128
- Crankshaft Sensor Replacement
  
  130
  - Crankshaft Sensor Disassembly
    130
  - Crankshaft Sensor Assembly
    130
- Freewheel Gear Replacement
  
  131
  - Freewheel Gear Disassembly
    131
  - Freewheel Gear Assembly
    131
- Clutch Disassembly and Reassembly or Replacement
  
  132
  - Clutch Cover Disassembly
    132
  - Removing Clutch Pressure Plate
    132
  - Removing Clutch Plates
    133
  - Clutch Hub Disassembly
    133
  - Clutch Housing Disassembly
    133
  - Clutch Crankcase Clearance Check
    134
  - Clutch Housing Clearance Reading
    134
  - Clutch Housing Assembly
    136
  - Clutch Hub Assembly
    136
  - Removing Clutch Plates
    136
  - Pressure Plate Assembly
    137
  - Clutch Cover Assembly
    137
- Replacing Clutch Disengagement Bearing
  
  138
- Engine Right Crankcase
  
  139
  - Engine Right Crankcase Cover Disassembly
    139
  - Engine Right Crankcase Cover Assembly
    139
- Clutch Thrust Washer
  
  141
  - Clutch Thrust Washer Disassembly
    141
  - Clutch Thrust Washer Assembly
    141
- Clutch Housing Axial Bearing
  
  142
  - Clutch Housing Axial Bearing Disassembly
    142
  - Clutch Housing Axial Bearing Assembly
    142
- Coolant Pump Disassembly and Assembly
  
  143
  - Coolant Pump Cover Disassembly
    143
  - Coolant Pump Rotor Disassembly
    143
  - Coolant Pump Rotor Assembly
    144
  - Coolant Pump Cover Assembly
    144
- Coolant Pump Inside Crankcase Oil Seal Replacement
  
  145
- (Crankcase Cover Removed)
  
  145
- Coolant Pump Drive Replacement (Crankcase Cover Removed)
  
  146
  - Slider Loosening at the Lower Area
    146
  - Coolant Pump Shaft Disassembly
    146
  - Coolant Pump Shaft Assembly
    147
  - Slider Assembly at the Lower Area
    147
- Chain Front Sprocket
  
  148
  - Chain Front Sprocket Removal
    148
  - Front Sprocket Assembly
    148
- Chain Tensioner Disassembly and Reassembly or Replacement
  
  149
  - Chain Tensioner Disassembly
    149
  - Chain Tensioner Assembly
    149
- Cylinder Head Disassembly and Reassembly/Head Gasket Replacement
  
  150
  - Preliminary Operations
    150
  - Cylinder Head Disassembly
    150
  - Cylinder Head Assembly
    150
- Cylinder Head Replacement (Cylinder Head Removed)
  
  151
  - Valve Disassembly
    151
  - Removing Valve Spring
    152
  - Removing Valve Stem Seal
    152
  - Rocker Arm Disassembly
    153
  - Rocker Arm Shaft Disassembly
    153
  - Valve Seat Width Check
    154
  - Valve Guide Clearance Check
    154
  - Rocker Arm Shaft Assembly
    155
  - Rocker Arm Assembly
    156
  - Fitting Valve Stem Seal
    156
  - Valve Spring Assembly
    156
  - Valves Assembly
    157
- Chain Slider
  
  158
  - Chain Tensioning Slider Disassembly
    158
  - Slider Disassembly
    158
  - Chain Sliding and Tensioning Slider Check
    158
  - Slider Assembly
    159
  - Chain Tensioner Assembly
    159
- Cylinders Disassembly and Reassembly or Replacement
  
  160
  - Cylinder Disassembly
    160
  - Piston Disassembly
    161
  - Cylinder Check
    161
  - Piston Assembly
    162
  - Piston Diameter Check
    162
  - Piston Stroke Clearance Definition
    162
  - Piston Ring Assembly
    163
  - Piston with Cylinder Assembly
    163
  - Subsequent Actions
    164
- Timing Chain Disassembly and Reassembly or Replacement
  
  165
  - Timing Chain Disassembly
    165
  - Timing Chain Assembly
    166
  - Subsequent Actions
    166
  - Chain, Chain Sprocket Check
    166
  - Timing Chain Check
    166
- Replacing Oil Pump Gears (Crankcase Cover Removed)
  
  167
- Oil Intake Pump Replacement (Crankcase Cover Removed)
  
  170
  - Removing Oil Intake Pump
    170
  - Fitting Oil Intake Pump
    170
- Removing and Assembling or Replacing Pressure Oil Pump
  
  171
  - Oil Force Pump Disassembly
    171
  - Oil Force Pump Assembly
    171
- Oil Pump Shaft
  
  172
  - Oil Pump Shaft Disassembly
    172
  - Oil Pump Shaft Assembly
    172
- Replacing Gearbox Control Shaft Radial Sealing Ring
  
  173
  - Removing Oil Seal from Gearbox Shaft
    173
  - Fitting Gearbox Shaft Oil Seal
    173
- Replacing Output Shaft Oil Seal
  
  174
- Disassembling/Assembling Starter Motor
  
  175
  - Disassembling Starter Motor
    175
  - Assembling Starter Motor
    175
- Starter Drive Gear Replacement
  
  176
- Starter Motor Drive Gear
  
  179
- Crankshaft, Countershaft, and Relevant Bearings
  
  180
- Gearbox Unit - Disassembly / Assembly
  
  191
- Crankcase Left Half Assembly
  
  207
- Stop Lever Replacement
  
  208
  - Gear Selector Lock Disassembly
    208
  - Gear Selector Lock Assembly
    208
Front Suspension

212
Table of Contents

258
- Lubrication Points (Grease)
  259
- Rear Shock Absorber
  259
- Rear Suspension
  259
- Rear Shock Absorber Removal
  261
- Disassembling and Servicing the Swinging Arm
  262
- Linkage Disassembly
  264
- Chain Roller, Chain Guide, Chain Slider
  265
- Chain Sprocket Removal
  265
Brakes

268
- Braking System
  269
- Brake Disc
  271
- Checking Brake Pads for Wear / Replacing the Pads (TC-TE-TXC)
  272
- Bleeding the Front Braking System (TC-TE-TXC)
  274
- Bleeding the Front Braking System (SMS)
  275
- Bleeding the Rear Braking System
  276
- Changing the Fluid
  277
Electrical System

282
- Engine Wiring Diagram (TC)
  284
- Engine Wiring Diagram (TE-TXC-SMR)
  286
- Adapter (TXC)
  288
- Electrical Components Location (TC)
  290
- Electrical Components Location (te - SMR)
  293
- Electrical Components Location (TXC)
  298
- Generator No-Load Performance
  302
- Generator Stator Windings Resistance (1) Inspection
  302
- MAX 13A at 14V
  302
- Condenser Inspection
  303
- Ignition System (TC)
  304
- Ignition System (te - TXC - SMR)
  306
- Charging System
  308
- Charging System Wiring Diagram
  308
- Charging System Inspections
  309
- Current Loss at the Battery
  309
- Electrical Starting System
  309
- Voltage Regulator
  309
- Voltage Regulator/Rectifier Inspection
  309
- Voltage Regulator/Rectifier Wiring Diagram
  309
- Solenoid Starter Inspection
  311
- Solenoid Starter Wiring Diagram
  311
- Starter Motor Inspection
  311
- Starting System Inspection
  311
- Coil Windings Resistance Inspection
  312
- Electronic Control Unit (ECU)
  312
- Battery
  313
- Battery Charger
  313
- Spark Plug
  313
- Headlamp Adjustment
  314
- Headlamp Bulb Replacement (te - SMR)
  314
- Headlamp, Tail Light (te - Smr)
  314
- Tail Light Replacement (te - SMR)
  317
- Turning Indicator Bulb Replacement (te - SMR)
  317
- Handlebar Switches
  318
- Left-Hand Switch (TC)
  318
- Number Plate Bulb Replacement (te - SMR)
  318
- Left-Hand Switch (te - SMR)
  319
- Right-Hand Switch (te - TXC - SMR)
  320
- Right-Hand Switch (TC)
  321
- Fuses
  322
- Semiconductor Parts
  322
- Relay Test
  323
- Digital Dashboard, Warning Lights (Te)
  325
- Speed
  325
- Dashboard Replacement (te - SMR)
  327
- Charging System
  328
- Electronic Ignition System
  328
- Starting System
  328
- Troubleshooting
  328
- Connector Position (te - SMR)
  329
- Connector Position (TC)
  333
- Connector Position (TXC)
  335
- Important
  338
Hydraulically Controlled Clutch

346
- Hydraulic Clutch System
  347
- Draining Clutch Fluid
  348
- Clutch Master Cylinder Servicing
  349
- Bleeding the Clutch System
  350
Chassis and Wheels

364
- Chassis
  365
- Lubrication Points (Lubricant)
  366
- Front Wheel (TC - te - TXC)
  367
- Front Wheel (SMR)
  368
- Removing the Front Wheel
  369
- Reassembling the Front Wheel
  370
- Rear Wheel (TC - te - TXC)
  373
- Rear Wheel (SMR)
  374
- Removing the Rear Wheel
  375
- Axle Runout over 100 MM
  376
- Wheel Axle Warpage
  376
- Wheel Servicing
  376
- Wheel Rim Warpage
  377
- Wheel Spokes
  377
- Rear Chain Sprocket, Secondary Drive Sprocket and Chain
  378
- Tightening Torque Figures
  378
- Checking Pinion and Sprockets for Wear
  379

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Husqvarna TE511 Off-Road Motorcycle Manuals

Husqvarna TE511 Workshop Manual (385 pages)

Table of Contents

Table of Contents

Table of Contents

Settings and Adjustments

Table of Contents

Table of Contents

Oil Filter Cover on Crankcase

Oil Filters Replacement

Spark Plug Recess Ignition Coil

Spark Plug Recess

Spark Plug

Oil Pressure Adjustment Valve Replacement

Cylinder Head Cover

Engine Positioning at Ignition TDC

Camshaft Disassembly

Camshaft Assembly

Engine Left Crankcase

Alternator Replacement

Crankcase Left Cover Replacement

Crankshaft Sensor Replacement

Freewheel Gear Replacement

Clutch Disassembly and Reassembly or Replacement

Replacing Clutch Disengagement Bearing

Engine Right Crankcase

Clutch Thrust Washer

Clutch Housing Axial Bearing

Coolant Pump Disassembly and Assembly

Coolant Pump Inside Crankcase Oil Seal Replacement

(Crankcase Cover Removed)

Coolant Pump Drive Replacement (Crankcase Cover Removed)

Chain Front Sprocket

Chain Tensioner Disassembly and Reassembly or Replacement

Cylinder Head Disassembly and Reassembly/Head Gasket Replacement

Cylinder Head Replacement (Cylinder Head Removed)

Chain Slider

Cylinders Disassembly and Reassembly or Replacement

Timing Chain Disassembly and Reassembly or Replacement

Replacing Oil Pump Gears (Crankcase Cover Removed)

Oil Intake Pump Replacement (Crankcase Cover Removed)

Removing and Assembling or Replacing Pressure Oil Pump

Oil Pump Shaft

Replacing Gearbox Control Shaft Radial Sealing Ring

Replacing Output Shaft Oil Seal

Disassembling/Assembling Starter Motor

Starter Drive Gear Replacement

Starter Motor Drive Gear

Crankshaft, Countershaft, and Relevant Bearings

Gearbox Unit - Disassembly / Assembly

Crankcase Left Half Assembly

Stop Lever Replacement

Front Suspension

Table of Contents

Brakes

Electrical System

Hydraulically Controlled Clutch

Chassis and Wheels

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