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SMR-510
Husqvarna SMR-510 User Manual
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W
orkshop Manual
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Table of Contents
Table of Contents
5
Workshop Manual
3
Important Notices
7
General
11
General
12
Cooling
13
Engine
13
Fuel Feeding
13
Ignition
13
Lubrication
13
Timing System
13
Transmission
14
Brakes
16
Frame
16
Suspensions
16
Tires
16
Wheels
16
Weights
18
Capacities
19
Maintenance
21
Troubles and Remedies
29
Settings and Adjustments
35
Settings and Adjustments
36
Adjustment of Starter Decompression Device
41
Throttle Cable Adjustment
42
Carburettor Adjustment (TC, TXC)
43
Idle Adjustment (TC, TXC, SMR 450-R)
43
Idle Adjustment (TE, SMR)
43
Clutch Discs Replacement (TC-TE-TXC-SMR)
44
Adjustment of the Control Lever and Check of the Clutch Fluid Level
45
Adjustment of Front Brake Control Lever and Fluid Level Control (TE-TC- TXC-SMR)
46
Rear Brake Pedal Position Adjustment
47
Checking the Rear Brake Fluid Level
48
Rear Brake Idle Stroke Adjustment
48
Checking the Engine Oil Level
49
Engine Oil Replacement and Bag Filters-Cartridge Filter Cleaning or Replacement
50
Coolant Level Check
51
Replacement of Coolant
51
Air Filter Check (TC-TXC)
52
Air Filter Check (TE-SMR)
53
Secondary Transmission Chain Adjustment
55
Adjusting the Suspensions According to Particular Track Conditions
57
Adjusting the Shock Absorber
58
Adjusting the Shock Absorber Spring Preload
59
Shock Absorber Hydraulic Brake Adjustment
60
Shock Absorber Springs
60
Adjusting the Front Fork
61
Front Fork Springs
63
Lock Adjustment
65
Steering Bearings Play Adjustment
65
Handlebar Position and Height Change (TE, TC, TXC, SMR)
66
Checking the Fuel Hose
67
Replacing the Muffler Deadening Material (TC-TE-TXC)
68
Replacing the Muffler Deadening Material (SMR)
69
Checking the Exhaust System
70
General Operations
71
General Operations
72
Foreword
73
Removal of Engine from Motorcycle
74
Removal of Saddle and Battery
85
Removal of Side Panels
86
Removal of Rear Frame with Fender (TE- SMR: with Tail Light) and Air Filter Box Assy
87
Removal of Exhaust System
90
Removal of Fuel Tank, Conveyors and Spoiler
93
Removal of Cooling Fan (TE-SMR), Radiators and Coolant Expansion Tank (TE-SMR)
95
Removal of Electronic Power Unit C.D.I., Electronic Coil, Voltage Regulator and Clutch Hose
96
Removal of Secondary Drive Chain
96
Engine Disassembly
97
Engine Disassembly
98
Camshaft Disassembly
100
Cylinder Head Cover Disassembly
100
Water Pump Body Disassembly
102
Cylinder Head Disassembly
103
Valve Disassembly
104
Cylinder Disassembly
106
Piston Disassembly
106
Flywheel Disassembly
107
Kick Start Pedal Disassembly (TC-TE-TXC)
108
Clutch Disassembly (TC, TE, TXC; SMR 450-510)
109
Transmission Cover Disassembly
109
Kick Start Components Disassembly (TC-TE-TXC)
111
Electric Starting System Disassembly (TE, TXC; SMR 450-510)
112
Oil Pump Disassembly
113
Gear Control Pedal and Gear Shifter Disassembly
114
Primary Transmission Driving Gear Disassembly
116
Crankcase Disassembly
117
Gearbox Disassembly
118
Crankshaft and Counter Balancing Shaft Disassembly (SMR 450-510)
120
Engine Overhauling
123
Assemblies
124
Cleaning of Components
124
Cylinder Head
124
Recutting the Valve Seats
125
Replacement of Valve Guides
127
Valve Guides
127
Valve
128
Valve Spring
128
Installation of Valves
129
Inspection of Rocker Arm
130
Starter Decompressor
130
Camshaft
131
Camchain Tensioner
132
Camshaft Chain and Gearing
132
Cylinder
133
Piston
133
Cylinder-Piston Fitting
134
Gudgeon Pin
135
Piston Rings
136
Piston Rings/Cylinder Clearance
136
Piston Ring/Piston Rings Groove Clearance
137
Connecting Rod Big End Side Clearance
138
Crankshaft
138
Connecting Rod Small End Bush Replacement
139
Clutch Housing-Friction Disc Clearance
140
Clutch Spring
140
Clutch Unit
140
Gear Selector Fork and Gearing
142
Oil Pump
142
Carburettor Overhauling (TC-TXC)
143
Selector Drum
143
Keihin" Carburettor Adjustment (TC-TXC)
144
Carburettor Checking
145
Engine Reassembly
149
Engine Reassembly
150
General Directions
151
Instructions for Assembly and Lubrication
152
Reassembly of Counter Balancing Shaft Driving Gear (SMR 450-510)
164
Reassembly of Transmission (TE-TXC-SMR)
165
Reassembly of Crankcase
168
Reassembly of Gearshift Mechanism, Electric Starting System and Oil Pump
172
Reassembly of Kick Start Components (TE-TC-TXC)
174
Reassembly of Clutch (TE-TXC-TC; SMR 450-510)
175
Reassembly of Timing System Drive Gear and Chain
177
Reassembly of Flywheel
178
Reassembly of Transmission Cover
179
Reassembly of Cylinder Head Cover, Spark Plug, Lubrication Hose
187
Reassembly of Gear Shift Position Sensor
187
Reassembly of Flywhel Cover
188
Reassembly of the Engine Oil Filters and Drain Plug
189
Engine and Motorcycle Reassembly
190
Cylinder Head Gasket Selection Chart
192
Table of Contents
194
Removing the Front Fork
196
Front Suspension
198
Front Suspension (te 310 EU-SMR)
198
Instructions for Use of Ø50USD Fork (te 310 EU-SMR)
199
Components of the Fork
200
General Rules for a Proper Overhauling
201
Instructions for Clamping in the Vice
201
Problems - Possible Causes - Solutions
202
General Maintenance Operations
202
Cleaning the Dust Seal
203
Bleeding the Air
203
Draining the Oil
204
Braking down the Pumping Element and the Bottom Valve
205
Braking down the Fork Leg - Slider and Removing the Oil Seals
207
Overhauling and Modifying the Cartridge and Bottom Valve Setting
208
Cartridge Overhauling (Rebound Braking)
208
Bottom Valve Overhauling (Compression Braking)
209
Re- Assembling the Fork Leg - Slider and Oil Seals
210
Re- Assembling the Pumping Element Unit and the Bottom Valve
212
Filling with Oil
215
Fitting the FORK Back on Themotorcycle
216
Adjustments
217
Rebound Adjustment
217
Compression Adjustment
217
Front Suspension (TC 450 - TXC 450-510)
218
(Models TC 450 - TXC 450-510)
219
Front Suspension (te 310 USA/AUS- te 450-510)
230
(Models te 310 USA/AUS- te 450-510)
230
Rear Suspension
241
Rear Suspension
242
Checking the Shock Absorber
245
Disassembly, Overhauling and Reassembly of the Rear Shock Absorber
245
Removing the Reservoir Plug and the Valve
246
Checks on the Piston Unit
248
Replacing the Gasket
248
Checking the Adjustment
249
Reservoir Replacement
250
Disassembling the Air/Oil Diaphragm of the Reservoir
251
Reassembling the Shock Absorber
251
Shock Absorber Damping Adjustment
254
Overhauling the Rear Swing Arm Axle
256
Overhauling the Rocking Lever and the Rear Suspension Tie Rod
256
Chain Tension Rollers, Chain Driving Roller, Chain Guide, Chain Runner
257
Brakes
259
Brakes
271
Cable Colour Coding (TE, SMR)
272
Cable Colour Coding (TC 450, TXC 450-510)
273
Electrical Components Location (Te-Smr)
274
Electrical Components Location (Tc-Txc)
276
Charging System (Te-Smr)
278
Battery Current Leakage
280
Charging System Checks
280
Generator Stator Coil Resistance Check
280
Regulated Voltage
280
Electric Starting System (Te-Smr)
284
Electric Starting System (Txc)
284
Starter Motor Check
285
Starter Motor Disassembly
285
Starter System Checks
285
Electric Start Remote Control Switch Check (TE-SMR-TXC)
286
Starter Motor Maintenance
286
Starter Motor Test Diagram
286
Electronic Ignition System (Tc-Txc)
287
Electronic Ignition System (Te-Smr)
288
Electronic Power Unit Wiring Diagram (Ecu) (Te-Smr)
292
Voltage Regulator (TE-SMR-TXC)
293
Voltage Regulator-Rectifier Wiring Diagram
293
Spark Plug
294
Gear Shift Position Sensor Check (GPS)
295
Battery Recharge
297
Headlamp Adjustment
298
Headlamp, Tail Lamp (Te-Smr)
298
Rear Tail Light Bulb Replacement
299
Replacing the Licence Plate Light Lamp
300
Handlebar Commutators
301
Connectors
303
Couplings
303
Notes
303
Battery
304
Fuses
304
Semiconductors Parts
304
Digital Instrument, Warning Lights (Te-Smr)
305
Instrument Replacement
308
Locating Operating Troubles
308
Wire Harness TC-TXC
309
Wire Harness TE-SMR
309
Cable Runway and Assembling Instructions for the 'Te/Smr' Electric Parts
310
Important Recommendation
323
Engine Cooling System
325
Hydraulic Control Clutch
369
Optional Parts List
375
Fuel Injection System
379
Fuel Injection System
380
Operating Instructions for the "DIAGNOSIS SOFTWARE KIT" on the Fuel Injection
381
Fuel Pump Check
383
Relay Check
384
Lubrication System
385
Specific Tools
389
Torque Wrench Settings
391
Frame
398
Front Wheel
401
Removing the Front Wheel
402
Reassembling the Front Wheel
403
Rear Wheel
406
Wheels Overhauling
408
Wheel Spokes
409
Rims Warpage
409
Notes for USA/CDN-AUS Models
413
4
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Husqvarna SMR-510 Specifications
General
Engine Type
Single cylinder, 4-stroke
Displacement
510cc
Transmission
6-speed
Cooling System
Liquid-cooled
Ignition
Electronic
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