Husqvarna TE510 2005-2007 Service Manual

The TE510 is a genuine 501cc liquid-cooled DOHC single delivering 59.8 hp (44 kW) at 8,000 rpm and roughly 49 Nm (36 lb-ft) of torque at 6,400 rpm, built to straddle the line between serious off-road capability and street legality. Early bikes in this range ran a 40mm Mikuni carburetor before switching to a 41mm Keihin MX unit, feeding a genuine 6-speed wet multiplate transmission with chain final drive and both electric and kick starting.

The steel single-tube cradle frame with a light-alloy rear subframe gives it a genuinely stiff backbone, while minimalist bodywork keeps weight down to a featherlight 112-117kg (246-258 lbs) depending on the exact year. A 45mm Marzocchi upside-down telescopic fork with adjustable compression and rebound handles front suspension, paired with a Sachs progressive "Soft Damp" rear shock offering adjustable spring preload, compression, and rebound damping.

Seat height runs genuinely tall at 970-980mm (38.2-38.6 inches), and the slim 9.2-litre (2.4 US gallon) fuel tank is deliberately narrow enough to let riders hug the bike with their knees during aggressive standing sections. Standard equipment throughout this range included a raised front fender, a compact headlight in a small cowl, a single seat, a protective engine skid plate, and a single exhaust with the muffler mounted high on the right-hand side.

Braking uses a single disc at each wheel, with Michelin Enduro Comp III tires (90/90-21 front, 140/80-18 rear) standard across this exact 2005-2007 range. This configuration represents the earlier, carbureted chapter of the TE510's longer production run — a 2008 update brought a 15mm-forward footpeg position and revised subframe for reduced chassis flex, genuine hardware distinctions worth knowing before assuming parts interchange with later, post-2007 examples.

This factory service manual covers the procedures, torque specs, and diagrams needed to keep a 2005-2007 TE510's engine and driveline running the way it was built to.