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Husqvarna
Motorcycle
2009 TE 310
Page 357
Husqvarna 2009 TE 310 - Page 357
412 pages
Manual
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O.25
Part. N. 8000
H0368
(
09
-2008)
“KIT” ASSEMBLING INSTRUCTIONS
Loosen the nuts of the throttle cables.
Remove the throttle cables from their housings.
Loosen both screws fastening the pulley locking plate.
Remove the locking plate.
356
358
Table of Contents
Main Page
Table of Contents
5
Workshop Manual
3
Important Notices
7
General
11
Table of Contents
12
Cooling
13
Fuel Feeding
13
Ignition
13
Lubrication
13
Timing System
13
Transmission
14
Brakes
16
Frame
16
Suspensions
16
Tires
16
Wheels
16
Capacities
19
Maintenance
21
Troubles and Remedies
29
Settings and Adjustments
35
Table of Contents
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
Lubricating the Transmission Chain
56
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
62
Lock Adjustment
63
Steering Bearings Play Adjustment
63
Handlebar Position and Height Change (TE-TC-TXC-SMR)
64
Checking the Fuel Hose
65
Replacing the Muffler Deadening Material (TC-TE-TXC)
66
Replacing the Muffler Deadening Material (SMR)
67
Checking the Exhaust System
68
General Operations
69
General Operations
70
Foreword
71
Removal of Engine from Motorcycle
72
Removal of Saddle and Battery
83
Removal of Side Panels
84
(TE- SMR: with Tail Light) and Air Filter Box Assy
85
Removal of Rear Frame with Fender
85
Removal of Exhaust System
88
Removal of Fuel Tank, Conveyors and Spoiler
91
Removal of Cooling Fan (TE-SMR), Radiators and Coolant Expansion Tank (TE-SMR)
93
Removal of Electronic Power Unit C.D.I., Electronic Coil, Voltage Regulator and Clutch Hose
94
Removal of Secondary Drive Chain
94
Engine Disassembly
95
Table of Contents
96
Camshaft Disassembly
98
Cylinder Head Cover Disassembly
98
Water Pump Body Disassembly
100
Cylinder Head Disassembly
101
Valve Disassembly
102
Cylinder Disassembly
104
Piston Disassembly
104
Flywheel Disassembly
105
Kick Start Pedal Disassembly (TC-TE-TXC)
106
Transmission Cover Disassembly
107
Kick Start Components Disassembly (TC-TE-TXC)
109
Electric Starting System Disassembly (TE, TXC; SMR 450-510)
110
Oil Pump Disassembly
111
Gear Control Pedal and Gear Shifter Disassembly
112
Primary Transmission Driving Gear Disassembly
114
Crankcase Disassembly
115
Gearbox Disassembly
116
Crankshaft and Counter Balancing Shaft Disassembly (SMR 450-510)
118
Engine Overhauling
121
Assemblies
122
Cleaning of Components
122
Cylinder Head
122
Recutting the Valve Seats
123
Replacement of Valve Guides
125
Valve Guides
125
Valve
126
Valve Spring
126
Installation of Valves
127
Inspection of Rocker Arm
128
Starter Decompressor
128
Camshaft
129
Camchain Tensioner
130
Camshaft Chain and Gearing
130
Cylinder
131
Piston
131
Cylinder-Piston Fitting
132
Gudgeon Pin
133
Piston Rings
134
Piston Rings/Cylinder Clearance
134
Piston Ring/Piston Rings Groove Clearance
135
Connecting Rod Big End Side Clearance
136
Crankshaft
136
Connecting Rod Small End Bush Replacement
137
Clutch Housing-Friction Disc Clearance
138
Clutch Spring
138
Clutch Unit
138
Gear Selector Fork and Gearing
140
Oil Pump
140
Selector Drum
141
Engine Reassembly
147
Engine Reassembly
148
General Directions
149
Instructions for Assembly and Lubrication
150
Reassembly of Counter Balancing Shaft Driving Gear (SMR 450-510)
162
Reassembly of Transmission (TE-TXC-SMR)
163
Reassembly of Crankcase
166
Reassembly of Gearshift Mechanism, Electric Starting System and Oil Pump
170
Reassembly of Kick Start Components (TE-TC-TXC)
172
Reassembly of Clutch (TE-TXC-TC; SMR 450-510)
173
Reassembly of Timing System Drive Gear and Chain
175
Reassembly of Flywheel
176
Reassembly of Transmission Cover
177
Reassembly of Cylinder Head Cover, Spark Plug, Lubrication Hose
185
Reassembly of Gear Shift Position Sensor
185
Reassembly of Flywhel Cover
186
Reassembly of the Engine Oil Filters and Drain Plug
187
Engine and Motorcycle Reassembly
188
Cylinder Head Gasket Selection Chart
190
Front Suspension
191
Table of Contents
192
Front Suspension (TE-SMR)
194
Components of the Fork
196
General Rules for a Proper Overhauling
197
Instructions for Clamping in the Vice
197
General Maintenance Operations
198
Problems - Possible Causes - Solutions
198
Bleeding the Air
199
Draining the Oil
200
Braking down the Pumping Element and the Bottom Valve
201
Braking down the Fork Leg - Slider and Removing the Oil Seals
203
Cartridge Overhauling (Rebound Braking)
204
Overhauling and Modifying the Cartridge and Bottom Valve Setting
204
Bottom Valve Overhauling (Compression Braking)
205
Re- Assembling the Fork Leg - Slider and Oil Seals
206
Re- Assembling the Pumping Element Unit and the Bottom Valve
208
Filling with Oil
211
Fitting the Fork Back on Themotorcycle
212
Adjustments
213
Compression Adjustment
213
Rebound Adjustment
213
Removing the Front Fork
214
Front Suspension (TC-TXC)
216
Components of the Fork
218
General Rules for a Proper Overhauling
219
Instructions for Clamping in the Vice
219
Cleaning the Fork Legs
221
Bleeding the Air
222
Draining the Oil
223
Valve Setting
224
Checking the Rebound Adjusting Unit
226
Compression Valve Overhauling
227
Re-Assembling the Cartridge Unit
228
Breaking down the Fork Leg - Slider and Removing the Sealing Rings
231
Re-Assembling the Fork Leg - Slider and Sealing Rings
232
Re-Assembling the Cartridge
233
Filling with Oil
234
Fitting the Fork Back on Themotorcycle
234
Adjustments
235
Initial Suspension Bottoming Adjustment
235
Rebound Adjustment
236
Spring Preload Adjustment
236
Compression Adjustment
237
Removing the Front Fork
238
Rear Suspension
241
Rear Suspension
242
Checking the Shock Absorber
245
Disassembly, Overhauling and Reassembly of the Rear Shock Absorber
245
Overhaul the Spring
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
Disassembly and Overhauling the Rear Swing Arm
255
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)
273
Cable Colour Coding (TXC 250)
274
Cable Colour Coding (TC, TXC 450-510)
275
Electrical Components Location (Te-Smr)
276
Electrical Components Location (Tc-Txc)
278
Charging System (Tc-Txc)
280
Charging System (Te-Smr)
280
Battery Current Leakage
282
Charging System Checks
282
Generator Stator Coil Resistance Check
282
Regulated Voltage
282
Voltage Regulator-Rectifier Check (TE-SMR-TXC)
285
Electric Starting System (Te-Smr)
286
Electric Starting System (Txc)
286
Starter Motor Check
287
Starter Motor Disassembly
287
Starter System Checks
287
Electric Start Remote Control Switch Check (TE-SMR-TXC)
288
Starter Motor Maintenance
288
Starter Motor Test Diagram
288
Electronic Ignition System (Tc-Txc)
289
Electronic Ignition System (Te-Smr)
290
Electronic Power Unit (ECU)
290
Electronic Power Unit Wiring Diagram (Ecu) (Te-Smr)
294
Voltage Regulator (TE-SMR-TXC)
295
Voltage Regulator-Rectifier Wiring Diagram
295
Spark Plug
296
Gear Shift Position Sensor Check (GPS)
297
Battery Recharge
299
Headlamp Adjustment
300
Headlamp, Tail Lamp (Te-Smr)
300
Rear Tail Light Bulb Replacement
301
Replacing the Licence Plate Light Lamp
302
Handlebar Commutators
303
Connectors
305
Couplings
305
Notes
305
Battery
306
Fuses
306
Semiconductors Parts
306
Digital Instrument, Warning Lights (Te-Smr)
307
Instrument Replacement
310
Locating Operating Troubles
310
Wire Harness TC-TXC
311
Wire Harness TE-SMR
311
Cable Runway and Assembling Instructions for the 'Te/Smr' Electric Parts
312
Important Recommendation
325
Engine Cooling System
327
Table of Contents
333
Assembling Instructions for Full Power Version on TE-SMR Models
334
Blinkers Kit (SMR)
334
Blinkers Kit (TE)
334
Central Engine Guard
334
Hand Guards Kit (TE)
334
Hook Kit for Race Starting Phase (TC-TXC)
334
Kick Starter Kit (SMR)
334
Passenger Footrest Kit (SMR)
334
Hydraulic Control Clutch
369
Hydraulic Clutch System
371
Discharge of Hydraulic System Fluid
372
Overhaul of the Control Pump for Clutch Release
372
Bleeding of the Hydraulic System
373
Optional Parts List
375
Fuel Injection System
379
Lubrication System
385
Specific Tools
389
Torque Wrench Settings
391
Frame
398
Front Wheel
401
Rear Wheel
406
Wheels Overhauling
408
Wheel Spokes
409
Rims Warpage
409
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