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Husqvarna SMR 511 2011 I.E. User Manual

Husqvarna SMR 511 2011 I.E.
414 pages
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TC 449 2011/2012 I.E.
TE 449 - 511 2011/2012 I.E.
TXC 449 - 511 2011/2012 I.E.
SMR 449 2011 I.E.
SMR 511 2011/2012 I.E.
Workshop Manual Ed. 03-2012
Rev 02

Table of Contents

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Husqvarna SMR 511 2011 I.E. Specifications

General IconGeneral
Compression Ratio12.5:1
Fuel SystemElectronic Fuel Injection
CoolingLiquid-cooled
StarterElectric
Transmission6-speed
Final DriveChain
Rear SuspensionMonoshock
Front Tire120/70-17
Rear Tire150/60-17
Engine TypeSingle cylinder, four-stroke
Front SuspensionUSD forks, 48 mm
Front BrakeBrembo 320 mm disc, 4-piston caliper
Rear BrakeSingle disc, 1-piston caliper
Dry Weight118 kg

Summary

IMPORTANT NOTICES

GENERAL INFORMATION

Engine

Details on the engine specifications including bore, stroke, displacement, and compression ratio.

Ignition system

Information on the ignition system, including spark plug type and electrode gap.

Suspension

Details on the front and rear suspension systems, including fork types and travel.

Brakes

Information on the braking system, including disc types, caliper details, and brake pad surface area.

Electrical components location

Location of electrical system components for TC, TXC, TE-SMR models.

MAINTENANCE

TABLES OF PERIODIC MAINTENANCE MY11

Periodic maintenance schedule for MY11 models, covering engine and chassis components.

SCHEDULED MAINTENANCE CHART (TE -TXC 449 /511 MY11)

Scheduled maintenance for competition motorcycles (TE-TXC 449/511 MY11) with full power engine.

TABLES OF PERIODIC MAINTENANCE MY12

Periodic maintenance schedule for MY12 models, covering engine and chassis components.

SCHEDULED MAINTENANCE CHART (TE -TXC 449 /511 MY12)

Scheduled maintenance for competition motorcycles (TE-TXC 449/511 MY12) with full power engine.

TROUBLESHOOTING

ENGINE

Troubleshooting guide for engine-related issues like starting, stalling, and noise.

CHASSIS

Troubleshooting guide for chassis-related issues like handlebar, damping, and rear suspension.

ELECTRICAL SYSTEM

Troubleshooting guide for electrical system issues like spark plug and generator problems.

SETTINGS AND ADJUSTMENTS

Saddle removal

Procedure for removing the motorcycle saddle.

Throttle cable adjustment

Instructions for adjusting the throttle control cable for proper operation.

Hydraulic clutch lever adjustment

Procedure for adjusting the hydraulic clutch lever and checking fluid level.

Front brake lever adjustment

Procedure for adjusting the front brake lever and checking fluid level.

Engine oil replacement

Steps for replacing engine oil and cleaning/replacing mesh filters.

Suspension setup

Guidelines for adjusting suspension based on track conditions.

GENERAL PROCEDURES

Saddle removal

Procedure for removing the motorcycle saddle.

Tank removal

Steps for safely removing the fuel tank from the motorcycle.

Throttle body removal

Instructions for removing the throttle body assembly from the engine.

Exhaust system removal

Procedure for removing the exhaust system components.

ADJUSTMENTS - ENGINE

Valve clearance check

Procedure for checking valve clearance using a feeler gauge.

Camshaft disassembly

Steps for disassembling the camshaft, including timing chain removal.

Camshaft assembly

Procedure for assembling the camshaft, ensuring correct timing chain tension.

Bearing mount securing

Instructions for securing the bearing mounts with specified torques.

ENGINE DISASSEMBLY/REASSEMBLY

Oil filter replacement

Procedure for replacing the oil filter and cleaning mesh filters.

Cylinder head disassembly and reassembly/head gasket replacement

Detailed steps for cylinder head disassembly, reassembly, and gasket replacement.

Piston disassembly

Procedure for disassembling the piston, including rings and pin.

Clutch disassembly and reassembly or replacement

Steps for disassembling, reassembling, or replacing the clutch system.

Gearbox unit - disassembly / assembly

Procedures for disassembling and assembling the gearbox unit.

FRONT SUSPENSION

Front fork removal

Procedure for removing the front fork legs from the motorcycle.

Front suspension (TC - TXC)

Overview of the front suspension system for TC and TXC models.

Front fork disassembly (TC - TXC)

Detailed steps for disassembling the front fork for TC and TXC models.

Front suspension (TE)

Overview of the front suspension system for TE models.

Front fork disassembly (TE)

Detailed steps for disassembling the front fork for TE models.

General rules for a proper overhauling

Essential guidelines and precautions for fork maintenance and overhauling.

REAR SUSPENSION

Rear shock absorber

Information and specifications for the rear shock absorber.

Lubrication points (grease)

Locations requiring lubrication with grease for the rear suspension components.

Rear shock absorber removal

Procedure for removing the rear shock absorber from the motorcycle.

Disassembling and servicing the swinging arm

Steps for disassembling and servicing the swinging arm assembly.

Chain sprocket removal

Procedure for removing the chain sprocket from the rear wheel hub.

BRAKES

Braking system

Overview of the motorcycle's braking system, including circuits and components.

Brake disc

Information on brake disc specifications, including diameter and wear limits.

Checking brake pads for wear / replacing the pads

Procedure for checking and replacing brake pads for various models.

Bleeding the front braking system

Procedure for bleeding the front brake system to remove air.

Bleeding the rear braking system

Procedure for bleeding the rear brake system to remove air.

Changing the fluid

Instructions for changing the brake fluid, including precautions.

ELECTRICAL SYSTEM

Engine wiring diagram

Wiring diagrams for engine systems across different model years.

Electrical components location

Identification and location of electrical components for TC, TE-SMR, and TXC models.

Ignition system

Details on the ignition system, including components and operation.

Charging system

Information on the motorcycle's charging system and its components.

Starter motor inspection

Procedure for inspecting and testing the starter motor.

Electronic control unit (ECU)

Description and function of the Electronic Control Unit (ECU).

Headlamp, tail light (TE - SMR)

Information on headlamp and tail light systems for TE and SMR models.

CHASSIS AND WHEELS

Chassis

Description of the motorcycle's frame construction and material.

Front wheel

Overview of the front wheel components for TC, TE, TXC, and SMR models.

Removing the front wheel

Procedure for safely removing the front wheel from the motorcycle.

Rear wheel

Overview of the rear wheel components for TC, TE, TXC, and SMR models.

Removing the rear wheel

Procedure for safely removing the rear wheel from the motorcycle.

Wheel servicing

Maintenance procedures for wheels, including bearing and spoke checks.

Rear chain sprocket, secondary drive sprocket and chain

Information on checking and replacing the rear sprocket and chain.

NOTES FOR USA/CDN

Spark arrester (TE - TXC - SMR)

Maintenance and cleanout instructions for the spark arrester.

Assembly

Procedure for assembling the spark arrester unit after cleaning.

KIT Canister (TE - TXC - SMR)

Information and diagram for the Canister Kit installation.

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