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TE511
Page 121 (Engine Positioning at Ignition TDC)
Husqvarna TE511 - Engine Positioning at Ignition TDC; Securing Crankshaft at TDC
385 pages
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F1.15
H01727
H01712
H01713
8000H5009
ENGINE DISASSEMBL
Y/REASSEMBL
Y
1
st
edition (08-2010) _Rev
. 1
1-2010
Engine positioning at ignition TDC
•
T
urn engine until reaching
TDC.
•
Reference marks (arrows) parallel with cylinder head.
Securing crankshaft at TDC
•
Remove screw (1) with sealing ring.
•
Lock crankshaft at
TDC using special tool (8000H5009).
120
122
Table of Contents
Main Page
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
Saddle Removal
34
Side Panel Removal
34
Engine Guard Removal
36
Scoop Removal
36
Idle Adjustment (TC)
38
Idle Adjustment (te - TXC - SMR)
38
Front Brake Lever Adjustment and Fluid Level Check (TC - te - TXC)
39
Hydraulic Clutch Lever Adjustment and Fluid Level Check
39
Front Brake Lever Adjustment and Fluid Level Check (SMR)
40
Rear Brake Pedal Free Play Adjustment
41
Rear Brake Pedal Position Adjustment
41
Engine Oil Level Check
42
Rear Brake Fluid Level Check
42
Engine Oil Replacement and Mesh Filters-Filter Cartridge Cleaning or Replacement
43
Coolant Level Check
44
Coolant Replacement
45
Air Filter Check
46
Air Filter Cleaning
46
Chain Adjustment
47
Chain Lubrication
48
Disassembling and Cleaning
48
Lubricating Chain with O-Rings (te - TXC - SMR)
48
Lubricating Chain Without O-Rings (TC)
48
Washing Chain Without O-Rings (TC)
48
Suspension Setup According to Track Condition
49
Shock Absorber Adjustment
50
Shock Absorber Spring Preload Adjustment (TE-TC-TXC)
51
Shock Absorber Spring Preload Adjustment (SMR)
52
Shock Absorber Damping Adjustment
53
KAYABA Fork Adjustment (TC - te - TXC)
54
Fork Oil Level (SMR)
55
Marzocchi Fork Adjustment (SMR)
55
Steering Angle Adjustment
56
Steering Bearing Clearance Adjustment
56
Fuel Supply Hose Inspection
57
Exhaust System Check
58
General Procedures
59
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
Clutch Disengagement Bearing Disassembly
138
Clutch Disengagement Bearing Assembly
138
Checking the Clutch Pack Thickness
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 Control Rear Oil Seal Disassembly
145
Coolant Pump Control Shaft Check
145
Coolant Pump Control Rear Oil Seal Assembly
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 Pump Idler Gear Disassembly
167
Oil Pump Control Gear Disassembly
167
Disassembly of Crankshaft Gear Pointing Oil Pump Idler Gear
168
Assembly of Crankshaft Gear with Oil Pump Idler Gear
168
Oil Pump Control Gear Assembly
168
Oil Pump Idler Gear Assembly
169
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
Gearbox Output Shaft Left Oil Seal Disassembly
174
Gearbox Output Shaft Right Oil Seal Disassembly
174
Gearbox Output Shaft Right Oil Seal Assembly
174
Gearbox Output Shaft Left Oil Seal Assembly
174
Disassembling/Assembling Starter Motor
175
Disassembling Starter Motor
175
Assembling Starter Motor
175
Starter Drive Gear Replacement
176
Gear Disassembly with Starter Motor Protected against Overload
176
Starter Motor Drive Gear Disassembly
176
Freewheel Gear Disassembly
177
Freewheel Gear Assembly
177
Starter Motor Drive Gear Fitting
178
Gear Assembly with Starter Motor Protected against Overload
178
Starter Motor Drive Gear
179
Starter Motor Drive Gear Disengagement
179
Starter Motor Drive Gear Fitting
179
Crankshaft Axial Clearance Check
180
Crankshaft, Countershaft, and Relevant Bearings
180
Crankcase Left Half Disassembly
180
Control Gear Disassembly
181
Removing Crankshaft and Countershaft
181
Crankshaft Right Bearing Bushing Disassembly
182
Crankshaft for Countershaft Gear Disassembly
182
Crankshaft Left Bearing Bushing Disassembly
183
Crankshaft Axial Clearance Adjustment
183
Crankshaft Wear Check
184
Connecting Rod Wear Check
184
Crankshaft Replacement
184
Crankshaft Axial Clearance Adjustment, Left Side
185
Crankshaft Axial Clearance Adjustment, Right Side
185
Crankshaft Left Bearing Disassembly
186
Crankshaft Right Bearing Disassembly
186
Crankshaft Left Bearing Assembly
186
Crankshaft Right Bearing Assembly
187
Countershaft Right Bearing Disassembly
187
Countershaft Left Bearing Disassembly
187
Countershaft Left Bearing Assembly
188
Countershaft Right Bearing Assembly
188
Crankshaft Left Bearing Bushing Assembly
189
Oil Pump Gear Assembly Onto Crankshaft
189
Control Gear Assembly
190
Fitting Crankshaft and Countershaft
190
Crankshaft Right Bearing Bushing Assembly
190
Gearbox Unit - Disassembly / Assembly
191
Crankcase Left Half Disassembly
191
Gearbox Disassembly
191
Gearbox Check
191
Disassembly/Reassembly of the Gearbox (5 Speed) (TC)
192
Disassembly/Reassembly of the Gearbox (6 Speed) (TE-TXC-SMS)
194
Gearbox Oil Pipe Disassembly
196
Gearbox Oil Pipe Assembly
196
Gearbox Input Shaft Right Bearing Disassembly
196
Gearbox Input Shaft Left Bearing Disassembly
196
Gearbox Output Shaft Right Bearing Disassembly
197
Gearbox Output Shaft Left Bearing Disassembly
197
Gearbox Shaft Right Bearing Disassembly
198
Gearbox Shaft Left Bearing Disassembly
198
Gearbox Input Shaft Idler Gear Bearing Disassembly
198
Gearbox Input Shaft Idler Gear Bearing Assembly
199
Gearbox Shaft Left Bearing Assembly
199
Gearbox Output Shaft Left Bearing Assembly
200
Gearbox Output Shaft Right Bearing Assembly
200
Gearbox Shaft Right Bearing Assembly
200
Gearbox Input Shaft Left Bearing Assembly
201
Gearbox Input Shaft Right Bearing Assembly
201
Clutch Check Inside Primary Drive Unit
201
Idler Gear Disassembly
203
Idler Gear Assembly
203
Gearbox Shaft Replacement (Crankcase Cover Removed)
204
Selector Cylinder Replacement
205
Gear Selector Fork Replacement
206
Gear Selector Forks Assembly
206
Gearbox Assembly
207
Crankcase Left Half Assembly
207
Stop Lever Replacement
208
Gear Selector Lock Disassembly
208
Gear Selector Lock Assembly
208
Front Suspension
212
Front Fork Removal
213
Service Instructions for Ø48USD Kayaba Fork - TC-TXC
215
Front Suspension (TC - TXC)
216
Front Fork Disassembly (TC - TXC)
217
Front Suspension (TE)
227
Front Fork Disassembly (TE)
228
Front Suspension (SMR)
237
Instructions for Use of Ø50Usd Fork (Smr)
238
Components of the Fork
239
General Rules for a Proper Overhauling
240
Instructions for Clamping in the Vice
241
Problems - Possible Causes - Solutions
242
Bleeding the Air
243
Cleaning the Dust Seal
243
Draining the Oil
244
Braking down the Pumping Element and the Bottom Valve
245
Braking down the Fork Leg - Slider and Removing the Oil Seals
247
Cartridge Overhauling (Rebound Braking)
248
Overhauling and Modifying the Cartridge and Bottom Valve Setting
248
Bottom Valve Overhauling (Compression Braking)
249
Re- Assembling the Fork Leg - Slider and Oil Seals
250
Re- Assembling the Pumping Element Unit and the Bottom Valve
252
Filling with Oil
255
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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