• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

2006/2007 TE610e Workshop Mechanical Instructions

icebergstu

icebergstu

Husqvarna
AA Class
Here are my backups: SOME FILES ARE UP TO 30Mb

Chapter 1: Introducton
http://www.adrive.com/public/Nz6PHF/sm-te 610, 06- chapter M.pdf

Chapter 2: General

Engine
Timing system
Fuel feeding
Lubrication
Cooling
Ignition
Starting
Transmission
Frame
Suspensions
Brakes
Wheels
Tires
Ignition system- electric system
Weights
Overall dimensions
Capacities

http://www21.adrive.com/filemanager/downloadfile/6860172

Chapter 3: Maintenance Schedule & List of duties from Pre-Delivery onwards
http://www21.adrive.com/filemanager/downloadfile/6860179

Chapter 4: Troubles and Remedies (Troubleshooting)
http://www21.adrive.com/filemanager/downloadfile/6860169

Chapter 5: Settings and Adjustments

Adjustment of valves play ........................................
Compression check ...............................................
Carburettor adjustment. . .................................................
Idle adjustment .................................................................
Checking the engine oil level ..................................
Oil change, cleaning and changing oil filters ..........
Cleaning the bag filters ...........................................
Coolant level check .................................................
Replacement of coolant ..........................................
Air filter check and cleaning ....................................
Throttle cable adjustment .......................................
Clutch adjustment ..................................................
Adjustment of front brake control lever and fluid level control ....................................................................
Adjustment of rear control pedal .............................
Steering bearings play adjustment .........................
Front fork adjustment and oil level checking ............
Adjusting the shock absorber .................................
Secondary transmission chain adjusment .............
http://www21.adrive.com/filemanager/downloadfile/6860166

Chapter 6: General Operations:

FOREWORD ...........................................................
Removal of saddle ...................................................
Removal of side panels ...........................................
Removal of air filter box and carburetor ...................
Removal of conveyors and fuel tank ........................
Removal of exhaust system ....................................
Removal of electrical connections and spark plug cap
Removal of cooling system hoses ............................
Removal of cooling fan, radiators and coolant expansion tank
Removal of engine from the frame ...........................
Removal of rear frame with fender ..........................
http://www21.adrive.com/filemanager/downloadfile/6860168

Chapter 7: Engine Disassembly

Disassembly of gear lever ...................................... F.4
Disassembly of alternator side cover ...................... F.5
Disassembly of alternator ....................................... F.6
Disassembly of the water pump body ..................... F.8
Disassembly of cylinder head cover ....................... F.9
Disassembly of cylinder head ......................... F.11
Disassemby of valves .....................................F.13
Disassembly of cylinder ......................................... F.14
Disassembly of piston .....................................F.15
Disassembly clutch cover ....................................... F.16
Removal of the starter motor and holding flange ..... F.17
Disassembly of clutch ............................................ F.18
Disassembly if the gearbox control shaft ................ F.21
Disassembly of crankcase, cranckshaft and lay shaft .........F.25
Disassembly of the gearbox ................................... F.37
Disassembly of the oil pump .................................. F.38
Disassembly of the stator ....................................... F.39
Disassembly of the cranckshaft components ......... F.40
http://www21.adrive.com/filemanager/downloadfile/6860170

Chapter 8: Engine Overhaul

Cleaning of components ......................................... G.5
Assemblies ............................................................. G.6
Cylinder head .......................................................... G.7
Valve seat .............................................................. G.8
Replacing oversize valves ....................................... G.13
Valve guides ............................................................ G.14
Replacing the valve guide ........................................ G.15
Valve ......................................................................G.17
Valve spring ............................................................. G.18
Installation of valves ................................................ G.20
Inspection of rocker arm .......................................... G.22
Replacement of rocker arm bushing ....................... G.24
Camroller replacement ........................................... G.25
Camshaft ................................................................ G.26
Timing chain and gears .......................................... G.27
Timing chain stretcher sliding ................................. G.27
Cylinder ............................................. G.28
Piston .....................................................................G.29
Cylinder piston fitting ............................................... G.30
Piston diameter ....................................................... G.31
Gudgeon pin ............................................................ G.32
Gudgeon pin-connecting rod small end clearance ...................G.33
Piston rings ............................................................. G.34
Piston rings-cylinder clearance ............................... G.35
Piston rings thickness ............................................. G.35
Piston ring-piston rings groove clearance ............... G.36
Connecting rod big end radial clearance ................. G.37
Connecting rod big end axial clearance .................. G.37
Balance countershaft .............................................. G.38
Crankshaft ............................................................... G.39
Crankshaft run-out ................................................... G.39
Replacing the small end bush ................................ G.40
Clutch unit ............................................................... G.41
Clutch housing-friction disc clearance ..................... G.42
Clutch spring ........................................................... G.43
Gear selector fork and gearing ................................ G.44
Fork drum - fork pins coupling ................................. G.45
Oil pump ...............................................................G.46
Carburettor overhauling ........................................... G.47
Carburettor setting ................................................... G.49
Fuel draining ........................................................... G.59
Fuel filters cleaning ................................................. G.60
http://www21.adrive.com/filemanager/downloadfile/6860167

Chapter 9: Engine Reassembly

General directions
Reassembly of crankshaft
Reassembly of transmission
Reassembly of crankcase
Assembly of gear fixing click and gear box control shaft
Assembly of counterweight and layshaft gear
Reassembly of flywheel
Reassembly of stator and pick-up
Assembly of starting motor and starting intermediate gear
Reassembly of piston and cylinder
Reassembly of cylinder head
Reassembly of camshaft
Reassembly of cam-chain tensioner
Reassembly of water pump impeller
Reassembly of cylinder head cover
Reassembly of pump housing
Lay-shaft timing
Reassembly of clutch
Reassembly of oil pump and oil filter cartridge
Reassembly of alternator cover
Reassembly of rear pinion, gear shift pedal and neutral sensor
Instructions for lubrication
http://www21.adrive.com/filemanager/downloadfile/6860176

Chapter 10: Front Suspension

Front suspension ................................................... I.4
Instructions for use of Ø45USD fork ........................ I.16
General ................................................................. I.16
Spring table ............................................................ I.16
Forkworking ............................................................ I.17
General rules for a proper overhauling .................... I.18
Troubleshooting guide ............................................ I.18
Maintenance recommendations ............................. I.19
Oil change .............................................................. I.19
Oil seal change ...................................................... I.21
Air bleeding ............................................................I.23
Slider disassembly ................................................. I.23
Stanchion disassembly .......................................... I.24
Rebound setting change ........................................ I.24
Compression setting change ................................. I.24
Slider plug disassembly ......................................... I.24
Damping unit reassembly ...................................... I.25
Foot valve and stanchion reassembly ..................... I.25
Slider and stanchion reassembly ........................... I.25
Adjustment ............................................................. I.26
Removing the front fork ........................................... I.60
http://www21.adrive.com/filemanager/downloadfile/6860157

Chapter 11: Rear Suspension

Rear suspension .................................................... J.3
Removal of rear shock absorber ............................. J.3
Overhaul of rear shock absorber ............................. J.4
Overhaul the spring ................................................. J.4
Checking the shock absorber ................................. J.5
Reassembling the shock absorber ......................... J.17
Disassembly and overhauling the rear swing arm .. J.26
Overhauling the rear swing arm axle ....................... J.28
Overhauling the rocker arm and the tie rod of the rear suspension J.29
Chain tension rollers, chain guide, chain runner ..... J.31
http://www21.adrive.com/filemanager/downloadfile/6860164

Chapter 12: Brakes

Braking system .......................................................
Brake disc ..............................................................
Wear check and brake pads replacement ...............
Front braking system bleeding ...............................
Rear brakin system bleeding ................................
Fluid replacement
http://www21.adrive.com/filemanager/downloadfile/6860162

Chapter 13: Electrical System

http://www21.adrive.com/filemanager/downloadfile/6860163

Chapter 14: Engine Cooling System

Checking the cooling fluid level ............................... N.2
Cooling system .............................................. .. N.4
Engine cooling system overhauling ........................ N.6
http://www21.adrive.com/filemanager/downloadfile/6860174

Chapter 15: Lubrication Circuit

http://www21.adrive.com/filemanager/downloadfile/6860175

Chapter 16: Specific Tools

http://www21.adrive.com/filemanager/downloadfile/6860160

Chapter 17: Frame and Wheels

Frame ......................................................................
Front wheel ..............................................................
Removing the front wheel ........................................
Reassembling the front wheel ..................................
Rear wheel ..............................................................
Removing rear wheel ...............................................
Wheels overhauling .................................................
Bending the wheel pin ..............................................
Wheel spokes ..........................................................
Rims warpage ..........................................................
Rear sprocket, transmission sprocket, rear chain .....
http://www21.adrive.com/filemanager/downloadfile/6860177

Chapter 18: NOTES FOR USA/CDN- AUS MODELS

http://www21.adrive.com/filemanager/downloadfile/6860159
 
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