1995 Husqvarna TE 350/410/610 & TC 610 Workshop Manual (P/N 800079881)

The Husqvarna workshop manual, P/N 800079881 (first edition, December 1994), covers the 1995 TE 350, TE 410, TE 610, and TC 610. Language coverage varies: shared pages include English, Italian, French, German, and Spanish, while some specification and service pages are available only in German or German/Spanish.

• Engine repair: Engine removal, crankcase separation, cylinder-head and valve service, crankshaft overhaul, and cam-chain timing illustrations.

• Clutch and transmission: Kickstart mechanism teardown, clutch inspection and adjustment, selector-fork and drum checks, and TE transmission-shaft assembly drawings.

• Fuel and lubrication: Dell'Orto PHF/PHM carburetor overhaul, model-specific setting tables including Mikuni TM 36, oil-filter cleaning, and oil-reed inspection.

• Suspension and steering: Marzocchi Magnum fork overhaul, Showa rear-shock disassembly and reassembly, shock bleeding, and steering-head bearing adjustment.

• Brakes and cooling: Brake-pad replacement, disc inspection, front and rear brake bleeding, water-pump service, and radiator checks.

• Electrical fault finding: TE wiring diagram and wire-color key, ignition timing curve, and symptom/cause/remedy tables for engine, chassis, and electrical faults.

The internal overhaul procedures and use of dedicated pullers and measuring equipment make this manual suited to mechanics experienced in engine rebuilding.

Cylinder Head, Crankshaft and Transmission Repair

The overhaul sections describe valve-seat recutting and guide replacement, supported by seat-cutting diagrams. Reference data covers piston-to-cylinder clearances, connecting-rod radial and side clearances, crankshaft alignment, and component-specific torque tables.

Cylinder/piston matching categories and a separate cylinder-liner replacement procedure for the 410 help distinguish the relevant inspection and replacement work.

Valve spring compressor 1519792-01 and spacer 1517484-01 are identified for valve removal. The accompanying warning explains that a misaligned compressor can bend the valve stem.

Crankcase puller 1517947-01 is specified for engine separation. Crankshaft pressing, shim selection, rocker-arm bushing replacement, and needle-bearing inspection add detail beyond routine adjustment. The illustrated transmission-shaft reassembly sequence is specifically labeled for TE models.

Carburetor, Lubrication and Cooling Checks

Model-specific carburetor tables provide jetting and needle-position data, including a separate Mikuni TM 36 chart. Dell'Orto service material adds float-height and accelerator-pump output checks. The R.A.L. lubrication material links oil-reed damage with abnormal engine heat, giving another documented cause to consider during overheating diagnosis.

Water-pump procedures cover the impeller, spacer, and seals. The cooling-system section addresses restricted radiator airflow, coolant loss, and hose deterioration.

Fork, Rear Shock and Chassis Inspection

Compression and rebound oil-flow diagrams explain the Magnum fork's operation alongside cartridge service, seal replacement, and a fork fault chart. The Showa shock section covers bladder and damper-rod work, oil bleeding, nitrogen charging, and an exploded assembly view.

Frame checking dimensions, wheel-rim runout data, and axle-bend limits support chassis inspection. Before starting any major teardown, ensure proper workshop ventilation and follow the manual's precautions for engine fluids, ignition components, and pressurized suspension parts.

Ducati Energia Ignition and TE Wiring Coverage

The ignition-module section distinguishes the red cable sheaths used on the 350 from the black sheaths used on the 410/610, helping identify the correct unit before fault tracing. It also warns that poor coil grounding can damage the coil and cause ignition faults.

The TE wiring diagram has a component legend and numbered wire-color table. The TC-specific wiring pages listed in the contents are not included in this PDF. Ignition timing references and the advance curve accompany the generator, coil, and TE voltage-regulator information.

A Preview of Valve and Decompressor Settings

These valve-train settings are a small sample of the manual's adjustment data. With the engine cold, specified valve clearance is 0.10 mm at the intake and 0.15 mm at the exhaust.

The starting-decompressor section specifies 1–2 mm of lever free play at top dead center at the end of the compression stroke, covering both the kickstarter-operated and handlebar-operated cables.

Printable PDF, Text Search and Diagram Detail

Search, navigation and wiring detail: PDF text search and embedded bookmarks are not available. Small wiring numbers require zooming, and some labels remain blurred in dense connector areas.

Supplied as one printable, 218-page PDF. The total includes the cover, publication page, and section dividers.