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

• Covers 1995 Husqvarna TE 350, TE 410, TE 610, and TC 610 competition motorcycles. Details both enduro and motocross engine configurations.
• Official OEM publication Part N. 800079881 (issued December 1994). Contains technical specifications and mechanical parameters for the original factory build.
• Features 64 highly detailed engine disassembly diagrams. Also includes comprehensive torque setting tables and exact valve clearance adjustment specifications.
• Spans 218 pages of in-depth service data covering the complete engine, chassis, suspension, and electrical systems.
• Acts as the definitive primary reference for the 350–610 series launch build to provide exact tolerances for initial factory engines.
• Detailing specific components: Marzocchi Magnum front forks, Showa rear shock, Ducati Energia ignition systems, Mikuni TM 36 carburetors, and Dell'Orto PHF/PHM assemblies.
• Outlining essential service tasks: Valve seat recutting, kickstart mechanism teardown, crankcase splitting, steering bearing calibration, automatic decompressor adjustment, and complete wiring diagrams.

Technical Overview and Specifications

This OEM PDF publication documents the mechanical specifications, required maintenance intervals, and procedural workflows for the Husqvarna TE and TC 350–610 series. The technical data section lays out precise tolerances for internal engine components. You get exact measurements for valve seat cutting angles, piston-to-cylinder clearance limits, and big-end side clearances for the crankshaft assembly. Specialized sections break down the lubrication requirements essential for maintaining high-performance output. Having these factory clearances on hand eliminates the trial-and-error often associated with rebuilding mid-90s European four-strokes, accelerating your workflow during complex repairs.

The documentation provides clear troubleshooting pathways and step-by-step guides for procedures that usually require expensive dealer visits, such as complete crankcase splitting, precise valve seat recutting, and steering head bearing recalibration. To support these tasks, the text is heavily supplemented with visual aids, including exact valve timing diagrams, electrical system schematics, suspension damping charts, and exploded clutch assembly views. The factory documentation is specifically structured to facilitate major mechanical evaluations and routine bench adjustments. Before starting any major teardown, always ensure proper workshop ventilation and adhere to standard shop safety protocols when handling engine fluids, high-tension electrical components, or high-pressure suspension internals.

Precision Data and Maintenance Values

Cylinder head fastening torque is strictly specified at 23.73–26.28 Nm across the covered engine range. Intake valve clearance rests at a documented 0.10 mm. Meanwhile, the service data table lists the exhaust valve clearance at 0.15 mm. Proper tire setup matters for competition handling. The recommended front tire pressure for these units sits at 0.9–1.0 kg/cm².

When servicing these specific models, technicians should be aware of a few notorious service traps. First, improper adjustment of the automatic starting decompressor cable (which requires a strict 1-2 mm play) frequently leads to burned exhaust valves or severe kickstart mechanism damage. Furthermore, attempting to split the crankcases without the designated OEM puller tool often results in misaligned transmission shafts or cracked bearing bosses, making the correct sequence outlined in the literature absolutely critical. The manual also provides extensive reference charts for carburetor tuning and transmission gear ratios. These charts ensure precise identification and setup of original components for the 1995 model year.