2004 Husqvarna TE570, SM570R, TE-SMR 570 Service & Repair Manual (P/N 8000A2943)

• Coverage: 2004 Husqvarna TE 570 and SMR 570, including the TE 570 ENDURO USA and SMR 570 ENDURO USA configurations. Factory validity begins at VIN ZCGH601AA4V006900 for TE and ZCGH601AB4V001400 for SMR.
• Engine chapters cover removal, full internal disassembly, inspection, overhaul, timing, adjustment, and reassembly for the cylinder head, bottom end, R.A.L. lubrication system, clutch, transmission, and Mikuni carburetor.
• Chassis repair material addresses Marzocchi USD fork removal and overhaul, Sachs rear shock setup, swingarm and linkage service, steering-bearing adjustment, wheel and hub inspection, and TE/SMR-specific brake work and bleeding.
• Electrical coverage spans the TE/SMR and USA harnesses, digital ignition, generator/stator, voltage regulator, lighting equipment, and the “Racing” main wiring harness, with system-specific schematics and test references.
• Factory reference sections provide symptom/cause/remedy charts, competition- and road-use maintenance matrices, component-specific torque tables, fluid-capacity data, inspection limits, clearances, adjustment specifications, and special tools with part numbers.
• A 383-page PDF of the five-language factory publication, first edition dated September 2003, P/N 8000A2943. Separate USA/AUS material identifies Enduro configurations, noise-control equipment, and regional service requirements.

Model and Publication Scope

This factory workshop manual is written for the 2004 570 platform, not for a generic Husqvarna single-cylinder engine. It identifies the 576.28 cc four-stroke powerplant with four valves, a chain-driven single overhead camshaft, Mikuni TMR 41 carburetor, wet multi-disc clutch, and six-speed gearbox. TE/SMR differences are called out in the chassis, brake, gearing, electrical, suspension, tire, and maintenance data.

The lubrication section identifies the R.A.L. (Reed Activated Lubrication) system with oil pump, then connects that system to oil-level checks, filter cleaning, reed-valve inspection, oil-pump overhaul, lubrication passages, and related repair specifications. Cooling coverage follows the twin-radiator circuit through coolant checks, system diagrams, water-pump removal, inspection, and reassembly.

The publication carries Italian, English, French, German, and Spanish text throughout the same five-language layout rather than as separate language volumes.

Engine, Chassis, and Brake Repair Depth

The engine chapters progress from motorcycle preparation and engine removal through crankcase separation and internal inspection. Top-end coverage includes the cylinder head, valves and guides, rocker arms, camshaft and chain drive, automatic decompressor, piston, and rings. Bottom-end and drivetrain repair extends to the connecting rod, crankshaft, clutch and primary drive, selector mechanism, transmission shafts, and oil pump; the Mikuni carburetor has its own overhaul and factory-setting section. Corresponding reassembly chapters cover installation, cam timing, and adjustment references.

Chassis sections document frame reference dimensions, wheel removal and overhaul, axle and rim checks, spoke and sprocket inspection, and steering-head play. Separate material covers the swingarm pivot, linkage bearings, and rear suspension removal. The 45 mm Marzocchi USD fork chapter contains internal disassembly and reassembly procedures, damping components, oil-level data, and setup information for different track conditions. Sachs shock coverage includes spring preload and compression/rebound adjustment.

The brake chapter distinguishes TE and SMR front-brake arrangements and covers pad and disc inspection plus front and rear circuit bleeding. Its scope has an important factory limit: Husqvarna advises against internal overhaul of brake calipers or master cylinders; replacement work is limited to pads, retaining parts, and the bleed assembly.

The overhaul cautions explain that incorrect cylinder-to-piston clearance can cause seizure or accelerated wear. The Mikuni section warns against using metal wire on jets and passages because their calibrated openings can be altered, while the fork chapter flags incorrect spring-guide orientation as a cause of defective operation at the end of the compression stroke.

Electrical Reference, Diagrams, and Factory Tools

Useful visual references include the TE/SMR main wiring diagram, the separate USA wiring diagram, the ignition timing curve, the stator/alternator test layout, Marzocchi fork exploded and sectional views, and front/rear brake-system layouts. The troubleshooting chapter adds symptom/cause/remedy tables for engine, drivetrain, chassis, brake, and electrical faults.

The specific-tools table identifies fixtures for deeper repair work, including crankcase puller 1517 94701, flywheel extractor 1615 13302, clutch-gear puller 1519 80501, crankshaft installing tool 8000 70637, clutch-hub retaining wrench 8000 79015, and fork pumping retainer 8000 91289. USA/AUS notes add U.S. Forest Service-approved spark-arrester inspection and cleanout material, along with TE Enduro kit P/N 8000A0436 and SMR Enduro kit P/N 8000A0814.

Before starting any maintenance or repair operation, make sure the motorcycle is securely supported on a suitable stand to prevent accidental movement or a fall.