Husqvarna SM 610 2006 Instruction manual

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Workshop Manual
SM 610, TE 610/ 2006
Part. N. 8000 A4640 (04-2005)

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Copyright by
MV Agusta Motorcycles S.p.A.
Servizio Assistenza Tecnica - Via Nino Bixio, 8
21024 Cassinetta di Biandronno (VA) - Italy
Tel. ++39 0332 254111- Fax ++39 0332 756509 -
www.husqvarna.it
USA model
Cagiva U.S.A.
2300 MARYLAND ROAD
WILLOW GROVE, PA 19090 - 4193
215 - 830 - 3300
1st Edition (04-2005)
Printed in Italy
Print No. 8000 A4640
VALIDITY (from vehicle identification number)
SM 610 (39 KW): ZCGA100AB5V000001
SM 610 (22 KW): ZCGA101AB5V000001
TE 610 E (39 KW): ZCGA100AA5V000001
TE 610 E (22 KW): ZCGA101AA5V000001
USA/CDN models
SM 610: ZCGAFEKP#6V400000
TE 610: ZCGEAEKP#6V300000
To the best knowledge of MV Agusta Motorcycles S.p.A. - Varese, Inc. the material contained herein is accurate as of the date
this publication was approved for printing. Cagiva Motor S.p.a. - Varese, Inc. reserves the right to change specifications,
equipment, or designs at any time without notice and without incurring obligation. Illustrations in this manual are merely for
demonstration purposes and could not exactly match the detail described. No part of this manual can de reproduced without
permission in writing of the copyright holder. All the motorcycles and their detailed parts taking part in competitions of any
type are excluded from the guarantee.
1st Edition (04-2005)

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Foreword
This publication intended for HUSQVARNA Workshops has been prepared for the purpose of helping the authorized personnel in
the maintenance and repair work of the motorcycles herewith dealt with. The perfect knowledge of the technical data contained
herein is essential for a more complete professional training of the operator.
The paragraphs have been completed with schematic illustrations evidencing the subject concerned, in order to enable a more
immediate understanding.
This manual contains information with particular meanings:
Accident prevention rules for the operator and for the personnel working near by.
Possibility of damaging the vehicle and/or its components.
Additional information concerning the operation under way.
Useful suggestions
HUSQVARNA suggests, in order to prevent troubles and in order to have an excellent final result, to generically comply with the
following instructions:
in case of repair work, weigh the impressions of the Customer who complains about the improper operation of the motorcycle,
and formulate proper clearing questions about the symptoms of the trouble.
detect clearly the cause of the trouble. This manual gives the theoretical bases which however shall be integrated by the per-
sonal experience and by the attendance to training courses periodically organized by HUSQVARNA.
rationally plan the repair work in order to prevent dead time as for instance procurement of spare parts, tool preparation, etc.
reach the component to be repaired and perform only the required operations. In this connection, it will be useful to consult the
disassembly sequence contained in this manual.
1 Always replace the seal rings and split pins with new components.
2 When loosening or tightening nuts or bolts, always start from the bigger ones or from the center. Lock at the prescribed torque
wrench setting following a crossed run.
3 Always earmark the components or positions which could be mistaken one for another at the time of assembly.
4 Use original HUSQVARNA spare parts and the lubricants of the recommended brands.
5 Use special tools, where specified.
6 Consult the Service Bulletins as they may contain up-dated adjustment data and repair methodologies.

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- Where not otherwise specified, data and instructions refer to all models.
SM 610
TE 610

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Chapter Section
General A
Maintenance B
Troubles and remedies C
Settings and adjustments D
General operations E
Engine disassembly F
Engine overhauling G
Engine re-assembly H
Front suspension I
Rear suspension J
Brakes L
Electric system M
Engine cooling system N
Lubrication circuit O
Specific tools W
Torque wrench settings X
Frame, wheels Y
Notes for USA/CDN-AUS models Z
Summary

6

1
GENERAL
Section

2
Engine A.3
Timing system A.3
Fuel feeding A.3
Lubrication A.3
Cooling A.3
Ignition A.3
Starting A.3
Transmission A.4
Frame A.5
Suspensions A.5
Brakes A.5
Wheels A.5
Tires A.5
Ignition system- electric system A.6
Weights A.7
Overall dimensions A.7
Table of Contents
Capacities A.8
GENERAL

3
GENERAL
ENGINE
4-stroke, single cylinder
Bore 3.85 in.
Stroke 3.01 in.
Displacement 35.15 cu. in.
Compression ratio 11.1:1
TIMING SYSTEM
Single overhead camshaft; 4 valves
Valve angle in relation to cylinder:
INTAKE 20°
EXHAUST 20°
Valve clearance with cold engine:
INTAKE 0.002 in.
EXHAUST 0.002 in.
FUEL FEEDING
Gravity
Dry type air filter
Carburetor type Keihin FCR-MX 41 with acceleration
pump and T.P.S. (Throttle Position Sensor)
LUBRICATION
Forced type with lobe twin-pump
COOLING
By fluid with double cooler, electric fan and expansion tank
IGNITION
Electronic with capacitive discharge; Digital controlled variable
spark advance
Spark plug type "NGK" CPR8E
Spark plug gap 0.022÷0.026 in.
STARTING electric

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GENERAL
TRANSMISSION
Multi-plate clutch in oil bath 6-speed gearbox, constant
mesh gear type
Drive between engine and gearbox main shaft by straight
toothed gears
Primary drive
Drive pinion gear z 32
Clutch ring gear z 75
Transmission ratio 2.343
Gearbox ratios
1st gear 2.615 (z 34/13)
2nd gear 1.812 (z 29/16)
3rd gear 1.350 (z 27/20)
4th gear 1.091 (z 24/22)
5th gear 0.916 (z 22/24)
6th gear 0.769 (z 20/26)
Final drive
Drive between gearbox and rear wheel by 5/8" x 1/4" chain
(with O Rings )
* Transmission sprocket z 15
Rear wheel sprocket z 45
* Transmission ratio 3.000
Rear chain size 5/8 x1/4
(112 links)
* Total drive ratios
1st gear 18,389
2nd gear 12,744
3rd gear 9,492
4th gear 7,670
5th gear 6,445
6th gear 5,409
*: replace data on owner s manual no. 8000 A4860 (page 22)

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GENERAL
* FRAME
Single-beam in steel tubes of circular section splitting approx.
on line with the exhaust; light alloy rear frame
Steering angle 39° each side
Steering axis angle 27° (SM); 28° (TE)
Forward travel (in.) 2.7 (SM); 3.9 (TE)
*: replace data on owner s manual no. 8000 A4860 (page 24)
SUSPENSION
Front
MARZOCCHI Overturned forkrod telehydraulic fork with
advanced pin; forkrods 1.77 in. diameter; hydraulic brake
adjustment both in compression and extension
Axle travel on leg axis (in.) 9.84 (SM); 11.8 (TE)
Rear
Swinging arm in light alloy with progressive damping,
SACHS hydraulic mono-shock absorber with helical spring.
Spring preloading adjustment; hydraulic brake adjustment
both in compression (DOUBLE) and in extension.
Wheel travel (in.) 11.4 (SM); 12.6 (TE)
BRAKES
Front
Drilled fixed disc 10.24 in. dia. with floating caliper (TE);
drilled floating disc 12.6 in. dia. (SM) with fixed caliper
Pads area 5.02 sq. in. (TE); 6.14
sq. in. (SM)
Independent hydraulic circuit and pump with control on the
handlebar right side
Rear
Drilled floating disc ø 8.66 in. with
floating caliper
Pads area 4.57 sq. in.
Independent hydraulic circuit; controlled by pedal and pump
on the motorcycle right side.
WHEELS
Rims
Front (TE) "TAKASAGO Excel in
light alloy: 1,6x21
Front (SM) "SANREMO" in light
alloy: 3,50x17
Rear (TE) "Metzeler" MCE KA-
ROO- "Pirelli" MT 21;
140/80x18
* (SM) "Pirelli" MTR 22
DIABLO- "Dunlop"
D208; 150/60x17
*: replace data on owner s manual no. 8000 A4860 (page 26)
Cold tire pressure
(front SM- Road use, driver only) 25.6 psi
(front SM- Road use, driver and pas-
senger) 28.4 psi
(rear SM- Road use, driver only) 28.4 psi
(rear SM- Road use, driver and pas-
senger) 34.1 psi
(front SM- Racing use, driver only) 20 psi
(rear SM- Racing use, driver only) 22.7 psi
(front TE- Road use, driver only) 17.1 psi
(front TE- Road use, driver and pas-
senger) 21.3 psi
(rear TE- Road use, driver only) 21.3 psi
(rear TE- Road use, driver and pas-
senger) 25.6 psi
(front TE- Racing use, driver only) 14.2 - 15.6 psi
(rear TE- Racing use, driver only) 12.8 - 14.2 psi

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IGNITION SYSTEM - ELECTRIC SYSTEM
The ignition system includes the following elements:
- Generator;
- Ignition coil;
- Electronic power unit;
- Voltage regulator;
- Spark plug;
- Starting motor 12V-700W;
- Electric start remote control switch.
The electric system includes the following elements:
- SM- Headlamp with two filaments bulb of 12V-55/60W and parking light bulb of 12V-5W;
- TE- Headlamp with two filaments bulb of 12V-35/35W and parking light bulb of 12V-3W;
- Rear lights with stop bulbs of 12V-21W and parking light bulb of 12V-5W;
- Turn signals bulb of 12V-10W;
- Three15 A fuses (one of them is a spare fuse);
- Battery 12V-12Ah.
GENERAL

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WEIGHTS (§)/ DIMENSIONS mm
GENERAL
SM 610
TE 610
(§): Curb weight, without fuel
SM 610 .....................kg 142 (313 lbs)
TE 610 ..................... kg 140 (308.6 lbs)

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CAPACITIES
Fuel tank (reserve included) Unleaded gasoline (98 R.O.N.) 2.64 Imp. Gall./ 3.17 U.S. Gall.
Fuel reserve 2.64 Imp. Qt./ 3.17 U.S. Qt.
Change gear and main transmission oil AGIP RACING 4T (SAE 10W60) 1.76 Imp. Qt./ 2.11 U.S. Qt.
( oil and oil filter replacement)
1.14 Imp. Qt./ 1.37 U.S. Qt.
( oil replacement)
Front fork oil AGIP FORK 7,5 (SAE 7,5; SAE 5 for hard
climatic conditions) 4 in. (oil level) (*)
Oil for rear shock - absorber AGIP FORK 2,5 (SAE 2,5)
Fluid for cooling system AGIP COOL 2.45 Imp. Pints; 2.85 U.S. Pints
Front brake fluid AGIP BRAKE 4 (DOT 4)
Rear brake fluid AGIP BRAKE 4 (DOT 4)
Drive chain lubrication AGIP CHAIN LUBE
Grease lubrication AGIP BIKE GREASE
Electric contact protection AGIP ROCOL MOISTURE GUARD
Fillers for radiator AREXONS liquido
Air filter oil AGIP FORMULA FILTER "Foam air filter
protection oil"
Air filter detergent AGIP "Filter clean foam air detergent fluid"
GENERAL
WARNING! - Use of additives in fuel or lubricants is not allowed
(*): see page I.9

1
Section
MAINTENANCE

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Description Operation Pre-delivery
Engine oil
Coolant Check / Restore level #
Cooling system Check for leakage #
Spark plugs Check / Replace #
Throttle body / Carburetor Check and adjust #
Brakes / Clutch fluid Check level #
Brakes / Clutch Check operation #
Brakes / Clutch Check lines for leakage #
Throttle control Check operation #
Throttle control Check / Adjust play #
Choke control Check operation #
Flexible controls and transmissions Check / Adjust #
Drive chain Check / Adjust #
Tires Check pressure #
Side stand Check operation #
Electrical equipment Check operation #
Instrument panel Check operation #
Lights / Visual signals Check operation #
Horn Check operation #
Headlight Check operation #
Ignition switch Check operation #
Locks Check operation #
Screws and nuts Check / Tighten #
Hose clamps Check / Tighten #
General lubrication
General test
PRE -DELIVERY INSPECTION
MAINTENANCE

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MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
COUPO N A -
AFTER
1000 km (620
mi.) OR
6 M ONTHS
COUPO N B -
AFTER
5000 km (3100
mi.)
OR 12 MO NTHS
COUPO N C -
AFTER
10000 km (6200
mi.)
OR 24 MO NTHS
COUPO N D -
AFTER
15000 km (9300
mi.)
PRE-DELIVERY
INSPECTION W hichever comes first W hichever comes first W hichever comes first Only if reached within 24 m onths
Coolant C C C S C
Engine oil C S S S S
Engine oil filter cartridge S S
Engine oil suction filter P P
Valve clearance C C C C
Spark plug C C S
Timing system chain S
Clutch flexible coupling C
Ignition cover C C C
Starting gears assembly C
Connecting rod S
Clutch discs C
Ignition timing C
Fuel filter C S S S
Carburetor C C P
Carburetor throttle valve C
Air filter P S S S
Engine oil pressure C
Cylinder/Piston checking C C
Brakes fluid (**) C C C S C
Brakes hydraulic controls C C C C C
Brakes pads wear C C
Flexible controls C C L L L
Throttle control C C C C C
Tires pressure and wear (*) C C C C C
Electric fan C C C
Headlamp alignment C C
Lights/Visual signals, Horn C C C C C
Battery C C C C C
ITEM
COUPO N E -
AFTER
20000 km
(12400 m i.)
Only if reached
within 24 m onths
S
S
S
P
C
S
S
C
C
C
S
C
S
P
C
S
C
C
S
C
C
L
C
C
C
C
C
SEE PAG E
Instruments C

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MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
ITEM
COUPO N A -
AFTER
1000 km (620
mi.) OR
6 M ONTHS
COUPO N B -
AFTER
5000 km (3100
mi.)
OR 12 MO NTHS
COUPO N C -
AFTER
10000 km (6200
mi.)
OR 24 MO NTHS
COUPO N D -
AFTER
15000 km (9300
mi.)
COUPO N E -
AFTER
20000 km
(12400 m i.)
SEE PAG E
PRE-DELIVERY
INSPECTION W hichever comes first W hichever comes first W hichever comes first Only if reached within 24 m onths Only if reached within 24 m onths
Rims spokes stretch C C C C C
Steering head bearings play C C C
Transmission chain/Chain rollers C C-L C-L S C-L S
Rear sprocket/Pinion C S C S
Side stand screws C C C C C C
Wheels hubs bearings C C
Fuel tank P P
Front fork oil S-R S-R
Bolts and nuts general tightening C C C C C C
Lubricating/Greasing C L L L L L
Locks C
Motorcycle general test X X X X X X
KEY FOR MAINTENANCE SCHEDULE
C: Check and/or adjust
L: Lubricate and/or grease
P: Clean
S: Replace
R: overhauling
(*): replace if necessary
(**): system bleeding if necessary

1
TROUBLESHOOTING
Section

2
TROUBLESHOOTING
ENGINE
Trouble Cause Remedy
Engine don t start or starts with
difficulty
Inadequate compression 1. Piston seizure Replace
2. Con-rod small or big end seized Replace
3. Piston rings worn Replace
4. Cylinder worn Replace
5. Low torque cylinder head nuts Tighten
6. Head gasket blowing Replace
7. Spark plug loose Tighten
8. Incorrect valve play Adjust
9. Valve springs weak or seized Replace
10. Valves seized Replace
11. Incorrect decompressor adjustment Adjust
No or weak spark 1. Spark plug faulty Replace
2. Spark plug dirty or wet Clean or dry
3. Spark plug gap too large Adjust
4. Ignition coil faulty Replace
5. H.T. leads damaged or short circuiting Check
6. Electronic device faulty Replace
7. R.H. switch faulty Replace
Fuel not reaching carburetor 1. Fuel tank cap breather blocked Clean
2. Fuel cock blocked Clean
3. Fuel feed hose blocked Clean
4. Carburetor fuel filter dirty Clean
5. Worn out float valve or worn out floats Replace
6. Rocker blocking float valve Free
Carburetor flooding 1. High fuel level in float bowls Adjust
2. Worn out float valve or worn out floats in open position Replace or free
Worn out clutch switch on the
handlebar Clutch switch cable connected incorrectly or short circuit Connect correctly or replace