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

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1
GENERAL
Section

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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

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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)