• 4 Stroke Husqvarna Motorcycles Made In Italy - About 1989 to 2014
     TE = 4st Enduro & TC = 4st Cross

  • Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

08 TE 510 blowing fuse for lights/speedo

A

Afry

Husqvarna
B Class
Bike has 200 miles on it, and obviously has a pretty bad short. Before I tear into it and isolate components and check the harness etc. are there any known issues I should be aware of that may save me some time?

While trying a trail side repair I only had a 30 amp fuse (stock is 20 amp) and it immediately blew the main fuse and killed the whole bike. So I left the 20 amp lighting fuse (lower fuse on right side) out and after replacing the main fuse it runs great but no lights or speedo.

With such few miles it's hard to believe the wiring harness could have worn through somewhere but I did notice it is very tightly installed on the frame. Seems like it could have been a few inches longer in some places.

Any thoughts?
 
I can't think of any tips, just look for a chafed wire, exposing metal wire. If the bike has the upgraded LED taillight, might start there. Look under the tank, that's where I found my chafed wire, the 510 vibrates alot, so if a wire is situated in the wrong position, on the frame, on a zip tie, etc, it could rub bare in 200 miles.

HuskyWireBare.jpg
 
Okay, it only pops the fuse when on low beam. If I keep it on high beam all is good except for the bulb is burned out.

Took the switch apart and It looks like the green wire to switch is the power feed and when you are on low beam it powers the black wire so the problem must be downstream from this black wire. Where? I don't know yet.
 
Afry said:
Bike has 200 miles on it, and obviously has a pretty bad short. Before I tear into it and isolate components and check the harness etc. are there any known issues I should be aware of that may save me some time?

While trying a trail side repair I only had a 30 amp fuse (stock is 20 amp) and it immediately blew the main fuse and killed the whole bike. So I left the 20 amp lighting fuse (lower fuse on right side) out and after replacing the main fuse it runs great but no lights or speedo.

With such few miles it's hard to believe the wiring harness could have worn through somewhere but I did notice it is very tightly installed on the frame. Seems like it could have been a few inches longer in some places.

Any thoughts?
Click to expand...

I have the same issue on my 610
 
I had my stock stock headlight bulb fail and cause a short, you may want to pull the bulb and see if your short goes away.
 
I have a 09 te 450. I believe the same wiring than the 09, but has 07 headlight shell and speedo cluster.

A few rides back I had the same problem, no speedo or ANY lights. The fuse blown from the wires leaving the fuse holder rubbed against my subframe. The tab that pokes thru the rear fender broke and chaffed the wires... some electrical tape to insulate the conductor and some bare wire for a temp fuse.
 
Been gone from this site for a bit but it was the bulb. After a close look the filament post melted and bent over completing the ground all the time. I ordered an LED build as replacement so I won't be stuck riding home in the dark.
 
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