2004 TE250 Rod / Crank Kit

I have a 2004 TE250 that needs a new rod & bearing. I see 2005 & up kits I can buy all over the place, but can't find a kit for the 2004's. Anybody know where to find this kit? Or if the 2005 & up kit will work? Or if a 2005 crank will work in a 2004 case?

http://www.husqyparts.com/en/model/2004/te_250_3/oem/18863

I would go to a 2006 and newer crank. You will also need to use a 2006 and newer piston.

Husqvarna has discontinued the rod kit, 8000 99939 for an'04, BUT, I found a solution!! I got the '04 TC/TE 250 rod specs from Halls Husqvarna, they are:

Upper pin diameter 16mm
Lower pin ID of rod 38mm
Lower pin OD 30mm
Center to center rod length 92.5mm
Lower rod thickness 18mm
Lower crank pin length 56.5mm

Pro-X rod kit 03.4334 for an RMZ250 has this exact spec rod in it, with a big end bearing and 55mm length 30mm diameter crank pin. So its all good except for crank pin length.
Pro-X rod kit 03.6336 for an '06-'09 TC/TE 250 has the correct 30mm diameter 56.5mm length crank pin. Pro-X has this crank pin available separately for less than $30!!
So... You can find the 03.4334 Pro-X rod kit all day long on internet for around $100, plus the $30 for the crank pin and you now have an affordable and AVAILABLE rod kit! I'm gonna use this "kit" for my '04. Will let you all know how it works out.

Sad News.... Pulled crank out today, measured center to center of rod, and it measures 94.50mm.... I was given wrong rod length spec from Husky dealer. Back to rod search.... Or...

Send to Crank Works in Tempe, AZ.

I have an 05 apart. Need to send the crank off to Crank Works yet.

I sent my crank to Crank Works in Tempe, Az a couple weeks ago. I was lucky that they had just done a run of custon billet 94.5 mm rods for another customer. Lucky because they made a few extra! I just got my crank back with a super strong billet rod on it... Needless to say, it was expensive, but less than what Husky used to charge for a new crank. I think Gavin at Crank Works said they only made a few extra, so better hurry and send it in. Tell him John referred you, hopefully he'll still have one for you.

Nobody else makes this rod, I checked, they checked... Came up empty. I asked him to start making this kit available, I hope they do.

Just a note the 2004 TE 250 and 2005 TC 250 use different rod kits.

'03 - '05 use the same 94.5mm long rod and piston kit. '06 is when they changed the rod length and piston etc....

Can anyone chime in as to what is the best accepted method for crank/piston replacement for the 04' models?

It looks to me like the parts are available online, but probably around $500 for the rod and piston.

Rancher1 suggests using an 06'+ crank. Those are about $570. So maybe better to bite the bullet and get the later crank and an aftermarket rod and piston. Do any other changes need to be made (bearings, balance shaft etc.)?

John25: How much does the crank refurb cost from Crank Works?

I think the crank pin size changed from 04 to 05 and that is why the part number is different. The rod length remained the same though.

Back on the 05 TE250 project. Just need to get this lower end done. Can I use an 06-09 TE250 Wossner rod kit in this 05 crank? And simply use an 06 Piston?

Appreciate any info..

I do not think so.

Bike prob get pushed to back of shop for awhile. Seems like 05 is just difficult to find parts for and 06 and up is lots easier.

Engine is together and in. Haven't fired it yet. Used a 06-09 crank. Matching Wossner rod and piston kit. Few the trans gears didn't look so great. Got another trans. Had the gears detailed and shotpeened. Bike had so few hours from new and light usage. Surprised to see the few gears start to lose it. Hoping this engine now will go quite a few hundred hours if normal use.

Its alive and running. Sounds pretty healthy.

few more details on this 250 and its ready to ride. Took awhile but engine should be solid now.

The bike looks good !

thanks. No more projects like this for me. Started with this.

How did you line up the sprocket on crankshaft to match the balancer shaft? I've been doing the same as you, put in a 2007 crankshaft into a 03 engine..