Help! Debris found in my engine - 610/630 clutch issues

Discussion in '610/630' started by Rough Rider, Feb 9, 2011.

  1. CJBROWN Husqvarna
    AA Class

    Location:
    Orange County, CA
    Husqvarna Motorcycle:
    TE630
    Other Motorcycles:
    '15 R1200GS
    tap tap tap... :)

    The secret to it is backing the head, and being good enough with a hammer to have the tip of the ballpeen hit where you want it to. It's more like hammering than tapping. Wifey came out to the shop to see what the hell was going on.

    Some of the guys have used an airhammer. Anyway, the idea is that you beat down and roll over the end 'till it cinches up tight. It's more of a feel. Once you get it you got it...really pretty easy. Steel is definitely a lot tougher than brass or bronze. I once built a clinker planked skiff that had the plank lands riveted together with copper rivets. On that you could hear when they were getting tight.
  2. RDTCU Husqvarna
    Pro Class

    Husqvarna Motorcycle:
    '11 630SMS
    I normally use a ball-nosed punch and a 2lb hammer for steel rivets around this size.
  3. XLEnduroMan Heroes Ride Huskys. The others follow.

    Location:
    Paradise, CA.
    Husqvarna Motorcycle:
    '08 TE 510,'11 TE 630, Husky 4t HP!
    I am happy that I just ordered the Indy upgraded spring cup washers. My 630 is pushing 10k miles. I will be ordering the bronze bushing from MotoXotica for good measure. I plan to take pics of what I find. I have not ridden it as hard as I have my 510, but it has been ridden hard. The 630 is such a good bike I want to keep it around as long as I can. I don't think there is a better DS bike available, and yes I have rode an orange 690 off road. :cheers:
    Kenneth Webb likes this.
  4. Blazes Husqvarna
    AA Class

    Location:
    South Africa
    Husqvarna Motorcycle:
    Eddie Seel 634SMR works Replica -
    Other Motorcycles:
    Aprilla Dosodoro 2X 2009 610
    Just replaced the clutch actuator arm on my one 610TE than now has just over 42,000 km on ----checked the springs and washers --still in great condition ????

    Think I have been lucky with this bike never a days issue -- but must say I drop the engine oil every 2,500 km's sometimes 1,000km depending on the riding I have been doing. and do the oil filter every 5,000km
  5. CJBROWN Husqvarna
    AA Class

    Location:
    Orange County, CA
    Husqvarna Motorcycle:
    TE630
    Other Motorcycles:
    '15 R1200GS
    Just make sure none of the little spring cup washers aren't getting thin. I haven't heard of any that weren't. If they get too thin they come apart and go into your motor. Not pretty. For the $85 to do them it's worth it for prevention.
    I put it off and off and off...finally did it and it was way easier than I thought it would be and way worth it. The Indy washers look 'indy-car' grade compared to what came out of there. (see what I just did there. :D )
    Blazes likes this.
  6. Blazes Husqvarna
    AA Class

    Location:
    South Africa
    Husqvarna Motorcycle:
    Eddie Seel 634SMR works Replica -
    Other Motorcycles:
    Aprilla Dosodoro 2X 2009 610
    Luckily I have a new complete clutch unit hub and all that I got a few years ago --so when the day comes I will pull it--fit the new one and re-build the old one as a spare :)
  7. XLEnduroMan Heroes Ride Huskys. The others follow.

    Location:
    Paradise, CA.
    Husqvarna Motorcycle:
    '08 TE 510,'11 TE 630, Husky 4t HP!
    This is what mine looked like at 9,7xx miles. washers were thin and worn. You can see that the springs were banging around by the chew marks on the gear side of the hub. I am glad I got it fixed with the Indy spring cup washers. I took the clutch to a local shop and he drilled out the rivets and reassembled with a 20 ton press. I tapped the spring inward towards the clutch housing/away from the gear plate before reassembly in the bike. I am happy with the results. I have another set of Indy washers on hand for the other 630 fix I have to do.

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  8. Stujam Husqvarna
    A Class

    Location:
    Brisbane Austrlia
    Husqvarna Motorcycle:
    09te610, 11te630
    Where does everyone get there rivets , are they a husky specific size only available from dealers - last time i rivets sent from halls usa to oz but exchsnge rate was better then ..
  9. XLEnduroMan Heroes Ride Huskys. The others follow.

    Location:
    Paradise, CA.
    Husqvarna Motorcycle:
    '08 TE 510,'11 TE 630, Husky 4t HP!
    The rivets I used were included with the Indy Unlimited spring cup washer kits.
  10. jtemple Husqvarna
    Pro Class

    Location:
    Papillion, NE
    Husqvarna Motorcycle:
    2011 TE630
    Other Motorcycles:
    2013 Kawasaki ZX-14R
    I got the rivets from Halls as well.
  11. KLOC Husqvarna
    AA Class

    Location:
    Edmonton, Alberta
    Just heard from Indy Unlimited regarding the cup washers:

    "Sorry no longer have any available. No plans to make another batch of 10,000."
  12. Xcuvator Husqvarna
    Pro Class

    Location:
    Scholls Oregon
    Husqvarna Motorcycle:
    TE450,610 WB165,WR250 WR360 & XC430
    Other Motorcycles:
    yes
    Times and people change. He helped a lot of peeps though.
    The real fix is a cush hub though.
  13. FasYankee Husqvarna
    AA Class

    Location:
    Where you'd least expect
    Husqvarna Motorcycle:
    BOOM!
    Well WTF now? I just spent all this time reading this thread after getting referred here from my wonky clutch engagement thread. I was all set to just order this kit and get started on it in the fall/winter. Assuming that mine are at least partially worn bringing them to my machinist to reproduce would be asinine. Does anyone know the true dimensions of these washers/have a diagram? I love riding this bike but honestly I'm pretty close to going back to the *just put gas in it and change the oil* Japanese route. Damn thing is almost as high maintenance as my wife
    Flynn likes this.
  14. kirbybikes Husqvarna
    AA Class

  15. KLOC Husqvarna
    AA Class

    Location:
    Edmonton, Alberta
    Spice Weasel quoted these dimension for the spring cup washers:

    scudster likes this.
  16. Stujam Husqvarna
    A Class

    Location:
    Brisbane Austrlia
    Husqvarna Motorcycle:
    09te610, 11te630
    Jap sgls , katos -- they all have week points somewhere that need attention. .once you sort these issues you should be sweet .. My mates that maintain their bike dont have dramas - my mates that are crap at maintenance have dramas . I have done a fair bit of saddle time in 610 and now 630 and i have never been left stranded .

    Pull your clutch out and check the washers ( they may need changing or may be ok for a while ) but i reckon what you describe is likely more the bushing the hub sits on is worn , creating slop and hence rough engagement .

    Your issue should hopefully be easily and cheaply fixed ..
  17. mjskier Husqvarna
    A Class

    Location:
    Northern Colorado
    Husqvarna Motorcycle:
    2011 TE 630
    Other Motorcycles:
    2012 KTM 990 SMT

    So no hitting the rivets with a hammer, he just put them in the press and that was good enough to squish/expand them?
  18. mjskier Husqvarna
    A Class

    Location:
    Northern Colorado
    Husqvarna Motorcycle:
    2011 TE 630
    Other Motorcycles:
    2012 KTM 990 SMT
    Old vs. New (Indy unlimited kit)

    Dimensions:

    [IMG]


    [IMG]
  19. XLEnduroMan Heroes Ride Huskys. The others follow.

    Location:
    Paradise, CA.
    Husqvarna Motorcycle:
    '08 TE 510,'11 TE 630, Husky 4t HP!
    The factory installed rivets looked pressed to me, nice and uniform. A 20 ton press will do a better job then I ever would with a hammer. I will be doing the same on the next basket.
  20. mjskier Husqvarna
    A Class

    Location:
    Northern Colorado
    Husqvarna Motorcycle:
    2011 TE 630
    Other Motorcycles:
    2012 KTM 990 SMT
    Are the clutch spring bolt really only tightened to 5 N.m?
    That feels like barely compressing the springs! Doesn't show any locktite, so I assume the spring tension is enough to prevent them from backing out?

    teclutch1.png teclutch3.png