• 2 Stroke Husqvarna Motorcycles Made In Italy - About 1989 to 2014
     WR = 2st Enduro & CR = 2st 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 The previous version was outdated and no longer supported.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!

125-200cc 165 LONGER KICK STARTER

johnnyboy

johnnyboy

Husqvarna
Pro Class
Got bored looking outside at the pouring rain so thought there must be some sort of project I could have a fiddle with when I rememered I had a late model KTM 125 kick starter I got my hands on in the off chance it may of fitted the Husky engine, Fat chance the KTM splined part is around 1mm larger in bore.
Well not to be beaten by the fact it didnt fit out came the tools and after a bit of drilling tapping welding ect I ended up with this.
The KTM item is only a inch or so longer but boy does it make a difference in the starting of the 165, No more stabbing at the kicker its now just smooth arc type of kick and actually feels like the piston ring is missing it goes through its stroke so easily.
Was it worth the time and effort ? Yep it certainly was as even my mate Trig can now start the bike with ease and he has always struggled with it and now may become a 165 convert lol
 

Attachments

  • IMG_1830.jpg
    IMG_1830.jpg
    118.8 KB · Views: 104
  • IMG_1831.jpg
    IMG_1831.jpg
    139.8 KB · Views: 108
  • IMG_1825.jpg
    IMG_1825.jpg
    146.7 KB · Views: 94
Firstly I cut the KTM Round part off and drilled it through the center with a 5mm drill and tapped it M6 , Next come the fiddly bit setting the Husky part up to bore it dead center and then tap M6, Next saw / part off if you have a lathe the parts till you obtain the correct lenght (25mm I think it was) but making sure you keep the groove for the bolt with enough material under it to allow it to be V ed out for the welding, I cocked up a bit and had to recut the groove as I lost half of it by filling it up with weld :rolleyes: but as long as you have all the measurments written down its no great shakes to put it right after its welded
Useing a bit of M6 threaded bar or threaded bit of a M6 bolt screw it into the Husky part, I only went in around 6-7mm then screw the KTM part to it and do it all up good and tight and your done all bar the V ing out for the welding, I cut mine right into the threaded bar and tigged mine together but Mig would do it just as well if your alright with a welder.
Clean off and excess weld till all is round with no high spots on a lathe but again you could just file it I would think and lastly to finish the job off you have to drill a small hole in the rear of the KTM kicker 4mm I think it was !!! to line up with the Husky spring and ball afair and I think that was 6mm up from the base of the kicker and thats it job done, All told took me around 2 hours maybe a little more but after doing the first one I think I could do another one in around a hour.
Only real test the longer item has had is I pulled the plug cap off and kicked the living crap out of the poor thing for ever and then pulled it all to bits again to see if there was any kind of damage or stress marks and all was good so put a bit of grease in the thing and slapped it back together kicked it like a mad man again for a bit then fitted the plug cap again and started the bike and that took a good 8 kicks as it was a bit flooded.
Started first kick every time yesterday hot or cold and is much nicer to kick than the oem Husky item.
Opps neary forgot - I also laid a small amount of weld on the splined part where the kick start flat part rests when kicking as my old part was very worn due to being a very early part, Doubt it will be needed on a newer item.
Hope it make some sense as its easy in my head but bloody hard work to put into words :oldman:
 
You must log in or register to reply here.
Back
Top