• 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.

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    Thanks for your patience and support!

2004/5 te510 clutch slave cylinder damage? Midwest lever...?

One-speed

One-speed

Husqvarna
B Class
Hi all,
Had a bit of an issue fitting and setting up my midwest engineering clutch lever so thought I would pull the slave cylinder, when I did I noticed that the end of it that retains the circlip had broken off, it's certainly not a lot of metal and is the useless bubbly cast stuff so think I am ok there regarding oil etc (which I am changing) but why did it happen? I Googled and found a thread on here of someone with the exact same issue but no real reason for the damage was posted?
I have ordered a bilet oberon slave so that should sort that but would like to know why it happened? Lever over pressurising? Wear and tear? Age?
Thanks for any input and help
 

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Someone pulled the lever at the handlebar with the slave unbolted.....piston hits circlip that retains piston in bore.....cracks body of cylinder (where it is thin- where groove for circlip is).

oberon and you should be sorted.
Bugs
 
Hi Thanks for the reply , I have had the bike over a year and when I pulled the slave I could see a couple of bits of metal and I definitely didn't pull the lever with the slave umbolted ,Yeah should be fine with the oberon just the way my mind is I like to know the reason for something happening.
 
Your bike is old.
Check the length of the pushrod that goes into the motor....

I had a 2005 te 450 which had the clutch go a bit flakey with age..... based on the
advice of someone with far more experienced than me, I was told to buy a new pushrod (about $10.00) prior to disassembly/mucking about with new slave parts....

I was shocked when the new pushrod measured out about 1/16 of an inch longer than old one...updated part/old one worn/MFG tolerance variation.......No clue as to the nature of why the part was so different in length......I find it hard to believe the old actuator rod wore that much from use but who am I to argue with experience......

I suppose it could be possible that your old pushrod is so warn that when the slave piston is activated it hits the retainer circlip slightly before actually pressing on the rod...... thus breaking the cylinder at the thin circlip seating location. I think the scenario I mentioned earlier in the thread is far more likely but who knows.

Maybe the weird Midwest engineering clutch lever has a different throw length than OEM....and that is the problem????

Maybe a previous owner cracked it by a mistake and just stuffed the damaged parts back in???

Good luck,
Bugs
 
Thanks for taking the time to reply bugs,
Yeah I know the old girl is old,but a good un! don't think it has had a hard life though, good heads up on the pushrod, I wonder if the pushrod has worn down although it doesn't look mushroomed at the end........wonder if the manual has a stock length and wear limit for it? Will need to check that.
When I pulled the slave there was a bit of the slave cyclinder still there so it had clearly broken recently and the fact that I have just fitted the new lever makes me think that maybe it pressurised more than standard and possibly my slave has weakened with age/use.
When my new oberon comes today I may just order a new pushrod and go back to my standard lever, kind of lost confidence in the midwest lever now to be honest.
Thanks again for taking the time to reply
Onespeed
 
I hear you about an oldie but a goodie! My 05 TE was a peach.

Counterbalanced motor was much smoother than my current bike (08 TXC).
2005 bike was a demon in the sand...So stable.

All the best sorting out your clutch issues.

Bugs
 
Oberon cylinder fitted today and going to try one last try to get the midwest lever the way I want it...incase someone digs up this thread on Google again some day I have taken a pic of the length of my pushrod, have also ordered a new one from husky so will post a pic with the brand new rod length also- mine doesn't seem to have any wear, but can not find anywhere the serviceable length of the rod.
The quality of the oberon is outstanding, filled the slave by pushing the piston in and out prior to putting it on the bike to make sure no bubbles are trapped and bled it in about 3 minutes.
Note about the oberon is it doesn't have a circlip holding the slave piston in.
Hopefully give ride report this weekend
 

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No just the angle, directly above 183, had a quick spin last night and have given up completely on the Midwest lever, not willing to put up the issues you have to with it. Clutch action is smooth as silk now, not any easier pull unfortunately but very nice action.
 
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