• 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 The previous version was outdated and no longer supported.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!

2009 SMR 510 Dead Stator

banana944

banana944

Husqvarna
AA Class
Was riding along my 2009 SMR 510, pulled over for a break. Went to fire it back up, dead battery. Pop start it, barely running, no headlight/tailight, no good.

Battery is 3 months old, I replaced all the fuses, checked and cleaned all the connections. No charging voltage present at battery while bike was running. I did not have time to run the full procedure that is outlined in the service manual, but I did a resistance check between the 3 leads from the stator and was getting no reading.

I will do a full inspection procedure tonight, but that tells me that the stator is dead. I have only read a couple other threads regarding truly bad stators. Does not seem that this is too common. My concern is that something caused the stator to go bad. Is anyone aware of a common issue that would cause the stator to give up the ghost?
 
Well found my problem. The bolts that mount the stator to my 7602 ignition cover backed out. 1 or more of them loosed up, then bounced around inside the flywheel. Not sure how it happened, I put red loc-tite on the bolts, but perhaps I refilled the engine with oil too soon.

This will be a costly mistake and even more upsetting is that I believe I had the very last 7602 ignition cover. Now it's ruined :cry:anyone have one?
 
It pulled the threads and wallowed out the holes. It could be welded and retapped but this surface needs to relatively precise. It's an option if I cant find a cover.
 
Timesert maybe. Stronger than original threads too. Sounds like a pretty easy repair for a decent machine shop to fix.
 
I'll get a picture to share with the group. Timesert may be an option, but wonder if there is anything to be nervous about in a high vibration setting.
 
I think your overthinking this one. It was steel bolts threaded into aluminum? It might be as simple as tapping with the next bigger size standard thread, or refill, drill, tap to original. Or, if enough meat there, drill and press in a threaded sleeve of stainless or such.

You might even have some good threads left deep in the hole. Try a longer bolt just to test the end of the hole, unless you can see its botched. A 5mm longer bolt might be all you need but triple check depths and such.

Pics would help for sure.
 


See attached. Holes are too large to tap to the next size. Now considering filling with weld and then drill/tap. But Afraid its going to ruin the anodized finish on the outside due to heat transfer.
 
I can not tell from your photo if you have undamaged threads deeper into the cover- but if so, fill 'em with epoxy, screw new fasteners (slightly longer?) into the wet epoxy, give it 24 hrs... and never worry about it again. (This is assuming your stator is fine, of course... is it?)
 
Replacement stator is on its way. There are some threads left but when threaded all the way the bolts have some wiggle to them due to the rest of the hole being oblong.
 
banana944 said:
...There are some threads left but when threaded all the way the bolts have some wiggle to them due to the rest of the hole being oblong.
Click to expand...

you may be ok- but it's close. Can you tap any additional threads (2mm might be enough; use a bottoming tap). Once the epoxy sets up, that stator won't go anywhere. The magnets on the rotor provide a pulling force, but it's consistent and not super strong. Use plenty of brake cleaner before gluing.

otherwise, it's a stock cover for you... until you find a replacement or fix your 7602.

good luck.
 




Click the images for larger view.

Here's where I am at. Helicoil wouldn't have worked well enough for me to put faith in. I had it welded, wasn't the best job and it did discolor the anodizing on the front of the cover. I'm going to try to grind it down flat and then drill and tap it.

I know it won't end up the quality I want so I'm gauging interest in a group buy over in the 7602 forum.
 
Did it make any noise before it broke? I mean I kick started my 250 TE last week end and it was making a terrible noise on the low left side of the engine. I thought of a bearing. I unscrewed the ignition cover and turned the nut with a spanner... No noise. Then my son suggested something might have gone loose. He was right, the 8mm stator screws were a little loosed. The point is it was noticeable only when using the kick, when the engine was reving slowly before firing, because it was not that obvious once it was running.
 
You're kinda screwed now- unless you got a mill and lathe. those welds are about 50% too big. But the big issue is the bead on the inner rim, which aligns the stator on center.

Holes: remember that the stator also provides the ecu with timing info.

i wouldn't be concerned (at this time) about the heat marks on the outside of the cover. (but is there a bump on the cover from a fastener being put in too deep? or is it an optical illusion?)

good luck.
 
Yes, milling it will be tricky to keep the stator on center. In this case, the stator does not control the timing, the trigger reads teeth on the outside of the flywheel and the sensor is mounted on the upper portion of the cover. But ensuring the stator is mounted precisely is critical to keep the proper stator to flywheel gap. Yes there is also a slight dimply as I ran a non bottoming tap through it before it was welded.

I am going to regrettably use the stock cover for now. Not sure I will get this to a level where I am happy with it. Please guys if anyone wants any red husky items go over to the 7602 forum so we can convince them for a production run!

I'm bummed :(
 
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