• 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 The previous version was outdated and no longer supported.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 TE510 wont start/turn on

flyinryanmtb

flyinryanmtb

Husqvarna
AA Class
Hi, I've been lurking for some time and have been able so far to fix all the problems I've had with this bike thanks to you guys, but this one has me stumped.

First off my push start button randomly stopped working (not after washing or anything like that) but the bike would kick start just fine so I figured the relay just went bad or the wires came unsoldered inside the button no big deal. Then today the bike started "burping" or bogging for a split second every couple of minutes so I figured the fuel pump had slipped forward (did the mod of adding extra zipties previously) I also had a similar incident where the low fuel level sensor broke and was grounding out causing a similar bogging but I completely removed that as well as a short in the horn. So anyways after a few of these "burps" the bike started to pop and bog and completely died. As it was dieing I noticed the low fuel light came on which was weird because I had removed the unit. So as I come to a halt in the middle of nowhere I bust out the tools and start troubleshooting. Heres what I checked

Fuses-all good
battery-fully charged
broken wires/rubbing on the frame-nothing
pulled fuel pump etc.- all good
mixed and matched the 3 identical relays on the left side under tank- no change

This is where it gets weird-The speedo is completely dead when I turn the key on, fuel pump does not prime, however when I turn the key off the number 2.1 shows up and the numbers cycle then immediately turn off. Could this be an ECU failure? or do I just have a bad relay? Any help would be much appreciated!
 
I would put ECU failure at the bottom of your list.

Have you replaced all of the OEM fuses with auto fuses?

What is the standing voltage on the battery, bike off, is the voltage 12.7 or higher? What is it when the bike is running, 14.0 or higher?
 
Check your ignition switch. I had a similar issue, the key switch was my culprit. I could wiggle the key to get her going. I took mine off, cleaned it out the best I could, packed it full of dielectric grease and have not had that problem again. I really just want to get rid of the keyed ignition altogether...just need to find a quality switch to replace it with.
 
sharpie1 said:
Check your ignition switch. I had a similar issue, the key switch was my culprit. I could wiggle the key to get her going. I took mine off, cleaned it out the best I could, packed it full of dielectric grease and have not had that problem again. I really just want to get rid of the keyed ignition altogether...just need to find a quality switch to replace it with.
Click to expand...
Side note for sharpie1 http://sicassracing.com/store/products/switches/key_switches
http://sicassracing.com/store/products/switches/key_switches/2011-12_husky_te449-511_key_switch
 
Thanks for all the replys...I have only changed the main 20A fuse with an auto fuse but I will replace the rest. As for the voltage I had just swapped battery's with my buddy on the trail and my multi-meter just crapped out (harbor freight pos) but I will check it as soon as I buy a new one. I pulled the ignition switch apart, cleaned it and before putting it back together tested it and was able to get the display to light up (no fuel pump prime), however it just cycled on and off and whats weird is it would only light up when the kill switch was on (bike killed). just to eliminate the possibility of the ignition switch I hard wired a jumper on the 4 pin connector plug as if the key was on and had the same result-the display would light up cycle through the numbers and then go off then on and do the same thing over and over. I should also note the gas light is coming on during this so maybe its the fuel pump. I also took apart the kill switch and electric start button and they both look fine. Could this be a speedo failure?
 
Well I believe I have found the problem :D. I finally got a new multi-meter and checked the starter relay. I applied 12 volts to it and checked for continuity and had Nothing! I guess this explains why my bike was sputtering for a split second due to the relay failing and "clicking" off then on rapidly. I will post an update as soon as the new one arrives.
 
This thread has been well dead for awhile. But my bike is also dead with the exact same issue. Any change you guys are still around and know the fix? I rewired the pump and verified the switch is working. So thinking starter relay
 
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