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 The previous version was outdated and no longer supported.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

2011 TE310 replacement starter gear part number?

D

DRCA

Husqvarna
A Class
Ok, my 2011 TE310 has the dreaded e-start problem, here are the details:

  • Bike kick starts on the first kick when using the kickstarter
  • Electric starter can't turn the engine over (you hear the relay click and depending where the engine stopped in the stroke the estart might be able to move the engine a few degrees)
  • If I take the sparkplug off, the e-start is able to turn the engine over (altho not with much gusto!).
  • I checked the exhaust valve clearance (0.022) and went one shim size up to bring it to 0.017. That didn't help!
  • Jump starting of my truck battery doesn't help (so at least it's not the battery)
So next thing is probably changing the worm gear set (and if that doesn't work then the starter itself).
I have the following part number for the kit:
Husqvarna OEM Starter Transmission Kit - 8539725​
Can someone confirmed that this is the part number for the updated (hardened) parts and that's for the kit?
To replace the gears, I'll need a flywheel puller (M26 X1.5 RH Female) and what else? Flywheel holder?
Thanks.
DC
 
R_Little said:
!'m sure all the starter gears in stock at this point are hardened.

ZipTy Racing makes an awesome flywheel holder.

I have one.
Click to expand...


I ordered the gears and a flywheel puller, took everything apart swapped the gear, put the flywheel back in and... the starter turns the engine over now! I just need to put the cover back on, fresh oil and I'll see if it's enough to start the engine.

For the flywheel holder, I ended up making my own :)

2019-05-29 19.11.26 (Custom).jpg
 

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DRCA, do you have any issues with the bike flaming out?

Mine is shearing flywheel keys when it flames out, so I ended up going kicker only (removed every estart component), but I really miss the magic button, especially in the middle of a nasty hill climb!! Just trying to see if there is a way to have a reliable estart TE310.
 
WWWRU said:
DRCA, do you have any issues with the bike flaming out?

Mine is shearing flywheel keys when it flames out, so I ended up going kicker only (removed every estart component), but I really miss the magic button, especially in the middle of a nasty hill climb!! Just trying to see if there is a way to have a reliable estart TE310.
Click to expand...

Flameout is bad... The funny part is that when the bike flames out, it resets the odometer day trip (talk about a big spike in the electrical system).

My bike is a 2011 TE310 and I have upgraded to the 12 holes injector and TXC ECU, but that doesn't solve the problem. I've been thinking about messing around with electronic setup (I have the cable and software), but I just don't have the time (and it's not a bike I ride very often anyways).

The e-start is pretty weak (even with a bigger battery) but on the plus side, kick starting is pretty easy and reliable.

I haven't had any problem (yet?) with the flywheel key. But I don't see how using the e-Start vs the kick start would affect the flywheel key.

I am probably going to sell the bike in the next few weeks anyways, might put back the old injector and ECU and sell them separate (they are impossible to find these days).
 
you should look at getting your starter motor rebuilt at Ricks Motorsport Electrics, they rebuild my starter for 2010 TE250. I also had my valves reshimmed to .006"/.15mm, turns over no problem now.
 
xlite250 said:
you should look at getting your starter motor rebuilt at Ricks Motorsport Electrics, they rebuild my starter for 2010 TE250. I also had my valves reshimmed to .006"/.15mm, turns over no problem now.
Click to expand...

Well, after changing the worm gearset for the starter the starter was able to turn the engine over, but barely.

So before sending the started for a rebuilt (close to $200 when all taken into account), I took the starter apart, sanded the area where the brushes make contact with the stator (this was really glazed over) and sanded the tip of the brushes too (length was fine). Put it all back together and mounted in the bike.

The I traced back the connection between the starter motor and the battery (positive lead) and sanded ALL the connections to insure proper connection. I might run a thick lead from the negative of the battery to the starter body next.

Put everything together, pushed the starter button and the starter whiiiiiiirs along happily. Only problem: the starter freewheel / clutch is dead now, so the engine wasn't turning over. Arrrg!

Found a reasonably priced one on eBay, so I'll wait to get it to test again.

Bummer!
 
so if starter rotates engine half or full or tow times and then stops like something is balk or stuck...

i should change 1- stator 2- freewheel 3- worm gearset ??
 
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