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 The previous version was outdated and no longer supported.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

510 Seized Engine Disassembly

Guoseph

Guoseph

Husqvarna
AA Class
So, the adventure begins. I purposely didn't put "Rebuild" in the title because I'm not sure I will want to put it all back together after I find out what's inside.

Background on the bike, it's a 2008 TE 510 with less than 2700 miles. I bought it mostly as a parts bike after the PO reported it seized during a trail ride. My goal is to learn more about Huskies and working on bike engines in general, in case my working Husky decides to go boom at some point in the future.

I removed the valve cover (these 510's have very little clearance up top) and got my first surprise:

16211583989_833b2dbfe7_c.jpg


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Looks like something punched a hole through the valve cover. Looking inside the head it looks like one of the intake valve rocker arms is MIA, as in I don't see it anywhere in the head.

I'm gonna take out the engine and see where all that metal went.
 
Only had time to wiggle the engine out of the frame today. Would have been a lot easier with the rear shock removed but I couldn't get the top bolt loose. I hust unbolted the bottom linkage and pulled the swing arm as far back as I could.

16219260219_9f832854ac_z.jpg


No time to dig in but I did find some treasure inside the intake port:

16217504188_08a3b10320_c.jpg
 
So here's a question. The head on this engine looks almost identical to the head on my 630. Rumor is that the 630 got its head from the 450/510's. So how come I can check my 630 valves every 3000 miles while this one ate its intake valve at 2700?

Then it begs the question, can I get a 630 head to fit on here and would it actually require less frequent valve checks.
 
My 510 09 engine got about 3200miles on it and the valve clearance hasn't changed at all since I checked them the fist time (about 3hours). So my guess is bad luck or maybe it was to little oil on it?
Anyways it's a simple engine to work on and I'd think the 630 have the same head, I've never compered the two, but I seem to remember they look exactly the same. Would download the workshop manual for it if you dont have it. Real handy to have.
 
The carnage continues:

Missing Rocker Arm and Shim

16453738265_f60c45c092.jpg


Nice little piece of treasure found down in the head bolt hole

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Then the head comes off:

16451993461_b7f761cd3c.jpg


And it gets worse

16267488989_70db60a2a8.jpg


Where are the valves?

16267832577_b741518393.jpg


Found one!

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This is a better angle

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Cylinder looks surprisingly good

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Two marks from the broken valves

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So...how has your day been? :)
 
Looks good. I say button 'er on back up and ride!

Seriously- thanks for taking/posting pics so others can learn as you plug away. Good work and good luck!

Eric
 
EricV said:
Looks good. I say button 'er on back up and ride!

Seriously- thanks for taking/posting pics so others can learn as you plug away. Good work and good luck!

Eric
Click to expand...

Glad you enjoyed it :)

It's def been a learning experience for me as well. As I mentioned at the beginning, not sure I can or want to put it back together. Now, if I can figure out whether I can put in a taller 5th and 6th gear while I have the bottom end open, I might attempt it and make the bike a better dual sport, otherwise this bike will probably get put out to pasture.
 
Man, these pics are amazing to look at. Scary, but amazing, lol. Was it just lack of maintenance / neglect, or an internal flaw with the engine? Would love to have a parts bike to pull apart like this.
 
HuskyMax said:
I would say it was from the opposing valves.
Click to expand...


I'm also gonna guess the valve being punched up by the piston is what broke the rocker arm. But I'm not sure how the valves self destructed. As far as I know the valves were checked around 1,500 miles, oil changes on time, destruction happend with 2,637 on the ODO. PO said mostly easy trail riding, bike came to me with Shinko 700's, so probably wasn't doing much MX. Maybe a little too much highway to get to said trails? I dunno.
 
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