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 The previous version was outdated and no longer supported.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

950 hr case splittiing

ray_ray

ray_ray

Mini-Sponsor
Not really sure what is wrong yet but after my last excursion around the islands, my drain plug and oil filter were full of metal shavings when I changed the oil after returning... 100X as many shavings as compared to all previous oil changes ... Bright shiny ones in the filter ... The bike was running fine, no power loss, no odd sounds, no smoking... just metal in the oil ..

So I got some mains and a rod kit and and started reading the '2008 ALL 250-450-510 Repair.pdf' file ..

And read this thread and utilized macwood (thanks again) quite extensively at the start of the tear-down ...
http://www.cafehusky.com/threads/txc-250-main-bearing-failure-engine-noise.15159/

Any, all torn apart now except for pressing the connecting rod out ...

here are a few pics of the engine inners ... I don't see anything out of the ordinary but maybe you guys will..


100_5905.JPG

Top looks ok ...you can see the missing tip off the valve retainer pin (on the intake side rocker arm) that got eaten last yr 100_5932.JPG


Cams100_5933.JPG100_5924.JPG

This is the inner side of the tit I broke and had welded and cracked again and was welded a second time .. looks pretty ugly to me ... I'll probably do something else to it now that it is off ... Not sure what to do really other a small amount more welding ...
100_5930.JPG
 
No real bad places on the barrel but I could see some slight scuffing on the intake and exhaust sides of it ... the piston was scuffed some also on these same sides ... My camera was not doing too good a job showing the details of the parts ...

100_5941.JPG

First looks into barrel...
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100_5959.JPG
 
The crank, piston, and a side plate and main bearings ...

A little better look at the piston skirts ...
100_5996.JPG100_5997.JPG100_5998.JPG100_6012.JPG

mains look perfect to me ...
100_6013.JPG
 
I have an almost new piston&rings and matching cylinder PLUS new mains AND a rod kit for re-installing ...

Can that big end bearing be where all the metal shavings came from?

A few questions on left over parts..

1) Nothing could be felt when running your hands over any of scuffs so where does that leave this cylinder? Can that cylinder be honed out?

2) What about the visual scratches on the piston skirts? Can it be reused with new rings?

3) Anything else in the pics look suspect to anyone ...
 
I'd mic that cyl. to see what's what before anything is done with it. Check for taper, ovalness etc & see what stock specs and wear specs are..... The piston is definitely worn as your wear marks on the skirt are waaay bigger than mine were on my ~325-ish hour inspection on my TE 250 last year. There is a wear spec for it in the manual IIRC...
Put the old comp ring in the barrel, about 1" from the top, squared up, and check the end gap, just for fun........

May as well split the crank and do a full inspect of the rod/crank. I wouldn't be surprised if some of the metal particles are from the rod big end.......They've been known to do that

Since you got it apart, you may as well replace everything, including the mains, especially with the hours it has on it.
 
I'm curious Ray-

What is your oil change intervals and oil/filters used?

Also, how often per week are you riding in order to accumulate so many hours?
 
Slowpoke said:
I'd mic that cyl. to see what's what before anything is done with it. Check for taper, ovalness etc & see what stock specs and wear specs are..... The piston is definitely worn as your wear marks on the skirt are waaay bigger than mine were on my ~325-ish hour inspection on my TE 250 last year. There is a wear spec for it in the manual IIRC...
Put the old comp ring in the barrel, about 1" from the top, squared up, and check the end gap, just for fun........

May as well split the crank and do a full inspect of the rod/crank. I wouldn't be surprised if some of the metal particles are from the rod big end.......They've been known to do that

Since you got it apart, you may as well replace everything, including the mains, especially with the hours it has on it.
Click to expand...

I hope the metal came from the big end as I see nowwhere else for it to come from .. But I'm no real mechnic so I can miss alot ...

I''ll try to spec out the rings later and see what that number is.

If the barrel seems close to specs, is honing the normal path back to using it again? I'll probably buy a 300 kit from Kelly as my backup cylinder for the future (or another 250cc somewhere) and use this one as a 3rd stringer ...


Slowpoke said:
I'm curious Ray-

What is your oil change intervals and oil/filters used?

Also, how often per week are you riding in order to accumulate so many hours?
Click to expand...

I've tried to change the oil (1L Castrol full synthetic and 1L Castrol semi-synthetic or Rotella 40WT, mixed ) every 300 miles with a SS oil filter... sometimes Id hit 400 between changes ...I always felt bad over that ... My clutch drags bad unless I use some synthetic oil...

No job, sort of just quit\got laid-off working and moved over here 2 yrs ago, so I ride 12 months out of the yr here ... Not every day, as at age 54, my body can't take trails every day ... Your body has to adapt to riding so much as a life-style change ... So I'm a big mixture of street, trails, & tracks ... Usually under 10G RPM unless on the track or stuck in some mud ... This might be the key to a long lasting engine ...

Street riding, never over 6K RPMS usually for any distance.. I'm on an island... Why get in a hurry and how far can I actually go? ... I save my bike for the dirt ... 4-9K RPMs usually...

I'll probably pull my filter between oil changes at the ~200 mile mark or so to check for metal in the future also ... I could have caught this sooner (between oil changes) if I had checked the filter as it was full of metal also ..

The other side of the engine....

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A little better pic of the rings and piston .. No cleaning on the rings or the piston where they were removed from ...



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The marks on the bottom of the skirts are mine :(
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How is the cam chain. Is it stretched and maybe rubbing against something. My 610 has a reed valve near the bottom of the crank case that the chain will wear on if it is out of spec.
 
motogo1 said:
How is the cam chain. Is it stretched and maybe rubbing against something. My 610 has a reed valve near the bottom of the crank case that the chain will wear on if it is out of spec.
Click to expand...

I don't see any rubbing from the chain and I have a new one for re-installing .. But I'll re-check that area ...
 
take a good look at the transmission, possible from the gears themselves or the interface 'dogs'. Possibly the shift forks and shift drum as well.
More than likely the bottom end bearing as that takes a good pounding. Seems like you have all the parts covered. i noticed what appears to be a crack at the decompression boss and the cylinder and piston sure do look worn also.

keep us posted...
 
Yep, that piston is definitely worn. It was probably starting to 'rock' a bit judging by the scuff marks above the compression rings. Interesting that yours has 2 compression rings, as the 07 TE's only had one & I think my 09 TXC only had one IIRC - I'll have to go look tonite.......
The 05's had 2 compression rings.
 
Yep, I put that crack there in the woods putting the engine on a rock by mistake ..

Planepower said:
take a good look at the transmission, possible from the gears themselves or the interface 'dogs'. Possibly the shift forks and shift drum as well.
More than likely the bottom end bearing as that takes a good pounding. Seems like you have all the parts covered. i noticed what appears to be a crack at the decompression boss and the cylinder and piston sure do look worn also.

keep us posted...
Click to expand...
 
I would look at all the bearings real closely. If you had that much metal, it would seem like if it was just from the mains, they should be about to fly apart. Do they still turn fairly smoothly?
Have you had your transmision shafts out so you can feel the rest of the bearings?
The transmission was shifting fine?
If there was alot of metal, I would think about changing all the bearings.

I hope you can find the source.
 
Xcuvator said:
I would look at all the bearings real closely. If you had that much metal, it would seem like if it was just from the mains, they should be about to fly apart. Do they still turn fairly smoothly?
Have you had your transmision shafts out so you can feel the rest of the bearings?
The transmission was shifting fine?
If there was alot of metal, I would think about changing all the bearings.

I hope you can find the source.
Click to expand...

Yep seems weird to me also and iii have looked at all other bearings ... I don't see a real source of any metal shavings yet ...

both mains make a tiny noise when turning them ... They don't really feel loose though... Maybe this is the source ..

Gotta get them out next ...
 
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