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 The previous version was outdated and no longer supported.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

Athena 300 kit for a 2009 TXC 250

fitness2go

fitness2go

Husqvarna
AA Class
I ordered my Athena 300 kit from Kelly at Motosportz yesterday and it arrived TODAY**************************************** I'm not sure how it got here so quick, but I did see the back of mail man and he was bald with a Husqvarna emblem on his postal outfit.

Does anyone have any tips/suggestions on installing this thing? Are there instructions floating around?
 
We want a full report of your impressions post installation please.
Good luck and happy spanering
 
fitness2go;100259 said:
I ordered my Athena 300 kit from Kelly at Motosportz yesterday and it arrived TODAY**************************************** I'm not sure how it got here so quick, but I did see the back of mail man and he was bald with a Husqvarna emblem on his postal outfit.

Does anyone have any tips/suggestions on installing this thing? Are there instructions floating around?
Click to expand...

he he he, thought you might like that little surprise as i knew you were chomping at the bit.

As Jake says, match the gasket tot he cylinder, it is EZ to get on wrong and will work but leak some oil (slowly) Jake is an accomplished mechanic but still got it upside down so it is EZ to do.

We need to get the BB300 and BB144 on the trail together soon. :thumbsup:
 
the kit only inclued one cilinder head gasket! With one messure... Is a very stupid think, because put the correct compression ratio is very import... I dont understand why this think can cause a oil consupition
 
PRELIMINARY INSTRUCTIONS AND DISASSEMBLY:
• Remove the seat, the fuel tank and the exhaust manifolds.
• Drain the coolant.
• Disconnect the oil breather hose placed on the valve cover and the thread of the manual compressor.
• Remove the valve cover, the spark plug and the carburettor.
• Remove the oil delivery connection from the cylinder head.
• Take the piston to the T.D.C. during the firing stroke (picture 1).
• Check the clearance of the valves (suction 0,10-0,15 mm – exhaust 0,15-0,20 mm).
• Remove the chain tensioner.
• Detach the manifolds from the bottom part of the cylinder and from the head.
• Remove the cam shafts marking the position of the supports which shall remain unchanged.
• Remove the two lower screws of the water pump and slip off the pump from the head by holding up the distribution chain.
• Loosen the M6 screws that fasten the head to the cylinder and the cylinder to the base.
• Remove the front shoe of the distribution chain.
• Remove the clamping screws from the head.
• Remove the head, the cylinder and the piston circlip. Slip off the piston pin and remove the piston.
• Check the following components: wear of the small and big end, clean the combustion chamber from possible encrustations, check the tightness and the valve clearance by keeping
to the maintenance manual.
The health of your engine is guaranteed by the good conditions of these elements.
N.B. Reutilize from the original cylinder the two aluminium connections to connect the pipes of the cooling plant.
ASSEMBLING INSTRUCTIONS:
• Clean carefully all the bearing surfaces.
• Wash carefully al the new components and blow them with compressed air.
• Assemble the pins on the new piston as indicated in picture 2.
• Install the new piston. Make sure of the correct position of the piston pins.
• Install the cylinder base gasket.
• Assemble the aluminium connections into the cylinder, the cylinder itself after oiling the liner and the head gasket.
• Assemble the head and tighten the nuts in a cross and gradual pattern at 55 N•m (M10), 24 N•m (M8), 10 N•m (M6).
• Assemble the manifolds into the bottom part of the cylinder.
• Install the discharge cap of the coolant fluid with a new sealing gasket.
• Install the oil delivery connection with two new sealing gaskets.
• Take the piston to T.D.C.
• Install the front shoe of the distribution chain.
• Assemble the gear of the distribution with the two marks turned upwards and the front arm well tight.
• Install the water pump and the upper manifold by tightening the screws at 10 N•m.
• Let the chain tensioner run down, assemble it into the cylinder with its gasket, tighten the screws at 10 N•m, assemble the spring
and the cap.
• Assemble the cam shafts with their centre punches aligned to the bearing surface of the valve cover and both turned outside.
• Assemble the supports of the cam shafts by tightening gradually the screws at 10 N•m.
• Assemble the valve cover and the oil breather tube.
• Install the working cable of the manual decompressor by letting a free clearance of 5 mm measured on the cable.
• Install the carburettor, the spark plug with its grip and the exhaust manifolds.
• Add coolant up to the filler neck.
• Replace the engine oil and the filter.
• Assemble the fuel tank and the seat.
 
You should be very happy with the added boost. A buddy of mine just did the 300 kit on his TC and is super happy with it. Very noticeable power increase vs the 250.
 
Now might be a good time to break out UR digital camera and document this work ... :) ... yep, U 2 might can be a legend and maybe a even a sticky 2 day :)
 
Colo moto;100335 said:
You should be very happy with the added boost. A buddy of mine just did the 300 kit on his TC and is super happy with it. Very noticeable power increase vs the 250.
Click to expand...

:thumbsup: My 06 TC 300 conversion with Russ Fletcher ported head. Bike ripped. Hated the transmission spacing though (TC)

339737366_65s3X-L.jpg
 
Can anyone elaborate on the following:

• Install the front shoe of the distribution chain.
• Assemble the gear of the distribution with the two marks turned upwards and the front arm well tight.

• Assemble the cam shafts with their centre punches aligned to the bearing surface of the valve cover and both turned outside.
 
Well, I wouldn't call this MOD an easy one, but I did it! Sorry Ray...I didn't photo document it as I was so involved (scared) with screwing up the engine that I even think about pics. Also, I my hands were all oily and stuff. It's the first time I've ever torn into an engine.
 
wow ... first time, eh? I'm a shade tree guy and it did not sound too easy to me either...

You're finished already? Did it start? :)

What's UR break in procedure?

I'll go ahead and say good job!
 
At first it didn't start...it just turned over. So I looked at the Husky Maintenance Manual and noticed that I needed to get the piston TDC. Then I centered the middle of the three side-by-side markings on the cam chain gear and matted up the marking on each of the cam shaft gears with the outer markings of the cam chain gear...put everything back together and she started right up!

I did a couple of heat cycles and will do the same tomorrow morning followed by a short medium paced ride.

Now that I've done it once, the second time would be really easy.
 
wow Great story! That was so quick! It only took a couple of hours?

Now it is pics and kicking what ever a$$ needs kicking on the road ... I handed a yama wr250 his butt last weekend and it was great!

I bet 3rd and 4th gear wheelies will not be an issue now!
 
David is the Everyready Bunny in human form! Had a message on the phone this morning about going for a ride. You're already done?! Got a few minutes on it so we could compare 250's (now 250 vs. 300). It's got a nice bite to it for sure! I'm sure David will post up with a review shortly. He did good with that little of experience!
 
Motosportz;100396 said:
:thumbsup: My 06 TC 300 conversion with Russ Fletcher ported head. Bike ripped. Hated the transmission spacing though (TC)

339737366_65s3X-L.jpg
Click to expand...

Man I love the Italian colors, can I get those for a 08 TXC?

Awesome work on the 300 conversion:cheers:. I wish I had the skill and the guts to convert mine..
 
Yep... that 06 looks good ... The frame looks very different being silver instead of white ...
I have saw graphics out there somewhere like that but forgot where :(

I hope the us stock market flies so I might can afford one of these some day... :)


http://www.ferracci.com/store/cart.php?m=product_detail&p=540 -- this looks like his decal set and is for 04-07 bikes...


The kit includes all applicable tank and shroud pieces, front and rear fender decals, swingarm decals, airbox decals, upper and lower fork decals and seat cover.
But on backorder :(
 
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