• 2 Stroke Husqvarna Motorcycles Made In Italy - About 1989 to 2014
     WR = 2st Enduro & CR = 2st 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 The previous version was outdated and no longer supported.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!

250-500cc busted exhaust mount

shawbagga

shawbagga

Husqvarna
Pro Class
i run a PC platinum 2 pipe on me 10 wr300 which to get to fit i had to flip the exhaust mount bracket over. i recently discovered after cleaning the bike after a ride that the exhaust bracket mount(tubular piece of metal welded to frame RHS in front of brake pedal) was flogged out and yes i always checked they were tight! it appears there wasnt enough thread on the bolt going into the frame mount and as such the pipe bracket & bolt had enough leverage to just 'work' the mount threads(the very end of the bolt would still screw in but does bugger all as rest of thread was too loose). retapped to a larger thread but stupid heavy handed me snapped the tap off in there-DOH! cant get the remainder of tap out(damn hard steel) so now im stuffed! any ideas anyone? at the moment im just wire tieing the pipe bracket to the frame which does the job but i want it sorted. only thing i can think of is to cut off mount and reweld a new longer one on?! which leads me to ask what is necessary to disconnect if i have to weld the frame on the bike? please help me as my bike looks like a busted up POS as it is.
 
shawbagga said:
i run a PC platinum 2 pipe on me 10 wr300 which to get to fit i had to flip the exhaust mount bracket over. i recently discovered after cleaning the bike after a ride that the exhaust bracket mount(tubular piece of metal welded to frame RHS in front of brake pedal) was flogged out and yes i always checked they were tight! it appears there wasnt enough thread on the bolt going into the frame mount and as such the pipe bracket & bolt had enough leverage to just 'work' the mount threads(the very end of the bolt would still screw in but does bugger all as rest of thread was too loose). retapped to a larger thread but stupid heavy handed me snapped the tap off in there-DOH! cant get the remainder of tap out(damn hard steel) so now im stuffed! any ideas anyone? at the moment im just wire tieing the pipe bracket to the frame which does the job but i want it sorted. only thing i can think of is to cut off mount and reweld a new longer one on?! which leads me to ask what is necessary to disconnect if i have to weld the frame on the bike? please help me as my bike looks like a busted up POS as it is.
Click to expand...

I once broke a tap off in a part and HAD to get it out. I took it to my friends machine shop and he just took a torch to the broken tap until it was cherry red and then after it cooled a bit it drilled out like soft metal. I know this will cook the paint on the frame, but it's all I've got for you. Hopefully someone else will have a better idea.
 
Can you get ahold of the tap between the flutes with some skinny needle nose pliers? If its really stuck can you weld something to it and screw it out? Last resort is Electric discharge machining (EDM) if it's available near you.

 
I guess its an M8? you should be able to get maybe M6 bolt tacked to the end of the tap to wind it back out. It does depend on where it broke off, ie in the frame or if there is any kind of stub protruding.
I have had snapped taps spark eroded out, but it is hideously expensive and tricky because yours is in the frame rather than in a component.
Post photo and I'm sure one of us can come up with a solution!
 
not a chance with the pliers! yeh M8. tried to remove it with a pick & mallet by gently tapping c/clockwise, worked a little then jammed & just damaged threads. no way its coming back out the way it went in-shes properly rooted! cant upload photos(well not me anyway) sorry. i reckon the mounts knackered so mite just hack it off & weld a new one on. correct me if im wrong but that mount is just externally welded to the frame(i.e. doesnt go into main frame section at all). gotta mate whos a boilermaker/engineer so getting new one made and welded isnt a drama. what do you need to disconnect before welding on these bikes? should be right to do it with everything bar expansion chamber on the bike hopefully. really sh#%s me that i turned a simple job into a major mission-it was profanity central! BTW me old mate will know by looking but how are these frames welded-i mean what type of welding?(& no i didnt pay attention in metalshop) might just leave stock pipe on when i buy a 2012 & stop bashing it on logs & rocks!-yeah right:)
 
Same thing happened to my frame, got a mate to mig it back on and now I'm up for some electrical work.. Has fried something!! Bummer!!
 
Please post a picture of it.
You may have to weld something on it, so you can get a hold on it with a plier
 
Gasman said:
Same thing happened to my frame, got a mate to mig it back on and now I'm up for some electrical work.. Has fried something!! Bummer!!
Click to expand...
spewin'! what did or didnt you disconnect? im as good with electrics as i am with retapping threads so id love to know what i gotta disconnect & how to do so, so i dont do the same. ignition, voltage regulator, spark plug lead?
 
Harbinger said:
Please post a picture of it.
You may have to weld something on it, so you can get a hold on it with a plier
Click to expand...
i cant upload photos sorry. tried to tap it out & drill it but just destroyed more threads. due to the fact i was retapping the thread out one size larger there isnt much 'meat' left of the outer diameter of the mount so i reckon shes knackered! wont be able to retap it again so just gonna have to lop it off and weld a newy on
 
try welding a nut onto the exhaust bracket drilling out the frame mount and bolting through frame mount onto exhaust bracket.
 
I had the same initial problem with the flogged out thread, but I've just left it (ie, I don't have a bolt in there now) with no ill effects.
I don't reckon you need that mount.
 
Try to weld a nut to the broken tap & wind it out.
Or you can shatter the tap with a centre punch if it is not too far into the thread & knock the remains through then put a helicoil in afterwards.
 
jo360 said:
try welding a nut onto the exhaust bracket drilling out the frame mount and bolting through frame mount onto exhaust bracket.
Click to expand...
you mean drill right thru the frame so bolt goes thru it from exhaust side to outer side of frame?
 
Twatty said:
I had the same initial problem with the flogged out thread, but I've just left it (ie, I don't have a bolt in there now) with no ill effects.
I don't reckon you need that mount.
Click to expand...
yeah im not sure twatty, ive just got it wire tied at the moment but the pipe seems to move a bit. been ok for a few rides but reckon id still rather have something there to make that pipe a bit more rigid.
 
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