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 The previous version was outdated and no longer supported.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

Clutch issue

Ruffus

Ruffus

Husqvarna
AA Class
Went to start my bike this morning, pulled in the clutch after it warmed up a bit, put it in gear & it takes off with clutch still pulled in. Lever didn't return.

Tried to bleed it conventional way & back bleed like I've done a half dozen times before, didn't work & clutch lever has no pressure.
Res. was full, all I managed to do was inject enough fluid to get some lever feel back, but res level didn't change. It's like I injected enough to compress an air pocket and no more would go in, if that makes any sense.
I had the 7602 piston in there, & put in a brand new 7602 piston, no difference (no noticeable scoring on cylinder).
There seems to be some sort of blockage. I'm guessing it has to be at the master.
Right now I've got the bleeder valve out completely hoping the res will empty out over night, been a couple hours & no change in res. level yet.
So what do the members in the know think?
Anyone had this issue?
Is it time for a master rebuild?

Need to get this fixed in the next couple days. Heading out to Hatfield McCoy in a week :banghead:

P.S. I put in a new clutch lever last week, worked great on the weekend at the Husky get together & rode for a couple hours yesterday, no issues.:excuseme:
 
It sounds like *maybe* the master cylinder piston isn't returning far enough to open the relief port (which opens into the reservoir). Perhaps this is something to do with the new lever, perhaps it's just a coincidence.

I had something similar a couple of years ago where some dirt had got past the outer boot and the m / cylinder piston got a bit sticky and wasn't returning the last mm or two. I pulled the piston, cleaned everything up and checked the bore (it was ok-ish), made sure the piston was moving freely and being a sketchy kind of guy I reassembled it with the original piston and seals (they looked a1). One other thing I did was stretch the return spring a few mm as I reckon this little guy is key to not getting that mysterious "spongy lever but no leak" thing that had happened occasionally. It's holding up pretty good so far.

As you're riding out pretty soon it may be worth getting a repair kit though, just in case. I think they're 9.5mm diameter and look like this:

http://www.venhill.co.uk/Magura_Con...HYMEC_PISTON_KIT-MIN_OIL_9_5MM__163_2ZEM.html

(This is the UK supplier btw)

This is an uprated part with a vee shaped outer piston seal instead of the o-ring fitted to older models.
 
7point62 said:
It sounds like *maybe* the master cylinder piston isn't returning far enough to open the relief port (which opens into the reservoir). Perhaps this is something to do with the new lever, perhaps it's just a coincidence.
Click to expand...

:banana::banana: Woohoo, you ROCK, when I changed levers I measured the adjusting knob & placed it in the new lever exactly as the old one. I was told it had a different angle, I thought that meant the bend of the lever. It apparently means actuation angle. backed it out all the way & was able to bleed it in a couple minutes. THANK YOU :cheers:

P.S. it's a roller bearing EE lever if anyone else gets this problem.
4 hours of headaches yesterday solved in a minute today :thumbsup::applause:
 
Am so glad it wasn't something involving getting oil all over the garage floor! Enjoy the ride out. :cheers:
 
Ummmm too late on oil all over the floor. That 4 hours of headaches involved a lot bleeding attempts with the tube flying off the syringe on many occasion from pressing hard on the plunger & numerous removals of slave etc. :D
I got plenty of kitty litter to soak it up & a huge weight lifted off my chest with such a simple fix.
 
At least no flying circlips and springs though! Do you have a link to your new clutch lever - Google's not being my friend searchwise... If I know exactly what it it I may be able to track one down in the UK. Anything would be more comfortable for me than the stocker!
 
7point62 said:
At least no flying circlips and springs though! Do you have a link to your new clutch lever - Google's not being my friend searchwise... If I know exactly what it it I may be able to track one down in the UK. Anything would be more comfortable for me than the stocker!
Click to expand...

Enduro Engineering EZ-Pull Clutch Lever Part# 23-003
 
I do like it when a seemingly complicated problem turns into an easy fix. That's the power of this forum that we all benefit from!
 
ScottyR said:
If the lever is the issue, just send it back and I will send you a different lever.
Click to expand...

No need, Scott, the issue was me not adjusting the knob correctly, soon as I backed it off (adjusting knob) all was good. Just wanted people to know that there is a slight difference & going by the original levers setting I had a small problem.
I'm quite happy with this lever & in no way blame anyone but myself :cheers:
 
Ruffus said:
No need, Scott, the issue was me not adjusting the knob correctly, soon as I backed it off (adjusting knob) all was good. Just wanted people to know that there is a slight difference & going by the original levers setting I had a small problem.
I'm quite happy with this lever & in no way blame anyone but myself :cheers:
Click to expand...

P.S. I do like the feel of this lever much better than the factory, seems to be smoother engagement & I noticed the lack of a blister on the web of my left hand, which I got almost always on a trail with lots of clutch use. Happy camper here :)
 
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