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 The previous version was outdated and no longer supported.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

Flywheel Key Sheared?

R

R_Little

Husqvarna
Pro Class
Sometimes it is just better to do it yourself.

I recently took my TE250 to a dealer who told me he could fix the hot starter issues me and others have been having.

Anyway, I pick up the bike and it starts and runs okay...took it for a 15 minute ride and the starter seems a little better.

The following weekend I toss it in the truck and drive 100 miles to my usual stomping ground just to find the bike barely starts and runs like crap. Ride a bit and take it home and begin to check plug, valves, fuel pump, coil....all items that have acted up in the past.

I put a shim in a tight intake valve and after a little helicoil drama put the bike back together.

Well it cranks and cranks.....nuthin'.....pull out plug which requires a removal of the valve cover to remove the shark plug socket. Eventually the bike starts kicking back like the timing is out. I stop for now.

After my wife asks me once again why I spend so much time on this bike I drop it for the weekend.

When I get home I pull the bike out again and pop off the IGN cover.

The bolt on the flywheel is about 25ft lbs and I notice a touch of loctite behind the bolt...a quick pop of the puller draws out the flywheel and ......you guessed it...the key is sheared. The flywheel shifted about 20 degrees.

The crank looks okay but the flywheel mating surface is marred pretty good where the it slipped over the sheared key.

What do I do to fix this properly?

How hard is it to tighten the flywheel to spec anyway? Had they done so I'd have been riding for the last 2 weeks.

Can't seem to catch a break.
 
Rich,
That bike was born under a bad sign.....

I'd lightly sand out the marred spot and the get some valve grinding compound and lap the flywheel on the crank, clean them up, install and properly torque the flywheel..... and then put it on Ebay.
 
Norman Foley said:
Rich,
That bike was born under a bad sign.....

I'd lightly sand out the marred spot and the get some valve grinding compound and lap the flywheel on the crank, clean them up, install and properly torque the flywheel..... and then put it on Ebay.
Click to expand...

Don't I know it!

I have all of 23 hrs on the bike so says I-beat. I own 8 bikes right now from '97 to '10. Five are Huskys.
They all run perfect except this one. 23 hrs and I've replaced the fuel pump, the coil, the starter, the starter gears, now I need a flywheel. Your 02 Wr125 hauls and is raced constantly.....the TE, I would never race. I has like 3 trail rides on it and one DNF enduro.
Still has the original chain and sprockets.

I would ebay it but I don't like selling anything unless it is good to go...I guess I can never be a MC dealer!

I may be able to get a flywheel from another bike. Do you think it'll be better to use that?

Thankfully, the crank looks good..if I can get the old key out of it.

Wanna sell me your 125? it is the best handling bike I ever rode....your old '02 is faster though.
 
Rich, I could help you out with a 2010 TE 250 flywheel.. Brandie new.. $50 The only other way to get one is a whole $600 ignition

Give me a holler if you want it.. Chow, Carl
 
CARL REHATCHEK said:
Rich, I could help you out with a 2010 TE 250 flywheel.. Brandie new.. $50 The only other way to get one is a whole $600 ignition

Give me a holler if you want it.. Chow, Carl
Click to expand...


I may do that, thanks! Gotta see if I can use Bobby Kitchen's old flywheel first.

Does the new one have the starter clutch riveted to the back?

What did you do with Kyles old TE250?
 
R_Little said:
Sometimes it is just better to do it yourself.
Click to expand...


You said it! What did the dealer do anyhow to supposedly fix your hot start issues? Sorry to hear of the problems.

I think if I wasnt somewhat handy at working on my bikes id be back on a carbed model just to rid the bike of electronics.
 
JasonfromMN said:
You said it! What did the dealer do anyhow to supposedly fix your hot start issues? Sorry to hear of the problems.

I think if I wasnt somewhat handy at working on my bikes id be back on a carbed model just to rid the bike of electronics.
Click to expand...

Replaced the starter ring gear...said he would do it under warantee, had the real fix, etc. Drove 2 hrs to drop it off.

When I Picked up the bike. He said Husky would not warantee it. It ran for about 5 miles then started lossing power.

Found about 25 ftlb on the Flywheel nut. Another guy just PM'ed me. He had the same thing happen to his 2011...Husky is waranteeing his. My 23 hrs use is too much I guess.

I'll get it to run if it wipes out my bank account.

There is a guy on this site selling a complete TC250 Ign flywheel and harness.

Maybe you should buy that? You can block off the starter motor and gears.
 
Wow sorry to hear of all your issues on such a low hour bike.:( I'd go with what Norman said except for the E-bay thing, if that doesn't work you could always buy Carls flywheel and be set with a new one if that will fit your bike.
 
waserman said:
Wow sorry to hear of all your issues on such a low hour bike.:( I'd go with what Norman said except for the E-bay thing, if that doesn't work you could always buy Carls flywheel and be set with a new one if that will fit your bike.
Click to expand...

It should fit. I just don't know why they only sell them as a set with the ignition, if that is the case.

I'm not going to reuse the old one.
 
This was a problem Husqvarna was aware of, Husqvarna Engineers solution was to just put loctite on it and stick it back on. A typical Husqvarna italy fix for a problem. The taper on the crank shaft and the taper on the flywheel are not the same and they loosen up and break the key way. The solution is to use some laping compound and lap the two parts together until they mate more evenly then you will not have the problem. You can get a new key way and put it in. That will fix the problem and will not reoccur.
 
Geno said:
gee i wonder if that is the cause of all the starter gear binding troubles which lead to starters burning out , and etc. would be nice if corporate just fessed up to the dealers about this so it could be taken care of and we could just go ride our bikes instead of making multiple trips to the dealer with these issues.
my bike has more miles on my trailer than on the trail.
nuff said enjoy the ride
Click to expand...

Bet you are right Geno.

I can tell you that the tapers look a bit different on the two flywheels I currently have.

One has the shiny wear marks in the back and the other has them in the front...like they are mating in different places. The keyways look different too.

There was loctite on the one I took off.....the dealer said he used some and he was actually very apologetic. I'm not going to take it back...I'll fix it myself.
 
Bigred97 said:
This was a problem Husqvarna was aware of, Husqvarna Engineers solution was to just put loctite on it and stick it back on. A typical Husqvarna italy fix for a problem. The taper on the crank shaft and the taper on the flywheel are not the same and they loosen up and break the key way. The solution is to use some laping compound and lap the two parts together until they mate more evenly then you will not have the problem. You can get a new key way and put it in. That will fix the problem and will not reoccur.
Click to expand...

I'm going to do that!


Thanks
 
Just make sure if the flywheel goes in a bit with the lapping that it does not hit anything,did this on my 82 Automatic and it moved in just enough to rub the wires.Not much fun towing a bike using a jursey as a tow rope.BTW the taper takes the load,all the key should do is locate it on the sharft
 
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