Help: TE630 Rear Sprocket Fell off at 65mph!

[ioneater]

Had seen an issue similiar posted a year or 2 ago and have been slightly paranoid since then. Neither of my 2 Husky's (TE510 and TXC250)ever loosened up at the sprocket bolts (isn't that how it works, lol). If I never looked at them they'd have fallen out for sure! They always were at spec. Engine mounts, different story.....

 

[SilverBullet]

Over 7000 miles on my 630 and the rear sprocket is pretty much the only thing that hasn't broken or fallen apart on it.

RE: your other thread, you jinxed yourself by posting this. But after finding out the 630 rear sprocket is aluminum excellent lifespan to reach 9K miles.

_

 

[Brainstorm]

I sure am glad to read this as the EXACT same thing happened to my HuskyTE630. rear sprocket and wheel exploded on the road at only 25mph. This is one of many problems with this bike.This happened to be the last straw with my experience of buying a Husky630. I will start another thread on the horrible experience I have had but wanted to jump in on this link. There should be a pic posted with this.
Support for these bikes in non existant and parts are a nightmare. You call supposed customer service in OHIO and the kids there don't even know that Husky has an office is in Calif!!! So the TE630 is out of service for another month for the second time this year. Parts fell of it. The bike stalls repeatedly and is unridable in the woods and dangerous on the street. The new owners have ruined a great brand and when people read posts like this they should stay away.
I have owned more than 40 motorcycles and never had such problems as with this bike and its service. Sorry but have to tell the truth even if it hurts. Give me a KTM anytime

 

[NWRider]

I mark all my sprocket bolts with a paint pen. That way I know if anything has moved at a quick glance.

If you end up needed a hub I think Taskys had some cheap on their garage sale page.

 

[jtemple]

I sure am glad to read this as the EXACT same thing happened to my HuskyTE630. rear sprocket and wheel exploded on the road at only 25mph. This is one of many problems with this bike.This happened to be the last straw with my experience of buying a Husky630. I will start another thread on the horrible experience I have had but wanted to jump in on this link. There should be a pic posted with this.
Support for these bikes in non existant and parts are a nightmare. You call supposed customer service in OHIO and the kids there don't even know that Husky has an office is in Calif!!! So the TE630 is out of service for another month for the second time this year. Parts fell of it. The bike stalls repeatedly and is unridable in the woods and dangerous on the street. The new owners have ruined a great brand and when people read posts like this they should stay away.
I have owned more than 40 motorcycles and never had such problems as with this bike and its service. Sorry but have to tell the truth even if it hurts. Give me a KTM anytime

Wow, that's terrible. As far as the stalling goes, have you installed the power up kit? It really makes it a completely different bike, for about $40 in parts. Not that it'll help your busted rear end at all....

 

[Jim M]

I understand your disappointment but don't agree with everything you post. I am a total noob rider and had my bike in the woods / street / highway today...felt comfortable and had a lot of fun. When my bike came from the dealer it was idling around 1350 rpm, bumping that up to 1650 made the stalling issue just about disappear. I am surprised Husqvarna hasn't put out a recall or at least have all bikes checked by a mechanic to make sure the sprocket issue does not happen again.

Hope you get it all sorted out soon.

 

[jtemple]

I am surprised Husqvarna hasn't put out a recall or at least have all bikes checked by a mechanic to make sure the sprocket issue does not happen again.

Oh, but they have. Hall's sent me new sprocket nuts just the other day. The new ones are nylocks; the OEM ones were not.

 

[johngil]

800 miles and the updated parts were installed at delivery.
Checking the sprocket bolts before I head out tomorrow and noticed they were all loose.

 

[blakebird]

I replaced my rear sprocket with an Ironman the other day, knowing the alloy oem (Supersprox) one would not last long. I was doing the countershaft (14t) anyway, so a good time for a little PM in the drivetrain.

My 525 sprocket bolts needed to be checked occasionally, and seeing this thread title naturally made me check the 630.
They were all tight as can be, and when swapping the sprockets I noted that my bolts had Fuji-lock nuts and thread locker on the threads.
Not sure if that was a dealer retro-fix or how the bike came from Husqvarna.

And regarding the earlier post a while back about all the poor running, etc on that one guy's bike.
Never saw any response to the question put to him whether he'd had the power-up kit installed... but I will say that my bike was correctly set up by the dealer, and before I took delivery I had them install the power-up kit.

The bike has been flawless, and feels like a better prepped version of my TE 610. I've built a lot of dirtbikes from the ground up, and this is the best one straight from the factory yet.
(the TE 630 is my 52nd bike, having had at least one in the garage every year since age 12 in 1968)

 

[johngil]

I replaced my rear sprocket with an Ironman the other day, knowing the alloy oem (Supersprox) one would not last long. I was doing the countershaft (14t) anyway, so a good time for a little PM in the drivetrain.

My 525 sprocket bolts needed to be checked occasionally, and seeing this thread title naturally made me check the 630.
They were all tight as can be, and when swapping the sprockets I noted that my bolts had Fuji-lock nuts and thread locker on the threads.
Not sure if that was a dealer retro-fix or how the bike came from Husqvarna.

And regarding the earlier post a while back about all the poor running, etc on that one guy's bike.
Never saw any response to the question put to him whether he'd had the power-up kit installed... but I will say that my bike was correctly set up by the dealer, and before I took delivery I had them install the power-up kit.

The bike has been flawless, and feels like a better prepped version of my TE 610. I've built a lot of dirtbikes from the ground up, and this is the best one straight from the factory yet.
(the TE 630 is my 52nd bike, having had at least one in the garage every year since age 12 in 1968)

Been on a bike since 1977. I also love the build quality of the 630, but I have never had all the sprocket bolts come loose. Just sayin'.

 

[EricV]

Johngil typed my response perfectly except, for me, I've been riding since '75. Ah, so many good times...

 

[rjdenya]

I sure am glad to read this as the EXACT same thing happened to my HuskyTE630. rear sprocket and wheel exploded on the road at only 25mph. This is one of many problems with this bike.This happened to be the last straw with my experience of buying a Husky630. I will start another thread on the horrible experience I have had but wanted to jump in on this link. There should be a pic posted with this.
Support for these bikes in non existant and parts are a nightmare. You call supposed customer service in OHIO and the kids there don't even know that Husky has an office is in Calif!!! So the TE630 is out of service for another month for the second time this year. Parts fell of it. The bike stalls repeatedly and is unridable in the woods and dangerous on the street. The new owners have ruined a great brand and when people read posts like this they should stay away.
I have owned more than 40 motorcycles and never had such problems as with this bike and its service. Sorry but have to tell the truth even if it hurts. Give me a KTM anytime

Wow man I'm happy to hear you weren't hurt when your rear sprocket and wheel "exploded." It sounds like you've got a bad taste in your mouth due to a poor experience with your bike. That doesn't mean you scrap the bike and trash the brand. I'm not so sure your frustrations are directed at the right party here. Your dealer sells Husqvarna and needs to stand behind the product they sell. Let your dealer and Husky battle out any warranty or factory defect your bike may have. It's not your responsibility to make phone calls to Husky, that's why dealers sell and service bikes. In business don't let someone else's problem become your own. For instance, if my Toyota's oem JBL CD changer malfunctions and it's still under warranty, I bring it to the car dealer for repair. I wouldn't bother calling JBL directly because that would take the car dealer out of the equation. Not to mention JBL would promptly direct me back to the dealer for warranty work.

Did you bring your bike to the dealer for the manufacture's recommended first service? If not did you go through the bike with the service manual and do everything yourself? Who ever performed the service on your bike should have found the loose sprocket hardware. Husky recognized there was a problem with the oem sprocket nuts and issued a service bulletin sending dealers nylock nuts. BTW, the rear sprocket bolts should have come from the factory with thread lock at the very least. My sprocket hardware was all loose with low mileage and actually grooved out the sprocket bolt holes. Husky did replace my chain and sprockets under warranty because my dealer found the problem went to bat for me.

If it doesn't say Honda, Suzuki, Yamaha or Kawasaki on the side panel expect some less than perfect lead time for parts and support. That's the nature of "niche" bikes with a handful of dealers who sell and service theses toys. As you stated above, owning more than 40 bikes you must have known this quite well.

With regards to KTM, even though they are currently the largest manufacturer of dirt bikes in the world, they too have issues. Take a 2011 KTM 530 EXC for instance. A good friend of mine bought one brand new for just over $10,000.00 a few months ago. He has had his share of problems with the mighty pumpkin. The bike was jetted so lean from the factory it wouldn't even start. The oem rear turn signal burned off because the muffler outlet points directly at it. The bike holds less than a quart of engine oil?? Did you ever read the KTM required engine maintenance schedule?? The bike doesn't come equipped with an auxiliary cooling fan?? The engine grenaded after only 1,500 miles of typical dual sport use. The bike sat in the shop for almost two months while KTM finally agreed to cover most of the repair.

I'm not bashing here...am I??? This is a Husqvarna forum right?

 

[duca99]

I sure am glad to read this as the EXACT same thing happened to my HuskyTE630. rear sprocket and wheel exploded on the road at only 25mph. This is one of many problems with this bike.This happened to be the last straw with my experience of buying a Husky630. I will start another thread on the horrible experience I have had but wanted to jump in on this link. There should be a pic posted with this.

Dear all,

I'm introducing myself on this post as I have the same problem with the rear sprocket.

Fiirst of all, sorry for my english, particularly I don't know some technical therms..

I'm to be considered as a lucky guy as I letf only bolts of my 6.....third was out of his hole while I was moving my bike by hands...the bike stopped and I noticed of 2 bolts gone away and the third was stopping the bike by pushing against the ...I don't the correct name, in Italy we call it as "mono arm"
Biggest problem for me is that one bolt, maybe the second, made a notch on the internal face of that thing I'm calling as mono arm, as in that moment I was'nt driving so fast to make it broken by the contact to the arm itself, and the bolt's head made the notch in the aluminium arm before to go away...

I would like to know if Flyingbeard and Brainstorm had the same notch on ; their bikes, I cannot see this from the posted pictures.

Concerning the assistance, mine is official Husquarna dealer from 20 years, he was an Husky Enduro driver and he knows personally most of Husky's technicians in the factory; he replaced me the bolts with standard and is waiting for the new lot from Husqvarna directely. I do hope they will be the nyloks jtemple posted above; I can confirm no official recall have been issued here in Italy (I noticed that TE630 is more successfully sold in the USA and Australia than in Europe)..

Anihow, also if I'm waiting for an Husquarna official conformity statement on my notched mono arm (they don't want to do that), I still remain a fanatic of my bike, as the first moment I've seen it on the wed in fall 2009...

Thanks an read you soon,

 

[jtemple]

Nylocks should cure your problem.

 

[J.R.]

Dear all,

I'm introducing myself on this post as I have the same problem with the rear sprocket.

Fiirst of all, sorry for my english, particularly I don't know some technical therms..

I'm to be considered as a lucky guy as I letf only bolts of my 6.....third was out of his hole while I was moving my bike by hands...the bike stopped and I noticed of 2 bolts gone away and the third was stopping the bike by pushing against the ...I don't the correct name, in Italy we call it as "mono arm"
Biggest problem for me is that one bolt, maybe the second, made a notch on the internal face of that thing I'm calling as mono arm, as in that moment I was'nt driving so fast to make it broken by the contact to the arm itself, and the bolt's head made the notch in the aluminium arm before to go away...

I would like to know if Flyingbeard and Brainstorm had the same notch on ; their bikes, I cannot see this from the posted pictures.

Concerning the assistance, mine is official Husquarna dealer from 20 years, he was an Husky Enduro driver and he knows personally most of Husky's technicians in the factory; he replaced me the bolts with standard and is waiting for the new lot from Husqvarna directely. I do hope they will be the nyloks jtemple posted above; I can confirm no official recall have been issued here in Italy (I noticed that TE630 is more successfully sold in the USA and Australia than in Europe)..

Anihow, also if I'm waiting for an Husquarna official conformity statement on my notched mono arm (they don't want to do that), I still remain a fanatic of my bike, as the first moment I've seen it on the wed in fall 2009...

Thanks an read you soon,

The term you're looking for is swingarm, but mono-arm gets the point across. I hope they replace the swingarm for you! That is too bad that the bolts got so far before you noticed them. Lets see some pictures, the swingarm/mono-arm may still be useable.

 

[duca99]

The term you're looking for is swingarm, but mono-arm gets the point across. I hope they replace the swingarm for you! That is too bad that the bolts got so far before you noticed them. Lets see some pictures, the swingarm/mono-arm may still be useable.

Dear J.R., thanks for your clarification, now I do know a new term.

I took the bike from the assistane just Saturday afternoon; they assured me the inconvenient with the swingarm has not influence with the bike's conformity. Got a wonderful 2hours ride in the woods, and I felt very confident with the bike.

I'll take some pictures of the swingarm, and I'll measure his thickness on that point and notch's depth to make a comparision.

 

[duca99]

The term you're looking for is swingarm, but mono-arm gets the point across. I hope they replace the swingarm for you! That is too bad that the bolts got so far before you noticed them. Lets see some pictures, the swingarm/mono-arm may still be useable.

Hi,

I'm trying to post some pictures. Unfortunately, I'm not able as a lot of you are, so I cannot disassemble the whell by myself. So, I took pictures not so exaustive as they could with the rear whell took off.

Also, I forgot to take home my UT thickness gauge, so i cannot be sure of swingarm's wall thickness in that point, but should not be too much higher than the notch machined by the bolts' head when they went off.

P.S.: in the last picture, everything is shining behind the holes is the rounded notch.

 

[KLOC]

Yeah ... I wouldn't be riding the bike with that gouge in the swingarm.

I had loose rear sprocket bolts on my TE630 as well, but luckily a friend saw them rattling around
as the bike sat idling before a ride. Loctite (blue) on the threads and under the bolt head and they haven't moved.

I tighten the bolts cold, go for a ride to heat things up, and then re-install the bolts with
the Loctite.

My bike gets Trellies in the fall and endurance ice racing tires in the winter. I've found that fasteners tend to have more tendency to loosen up as the parts go from -25C to whatever operating temperature they manage to reach.

 

[J.R.]

Is the gouge that deep all the way down the side of the swingarm or just towards the top?

 

[duca99]

Is the gouge that deep all the way down the side of the swingarm or just towards the top?

Thanks Clock for your description of your experience.

J.R., the gouge doesn't start from the top (and this is quite strange). You can see the top side of swingarm shown in picture named as "ok 3". The gouge starts just after the top and continues all the way down at the same deep. At least it is 2 mm deep at the bottom, because I could measure only this side. I don't know why the gouge dosesn't starts from the top, I think it's because the bolts' head intaked the top side, was bent and then started to machine the gouge.
Anyhow, when I'll come back in Italy I'll discuss again with the dealer, I thin he didn't advise how deep the gouge is.

Let's see what will happen..