• 4 Stroke Husqvarna Motorcycles Made In Italy - About 1989 to 2014
     TE = 4st Enduro & TC = 4st Cross

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I need advice on a '09 510 EFI problem

Holland

Holland

Husqvarna
A Class
Dear everyone,

Since two weeks I am the proud owner of a '09/'10 model Husqvarna 510 SMR which I bought with 1700km on the clock.
However, past days I've been trying to figure out what mods are must haves and how to fix some problems, but admit-tingly it's all so confusing that I'd dearly appreciate someone explaining it directly to me.

As far as I know the bike is fully standard. Previous owner rode it on the street, and after 800km or so started to do track riding with the bike (put on slicks, and did some weight reduction). Then he realised it wasn't for him, and wanted to sell the bike. Or that's how the story goes.

I have a issue that often when riding, in both cold and warm conditions, the bike tends to stall when slowing down. Usually when I'm shifting down (de-clutched) the bike tends to die on me which can be aggregating in traffic. Most of the time I get it running by either starting it or dropping the clutch before I come to an absolute stop, but sometimes it won't start for a while and I'm just a sitting duck on the side of the road.

Now this is my first Fuel Injected bike, and I'm a complete noob when it comes to fuel injection knowledge. I always read the '08's had issues with EFI's, which is why I set my focus on finding a '09 or '10 model, among other reasons.

the bike used to run about 1650rpm idle, and I upped it to 1950rpm to see if that fixes it, it didn't.
I understood that the shop I bought it from slightly adjusted a few settings with iBeat to get rid of lean emission areas, I do not know if that affects the stalling.

I read about a lot of guys with '08's that say a power commander is a must have, and I also see some 09/10's using it. I'm wondering if it also apply's to 09 and 10 models. I can get a PCV for €125 second hand, and I'll probably get myself an auto-tune for while I'm at it, but all-together it's quite pricey and being a student I just invested most of my savings buying my dream-supermoto (stupid I know, but my Aprilia was costing me alot in replacement parts alone, and I happen to have a Husqvarna-fetish that I've long waited for to satisfy).

So my questions is, would a PCV+autotune solve my problems, up my engine life, give me more torque, and be a good adaptive system for the future mods I'm planning (slip-on leovince, arifilter)? Or would it be a waste of money because my standard EFI unit is good enough and just needs good tuning or something (I also read about people putting it in "track mode")? Also, are the CDI, EFI unit, and PCV the same thing or are they all different?

Or if anyone reconizes the issue and thinks it's due to something else, please to speak out.
Thank in advance!
 
Fill the gas tank up full and take it for a ride and do all the stoppies and stuff that makes it die. If it doesnt die with a full tank, pull the fuel pump out and see if it has slipped upwards in the holster.

If that fails, the first thing I would do is replace the fuel pump.
 
Is the sniffer in the exhaust pipe? If the bike hasnt been powered up into the race map, it is probably running very lean. What MPG do you get?
 
My 510 also used to stall occasionnally, especially when I twisted the throttle when idling. The 250 also does it, though it is carbed. The only remedy I have found so far was to up idling to 2000 rpms like you did and it solved the problem at 99%. I am kinda hijacking your post to see if anyone can bring a cleaner solution to our problems ( I have 3 bikes out of 6 running high idling and I don't like that )
 
I had similar problems when i first got my 510. Had a powercommander with "auto tune" setup. Always ran crappy down low, basically from idle up to 6k rpm. Stalled frequently, especially on downshifts while disengaging the clutch and lugging the engine in tight trails. It would also stall or bog badly if i gave it to much throttle to rapidly off of idle. Bought a new 510 a few years ago, installed a power commander 5 and had a local dynojet shop make a custom map for it. Problem completely or say 99% disappeared. No hesitation off idle barely stalls when lugging the engine if ever. Any fuel injected bike should be able to rev freely from idle to redline even if you blast the throttle wide open rapidly. The tune also woke the bike up a nice amount and smoothed out the torque and power curve alot! I run my idle at about 1700 now. Here are the dyno charts IMG_1569.JPG
 

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Wow! That's a big increase RideLI! Aside from the increase it's much smoother too! Before you got the PCV, was your bike standard or "full-power"?

OlderHuskyRider, I'm going to derestrict the bike today, put in the O2 plug, lambda resistor, and isntall the airfiltercage. Than it should be in racemap. After I'm done I'll take it for a spin to see how the bike reacts, if the Dutch weather allows it. I can get a PCV+autotune for €180 so I'll probably take it anyway.
 
Holy banana's what a world of difference....
I just put in the O2 plug, lambda resistor en airfilter cage. Everthing that should allow it to run the Race-mapping.
I let it idle for a few mins, it smelled notably more than before.
Also there was grey smoke coming from the right silencer. Even when I angled to bike to the right for a while it still only came from the right silencer. After a while it became less. Untill it stopped so it probably has something to do with the muffler itself.
When I took it for a test ride I was astounded.. It's like an entirely different bike now. If the mapping issue was at 100% before, this straight out solved 75% of it.
-So far it did not stall anymore
-It runs much smoother now when idling
-There's no constant backfires anymore when off the throttle (kind of a bummer, I must admit that I enjoyed scaring the heck out of pedestrians quite abit :P )
-It just wants to wheeeeelieeee. It's like a badly trained dog that keeps jumping up against you, even after you order it to be gentle it still goes whoop whoop whoop :D
-Overall more POWERRRR
-It's much smoother everywhere, low/high rev, half/full throttle
-It seems to pick up better, no "delay" like before, where it almost felt liked a carbed bike sometimes.
-the boggy, shaky and bad running area around 3000rpm seems much less prominent now.

The only things that don't feel 100% smooth yet are:
-on low rpm's between 2000rpm and 3500rpm, where it is still a bit boggy and not fluently with the torque. However it's much better than before
-There's still the on/off effect feeling when either on or off the trottle. Now it should be there in some degree ofcourse, being a powerfull 1Cil and all, but still I feel like it could be less.

Since I'll likely get some aftermarket silencers, that will require me to readjust the mapping anyway, I'll probably get the PCV+Autotune. Do you guys think I would resolve the last two remaining issues with that too?

Thank you for your assistance guys.
 
RideLI631 said:
I had similar problems when i first got my 510. Had a powercommander with "auto tune" setup. Always ran crappy down low, basically from idle up to 6k rpm. Stalled frequently, especially on downshifts while disengaging the clutch and lugging the engine in tight trails. It would also stall or bog badly if i gave it to much throttle to rapidly off of idle. Bought a new 510 a few years ago, installed a power commander 5 and had a local dynojet shop make a custom map for it. Problem completely or say 99% disappeared. No hesitation off idle barely stalls when lugging the engine if ever. Any fuel injected bike should be able to rev freely from idle to redline even if you blast the throttle wide open rapidly. The tune also woke the bike up a nice amount and smoothed out the torque and power curve alot! I run my idle at about 1700 now. Here are the dyno charts View attachment 62004
Click to expand...
Wow! That's a big increase RideLI! Aside from the increase it's much smoother too! Before you got the PCV, was your bike standard or "full-power"?
 
It had the "power up" map from the dealer, Fmf Q4 exhaust and just the airfilter and cage no screen or restrictor. It was literally unrideable. Would bog a cough from idle to 6k rpm constantly. Tuner said it was dangerously lean. You can see from the fuel table i posted that some spots he had to add up to 25-30 times the amount of fuel than what it was getting.
 
Thank you, that's what I wanted to hear!

Just ordered the PCV + autotune, I'll install it sometime in the coming weeks and will share my results here, so admins please don't close the topic yet (if that's a thing on this forum).

Thank you all for helping and thinking with me!

-Holland
 
I would say, that make better change maps, but nothing critical, if compare in dyno adjusted custom map...To me that autotune is good when dont have enough money, but what i have seen that custom map is in someway better..
 
Okay, today I finally got it working after much hassle with Dynojet support and countless times of putting everything back together, it appeared the Dynojet manual was wrong about which wire to tap (should have been the orange/black one instead of the orange one). This resulted in a 5V always going trough the grey wire and made the PCV think that the TPS always gave 100% throttle (5V>4.3V).

Now that it works the bike runs much better, I still need to improve the mapping by doing many km's and PC updates with the autotune, but I believe it will be very nice!
Thanks everyone!
 
OK on my 08 te510 the 3rd wire top row from right is ALSO orange/black. taped in there and 0v is shown ..... this cant be right?
The bike starts and runs great. What could I have done wrong ?
 
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