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 The previous version was outdated and no longer supported.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

Leaky 2003 TE610

mnb

mnb

Husqvarna
Pro Class
I'm trying to determine where/what the leak is before I take this to a shop. If I start it up, it's not 30 seconds before something is dripping on the exhaust pipe right at the cylinder head and smoking.

There's oil/grime all around. In the front of the engine, the grime looks odd. I've included a left, right and front side of engine shot below. Any suggestions/insight would be appreciated.

Right
IMG_1947.jpg


Left
IMG_1948.jpg


Front
IMG_1949.jpg
 
mnb said:
I'm trying to determine where/what the leak is before I take this to a shop. If I start it up, it's not 30 seconds before something is dripping on the exhaust pipe right at the cylinder head and smoking.

There's oil/grime all around. In the front of the engine, the grime looks odd. I've included a left, right and front side of engine shot below. Any suggestions/insight would be appreciat
Click to expand...

The valve cover (not the inspection covers) may most likely the culprit.
My 07 and 08 both leaked there.
Clean it up and take a close look.:)
 
Found a little time and pulled the tank last weekend. It's the breather hose going to the valve cover. Both breather hoses need replacing. One of the fuel lines is not flexible, either. So I'm going to replace all that stuff. I sprayed B12 Chemtool all over the place and wiped it down to clean it up a bit so any future leak should be more identifiable. At least if I catch it early enough.

The petcock on it isn't stock (prior owner was too cheap to put the OEM one onds when replacing?), so the low fuel light is ALWAYS on. I have the stock petcock (ordered it a long time ago), but it hasn't really been a priority. Since I'm going to be doing hoses, it sounds like a good opportunity to install the OEM petcock. I bet it was replaced because the fuel light was flaky. The gauge seems to work fine. :excuseme:

I haven't been giving the 610 as much love since I got the 310. I put it in supermoto mode and did a few rides. But there's some dual sport rides coming up that it'd be good for. The 610 has better range and gearing for street than the 310, so I'm probably going to put her back into dual sport mode. I need to change the supermoto gearing anyways... I went a bit long in the gearing and want to shorten it back up some.
 
Looks like all the parts are shipping out tomorrow. I expected a much longer wait. I ordered some fuel line too since it seemed pretty brittle. And new clamps all around.


Here's the hose damage:

left side
10521059_10155205339380157_1854894786629993559_n.jpg

The primary leak culprit (left side, top of engine, to the left a few inches of the spark plug.
10947188_10155205339465157_770358924154823422_n.jpg


right side
I'm not sure what's up with the melting, they aren't touching anything...
10954551_10155205339555157_5800513889176217681_n.jpg


Hopefully, they get here quick and I can work on the bike this weekend. I need to free up the lift.
 
mnb said:
Looks like all the parts are shipping out tomorrow. I expected a much longer wait. I ordered some fuel line too since it seemed pretty brittle. And new clamps all around.

Hopefully, they get here quick and I can work on the bike this weekend. I need to free up the lift.
Click to expand...


Wow,
Is that the first time you've had the tank off? :)
 
Actually, yes. Have never needed to pull it myself until now.

I've had it since April 2010. I'm the 3rd owner, got it with 2k miles on it. Put 100 miles on it and the cam broke. My suspicion is the 2nd owner over tightened the cam chain somehow. I had a shop fix it. Damage from cam parts ruined the stator as well. The shop fixed it up well.

I rode it for about a year at a local dirt bike park then got some supermoto wheels for it. Switched over to sumo and did a several rides on it over the course of a couple years. It's mostly sat for the last couple of years until I felt motivated to deal with the leak.

I have several other bikes, and I tend to prefer the TE310 for dirt, so it wasn't really a big deal. But the 610 is a great dual sport and I've been getting the itch for some dual sport action a bit lighter weight than my F800GS. As in 100lbs lighter. So we should have it back on the road soon. I've only put about 1000 miles on it since I bought it, IIRC.
 
mnb said:
Actually, yes. Have never needed to pull it myself until now.

I've had it since April 2010. I'm the 3rd owner, got it with 2k miles on it. Put 100 miles on it and the cam broke. My suspicion is the 2nd owner over tightened the cam chain somehow. I had a shop fix it. Damage from cam parts ruined the stator as well. The shop fixed it up well.

I rode it for about a year at a local dirt bike park then got some supermoto wheels for it. Switched over to sumo and did a several rides on it over the course of a couple years. It's mostly sat for the last couple of years until I felt motivated to deal with the leak.

I have several other bikes, and I tend to prefer the TE310 for dirt, so it wasn't really a big deal. But the 610 is a great dual sport and I've been getting the itch for some dual sport action a bit lighter weight than my F800GS. As in 100lbs lighter. So we should have it back on the road soon. I've only put about 1000 miles on it since I bought it, IIRC.
Click to expand...

Good for you, it is good you checked into the leak before it was a bigger problem.

They have a classic Swedish rooted motor and with the single down tube frame.
Great bikes :)
 
The airbox boot was cracked so I ordered a new one, but no matter how I approach installing it, it winds up popping off the airbox. Any tips for getting this back together?

image.jpg
 
The trick is to remove the battery from the airbox. Probably won't be an issue once this Odyssey dies and I put an EarthX in.
 
So I have the bike back together enough to start it up. I don't have much time to work on it, so it takes a while to do fairly small tasks. She just cranks and cranks. I can get it to fire for a second or two if I spray carb cleaner in to the carb.

I started it up about 4 months back and ran it for 15 min or so. It's been difficult to start (as in cranks a while before it starts) most of the time I've owned it. I've heard that's common. What causes that?

Sounds like besides that, I need the carb cleaned. I wanted to get it modified to be more like the TE570 carb for some more grunt anyways.

Any suggestions to get this beast started are welcome. I bypassed the battery and wired it up to my truck and she still wouldn't start.

And yes, I opened the petcocks. Both of them. :)
 
mnb said:
So I have the bike back together enough to start it up. I don't have much time to work on it, so it takes a while to do fairly small tasks. She just cranks and cranks. I can get it to fire for a second or two if I spray carb cleaner in to the carb.

I started it up about 4 months back and ran it for 15 min or so. It's been difficult to start (as in cranks a while before it starts) most of the time I've owned it. I've heard that's common. What causes that?

Sounds like besides that, I need the carb cleaned. I wanted to get it modified to be more like the TE570 carb for some more grunt anyways.

Any suggestions to get this beast started are welcome. I bypassed the battery and wired it up to my truck and she still wouldn't start.

And yes, I opened the petcocks. Both of them. :)
Click to expand...
What does the plug look like after all that cranking? Should be sloshed.
Plugged pilot jet?
Bad gas?
 
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