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 The previous version was outdated and no longer supported.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

Metal chunks found during oil change.

andyman

andyman

Husqvarna
AA Class
Thought I'd get the bike out and prep it for some riding. When I pulled the steel filters out, I noticed some rather large chunks of metal. I assume they're from the transmission? Any ideas?

The chunks aren't magnetic, I had to sweep them out with my finger. I'm sure there's more still in there, and some fell into the oil drain pan.

2009 TXC 450, ~50 hours, oil changed every 4-8 hours.

photo.JPG
 
Clutch plate/clutch basket aluminum?? I'd pull the clutch side cover and start there, it's an easy cover to pull (not just the round cover, the whole side cover).
 
Thanks OHR. That might be my next step. I had taken just the clutch cover off, and from what I could see, everything looked okay.

I'm tempted to put it back together and see what happens.
 
andyman said:
Thought I'd get the bike out and prep it for some riding. When I pulled the steel filters out, I noticed some rather large chunks of metal. I assume they're from the transmission? Any ideas?

The chunks aren't magnetic, I had to sweep them out with my finger. I'm sure there's more still in there, and some fell into the oil drain pan.

2009 TXC 450, ~50 hours, oil changed every 4-8 hours.
Click to expand...
I'd say a bearing cage but I think that would probably be magnetic. I always get small "filings" of ferrous metal in my filters but that looks chunky. Maybe pop the valve cover and make sure of the bearings and cages are intact. How does it run?
 
My first inclination was transmission... it's always shifted horribly. Although, I wouldn't think there is anything aluminum in there. That should all be pretty hard, ferrous stuff.

It's run flawlessly its entire life. Up to and including the last time it was started.

Here's a possible hint though... When I removed the clutch cover, There was a circular shiny ring that looked to coincide with the circumference of the little screws that hold the top plate of the rekluse on. The screw heads don't look particularly shiny, and there "appears" to be no damage to the clutch system. There are two "hump" areas in the case. One on either side of the clutch assembly. Through those humps, I can see the bottom of the clutch basket. Holding the decompression lever and slowly rotating the kickstarter, with a flashlight I can see the whole basket. That entire assembly looks fine. I see no evidence of shavings.

Unless a better idea comes along, I'll pull the outer case cover (behind the clutch cover), and the valve cover. see what I can see...

Thanks for feedback, keep it coming.
 
If I don't see anything after taking the valve cover and side covers off... if there any other option for diagnosing other than splitting the cases?
 
Did you check the bearings on the cams themselves? We had two go out, but they didn't produce that much metal.
 
Looks like at least part of it is the clutch. At a minimum, I'm going to need an inner clutch hub, steel plates and friction plates.

photo 1.JPGphoto 3.JPGphoto 5.JPG
 
andyman said:
Looks like at least part of it is the clutch. At a minimum, I'm going to need an inner clutch hub, steel plates and friction plates.
Click to expand...

Wow, were the cover screws tight? I think if it was me I would send those pictures to Rekluse and see what they say:excuseme:
 
They all looked tight, and felt relatively flush. None of them looked shiny... which I thought was weird. I "IMAGINE" what has happened is that one backed out a bit and got hung up enough on the back of that cover to crack some plates? I guess if it was revving high, that was enough to mash down the mountain area of the inner clutch hub? I dunno. It definitely reeked of smoked clutch when I got in there. LOL. Look how black some of the friction and steel plates are.
 
The burnt smell and black plates are indicative of high heat/high clutch slip. The slipping of the plates creates a ton of heat and it burnishes the drive plates. This may or may not have anything to do with what happened or why.
 
andyman said:
They all looked tight, and felt relatively flush. None of them looked shiny... which I thought was weird. I "IMAGINE" what has happened is that one backed out a bit and got hung up enough on the back of that cover to crack some plates? I guess if it was revving high, that was enough to mash down the mountain area of the inner clutch hub? I dunno. It definitely reeked of smoked clutch when I got in there. LOL. Look how black some of the friction and steel plates are.
Click to expand...
Were the screws locktited?
Clutch acting funny?
I have been known to not locktite the screws till I arrive at an acceptable spring/ball combination. My screws seem to stay tight. but it makes me nervous.
 
Pretty sure they were locktited. I always use LT Blue. Clutch seemed to be acting fine. It's always been noisy, but in a phone call to Rekluse they stated that sometimes they "growl" a lot.

I've only ever run Agip 10w-60
 
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