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 The previous version was outdated and no longer supported.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

Odd Clutch Issue

Ruffus

Ruffus

Husqvarna
AA Class
Last time I rode my bike at the Northeast Rendezvous my bike worked great. Wanted to ride today clutch felt great until I started it, then zero clutch lever pressure. Got home & bled it, seemed to work great no matter how many times I pulled the lever. Start up the engine & within 5 seconds, same thing. About to take the valve cover off & check the shims anyway, just wondering if it could be a plugged up crankcase evacuation tube, or should I be looking somewhere else?

T.I.A.

Edit: Not the CC evacuation hose, & I'm not losing any fluid from the master. Without the engine running it's easy to get full lever pressure. :excuseme:
 
That's really weird. Is the clutch engaged despite the no pressure at the lever? In other words, if you were to drop it into gear when running with no clutch pressure, would the back wheel spin? (probably a good idea to test this on a stand)
 
dfeckel said:
That's really weird. Is the clutch engaged despite the no pressure at the lever? In other words, if you were to drop it into gear when running with no clutch pressure, would the back wheel spin? (probably a good idea to test this on a stand)
Click to expand...

Yes, just like a normal run without touching the lever, clutch is fully engaged. If I shut it off, pump the lever a few times, I get full pressure back & it stays full until I start the engine again then gone in a couple seconds. Didn't get to the valve shim inspection yet. Hope it doesn't get serious on me.

I hid them gap gauges somewhere really well. :banghead: Hopefully in the morning I'll find them
 
Hmmm valves were in spec, but set them to the middle anyway just in case, rotated the engine with the valve cover off just in case any valves weren't moving properly (they all were).
Cleaned the air filter & first time I've used something called ReleaseAll biodegradable degreaser. Wow, my filter hasn't looked this clean since I bought the bike & I've used many product's over the years. Reverse bled the clutch system & still the same symptoms.

Next up is an oil & filter change & tear apart the slave. Weird that it only happens while running.

I guess no ones had or heard this problem before?
 
Ruffus said:
I guess no ones had or heard this problem before?
Click to expand...

Well, "close"... mine started to loose pressure on a ride- checked fluid and it was good. Pressure came back- would go out again, BUT would not be entirely useless- it still kinda worked. I adjusted the lever all the way out and finished my ride- but my timing with the lever was off- so it just felt weird... I then back bled it- should have been good... but the problem returned- semi limp pressure while riding/ intermittant...

I bought a 7602 piston- because I thought that would be the issue since I heard about the stock piston wearing cylinder. Bled it- but the problem returned. Then I rebuilt the Master cylinder... (new piston kit with spring (~$35-40)) Then I bled it again- same... then continued to bleed finding air near the master (back bleeding/ then pumping lever/ switching to standard bleeding- but leaving the back bleed hose on and Drawing out) Then it worked!

Inspect your hose, inspect the area where the plunger of the lever goes into the master for leaks. That would cause this- though mine did not show a disernable amount of leaking- (I cleaned it and left it sit with paper- and there was no leak) There are 2 seals in the master to my understanding- one to push the fluid and the other to seal at the plunger. My theory is that it was leaking at the "pusher" seal- or was dirty (again not noticably so). (the rebuild kit includes everything needed)

I think why it only shows up when running has to do with heat and vibration- and you are at the very early stage of failure of the clutch system.... My slave cylinder had one mark where the anodization was worn but thats it. So I think I am ahead of that game with the 7602 cylinder.

Anyway- alls well since and I have about 800 miles of mixed offroad in since...

Good Luck:thumbsup:
 
HUSKYnXJnWI said:
I think why it only shows up when running has to do with heat and vibration- and you are at the very early stage of failure of the clutch system.... My slave cylinder had one mark where the anodization was worn but thats it. So I think I am ahead of that game with the 7602 cylinder.

Anyway- alls well since and I have about 800 miles of mixed offroad in since...

Good Luck:thumbsup:
Click to expand...

Thanks for the info, I have had the 7602 piston in it for a couple years, I also have a brand new second one just in case this might be the issue. I can't see heat being an issue because it happens within a couple seconds of starting the engine. I'll update after checking the slave
 
AndrewS said:
I'm surprised no one has had the same issue.

Might be worth a quick call to George Erl?
Click to expand...

That was gonna be my next move, but I want to make sure I do everything else possible first. Needed a valve check\oil change\ air filter clean anyway :cheers:
 
Ruffus said:
That was gonna be my next move, but I want to make sure I do everything else possible first. Needed a valve check\oil change\ air filter clean anyway :cheers:
Click to expand...


Some times it's something so simple & obvious that I feel like a fool after I finally get it :lol:
 
Well it wasn't the oil :D

So I check the slave last since I'm not losing any fluid, open it up & the bore is scored 3/4 of the way around, I put back the factory piston because I didn't want to butcher my spare new 7602 piston and it's holding pressure just fine, I doubt it'll last long with the amount of scoring.

So anybody know a place to get a new reasonably priced slave?
 
I had a similar issue with clutch pressure loss. My clutch hose "L" at the fitting . The crimp broke free and the hose would rotate around the hose.
Kinda like drinking a soda with a broken straw.
 
Have you checked the center nut that holds the clutch hub?
Your clutch assembly may be moving away from the slave/push rod while the engine is running.
Mark
 
I've only had 3 clutch issues .. And the o-ring in the slave cylinder on the side of the engine was the issue 2 times ... The clutch action would just go away ...and while riding the bike ... The clutch action was random both times ... It would come and go ... The first O-ring from George's lasted me about ~800 hrs or so of riding time .. I'm on his second one now ... I'd guess this o-ring is your issue ....

On the 3rd issue with the hydo device, the master cylinder needs a new piston or seals ( gotta buy both ) because it is leaking a little too bad now and I've had to adjust the lever action so much my safety device on the lever the allows the starter to engage, does not work ...

So far, my hydro clutch is easy to decipher ... I think I'll try ATF when I replace the piston ...
 
QuadExpert said:
Have you checked the center nut that holds the clutch hub?
Your clutch assembly may be moving away from the slave/push rod while the engine is running.
Mark
Click to expand...
No I haven't checked that. Pretty sure I found the problem since I'm maintaining pressure now with the engine running. Just have to order a new slave.

Just might check it now that I'll have some down time. Thanks for the info. :thumbsup:
 
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