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 The previous version was outdated and no longer supported.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

Starter Problems

A

ADVRacer

Husqvarna
C Class
I'm still in the process of setting up the brand new 2012 TE 310. When I bought the bike, the starter worked intermittently. The tech at the dealer and I were certain it was due to the fact the battery hadn't been charged. It made sense to me. I took it home and it started fine for the initial break in ride to get it safety inspected. I took it to the trails and it started fine until I got in to the woods. It started clicking again. I thought it was the battery and I hadn't put it on the trickle charger because it had been starting fine. Anyway, I spent the rest of the day kick starting the bike. So now I'm at home and the starter won't work. I got the bike started briefly with the kick starter yesterday for about 8-10 seconds and then it stalled and occasionally sputters but won't stay running. I've installed the TXC ECU and have removed the O2 sensor and installed the sensor eliminator. All I get is a click from the relay the positive battery lead attaches to. The kill switch is in the correct position, the fuel pump spins up, the fuel valve is open, the lights come on, the computer is on and during the start up sequence it displays E41E. I had the battery tested and it reads 12.6 volts. I put it back on the trickle charger overnight just to make sure, same problem. Does anyone know what's going on? I'm hundreds of miles from a dealer so I'm on my own with this one. Any help is appreciated, I'm hoping to get this bike running before the season begins.
 
OK, sometimes I think you have to read the signs that life puts in front of you. I think the sign in front of me says: YOU'RE NOT SUPPOSED TO RIDE DIRT BIKES". I just attempted to kick start it again and the kick starter broke off at the shaft. The bike's new name is Christine! I'm going to go and meditate now.
 
As long as the kick start lever broke and not the shaft or case, you're still OK.

I'd be checking the easiest stuff first, the ground and the power lead to the starter, both of these could affect how the bike starts and the negative ground could also affect how the bike runs as well once it is started.
 
Thanks for the tips. I'll check it out. As far as the kick starter goes, do I have to open up the motor or will this shaft slide in from the outside?
 
ADVRacer said:
Thanks for the tips. I'll check it out. As far as the kick starter goes, do I have to open up the motor or will this shaft slide in from the outside?
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So...the shaft itself broke, not just the lever? If so, the case cover will have to come off. along with anything else that is in the way. If there is enough shaft left to keep the oil seal intact, you could continue to ride it, if you can get the e-start to work.
 
I try to laugh but this isn't even funny anymore. Is there a thread that details this repair? I'd take it to a dealer if I could but there's nothing anywhere near Norfolk, VA.
 
We are in similar boats, but mine is a bit closer to shore. Not the shore where my purchasing dealer lives, since he is 900 miles away. My e-start doesn't work and never has since it left the dealer. Kick start does though. I just can't imagine the kick start shaft breaking unless it was flawed from the factory. Are you still in the warranty period? If so, notify them now in writing and get it over there, hundreds of miles or not.
 
Here are the pics. It would still be able to ride if the estart worked. I attempted to bump start it today but have no hills and not enough energy to do by myself. It was sputuring like it wanted to start though. I have a dealer in WV about 270 miles away. I bought it brand new 2 months ago at a dealer 400+ miles away. It has 33 miles on it. I'm going to call a dealer on Tuesday. It seems like everyone is closed on Sunday and Monday.
 

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Wow! Can you tell if the shaft was forged, cast or extruded steel? 'Can't tell from the photos if there is a granular surface at the shear face. Looks like a flaw in the metal as I just can't see a foot twisting that shaft into two pieces.
 
Its a fairly easy job to replace the shaft (15 mins ?). Several broke on the 2010's as they had a M8 thread, newer ones have a M6 , you been unlucky .

Look at x-lite starter threads on here . There are several ! You may need updated starter gears ? Exhaust Valve settings / Auto Decompressor working ?

Seems some US Dealers are pretty hopeless ! Talk to an experienced dealer (Halls ?) they will be able to help.
 
I may have a spare kickstart shaft. But the dealer should be giving you a new one and putting it in too.

For the e-start:

The left exhaust valve cannot be loose and the flywheel should be checked to make sure it is not shearing the woodruff key. Sometimes they are not put on right at the factory.
 
For my e-start problem I'm looking for a good Husky dealer/mechanic within a days drive from Tucson. I need to get the 310 in before the warranty expires and am not sure about the Tucson dealer. 'Thinking of Malcolm Smith in So. Cal. MotoXotica is about twice as far from me. Any suggestions?
 
The starting issue is common, but the kick start shaft breaking is not one I hear about much. Hopefully your dealer can fix it under warranty, but then again, they should've known about the e start problems and gotten the recall kit before letting it go out the door IMHO.
 
Kenneth Webb said:
For my e-start problem I'm looking for a good Husky dealer/mechanic within a days drive from Tucson. I need to get the 310 in before the warranty expires and am not sure about the Tucson dealer. 'Thinking of Malcolm Smith in So. Cal. MotoXotica is about twice as far from me. Any suggestions?
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I went to Moto City in Phoenix when I was on vacation down there. They did a valve adjustment on my 511. Not sure about the x-lite estart issues, but might give them a call.
 
Sure hope the kick start shaft breaking problem isn't catching! Performance Cycles in Tucson has my 310 and will be turning in a warranty claim. The service dept. there sounds very competent. The dealer who sold the bike did look up any bulletins or recalls and found none on my bike. Maybe it is something very simple....
 
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