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 The previous version was outdated and no longer supported.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

TC 510 broken kick start shaft assy - hole

Kutis

Kutis

Husqvarna
B Class
Hi there

I was starting my TC 510 2006 model and managed to broke kick start shaft. I would blame my starting technique for this as I'm being used to my old CRF with auto decompressor.

Anyway I took the engine case cover off yesterday and so the shaft split in two where the shaft gets narrower.

The thing I'm a bit puzzled is a hole behind gear which goes onto the shaft. It looks like it's there for the oil flow but I'm not certain as the manual I have doesn't have a picture of this. Now I wonder if the broken shaft could have caused this?

Has anyone come across this?

I'll try to upload a picture this evening.

Thanks
Rad
 
Yes, it happened to me last year, right before the start of a moto. Anyway, easy fix. I can't remember how much it cost, but it wasn't to expensive. MotoXotica did the work and have had no problems since. The case was fine. I just broke the start shaft. I've posted this picture I few times on here. My '09 TC510:
bikepics-1921282-800.jpg
 
I have some cases tonight from a 2006 250, Ill take a look when I get home to see if they have that lower hole in the casting like yours
 
Great, thanks guys. I've ordered the part from Husqvarna UK for about £60 plus delivery. They didn't have it stocked so I must wait couple days.

When I asked them if they have some upgraded reinforced shafts he said that they supply the 07 model ones which should be stronger. I'll compare it and take some pictures when it arrives.
 
One thing I just thought about.. By buying a stronger shaft, you just made the case the weak point in the assembly.. I havent seen as many '06-newer broken cases, as I have seen of the older ones, but I have still seen it. Just something to think about, it got me wondering..
 
Thanks! One less thing to worry about. Good point about making the case weak point. I'll call Husqvarna UK and see what they say.

Cheers
 
Sorry for the delay I spoke with Husqvarna UK and they response was that it's absolutely fine and case doesn't have any problem with it.

I also asked the guy about option the option of adding electric start and the answer was: "Too expensive!". It's about £800. It involves changing some gears in the engine which puts me off.

Thanks
 
If you watch for some parts on eBay and around here, I bet you could put it together a LOT cheaper. Just go thru a parts fiche and look for the parts so you can make up a shopping list. Then start collecting! :thumbsup:
 
Hello everybody. Doing some research I found you, and I saw that also broke the shaft of departure, I have a TE 510 / 2008 and broke my bike, like the photo below. Pesso kind enough to let me know the email address of someone who has the shaft to sell new or used, but unfortunately at present we have representatives of the brand in Brazil. I am very grateful if you can count on friends and fans of the brand. Hugs.
 
hello im wondering how hard the kick starter gear is to put back in place i have the clutch cover off my( 08 tc 510) now but didnt want to touch it figuring i may not get it back in place ....besides the fact that this is the hardest bike i ever owned to find out info and parts ????? i live in newfoundland and the only dealer is 800 km away
 
Hi there.

the kickstart shaft isn't that difficult to put together. The only tricky bit was to take the clutch basket off (which you have to take off in order to put assamble it)... you need a special tool or you can make your special tool or you can try to somehow lock the back wheel in gear so you can undo the big bolt which holds it. I managed to lock it by sitting on the bike against wall and my mate was lucky to undo the bolt...

Otherwise try to memorize the order of the parts and it's straight forward.

Good luck.
 
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