• 4 Stroke Husqvarna Motorcycles Made In Italy - About 1989 to 2014
     TE = 4st Enduro & TC = 4st Cross

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    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.

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TE 250 non starter and engine not freely turning over

Vino

Vino

Husqvarna
Hi, my te 250 is a 2004 electric start only, last time out it lacked power and wouldn't rev right up . I was told later that it was also smoking . About 10 minutes into the ride I stopped and it cut out , it wouldn't start off the button so had to try and bump start . It did twice but cut out abruptly as soon as I rolled off. Wouldn't then bump at all, and I can't turn the engine over with ease , crank case off and spark plug out its still takes a fair amount of force to get it to turn . Any ideas before I split the head ??
 
Vino said:
Hi, my te 250 is a 2004 electric start only, last time out it lacked power and wouldn't rev right up . I was told later that it was also smoking . About 10 minutes into the ride I stopped and it cut out , it wouldn't start off the button so had to try and bump start . It did twice but cut out abruptly as soon as I rolled off. Wouldn't then bump at all, and I can't turn the engine over with ease , crank case off and spark plug out its still takes a fair amount of force to get it to turn . Any ideas before I split the head ??
Click to expand...
Lots of possibilities. My first thought would be bent valve. Check to see if the timing chain is loose. Could of slipped out of time. Had the same stuff and symptoms happen to me on an old Honda. Check Compression first before taking anything apart. My guess is that yours lacks what it needs to run.
 
Head and cylinder off will be minimal requirement, that way you'll see whether it's top end or bottom end issue. Draining the oil and examining any shrapnel will be your first indication of how bad things are.
 
dropped the oil and that seems pretty good , it's only had about 5 hrs of running time. the drain plug was more concerning though, that was full of swarf. timing chain looks good and the valves seem to be moving ok from above. there is a click when turning the engine over by hand but not sure if thats the auto decompression ? nothing left without the head off then . gutted, was even planning on trading up last week .
 
Hi again , getting prepped to split the head but there is a bit of a split within the home camp, my ktm riding buddies are convinced I need to split the timing chain while the yam and Kwak riders say no need . I don't have the splitting tool so before I order one and delay the post mortem , has anybody got some friendly advice ??
 
Don't split the cam chain, that's only necessary on a KTM (dumb design, but what do you expect right).
My bet would be the clutch between the electric start and crank, had a TE450 with that problem.
Everything was fine until it started bad, it run for a moment and stopped with a crack noise (like a backfire).
When that clutch (not the transmission clutch) was removed it could easily be turned.
 
Split the head tonight , barrel off and all looked good , piston was fine until I tried to move it . Big end bearing stiff as a stiff thing ! Looks like a full bottom end rebuild . Any uk members got an idea of cost ? I think it's probably too tricky for me .
 
Where about in the UK are you? Most bike shops should be able to strip the crank out if you're not comfortable doing it then will need to go to a reputable engineer to press out the old big end, press in the new one and balance the assembly, do the main bearings while you're in there and piston too, or at least rings. You'll have a good, fresh engine at the end of it, oh, and an empty wallet!!
 
I'm in Bridgend , South Wales . I only know one non dealer workshop, dean john / two wheel engineering . My other bike is a new triumph so I only go to the dealer . Any ideas of a price so if or something to gauge it off ? I had the top end rebuilt only a half a dozen rides ago , so it's turning into an expensive new hobby. Only been riding off road for a year . Funny all the road bikes I've had and never a penny spent other than service and tyres.
 
Con rod kit will be around £120 plus fitting to the crank and balancing so probably £200, that doesn't include dismantling and rebuilding the engine though. The road bikes are rarely stressed to their limits and are built to do tens of 1000's of miles, you can generally give them an oil and filter change each spring and ride it, these off road bikes are quite highly tuned and made to race, hence need more attention and maintenance, e.g. oil changes every 5 hours on mine. You've got an older bike there and probably little idea of what maintenance it's had over the years or how it's been ridden.
 
I've been told the con rod is no longer available for the 2004 engine and it will be a case of buying a new complete crank. suppose that will save on labour mind. yeah i appreciate that they take more of a beating , great fun mind and its improve my road riding no end..when the back of triumph starts to lighten up or move around it doesn't worry me ....well as much.
the only thing is some of the rides we do are far longer than 5 hrs..
how does £350 sound with the engine out of the bike ??
 
£350 doesn't sound too bad but I'd price a crank up first, last one I bought was for a Husaberg and cost £700, can't believe con rods aren't available though, it's not that old. Quick search and Mitaka make one.
 
Hi again , just wanted to say cheers . Finally got my engine back in the bike, the rebuild guy had a nasty off and was out of action for several months . First time out and faultless !! Can't wait for next time when I can really give it the gravy !
 
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