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 The previous version was outdated and no longer supported.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

TE250 Final drive bearing failure

Matt Shield

Matt Shield

Husqvarna
B Class
The bearing behind my countershaft sprocket disintegrated, taking a small chunk out of the case. Has anyone else had similar? I've been reading threads relating to the cam gear bearings failing. Perhaps Husky has skimpt a bit on the quality of bearings throughout? It's a 2010 TE250.

Now I'm in the midst of pulling her down to check out the damage. So far, barrel looks excellent, top end looks good, but I'll replace those cam gear bearings anyway now!

I can only think that I had the chain too tight, creating too much tension on the CS sproket. I haven't split the cases yet so Im just hoping the gears are all okay. As for the case I'm hoping it can be 'chemi-welded'.

I was left standed between the ghost-town of Maytown, and Laura on Cape York, far north Queensland, Australia. We tried towing it out but it just wasn't happening. My riding buddies went ahead and found some young 4wd enthusiasts coming the other way who said they'd pick me up and take me back to camp. They eventually arrived, drunk. mmm, go with drunk yahoos or risk being stranded in 'Wolf Creek' country where stray prospectors get shot and their bodies never found (true story). I went with the drunk yahoos who kept drinking, trying ridiculous 4wd obstacles with my bike on the back, nearly rolling the 4wd, shooting out of the 4wd, stopping to chase cattle, etc ect. Eventually I got dropped back to camp some 4hours later, and none of my riding buddies were back. Turned out one broke down outside of Laura and had to get towed in. The car that drove to Laura to pick them up burst a power streering hose so had to stop every 5 minutes to fill the resevoir, so took 7hrs to complete the round trip. 3 guys rode back in the dark. Then on the drive home the next day, a mates Husaberg fell off the trailer and skidded down the road. Great trip, NOT.

This site has been excellent. I found out where the cam markers are supposed to be on TDC when putting it back together, among other things (I took no notice when taking her apart). There's no marker or inspection hole on the flywheel cover. How are you supposed to know TDC on the crank??. I see one punch hole on the flywheel, but is there another on the case to match it to??
 
Rockabilly country. Lucky the crocks didn't get you.
Good luck with the rebuild. I agree the chain stress might have been the cause.
 
Matt Shield said:
This site has been excellent. I found out where the cam markers are supposed to be on TDC when putting it back together, among other things (I took no notice when taking her apart). There's no marker or inspection hole on the flywheel cover. How are you supposed to know TDC on the crank??. I see one punch hole on the flywheel, but is there another on the case to match it to??
Click to expand...

I'm curious also. Hopefully someone can help out who's done it before.
 
When i did mine i used a straw down the plug hole trick. It worked well. I made sure to not use anything that could cause a scrape or scuff. Just make sure your on TDC and compression stroke.
 
Thanks all. I split her open thismorning and luckily it looks like everything is okay apart from the blown bearing. Yes, there is shrapnel everywhere but it doesn't seem to have done too much damage to anything else (gears, selectors, selector barrel). I took the case to a bike engineer/machinist and he says he'll be able to repair the case. I'll replace all the bearings in the cases, including the main bearings, and the timing chain and piston rings while I'm at it. Anything else to replace while it's apart? I'll get the big-end checked for play tolerance but I'm hoping its fine. Its done just under 5000k's. Should be good for another 5 surely... I'll upload some photos of my progress when I fix a few things on this PC!!
 
We have replaced countless output shafts and bearings due to over tightening of the chain. Check your output shaft for sure. Also we offer a service that increases the flow of oil through the crankshaft, rod bearing, wrist pin and cylinder walls greatly increasing the engine life.
 
You're very welcome. We do ship them world wide. In the past, the mod was only available for factory racing teams and other racing sponsors. I've tried to bridge that gap and offer mods like this to the general Husky community. Just trying to help. :)
 
Sounds good. So can it be installed by owner? Do you have a link to somewhere with more info and pricing? Anything to enhance engine life is good, particularly while the cases are apart to start with! Did anyone come up with a taller sixth gear???
 
I rebuilt my engine. I put in a new shaft, seal, bush and all new bearings and seals in the cases, a new cam chain (the old one showed no signs of wear), and new ring set, plus new gaskets of course. The chipped case was able to be repaired thank goodness! It all come together very well, apart from sealing up the bottom end then discovering a circlip left on the bench when cleaning up. Turns out I'd left it off the selector shaft. Hillarious. I had to split the case again, and pull the crank right out to re-insert the clip.... Anyway, after that I put it all together again. I had the exhaust cam 1 tooth off, but it was simple to take apart and re-align, then bam, started and ran like a gem! Thanks to the knowledge of this forum, it was all quite easy. Thankyou all. I'd be confident in splitting this motor again. I know it inside out now!
 
Good work on the repair job. Sure the chain may have been too tight but I reckon cheap poor quality bearings don't help. I have experienced bad cam bearings.
 
Had a great ride on the weekend on the rebuilt te250. It went superbly. I flogged it too and it loved it. It previously also had a dislike of water and would 'miss' on initial turn of the throttle after I got it wet. While apart I applied dielectric grease to many of the connections, new spark plug, silicone around the plug cap, lithium ion battery. One or a combination of these things fixed the issue evidently. It also used to consume visibly a fair amount of oil each ride, now with the new rings I didn't notice any drop in oil level over the 2 days. Very happy!
 
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