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 The previous version was outdated and no longer supported.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

Te510 06 electrical help required

One-speed

One-speed

Husqvarna
B Class
Hi all
Long story short I am totally rebuilding a te510 and have run into some strange electrical problems, thought I was getting there but now have no headlight/taillight.
Looking at the wiring diagram it would seem the yellow wire coming from the stator/generator should power the lighting system, with the guage on it it am reading around 0,8v and review it its going to around 1.6 to 1.8 ish volts, is this right? Seems to me that should be 12v plus
Any help is appreciated
Thanks
 
Now I have checked again I don't seem to be getting any power to the white/yellow connector coming from the stator when I disconnected it (bike running), it is frying my brain now, everything on the bike works perfect now except lights arrrghhh, help please.....
 
You should be getting AC voltage from the stator when the bike is running. If not your stator has a poblem. There is a set of winding for the ignition and a set for charging/lights and also a pulse (hall sensor) down there. Your charging windings may be damaged.

Check for resistance (ohms) on the charging wires. Arcorss the 2 wires you should have resistance(manual will give you a range). This is the resistance of the copper widing. If it is out of range, open (no reistance) or very high resistance (like thousands of ohms) you have a problem.

I dont know the colors off hand but yellow sounds familiar. I think 2 yellows is your AC that runs up to your lights and also to a rectifier to charge the battery.
 
Yeah that's kind of what I thought, I now have no voltage at all coming from the stator (yellow white block connector) bike starts and runs fine, checked the ohms across the yellow white and getting no resistance at all so pretty sure it must be a problem, the manual gives resistance but is a bit vague about what you are testing. Think it is time to pull the stator and send it away.
Appreciate taking the time to reply.
Can you clarify what wire run the lights and what run the charging system. The manual mentions exciter, charge and lamp, are they what they sound like?
 
Ok, across the yellow and white I have 0.6 ohms with meter set to 200 ohms (as low as it will go) and yellow to frame earth I have 1.6 ohms
With the bike running 0v coming from either yellow or white when earthed to battery
 
The AC that comes off the stator goes straight to the lighting system. There is a regulator/recitifier on this system as well that convers to dc for charging the battery. So you may find that your not charging as well. Those numbers seam low?

I would pull the cover off and take a look. Maybe just a wire connection to the coils has broke.
 
Ok checked across the battery terminals when the bike was running and not getting above 13v in the two minutes as stated in the manual (should get 14v) is there a way of determining if the reg/rec is faulty as well as the stator? Surely can't be both?
Thanks for the help flash
 
Your stator is what is making the power. If you are not getting AC and your lights are not working then the stator is your problem. If your lights were working and you had no charge then might be the regulator/rectifier but that is not what you are seeing. You should see 14Volts or more at the battery when running. Your stator needs a look at.

The stator is just coils of wire. Dont be scared
 
Thanks again,
Pulled stator and found a video on YouTube that shows some basic checks, if I check for continuity between the yellow or white wire at the block connector and put the other probe on the body of the stator I am getting a beep, this is the opposite of what should happen according to the video, can't see anything obvious on the stator itself. If I check the exciter wires eg the red/white and red/black they seen to check out ok and am not getting a beep.
Does this sound right (or wrong lol)
 
IMAG0346.jpg Tried uploading photo! Found three wires that right at there ends the epoxy or whatever the coating is has come off, not much maybe 3/4mm you can see them if my photo uploaded below the red white wire on the right hand side, there is also a single copper wire on the opposite that has the same exposed copper, is this the problem?
 
I am not sure if they are grounding one side of the coils or not. If they are you will get a resistance to ground but should be like 5ohms or somehing. If you are getting almost no resistance from white or yellow to the body of the stator then you have a bare wire ground somewhere. Follow the wires through the stator and look for bare wire touching anything that it should not be touching. That orange copper color is insulation that is very thin. It can be scrapped off and if touching metal will cause a short.
 
Ok, sent the stator to the main stator repair place in the UK and they phoned today to say everything check out fine?? Really baffled by the whole situation now, just away to get some petrol and matches I think.............:excuseme:
Can anyone with a similar age TE tell me if you disconnect the yellow/white block connector and start the bike if you get a voltage to the yellow or white when you put the probe in and earth to the frame....Please :banghead:
 
So i looked up in your manual to see what they are doing. The white wire is some coils and the yellow is some other coils. They ground the other side of the coils. The yellow is your lights and the white it charge.
The manual says between yellow to ground you should have .65 ohms. I would make sure your meter is good, on Ac setting. Since you dont have either charge or lights the grounding of the stator/coils may be your issue. Check how the coils are grounded. They may be soldered to the stator frame. This may be broken. Not sure how the whole stator is grounded to the bike? Just the cover bolts that make the ground connection to the engine case?
 
Ok this is getting weird (or maybe I am missing something obvious) got the stator back today and fitted it fired the bike up probe into yellow, 24v at idle raising to 60+ when revved ye ha I thought, checked the white 26ish volts again raising as revved, perfect. Then connected the yellow/white block connector up behind the head and checked voltage going to the reg/rec and nothing?? Probe into the back of the block connector (stator wires) the way I usually check and 0v(as I was getting when I sent the stator away), probe into the back of the white wire and 6v.Eh? Disconnected connector check voltage back up 20v plus, plug it in and the voltage dissappears on the yellow and drops to 6 ish on the white surely this is not right? Any help is appreciated at this stage of the game, my wife is starting to worry about my obsession with husky wiring diagrams !
 
You regulator/rec may be pulling down your white and you may have a short in your lighting somewhere. Check your wiring and disconnect all your lights and see if you get it back. If you do, start plugging them back in till you loose it.
 
Hi once again thanks, yeah figured I have a short in the loom somewhere, all the lights are disconnected at the moment, is there a good way to narrow down where the fault is with the multimeter? Is is it just a matter of opening up the loom. Can you explain what you mean by the reg/rec is pulling the voltage down on the white?
Thanks again feel like I am starting to make progress!
Ps. Have disconnected the regulator from the loom also to rule it out as faulty
 
Ok, the saga ends, after disconnecting ever block connector and checking all the yellow wires throughout the loom, still getting not power to the stator, finally noticed a thin yellow of the rear sub loom, traced it to the rear brake pressure switch, opened the block connector and low and behold power restored to the stator :cheers: Thanks to flash for the help , Couple of lessons learned 1.don't check stator voltage when the stator block connector is plugged in 2. I am rubbish with electrics
 
Tough journey to locate your problem. Well done to figure it out.
You may think you are rubbish at electrics but I can guarantee you are far more advanced in diagnostics than me....Electrics are scary for those with out the "force"
 
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