TE610 Custom water pump housing reverse (normal) flow

[Bahr]

In a continuation of my sunk cost fallacy on this bike I've barely ridden; when I was ordering replacement valves from HTM (https://www.htmracing.it/prodotti-m...ssori-ricambi-husqvarna-sm-sms-te-tee-610-4t/)

I noticed they make (or made rather, it's discontinued) a cooling system kit that reverses the stupid 610 cold water in at the head and out at the barrel system, however; it's discontinued (like everything for these bikes...)

So; I decided to make my own system.

Step 1: design pump housing which can be 3d printed in PET-CF or PA6-CF (I used PA6-CF because that's what I had). Much measuring and lofting later:


Then to the bambu P1s:


Finally after 3 attempts (first was printed at recommended nozzle temp of 275 and had a cold layer near the very end when fan came on, 2nd was printed flat side down and I accidently made support z top distance 0...so it was one giant lump of plastic, 3rd was printed at an angle entirely on organic tree supports and at 295 on 110c bed (chamber was around 60).


1st attempt print I tried out today, was circulating into a bucket, it faired totally fine, got everything up to full temp.


I will need to do the cylinder connection and a different thermostat (maybe a thermobob or something, just simple inline); hoses will be very simple, almost straight up to a tee for the upper connection from the pump, then straight from the radiator bottoms into a tee fitting into the cylinder (haven't finished that yet).

Will update the lost void that is cafe husky as I progress.

 

[Theo]

I remember that kit and IIRC someone installed it, too back in the days.
So is that 3D printed housing what you are going to use permanently or is it just a prototype?

 

[Bahr]

I remember that kit and IIRC someone installed it, too back in the days.
So is that 3D printed housing what you are going to use permanently or is it just a prototype?

Yes I'll use the 3d printed housing. The finished one I annealed at 120c and bashed it with a hammer and it's bloody strong. I don't think it'll ever be an issue.

 

[Bahr]

I'll probably make one from PPA-CF once I know it all works properly, but that shit is $190cad for 0.7kg (or about $27 each go) so I don't want to stuff it up.

 

[darren7878]

Hi - So will the 3D version put up with the heat? I too enquired about the HTM kit but as you say its discontinued.

I have an original kit if you need more photo references?

Husqvarna even sold this kit as an option back in the day.

 

[Bahr]

Hi - So will the 3D version put up with the heat? I too enquired about the HTM kit but as you say its discontinued.

I have an original kit if you need more photo references?

Husqvarna even sold this kit as an option back in the day.

Hi Darren,

I'd love some photos of the original and the routing if you have it; you have an original HTM kit?

Pa6 is used for electric coolant pump housing on cars. PET-CF Will definitely withstand more heat, so if it's an issue I'll change to that or PPA if I think I want more strength.

As it is the 3d print seems very capable. I can't see temps getting over 120c.
Finished the design for the inlet and cut and welded the left hand radiator outlet at a better angle. Welding this was awful, just so much contamination seemingly coming from no where. Like welding cast.
Should be basically straight runs. Need to make a thermostat and tee for return line. I don't think HTM used a thermostat, but I'm pretty inclined to having a forged piston.

 

[darren7878]

Hi,

My kits not on the bike, but im aware that the radiator conections require modification.

Here are the photos T20 kit that i believe HTM sold. I purchased some other parts from them recently and tried to get this kit remade but no interest from their side.

I may be able to find some other photos from a fellow HVA enthuast of pipe routing if that helps? I do have 2 pipe kits for the inverted setup.

Theres one more part you need (Y piece) that can either be 3D printer or bought as a generic part.

No thermostat required that I'm aware of.

If you do a small run you maybe able to sell some. I'm told an Italian guy was looking into it but progress was slow.

 

[Theo]

HTM's kit didn't have a themostat:
link to where they say so
I am a native Italian speaker and basically what they say is that they didn't want it because:
1) if there is no thermostat, then no thermostat can be broken

2) in their opinion, without it the coolant flow rate is increased thanks to a bigger cross section of the cooling system in that point.

BTW it's great that they still sell stuff for our old Italian huskys. I dealt with them in the past and they seemed to be competent to me.

 

[Bahr]

Thanks @darren7878, I ended up using a silicon hose kit for an older 610 and some of it fit perfect (the long tee to the top mainly). There's is a little more low profile than mine, but I don't think it makes much difference, I was mainly looking for smooth flow.

I can get the parts MJF or SLS printed from GF35% PA6 from PCBway or JLC for around $55USD for the set. I used the silicon hose set from AS3: https://www.as3performance.com/prod...igh-performance-silicone-radiator-hoses-black

I made an M14x1.5 tee for fan switch, I'll use a KTM one. Piece of 5/16 push on air line (rated to 120C) for the top radiator bridge.

I haven't bothered with the expansion tank; do I really need one? I don't have one on my KTM 300 I'm doing hard enduro with all the time and the fan is always screaming. Seems not really needed.

 

[Bahr]

HTM's kit didn't have a themostat:
link to where they say so
I am a native Italian speaker and basically what they say is that they didn't want it because:
1) if there is no thermostat, then no thermostat can be broken

2) in their opinion, without it the coolant flow rate is increased thanks to a bigger cross section of the cooling system in that point.

BTW it's great that they still sell stuff for our old Italian huskys. I dealt with them in the past and they seemed to be competent to me.

The issue is that I live in Canada (thought to be frank I don't usually ride this bike in the winter); so I don't want a cold engine; but this bike seems to have pretty small radiators for the size of the engine, so I guess I could cover the left hand radiator in the winter with some cardboard.

Yes it's fantastic to be able to get valves (stainless ones at that), very happy. It's not cheap, but they're very nice parts. I with they'd do a double ring piston, I've got a wossner and it always leaks a bit before getting up to temp. I want the HTM high comp piston and the cam.

I've currently set it up without a thermostat. I guess they never had them in the older ones, only when the catalytic converters came on and that's long gone!

 

[Bahr]

@darren7878 I don't quite understand what the tee was for?

 

[darren7878]

@darren7878 I don't quite understand what the tee was for?

View attachment 107244

That goes between the top radiatior mount pipes but I'm told by experts to use a 'Y' shaped for better flow. Youve used the one piece part from you AS3 kit. On a side note the AS3 parts are good quality. Ive used them a few times now.

 

[darren7878]

HTM's kit didn't have a themostat:
link to where they say so
I am a native Italian speaker and basically what they say is that they didn't want it because:
1) if there is no thermostat, then no thermostat can be broken

2) in their opinion, without it the coolant flow rate is increased thanks to a bigger cross section of the cooling system in that point.

BTW it's great that they still sell stuff for our old Italian huskys. I dealt with them in the past and they seemed to be competent to me.

Hi Theo - I ordered an inlet manifold from them for Keihin FCR conversion. Nothing turned up for 2 months, no tracking and zero response on email. I kept trying to contact them and weirdly they suddenly responded and requested i pay the shipping again and this time item was tracked and arrived in 2 days. Sadly i think they have limited stock and demand is low so nothing will be reproduced now

 

[darren7878]

I haven't bothered with the expansion tank; do I really need one? I don't have one on my KTM 300 I'm doing hard enduro with all the time and the fan is always screaming. Seems not really needed.

I have one period modified 610 TC that is running one, but then the early bikes have an even less effective impellor and pump housing on them.

I can get the parts MJF or SLS printed from GF35% PA6 from PCBway or JLC for around $55USD for the set. I used the silicon hose set from AS3:

Have you tested yours yet? $55 USD sounds interesting proposition. Im using these bikes for vintage mx and find they get hot very quickly.

Yes it's fantastic to be able to get valves (stainless ones at that), very happy. It's not cheap, but they're very nice parts. I with they'd do a double ring piston, I've got a wossner and it always leaks a bit before getting up to temp. I want the HTM high comp piston and the cam.

You might have to check stock or maybe you have?!

 

[Bahr]

a

I have one period modified 610 TC that is running one, but then the early bikes have an even less effective impellor and pump housing on them.


Have you tested yours yet? $55 USD sounds interesting proposition. Im using these bikes for vintage mx and find they get hot very quickly.

You might have to check stock or maybe you have?!

Looking at the older 610's, they seem to have the same dimensions and setup? Might work with the new impeller and this housing?

I've only tested it in the shed, works great. Haven't taken it for a ride yet, I'm waiting on some parts from FrankMX to rebuild my FCR, they have a slide insert to compensate for worn carb body. It's a great idea. Replacing the floating slide plate and seal assembly at the same time for a new carb feel; it rattles like hell at the moment. https://www.thumpertalk.com/forums/topic/1252194-fcr-mx-slide-roller-replacement/page/3/

I haven't checked stock with HTM on the piston or cam; I'd spent enough on this bike! BTW when I was emailing and ordering info@htmracing.it, they were very responsive.

 

[darren7878]

Thought you might like a photo of Husqvarna's own version of the pump from their kit.

 

[darren7878]

Looking at the older 610's, they seem to have the same dimensions and setup? Might work with the new impeller and this housing?

Yes agree this will work. Its only the internals that are different.

Regarding Keihin FCR - Gamechanger on these bikes.

I haven't checked stock with HTM on the piston or cam; I'd spent enough on this bike! BTW when I was emailing and ordering info@htmracing.it, they were very responsive.

I found the same till i ordered If i ordered again I try to make sure the payment method i used allowed some sort of support for non supply.


I'll buy and test one of your kits if you up for it?

 

[Theo]

Hi Theo - I ordered an inlet manifold from them for Keihin FCR conversion. Nothing turned up for 2 months, no tracking and zero response on email. I kept trying to contact them and weirdly they suddenly responded and requested i pay the shipping again and this time item was tracked and arrived in 2 days. Sadly i think they have limited stock and demand is low so nothing will be reproduced now

Hi,
sorry to read that.
I dealt with them years ago last time and maybe the company is not run by the same people anymore; I don't know. Besides, I agree that the demand for old Huskys parts is surely lower than back then and so they probably have other priorities.

I haven't bothered with the expansion tank; do I really need one? I don't have one on my KTM 300 I'm doing hard enduro with all the time and the fan is always screaming. Seems not really needed.

A guy I used to know used his carbureted 2006 610 without the expansion tank. It was a modded 610 with aftermarket exhaust, different camshaft, ECU without rev limiter I think from an older 570 and something else. He rode it in the Italian summer, too (peak temperatures usually 35 °C or roughly 100 °F) and he didn't report issues but I don't know whether he lost some coolant from time to time.
HTM didn't want the users of their kit to keep it either: link to where they sat so.

 

[Bahr]

Thought you might like a photo of Husqvarna's own version of the pump from their kit.

So they made this but instead chose the wrong direction for production?? Was this a 570?

I don't want to sell it until it's tested properly, but I'm happy to have one delivered from PC way to you for just the cost.

DM me your address and I'll see what the total is.

I can also send you one of the FDM ones I can make for like $40 Canadian.