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 The previous version was outdated and no longer supported.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

The Dreaded Thread, 08 510 Woes

benwiggin2

benwiggin2

Husqvarna
AA Class
After 3 years of reading about issues I've never experienced, the time has come for mine...
My 08 510 te has an issue I can't figure out. In the desert a couple weekends ago, 73 miles into the loop, we stopped to look at a desert mining feature before heading back to camp. Very low on fuel but not a concerned because we were close to camp, we went to take off. Bike would turn over but not start. Hmm, pulled the tank to poke around...nothing out of the ordinary, checked for visible signs of wiring issues-none. My riding partner was concerned about my low fuel level, but I've ridden with less. But we took some gas out of his tank and added to mine. I put the tank back on the bike, crossed our fingers, and indeed it did start. Good times- for a minute. Coughing and bogging we made it back to camp. I realized that by the time I made it back to camp I had the throttle pretty much wide open. Seemed to be a fueling issue for sure. Next morning I pulled the tank, pulled the fuel pump to make sure it was still housed correctly- it was, then pulled the throttle body just to have a look. While the bike was semi disassembled, checked for the known places where chaffing occurs on the wiring. One wire at TPS connection was a tiny bit bare- but not grounding or contacting anything at all. I put everything back together, and the bike started right up. Pump primed real hard like it does when the fuel line has been disconnected, and the bike started right up. Back in business! But, just like the day before, not so fast- ran like shit, falls on its face, and isn't rideable.
Took it to George at UpTite, did a TPS reset, cleared a couple faults w/I Beat (open ignition fault-whatever that is), put it all back together, and seemed to run from there on. Getting ready to go out this weekend, took for a shakedown ride, and once i'm up in 3rd, 4th gear wide open, boom, she bogs and falls on here face- not much popping and no backfiring, just bog....

So what say you, lets hear the ideas please...
 

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I have to go with bare wire somewhere, there is so much wiring that is involved with the fuel pump, fuel injector, and coil. You wire colors may be different than mine so look at your wiring diagram to identify the wires that supply the pump, injector and coil.

When it gets to the bogging point, pull over, pull the plug and look at the spark, see if it is yellow instead of bright, fat blue.
 
You might want to try and do a fuel pressure test. Measure out of the top of the pump and also from the final spigot, the pump should do 50 psi easy, and then 43 psi out of the final spigot. I got a loaner from an auto parts store and put the pump in a 1 gallon cranberry juice bottle filled with gasoline.

Fuel-Pressure-Test-Kit-TU-443-.jpg
 
The Ibeat faults George found may be old faults or current and point to your cause- but something to check: worth checking coil ground bolts (loose/corroded/dirty) and connections for causing ignition intermittent failure. I had this problem when new, the motor's vibes would effect the coil connection and act like a rev limiter- die at the worst time- then usually start up immediately.

A friend's 2010 510 had some intermittent injector faults (bike would run great then randomly just die/not start)- I cleaned the ECU/CDI plug, Fuel Injector plugs, and it has remained stable/fixxed for 600 miles since. The only thing I really found was that someone packed those connectors with Dielectric Grease (too much of a good thing).

Possible also- unrelated to faults- fuel pump hoses leaking at connections under pressure-loose/bad connections, fuel filter...
 
Fuel pump and injector plugs and harness are good, tight, clean and secure.
Coil connections will be verified
However, the spark at the plug is YELLOW and not fat, bright blue. So what is causing the yellow spark?
 
Sat morning 4/26/14: stripped bike down to access all terminal connections- no visible issues. Bike started. Still yellow spark. Stalled at idle. Checked spark, no spark.

Could a loose terminal here (red /white) at the coil be the culprit? Crimp connection was wiggly, very loose, not sturdy at all. Tightened the crimp. Bike starts and runs predictably so far (only 2 miles). Will log some more miles and report back.

20140426_140134_S Poplar Ave.jpg
 
Yes, yellow spark is unacceptable, gotta be blue and fat, carry your plug wrench with you and be prepared to pull the plug if anything goes wrong.
 
benwiggin2 said:
Tightening the crimp on the wobbly loose red and black wire cured all the issues. Bike is back in shape running like a champ- admitted only 15 miles but the difference is night and day. Like OHR always says, can't stress enough the importance of keeping tabs on the status of the wiring on the big read heads.
Click to expand...
Nice find Benwiggin. Damnit, now I have to pull my tank and check the crimp!
 
My '09 TE450 was running like crap, was hard to start and had weak spark. It would also stumble intermittently at different RPM's and would sometimes run so lean it would overheat too easily. I tried a new injector, new coil, plug and plug wire, fuel pump, etc...nothing helped. It took me 6 months of replacing way too many parts before I swapped the ECU with a friends '08 TE510 to test, boom, I found the culprit!

On a side note, DO NOT believe the Husky manual when troubleshooting your coil, the instructions for troubleshooting the coil are not for the TE, the resistance measurements are wrong in the book. I wasted money on a new coil for nothing.
 
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