• 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 The previous version was outdated and no longer supported.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 good news is I found the leak...

benwiggin2

benwiggin2

Husqvarna
AA Class
The bad news is I have a leak....and it's from a broken cover. I had a bad feeling about the accumulation of oily dirt there on the bike, so after last weekend's ride I took the bash plate off to see.
Not sure how this happened, I don't remember any impact/event but it looks like there's a mark not to mention the crack. So, remove and replace? JB weld? Honestly, I'm not an engine tear down and put back together guy so I don't even know what's behind that cover, or what's involved with getting a new or replacement cover and what the install requires, so looking for your thoughts, ideas, advice guys. OHR?

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Looks like you cracked your ignition cover. Most likely your shift lever hit it. As you can see, it's cast, so it doesn't take all that much to crack.

I don't know about JB weld, but you can get a quality billet aluminum replacement from 7602 Racing, here: http://www.7602racing.com/husqvarna_te_tc_txc_sm_450_510.php

I'm not sure if there are other manufacturers, but I didn't see one on the Zip-Ty website.
 
I would try JB Weld on the inside so take the stator cover off, clean it as good as sterile with petrol and have a shot. It looks like your gear lever is the guilty party it might need a tad of prizing away from the cover.
 
Just to be clear, my comment about JB weld was just that I've never used it, and don't know if it would work. Re-reading my post, it almost sounds like I was doubting that it would work.
 
Put my shifter through the cover last year riding on ice. Put some JB weld on the outside and it held fine until I got my new 7602 cover.
 
Clean or glassbead the cover and then rough up the area to be repaired . Use West Systems two part epoxy .
 
On a side note.. I had a stick try and yank out the ignition wire bush wacking one day..After I picked myself up and started the bike oil was barfing out of the top grommet.. I managed to poke it back in trail side and get going. Cleaned it up and siliconed it.

My point being.. Try and route the wire in tight to the engine and away from the header .

JB weld and silicone repair still holding up after 6000km or so.

I have used the epoxy with good results as well..But I do not leave home without JB weld.
 
I'd replace the cover. I had a real clean KL 250 once that I didn't ride much since I had my 250OR so I long-term lent it to a buddy who couldn't afford a bike to ride. The chain broke and came forward and cracked the case. Rather than just tell me about it (chain broke...not his fault), he patched it with JB weld and kept riding it for another couple weeks. To make a long story short, all the oil leaked out and the engine seized.
 
Thanks for all the comments and clarifications- haven't looked any further into it yet, but I have another question- there is oil leaking from the crack. Does the mean that whole stator component and electrical windings are bathed in oil?
 
Maybe some quick steel instead of jb weld. Two part stick that you mix together. A little less of a mess than jb weld and the proportions are already taken care of. I keep some in my backpack every time I ride. Dries fast to.
 
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I tried a little bit out on a shelf bracket when I first got some quick steel to see how well it worked. It has cured even harder than jb weld does and a hella of a lot quicker. You could patch a hole in BFE and still ride out!
 
benwiggin2 said:
Thanks for all the comments and clarifications- haven't looked any further into it yet, but I have another question- there is oil leaking from the crack. Does the mean that whole stator component and electrical windings are bathed in oil?
Click to expand...

Yes. It's known as a wet stator. You should drain the oil before removing the cover. Although, you may be able to lay the bike on it's side, like some do to work on the clutch. Although, it's on the other side, so I'm not sure if that's a good idea.
 
268fords said:
Maybe some quick steel instead of jb weld. Two part stick that you mix together. A little less of a mess than jb weld and the proportions are already taken care of. I keep some in my backpack every time I ride. Dries fast to.
Click to expand...

I do carry that in my pack with me, good stuff.
 
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