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 The previous version was outdated and no longer supported.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

This could be the end . . .

Circus

Circus

Husqvarna
AA Class
I was the one who posted back in November about replacing the oil pump due to scoring at 26,000 miles, 2008 SM610. Suspecting that perhaps a single piece of metal had gotten into the pump I replaced oil pump and housing and checked the new one after 30 miles -- and found it scored again. Apparently it was not a single piece of metal but instead lots of metal.

Took the bike to the dealer suspecting at least a top end rebuild was in order. Before splitting the cases the parts and labor estimate was $2000. After splitting the cases the estimate is now . . . are you sitting down . . . $3500 that is comprised of $2200 for parts and $1100 for labor, plus another $265 machine shop charges (cylinder repair). Looking at the list below, it's probably a shorter list for what is not needed. So we are not doing that.

In the meantime I can't be without a bike, so what else was I to do . . . I bought a brand new 2015 BMW S1000R -- unbelievable power, and I have not even broken it in yet to rev past 7000RPM. I really wanted to rebuild and keep the Husky as a second bike. Now, I either find a good used motor, or I slowly part it out -- this is not a solicitation for offers either. I intend to hold onto the bike for awhile and hope a used motor shows up on Craigslist or ebay. This bike has been my daily ride for the last 6 years . . . don't want to see it end like this -- shooting an injured horse.

Part Number Description Qty Price Unit Extension Extension
161531501 CLUTCH CONTROL ROD 1 $5.22 $5.22 $5.22
800015659 BEARING 1 $18.88 $18.88 $18.88
800019768 BALL BEARING 42X15X13 1 $12.87 $12.87 $12.87
800043789 BALL BEARING NU205 1 $48.90 $48.90 $48.90
800058541 CHAIN, CAM SHAFT DRIVE 1 $60.68 $60.68 $60.68
800072964 ROLLERS BEARING 20X47X14 1 $45.44 $45.44 $45.44
800073518 HOUSING, OIL PUMP 1 $62.54 $62.54 $62.54
800074861 MAIN SHAFT T13 1 $91.12 $91.12 $91.12
800074864 DRIVEN GEAR 2ND SPEED T29 1 $38.93 $38.93 $38.93
800074864 DRIVEN GEAR 2ND SPEED T29 1 $38.93 $38.93 $38.93
800079687 GEAR DRIVE 5-6TH SPEED T24/26 1 $98.97 $98.97 $98.97
800079690 DRIVEN GEAR 3RD SPEED T27 1 $48.71 $48.71 $48.71
800079690 DRIVEN GEAR 3RD SPEED T27 1 $48.71 $48.71 $48.71
800079691 DRIVEN GEAR 6TH SPEED T20 1 $61.53 $61.53 $61.53
800079692 DRIVEN GEAR 5TH SPEED T22 1 $131.88 $131.88 $131.88
800079693 DRIVEN GEAR 4TH SPEED T24 1 $53.93 $53.93 $53.93
800082948 OIL SUCTION ROTOR 1 $15.47 $15.47 $15.47
800085380 BALL BEARING 85X45X19 2 $25.68 $25.68 $51.36
800098007 CRANKSHAFT 1 $551.06 $551.06 $551.06
8000A5013 PISTON ASSY 1 $323.44 $323.44 $323.44
8000A8071 GASKET SET, ENGINE 1 $98.66 $98.66 $98.66
8000A9320 VALVE, INTAKE 1 $32.89 $32.89 $32.89
8000H9064 CHAIN SLIDER KIT 610 1 $27.61 $27.61 $27.61
80C075766 HOUSING, WATER PUMP 1 $85.77 $85.77 $85.77
8A0060415 IMPELLER, WATER PUMP 1 $18.75 $18.75 $18.75
8A0063644 GASKET, WATER PUMP 1 $2.75 $2.75 $2.75
8A0082948 ROTOR, OIL PRESSURE 1 $14.08 $14.08 $14.08
BULKOIL Premium 100% Synthetic Oil 15W50 4 $14.95 $14.95 $59.80
KN-154 X-STREAM OIL FILTER HUSKY 1 $7.95 $7.95 $7.95
Shipping Shipping 1 $50.00 $50.00 $50.00
 
Bugger, always rough to have an imminent death in the family. Was the metal producing culpret found?

Good luck with engine hunting.
 
I feel your pain. I like to build in my garage in the evenings but hate when it is on the bike i am riding at the moment. It changes from "a fun project" to "I have to get this done".
Good luck with your decisions that are coming****************************************
 
The shop did not provide any specifics on what was coming apart. I spoke to George at UpTite before ever taking it to my local shop (George is not the one doing the work) and he said it was probably related to the crank bearings. I will ask my local shop today -- I only have an email from them from last night with the $3500 estimate -- we have not spoken live yet since they split the cases.

Interestingly though, they did say that the water pump impeller had two blades broken off. I have no idea how that could ever happen -- the cooling and oil systems are totally separate and their was no mixing. The impeller just spins, so not sure why two blades would break off.

Now that I have the new S1000R, I may actually take the time and slowly rebuild the motor at my leisure. Never done it before so not exactly sure what I am getting myself into it. I could not do that before as you pointed out -- with only one bike you had to get it done quickly. That said, the parts alone are still a pretty penny ($2200)
 
Grinder and Circus- you've both captured my thoughts on the process/mindset. When I went through this (am at the tail end of getting it worked out now) I initially thought "aw man...if this 'repair' is gonna cost me like 3500 plus then I might as well look for a low mileage replacement for the bike." They're out there, with patience. I've seen a few 610's out there w/ relatively low mileage at a great price.

Now Grinder hit the head of what was making me anxious... If the bike that's down is your one and only then that ups the stress. I'm a parent and here in VA we only have but so many great months for riding, so I did not want any more down time than I was already suffering. Working on my bike, I rediscovered, can be a great zen kind of thing, so my mind has been turning to getting a project bike.

Circus: so yeah, if I had another bike and didn't feel dependent upon the 630 then I'd have probably been willing to make it a learning project and do the tear-down/rebuild myself. Being my only bike, and one of value (to me and otherwise) I left the rebuild to the pros and did the engine removal/reinstall myself (and any other maintenance items along the way.) Congrats on that S1000R- great you're able to pull that off and, needless to say, it should scratch the HP itch for you pretty well.
 
Jinkies your better off looking for another motor to transplant than the repair bill, would a ktm lc4 640 motor fit in?
 
Hey guys. Thanks. I knew this day would come and so I have been looking at a second bike for awhile now. This pushed me over the edge. Glad to have the S1000R, not happy about the complete destruction of the Husky.

First the S1000R.
20150110_144000_zps0be1fd75.jpg

Like I said, not broken in yet. No supposed to go over 9000RPM until I hit 600 miles. But there is some crazy power under 9000RPM. The bike accelerates so hard from 6th gear at 70MPH. It's like one of those video games where you hit the turbo button. And it just keeps accelerating harder -- it's like a time warp. The demo bike I rode, dropped it into 2nd gear on the freeway at like 65MPH, and brought up the front end without clutching it . . . always wanted to be able to do that. Did I mention heated grips, cruise control, automatic damping control (with user modes soft, normal, hard), ABS, 4 driving modes: rain, normal, dynamic and dynamic pro -- that last one have not used yet. I went from one end of the spectrum to the other. From what I lovingly referred to as my lawn-mower (single cylinder, lots of vibes) to the S1000R.

Now, about the Husky, I am gonna tell them to throw the parts in a box, and I will get the rolling chassis home. Still can't believe that my ride on it over to the dealer may have been the last -- never had to shoot my own bike in the head. Don't want that to happen. Still want to have the supermoto. Still enjoy the raw simplicity of the bike.
 
Part Number Description Qty Price Unit Extension Extension
161531501 CLUTCH CONTROL ROD 1 $5.22 $5.22 $5.22
800015659 BEARING 1 $18.88 $18.88 $18.88
800019768 BALL BEARING 42X15X13 1 $12.87 $12.87 $12.87
800043789 BALL BEARING NU205 1 $48.90 $48.90 $48.90
800058541 CHAIN, CAM SHAFT DRIVE 1 $60.68 $60.68 $60.68
800072964 ROLLERS BEARING 20X47X14 1 $45.44 $45.44 $45.44
800073518 HOUSING, OIL PUMP 1 $62.54 $62.54 $62.54
800074861 MAIN SHAFT T13 1 $91.12 $91.12 $91.12
800074864 DRIVEN GEAR 2ND SPEED T29 1 $38.93 $38.93 $38.93
800074864 DRIVEN GEAR 2ND SPEED T29 1 $38.93 $38.93 $38.93
800079687 GEAR DRIVE 5-6TH SPEED T24/26 1 $98.97 $98.97 $98.97
800079690 DRIVEN GEAR 3RD SPEED T27 1 $48.71 $48.71 $48.71
800079690 DRIVEN GEAR 3RD SPEED T27 1 $48.71 $48.71 $48.71
800079691 DRIVEN GEAR 6TH SPEED T20 1 $61.53 $61.53 $61.53
800079692 DRIVEN GEAR 5TH SPEED T22 1 $131.88 $131.88 $131.88
800079693 DRIVEN GEAR 4TH SPEED T24 1 $53.93 $53.93 $53.93
800082948 OIL SUCTION ROTOR 1 $15.47 $15.47 $15.47
800085380 BALL BEARING 85X45X19 2 $25.68 $25.68 $51.36
800098007 CRANKSHAFT 1 $551.06 $551.06 $551.06
8000A5013 PISTON ASSY 1 $323.44 $323.44 $323.44
8000A8071 GASKET SET, ENGINE 1 $98.66 $98.66 $98.66
8000A9320 VALVE, INTAKE 1 $32.89 $32.89 $32.89
8000H9064 CHAIN SLIDER KIT 610 1 $27.61 $27.61 $27.61
80C075766 HOUSING, WATER PUMP 1 $85.77 $85.77 $85.77
8A0060415 IMPELLER, WATER PUMP 1 $18.75 $18.75 $18.75
8A0063644 GASKET, WATER PUMP 1 $2.75 $2.75 $2.75
8A0082948 ROTOR, OIL PRESSURE 1 $14.08 $14.08 $14.08
BULKOIL Premium 100% Synthetic Oil 15W50 4 $14.95 $14.95 $59.80
KN-154 X-STREAM OIL FILTER HUSKY 1 $7.95 $7.95 $7.95
Shipping Shipping 1 $50.00 $50.00 $50.00[/quote]

There is some serious stuff on that list, I would have a careful look at what is really needed if you can...granted though, you have a lot of miles on that bike and it's an SM so some things will be living a hard life.

Some question though....
Do you really need to replace the entire gear set? (and 2nd, 5th and 6th more than once???)
What about the piston, has it been replaced previously, if so when? (personally I'd measure the piston and skirt for wear and see if it actually needs replacing given the price - while you are at it, gap the rings to check for wear, but they're much cheaper to replace just speculatively if you are so inclined....)
Bearings - well, who knows,you basically have to take their word for it and suck up the cost and just do it, justify it against the significant the labour cost involved in breaking the engine down to that point anyway....
When is the cam chain due for replacement? (off the top of my head I'm guessing it would be close to replacement time if the 610 maintenance schedule is anything like the 630...so that's probably prudent/fair enough)
 
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