2007 TE450 problems starting

I can do it later tonight, but it's easy to find. It's the small black hose coming from the valve cover on the right hand side & going to the airbox. I guess if it's not free flowing enough (pinched/severely kinked) pressure builds up inside the engine & can push the clutch piston out enough to lose clutch lever pressure. It sounded odd to me, but the person who mentioned it was well experienced with Husky's so I gave it a shot. I only lost clutch lever pressure after a highway run at 50+MPH. Worked fine at trail & residential speeds. After straightening the hose routing & removing the kink, it worked great at all speeds.

Ah I know the one so no photo needed.
Actually this hose was very loose where it enters the case before I checked the shims. I put some loctite gasket glue on it for a better seal.
My mate had put the 7602 piston in a while back. Said it slipped in no worries so didn't think slave was bent.
So now not sure where to go with it.
There does seem to be some gunk, dirt and oil around the rubber boot near the lever so maybe a leak???
Clutch doesn't seem to disconnect now bike is off and in the garage.
Did a little bubble removal technique last night but doesn't seem to be a difference.
More ideas needed !

Your master cylinder most likely has some minor imperfections that allow a tiny bit of fluid to escape every time you squeeze the lever. Over time, your MC fluid level gets low, you go over a bump and squeeze the clutch and boom, you have air enter the stream, maybe it pumps out, maybe it doesn't. Only cure is a new master cylinder, you can try the little repair kir with new seal for $50, I tried 2 of 'em, no help. Now, I just check my fluid level before every 2nd ride, and I carry a small bottle of baby oil in case I need a booster on the trail.

Yes I'm thinking new master cylinder too, So which is recommended?
I heard ZipTy but cant find it on their website, need one in oz or prepared to post to oz?

At a mate's recommendation I did a zip tie clutch cable for few hours, release few hours and repeat and clutch went well today. Also have ordered an Oberon slave cylinder - which I may not need arghhh

Bike is running beautifully now shims adjusted!!!

BUT still after 30-40 mins it dies. Checked spark the other day when it died and it had spark. Checked today and no spark. Maybe it cooled down enough first time.
So this issue is electrical right??????????

How to isolate this problem that only happens after riding it for 30+mins (tried just idling at home and doesn't do it????

Same mate said take a can of CO2 and when dies spray on different electrical parts to cool down to isolate which component, sounds reasonable, very bright even!

Anyone got any other ideas of how to isolate which part is causing the problem?

I pulled the coil today and tried to test resistance but can't see which terminals to use on the crap pics on the PDF manual.
I'm getting readings of 10 ohms and 10000 ohms from different terminals. All readings higher than any stated in the manual.
So maybe new coil? Anyone know the correct test procedure?

Also when I had the left case cover off I noticed one of the wings (with coiled wire) that is in the bottom position is covered in gunk. Well it looks like smooth plasticky gunk like it could be meant to look like this. I forgot to take a photo doh! Can anyone confer if this is normal/abnormal?

There are other threads where the stator is bad and bike runs worse when hot.
Search on tls25rs and Jtrain users

Thanks OHR, am looking through them now. Jtrains issues seem a tad different to mine but tls seems very similar. Now just need to learn what all the bits and bobs and coils in this stator are!!!
What is this pickup coil and what is the pulser coil? Not sure yet how to check this all out!

Have pulled this photo off fleabay which shows the gunk on one of the coils - so is this normal or something that needs cleaning off?

That stator looks pretty good, not burnt. the hockey puck thing with 2 mounting holes is the gear position sensor. the small brownie square thing with the single mounting hole might be the pickup coil, but someone would have to firm that up.

Pretty sure the labels in the photo below are correct. If I'm wrong someone let me know please.

Seeing as they all come together as a single part your best bet will be to find a "known good" replacement and try it. Like I mentioned earlier in this thread I got lucky and had an entire running bike to pull good parts from to figure it out on my bike. I went through every possible electrical part on the bike until the only thing left was the stator with no luck. Finally swapped out the stator and it has been fine since. The big key for me was that it took quite a while of running to get the part in question hot enough to fail and the only thing I could think of that would heat soak like that was the stator. Everything else is mounted in such a way that it would remain relatively cool even when the bike was really warm.

As far as I know stators can be rewound to repair them but I haven't been able to locate anyone that is local to me and/or economical enough to bother getting it done.

I thought it might be of interest to some if I summarise the lifespan of this thread:

Alright, I started this thread nearly exactly a year ago ! This Husky has really put me to the test, I have spent a lot of time hating it but more time digging in and learning a heap. I think I can safely say (geez I hope I don't jinx myself) that I have the big issues sorted.
Initially the bike just didn't want to start, I had it through 3 mechanics with good reps, one doing a shim check. In their defense they were not Husky trained but the dollars spent didn't fix my issues, one didn't charge me as couldn't work it out.
Then I fiddled with the carby - did the recommended upgrade of needles etc - worse! So went back to standard! The aftermarket air/fuel mix screw was a good find.
So a mate of mine went over the rest of the bike - new wheel bearings, chain, sprockets, clutch master cylinder - all very helpful but none of which tackled the fact this bike didn't like to actually run.
So on the umpteenth weekend ride cut short, I decided to pull off bits till I found something wrong. Off came the cylinder head cover, a cursory look at the decomp setup, couldn't tell if anything was up there. Out with some feeler gauges and checked the valve clearances, exhaust were right on spec and one of the inlet was half way through acceptable range with the other being near the end of the range. So I took these back to spec. I really didn't think this could make a drastic difference so really thought the decomp could be a problem but it sounded too hard to get off with a high chance of damaging it so I decided to put it all back together and see if there was any improvement.
So back together and I push the starter button and kapow!!! instant start - you should have seen my smile!!!
So happy with myself I did a service, loaded with you beaut expensive oil and off on a test ride. Stop-start-stop-start hot cold and no worries until 30-40mins and the whole shebang dies, arrrghhh! More fiddling, checking sparks and head scratching to no avail.
All advice pointed to an electrical problem but where??????
Lots of forums mentioning stator or coil problems - Coil not too expensive so I nearly bought a new one to try my luck, the desk guy at the Husky dealer says "Bring us the bike, we are the service agents" so I did. They tried to get info off Husky Oz but of course they don't reply, so at my request they loosened the flywheel bolt and gave it back to me (no charge, thanks Graham Boyd Motorcycles) All that beautiful oil lost though.
Spoke to Steve at Betta Bikes in SA, 20 or 30 years experience and he promised he'd have it on his test bench for a day and fixed - the weeks went by, he wouldn't call, he wouldn't accept defeat, damn Husky electrics spent many hours on his test bench with heat applied, with cold applied and worked faultlessly. So we are at around the 5th week (he is busy and bench needed for other bikes too) and I suggest he give up and send it back, "give me one more day" - he wasn't going to let it beat him. So the next day we chat, he says he resorted to hitting bits while on test until something failed. This really didn't fill me with confidence - so a hammer broke something????
Anyhow what broke was the pulser and pickup coil. He replaced these, I handed over a significant amount of cash and he posted them back.
So put it back together, more expensive oil, Somehow got all wires running into correct connections as when I pushed that button, kapow She lives again! Had time for a half hour ride so off I went, all good on the trails but no time to push it past that 40 min mark. I get home, neighbours wife wants to berate me for never working so I push kill switch - nothing Now bike doesn't want to stop !!!
I stall it, have a chat, go to restart and dead ! Surprisingly I have reached some form of Zen (the book must be right) as I just smile at the bike and push it into the garage. I go off spend time with family and the tv and as everyone heads off to bed I know I will not sleep so down to garage and a dismantling I go...tank off and ting, ting, ting a bolt bounces its way through the bike and onto the floor. More smiles as a quick look shows the coil hanging loose. Put it all together and of course she lives again.
Have had a couple of hour+ rides now with no fault.
So now I feel like I have won, I would have preferred to have a bike that just went but I have learned a heap. Now I have some decisions to make, do I spend money on working up the suspension and there is still a possible leaking clutch hydraulics niggle?
I have ridden a little 200 2 stroke and really like it, I just don't need the grunt of this bike being the Captain Slow of dirt bikes!
I will likely keep it as I don't have the cash and wont get near what I have spent on the Husky. So off to search the suspension mod threads - anyone with recommendations of who to take it to in Newcastle or Sydney and how much?

So there's my story so far, being new to dirt bikes I have learned that these things are more than just something to ride, you have to involve yourself in their repair and sometimes you can do a better job yourself and need to find the right help for any problem. They are an expensive little hobby to have. Lastly, thank the heavens for sites like this, else my bike would never have breathed again!
Cheers All

Thanks for posting it, it is a challenge owning some Huskys, no doubt. Ya love 'em, ya hate 'em....