1. 4 Stroke Husqvarna Motorcycles Made In Italy - About 1989 to 2014
     TE = 4st Enduro & TC = 4st Cross

7062 piston install

Discussion in '4 Stroke' started by Supermoto, Apr 10, 2010.

  1. Supermoto Husqvarna
    C Class

    Location:
    New York
    Forgive me for beating a dead horse here, I did a ton of searching for some information on this install. I just really want to do this correctly. It seems pretty straight forward. I am no expert mechanic, I can do basic bike maintenance but I am eager to learn how to take care of my bike. The best way to learn is to ask people more knowledgeable then myself.

    The bike is a 2008 SMR 510.

    I will be following this procedure:

    http://www.cafehusky.com/forums/showthread.php?t=5032

    I ordered these two products and will have them on Friday:

    http://7602racing.com/prod_clutch_piston.php

    http://www.rockymountainatvmc.com/p...dlebars-Control&webCatId=12&prodFamilyId=8804

    This is how my fluid level looks:

    [IMG]

    [IMG]

    Not so good.

    So just to clarify, the master cylinder is located here correct?

    [IMG]

    [IMG]

    I am sorry for these very basic questions but I have never done this before any help is greatly appreciated. It looks like I will have to remove the front sprocket guard and I should be able to access the master cylinder correct?

    My first question is how would I go about draining all the fluid from the system. I'm not sure what is in there now and Id really rather just have all new fluid.

    Second question if you wouldn't mind is what are all the tools and parts I will require for this job.

    Pictures would also help wonders if anyone has them, right now I just want to be as prepared as possible for this job. All of the parts wont be here until Friday. Anything you guys have to tell me is great; just forgive my lack of knowledge. Its great to have a resource like this :thumbsup:
    Supermoto, Apr 10, 2010
    #1

  2. Colo moto CH Sponsor

    Location:
    La Jara, Colorado
    Husqvarna Motorcycle:
    7602racing.com
    Supermoto,

    Replacing the clutch piston is pretty straight forward.

    First use an 8mm socket to remove the plastic sprocket cover. Then use an allen to remove the steel backing plate under it.

    Now remove the three 8mm bolts on the slave cylinder. Pull the slave off. Be sure not to pull the clutch lever when the slave is off the engine and the snap ring is in. Remove the snap ring from the slave cylinder. Now you can pull the clutch lever to push the stock piston out.

    Remove the stock piston, oil up the x ring on our piston and slide the piston into the slave cylinder. Replace the snap ring.

    Turn the slave cylinder so that the piston faces down and lightly tap on the housing with a screwdriver handle to rattle the bubbles out of the cylinder into the clutch line.

    Put the slave cylinder back on the engine and tighten the three 8mm bolts.

    Take that reverse bleed kit you bought and fill the syringe with oil. Get all the bubbles out of the syringe and the tubing.

    Attach the tubing into the nipple on the slave cylinder. Crack the nipple open just enough to push fluid into the hose.

    Periodically check the master cylinder to be sure it doesn't overflow.

    That's pretty much it. Good luck.
    Colo moto, Apr 10, 2010
    #2

  3. Supermoto Husqvarna
    C Class

    Location:
    New York
    Fantastic, this helps wonders. :thumbsup:

    However I ran into a slight problem today. I was going through my bike I figured Id take off my front sprocket cover so I could get to the master cylinder easier. I believe the two bolts are stripped. They both turn in place but will not come out. I'm afraid I will have to cut the heads off and drill them out with a bigger thread. Really upset about this because I do not have to tools to do this, not sure where to go from here. I have a video of the blots but there is a lot of cursing and rage so Ill upload a new one tomorrow once I have cooled off. Just upset because this is a pretty new bike and a 20 minute job just turned into a huge job for me. I wanted a bike I could just ride immediately and its turning into some serious work. I have no problem doing normal maintenance, but this is a new bike to me and I was only able to ride it once with difficulties. :banghead:

    Edit:

    These are the stripped bolts

    [IMG]

    I'm not sure what to do now, looks like I will have to take it to a shop to get these fixed. Anybody know what to do in this situation?
    Supermoto, Apr 10, 2010
    #3

  4. DirtyOldMan Husqvarna
    AA Class

    Location:
    Pleasant Hill MO
    Husqvarna Motorcycle:
    13 Terra
    Other Motorcycles:
    15 Beta XTrainer 04 250 RFS
    Those two bolts just hold the plastic cover on the metal "C" shaped piece that wraps around your countershaft sprocket. There are two allen head bolts underneath the plastic that allow the metal piece to be removed. Most folks remove the plastic piece and do not re-mount it, it's a trap for mud and sticks and such. If it were me, I'd probably just destroy the plastic piece to gain access to the allen bolts underneath. You S/M guys may prefer a nicer look than me, if so you'll have to drill out the bolts and re-tap to the next size.
    DirtyOldMan, Apr 27, 2010
    #4

  5. waserman Husqvarna
    AA Class

    Location:
    Delaware,USA
    Husqvarna Motorcycle:
    09 TE510
    Other Motorcycles:
    BMW KTM Honda
    I'd also give serious consideration about buying some other type of chain guard/case saver.The stock mounting points for the guard are very fragile,mine snapped off last Saturday.There are several options available from different manufacturing shops on this web-site,which are much better than the Husqvarna stock piece. JMO
    waserman, Apr 29, 2010
    #5