Difference Between 04' And 05' Te250 Connecting Rod?

Afternoon folks,

Does anyone know what the difference is between these two rods? The fiche says 04' is #800099939 and the 05' is 8000A4522.

I'm a bit confused because Mitaka sells a rod they claim is good for the 04-05 TE250.

There's also a rod (part#8000A4188) listed for the 05' TC250, as if it weren't confusing enough.

I have a clean 04' TE250 that I bought new and have maintained. I'm just trying to see how difficult refreshing the engine will be when the time comes, knowing parts availabiity is challenging.

It's interesting that Mitaka now makes a rod for this bike, though I am unsure of the quality.

I've researched the forum and see that another user with an 05' put a 06-09 crank/rod/piston assembly in his bike. That might make good sense as rod availability is much better 06-09 with many aftermarket suppliers. Although, I note that the crankshaft main bearings are different in the 04' model, wheras the 05' and 06' use the same bearings. It may be possible on the 04', but that's murky territory.

I believe I have located an actual 04' TE250 rod. It's pricey, but may be the best choice. I just wonder what happens if I ever need another rod in the future.

Anyway, just looking for any knowledgeable input.

Regards,

Mike.

I believe the difference is the crank pin and bearing are 4mm larger in the 2005. You should be able to use the kit. The motor was shrunk in 2005 and husky went to smaller crank bearings although the bearing ID remained the same. In 2004 the motors were using the same main bearings as the 450/510. If you do switch to the newer crank 06-09 you would also need the newer piston kit.

Firstly, thanks for answering my question, Rancher. I'm a bit of a jerk for not reply to say "thanks."

I have it on pretty good authority that the 05' rods fit the 04', so I don't think the crankpin size changed between that model year. By "good authority," I mean I asked Eraldo Ferracci if the 05' TC250 rod (8000A41888) would fit my 04' and he confirmed it would. I also spoke to Jared at Halls and he agreed.

I believe Mitaka is the only aftermarket supplier of a rod for the 04/05 TE250. I don't any experience with them, but Jared at Halls said "they make a good rod."

Wossner and Pro-X make rods for the 06/07 motors. That's when the valves got bigger and the piston changed. I think I read that these rods are longer. I don't really know, dimensionally, what changed.

For the record:
04' valves: 4.5mm stem, 24mm/29mm
05' valves: 5mm stem, 24mm,/29mm
06+ valves: 5mm stem, 25mm/30.5

Stainless valves are available for the 04' for sure. I don't know if Halls still has any, but there is a supplier in the UK that has them (Talesin, or direct from REC valves). I've seen that Talesin lists stainless valves for 04', 05' and 06'/07' on Ebay. The 06/07' valves are available new from KTM/Husky (and SWM, same part), but they cost a FORTUNE. Those intakes are roughly $270 each!!!

I don't see any of the original titanium exhaust valves available for the 04' or 05' models. As mentioned, 06'/07' OEM intake valves are available. The SWM 300 part number for the exhausts is different; I don't know if they would work.

In summary: there are rod and valve options for all of the carbed TE250 models