I'm on a trip in Cloudcroft, NM with a new to me 08 TE610. As we were finishing up the first day's ride the bike started shaking like crazy. I rode it the last three miles back to the cabin and my hands and feet were both asleep from the vibration. I called George and he immediately said woodruff key and stepped me through the process. I do better with pictures. Can someone link me to write up on the replacement? I'm on a phone and can't search for shit. I appreciate any help you can give. Luckily we trucked them here so I can run into a larger town for parts.
Here's a thread on the issue, I'll see if I can find something with more pictures. http://www.advrider.com/forums/showthread.php?t=141762&highlight=Husky Husqvarna
It happened to me, too, twice. It was the crankshaft right Woodruff key both the times. It could also be one of the two counter-shaft Woodruff keys, but it's less likely. The problem was that the crankshaft key broke and so the two gears hold in position by it didn't rotate integral with the shaft any more. One of the gears drives the clutch, the other drives the counter-shaft gear. The latter must be in phase coincidence with the countershaft gear; when the key brakes, it isn't any more and so the bike shakes much more. Here is the procedure: -Remove the right cranckcase cover. -unscrew the cranckshaft nut after having bent its security washer; you'll need a 38 mm wrench, if I remember well: Now, without the friction of the nut, you should be able to understand whether the key is broken: if it is, the two gears will be able to rotate easily around the shaft. In the picture above, the crankshaft is damaged because I didn't align the crankshaft and the oil pump shaft: don't do the same mistake!! The oil pump shaft is here: -Remove the clutch. To do it, first of all you have to unscrew these six bolts and to remove their springs: Then, you have to remove the plate and other little parts you'll find under it (don't lose the little ball). Now, bend the security washer of the clutch and unscrew the central bolt (27 mm wrench, if I remember well); don't mind the red arrow, I re-used the image: -After having removed the clutch, you'll be able to remove the two gears from the cranckshaft and check the Woodruff key. Here are the Woodruff key codes: -right key on the crankshaft: 8000 22426 -Counter-shaft Woodruff Keys: 1513 71301, less likely to be broken. When you re-assemble everything, align these two dots to get the phase coincidence I've mentioned: I hope not to have forgotten anything.
Thanks fellas. I really appreciate it. I'm going to run into Alamogordo in the morning and buy the sockets and find a SAE key. George said I can file it down to fit. I hope I get her running. The trails out here are awesome I and I was having a blast with the bike. I'd sure hate for it to end after the first day.
Got her put back together an hour ago and all is well. The key was broken into four parts and the nut was finger tight. It runs a lot quiter too. It was knocking a lot before and I just thought it was normal. I want to give George at Up Tite some major kudos. I've only purchased about $100 in parts from him but he took care of me like I was his best customer. He took the time yesterday to diagnose the issue over rhe phone and step me through the repair. Then he called me back today just to check on how the repair was going. I can't even get dealers I'm paying to call me back so this was awesome service. Thanks George!
