TheRealBuzz
Husqvarna
AA Class
Should have mentioned - 2009 TE450
-
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 The previous version was outdated and no longer supported.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!
08 TE 450 problems after minor rebuild
- Thread starter 13101093
- Start date
Husqvarna
TheRealBuzz
Husqvarna
AA Class
This thing is driving me nuts!
New coil didn't work.
I checked out everything i could before deciding to replace the ecu. New ecu and still no spark.
I've pulled the wire harness apart and checked all over for bad connections.
I've checked kill switches and resistance on O2 sensor plugs and tilt sensor plug.
Fuel pump primes then quits when the power relay shuts off.
If I remove coil or injector from power relay circuit the relay shuts off faster so it's detecting a resistance from those components.
The only thing in that circuit that doesn't cause a change when removed is the O2 sensor delete plug but the resistance checks ok and I cant find a break in the circuit there.
AAAAAAAHHHHHHH!!
I'm going out for Chinese food!
New coil didn't work.
I checked out everything i could before deciding to replace the ecu. New ecu and still no spark.
I've pulled the wire harness apart and checked all over for bad connections.
I've checked kill switches and resistance on O2 sensor plugs and tilt sensor plug.
Fuel pump primes then quits when the power relay shuts off.
If I remove coil or injector from power relay circuit the relay shuts off faster so it's detecting a resistance from those components.
The only thing in that circuit that doesn't cause a change when removed is the O2 sensor delete plug but the resistance checks ok and I cant find a break in the circuit there.
AAAAAAAHHHHHHH!!
I'm going out for Chinese food!
Teaso
Husqvarna
B Class
Old thread, I know.
Bought a cheap, dirty, abused 08 TE450. Lights removed. New oil and battery got it running nicely. Stripped the loom out to clean the bike. Seems everyone has similar problems.
Now (using full battery):
- Power relay clicks once, then shuts off immediately
- Fuel pump not priming
- Starter motor kicks the engine over fine
- No spark when grounded to the engine
- When kill switch engaged, then released, power relay clicks again, still nothing
Checked:
- All connections connected
- Fuses sound (except 20 dash/lights fuse)
- No major abrasions or chafing throughout loom
- Spark plug sound
- Green/Red stripe has continuity throughout using multimeter, and power using test globe (ignition circuit)
- White/Red stripe has continuity from coil to ECU
- Coil gives spark when tested on another battery
- Fuel pump runs fine when tested out of the tank (has continuity from the connection plug to the pump)
- Cleaned kill switch
- Sanded coil earth points
- Swapped all three relays over (same:same:same)
As there is no spark AND no fuel pump (yet coil, plug, and pump test sound independently off the machine), and all three relays give the same outcome, I can only think that there is an earthing issue somewhere in the loom. I'm no sparky or mechanic, but I've read thread after thread. I'll persevere and if/when I find the fault, I'll post the outcome. Fingers crossed
Bought a cheap, dirty, abused 08 TE450. Lights removed. New oil and battery got it running nicely. Stripped the loom out to clean the bike. Seems everyone has similar problems.
Now (using full battery):
- Power relay clicks once, then shuts off immediately
- Fuel pump not priming
- Starter motor kicks the engine over fine
- No spark when grounded to the engine
- When kill switch engaged, then released, power relay clicks again, still nothing
Checked:
- All connections connected
- Fuses sound (except 20 dash/lights fuse)
- No major abrasions or chafing throughout loom
- Spark plug sound
- Green/Red stripe has continuity throughout using multimeter, and power using test globe (ignition circuit)
- White/Red stripe has continuity from coil to ECU
- Coil gives spark when tested on another battery
- Fuel pump runs fine when tested out of the tank (has continuity from the connection plug to the pump)
- Cleaned kill switch
- Sanded coil earth points
- Swapped all three relays over (same:same:same)
As there is no spark AND no fuel pump (yet coil, plug, and pump test sound independently off the machine), and all three relays give the same outcome, I can only think that there is an earthing issue somewhere in the loom. I'm no sparky or mechanic, but I've read thread after thread. I'll persevere and if/when I find the fault, I'll post the outcome. Fingers crossed
Teaso
Husqvarna
B Class
Had a think about it. Power relay must be receiving broken continuity (hence the click but no pump/spark). So it was between the battery and power relay. Electric start stilled powered the starter motor. So it had to be the mini fuse (15 amp) . Checked the Fuse. All good. Removed the grey sheath covering the fuse wires. BINGO. Partially worn Y/Gr output wire. Installed temporary bridge to test (pic), all systems go. This loom looks like it's made out of spaghetti, cheap spaghetti.
TheRealBuzz
Husqvarna
AA Class
Glad you found the problem and thanks for posting your solution.
I finally solved my no spark problem as well, though I was on the wrong track for a long time looking for bad wiring.
Ended up being a bad timing pickup in the stator assembly.
I overlooked or improperly tested the pickup first time around. Only after I had exhausted everything else and started over from scratch did I find it.
The stator itself was still good but the pickup comes pre-wired with it so I had to buy the whole thing.
Oh well... at least I know the bike inside out now.
I finally solved my no spark problem as well, though I was on the wrong track for a long time looking for bad wiring.
Ended up being a bad timing pickup in the stator assembly.
I overlooked or improperly tested the pickup first time around. Only after I had exhausted everything else and started over from scratch did I find it.
The stator itself was still good but the pickup comes pre-wired with it so I had to buy the whole thing.
Oh well... at least I know the bike inside out now.