• 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 The previous version was outdated and no longer supported.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!

1999 TE610 went out with a bang

Sandnes

Sandnes

Husqvarna
(posted this on thumpertalk as well, before I found this place just now)

I just got the bike last weekend, and yesterday was my first "real" ride other than cruising the neighborhood.
It was a blast, the bike had massive amounts of power, I can't remember the last time I had that much fun with a bike
smile.gif


But as I was riding home, it made a slight clunk in a corner, followed by a very short misfire, like a heart missing a beat and then continuing as if nothing was wrong.
Four minutes later, it made another sound, this time a not so slight bang (which probably woke up the kids and the elderly around the county), and the engine died.
As I came to a stop I concluded that there was a massive loss of compression, and I crossed my fingers that the plug had been shot out or that the head gasket was blown...

I arranged to bring the bike home, but couldn't get around to messing too much with it yesterday.
The plug was ok, though, and I guess the head gasket is fine as well..
I removed the rear valve cover and checked if there was any movement as I turned the engine. Nothing. So I hit a bottle of wine and went to bed
smile.gif

I'll tear it apart later, the wine must have given me the flu or something, I'm not feeling that well :D

Does anyone know if the engine from a 2001 TE610E will fit my bike, as there is one for sale nearby?
Mine is kicker only, left side, no battery or magic button to fire it up.

20131025_190004.jpg
 
Haven't gotten around to more than draining the oil yet, but I certainly don't like what I saw.
I expected the orange shavings to not be there on such an old bike, and the other shavings looked very fresh, as if they were made just yesterday.


20131026_152228.jpg20131026_155257.jpg
 
Go home, cam chain, you're drunk! 20131026_220827.jpg


The chain was not the only drunken part, the cam gear, water tunnel and the cam itself were pretty tipsy... Totally wasted, actually!
20131026_225014.jpg


The gear had almost punched through it.
20131026_225055.jpg


Something tells me I have to order a new gear as well...

20131026_225142.jpg
 
Ouch! Shavings look pretty ugly. You might want to move this over to the "older single cam" section. This section is geared more for the left chain e start bikes. The e start engines are way different, and the chain is on the opposite side as the kick start bikes. Any 92 to 2000 350/410/610 non e start should bolt up plus the '01 and '02 570. You'd need a smaller carb for a 350/400/410. Good parts sources are Uptite, Motoxotica, & Bills, in the west, and Halls in the East.
 
Huskyfatman said:
Ouch! Shavings look pretty ugly. You might want to move this over to the "older single cam" section. This section is geared more for the left chain e start bikes. The e start engines are way different, and the chain is on the opposite side as the kick start bikes. Any 92 to 2000 350/410/610 non e start should bolt up plus the '01 and '02 570. You'd need a smaller carb for a 350/400/410. Good parts sources are Uptite, Motoxotica, & Bills, in the west, and Halls in the East.
Click to expand...

Thank you, I got some great information in your post :)
Unfortunately I'm so new here that when I post, it doesn't show right away, it is (manually?) moderated before publishing.
You'll notice there will pop up a post #3 with more pictures between your reply and my first two posts :)
 
Don't want to start another thread with the same content in the older single cam section, hoping a mod will read this and move it to the right place :)

Question about setting the timing when I get all the parts:
Does it matter if the piston is at TDC on the exhaust stroke or compression stroke, or is there no difference between them when the engine is not running?
I cannot find any markings on the lower gears on the left side, only a dot on the cam gear (is that supposed to be flush with engine casing rearwards, forwards or pointing straight up?)
The alternator seems to line up at the same place through two cycles of the engine, so I assume I don't have to worry about what is exhaust and what is not.
 
Starting to lose hope on this one...
Got almost all the new parts, and went to a buddys place to assemble the new cam shaft.
The gear had such a tight fit that we managed to bend it slightly when we tried pressing it on... booo :(
Not sure how that will go.

In case it'll fail instantly, I'm browsing ebay for replacement cam shafts that are assembled, and I can only find two:
one from a TE - but it's missing the decomp.
one from a TC.

Does anyone know if I can use any of those, i.e. TE cam shaft without decomp, or the TC cam shaft.
The parts catalogue lists separate parts for the TE and TC cam shafts (8000-73150 for the TE, 8000-75780 for the TC)
To add to my confusion, the TE part has a note of 'wu' next to it, meaning "TE-model, US only", and the TC part has a 'c' next to it, meaning "TC-model".
So, nothing for my european TE then...?

I'm tired and confused and I really want to push the bike off a bridge.
While it's on fire.
 
The TE model cam is the one in your bike. The WU next to the part number has 2 different meanings "TE Model" and also "US only" which actually just means us models.
 
Also when you get to assemble the cam gear use a "sleeve retainer" loctite on the threads to prevent what happened to you. I do wonder if the previous owner did some work and didn't use thread locker on the cam bolts.
 
rancher1 said:
Also when you get to assemble the cam gear use a "sleeve retainer" loctite on the threads to prevent what happened to you. I do wonder if the previous owner did some work and didn't use thread locker on the cam bolts.
Click to expand...

Thank you :) Yes, he did some work, and I'm quite sure he forgot the loctite.
In fact, not one nut or bolt I have touched on it has traces of loctite on them...

I ended up bying a top end off ebay, just to find that someone at some point in time had drilled new holes in the cam gear and rotated it 10-15 degrees...
Not sure what good that did to the bike it was on, but I think I'll use those parts as a paper weight :)

I think I have enough parts to finally get around to putting it together now, I just need the time to do it.
 
I almost didn't think I'd hear it run ever again, but I finally got around to fixing it :)
Now I need to fix some leaks due to old rubber hoses... that should be a bit easier..

 
Borgschulze said:
You valves sound like they need adjustment, or the cam chain is slapping a ton.

It's a noisy engine, but not THAT noisy.
Click to expand...

I definitely need to check on the valves again ;)
The chain is new, I'll pull the cam chain tensioner and have a look, but I certainly hope it's good.

The bike sounds a little bit better now that I've changed its oil five times - lots of debris came out during the first three flushes...
Or, I should say it sounds cleaner, the noise is easier to identify.
If the chain is toast already, I'll just have to wait for a replacement that I have had on order since November :)
 
I noticed my auto tensioner didn't have enough spring pressure to adjust in to what I felt was enough tension. So I gave it an extra click manually, and it still has a good amount of slack in it. But it made the engine a lot quieter.
 
I adjusted the valves, they were 15 intake and 20 exhaust, and I set them to 10 and 15.
I might have gotten them a bit too tight now, though, as it got harder to start...
Pulled the left engine cover off to have a feel at the cam chain, and it was tight. Tried to fire it up with more slack just to see if it made a difference, but judging by my now angry neighbors, the noise was still the same :)

This bike is like having a moody girlfriend.
 
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