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

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 The previous version was outdated and no longer supported.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

2004 Tc 450 clutch not disengaging

DirtFreedom

DirtFreedom

Husqvarna
Hello,
I replaced my clutch lever today with an easy pull one finger lever, no other modifications or changes. Just swapped out the lever. Now my clutch will not disengage from gear at all whether the bike is running or not. I checked the oil in the reservoir and it is only a small amount low, nothing that would be of concern.

Is this a air issue from fully releasing the plunger on the clutch? Would bleeding the system help? I have not removed the slave to see what is going on there, but not sure if that is even necessary. I am mostly confused on how changing the lever only could cause the clutch to stop working.


Thanks!!!
 
DirtFreedom said:
Hello,
I replaced my clutch lever today with an easy pull one finger lever, no other modifications or changes. Just swapped out the lever. Now my clutch will not disengage from gear at all whether the bike is running or not. I checked the oil in the reservoir and it is only a small amount low, nothing that would be of concern.

Is this a air issue from fully releasing the plunger on the clutch? Would bleeding the system help? I have not removed the slave to see what is going on there, but not sure if that is even necessary. I am mostly confused on how changing the lever only could cause the clutch to stop working.


Thanks!!!
Click to expand...
Did U get a Mid West Mountain Engineering lever? If so, maybe U need to turn the lever adjusting screw in some. Also to avoid losing the clutch while riding, make sure that the breather hose between the top of the head and the air cleaner isn't clogged or kinked. U may need to bleed it. I found that using extra thick mineral oil in it helped the clutch feel stay constant.
 
Hey,
Yes I got the mid west clutch and brake levers. I am going to try to bleed the line today, but have never done that so should be an interesting experience. Crappy ass timing since today was my last chance for riding before my hate scramble next weekend. If I pull the slave off, should the piston move with pulling and releasing the lever? Just wondering if pulling the slave is a worthwhile troubleshooting step.

On side note I added billet evo foot pegs as well.
 
Hello,
I wanted to ping this issue since I have not had any resolution. I replaced my slave piston, bled the system and got the pressure back in the line, but the clutch still does not engage. When in gear pulling the clutch in does not disengage the gear. I tried doing it with the bike warmed up, but that did not do anything either.
Does anyone know where I can find a master cylinder for this bike or a master cylinder rebuild kit for it. I cant seem to find them online for my '04. Doing that is the last thing I can think of to do with the fact that everything worked perfectly until I changed to the Mid West Mountain levers. But, even now with the old clutch lever on it does not work. I seriously doubt my actual clutch is bad, it just has to be something I am missing on the lever system.
The closest service shop I can use is 1hour 45 mins away and I really just hope I can fix this myself.

Also, does anyone here know where I can find a compatible front suspension cartridge rebuild kit for this bike?
2004 Husky TC450

Thanks for any help.
 
You can get one off of amazon, just replaced mine last year, also try bleeding your clutch with syringe pushing fluid up through the bleeder at slave cylinder. Remove clutch master reservoir cover, open bleeder on slave- squirt a little fluid out hose on syringe to purge air- attach hose to bleeder and push fluid through. It is messy, also you want a big syringe wich you can get at most farm supply store.
 
Thanks for the tips. I have been unsuccessful at getting the reverse bleed to work. I can get fluid down out of the bleeder valve, but when I try to push it up the system into the master cylinder it either just does not go at all or oozes out of the bleeder valve. I try not to open the bleeder too far and if I pump the lever fluid moves through the hose, so I know the hose is not blocked. I ordered a new master cylinder piston set to see if that helps. I will try getting a larger syringe to see if that helps too.
Thanks again for the tips!!!
 
Remove the bleed nipple and see if it's plugged. Maybe try putting a zip Ty around the grip to hold the lever in while reverse bleeding.
 
The lever is your problem I think. The range of engagement gets much longer. I had them on a few KTMs and the lever had to go right to the bar to disengage or might even still drag at full pull, esp when hot. Put the stock lever back on and test it. I found it too much lever travel to keep them on. I even cut one down to a single finger trigger size. Better but not great. I ended up giving them away.
 
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