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 The previous version was outdated and no longer supported.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

Any help guys?

J.R.

J.R.

Husqvarna
AA Class
So I am struggling.. I can swap engines in like an hour but for some reason I cant get my 530 back up and running! Before anyone asks what year this is.. '06 head and carb(JD kit), couple different 06 harnesses to mess with, '04 bottom end, almost brand new 530 kit. The rest of the bike is a franken-mess of parts from different years/generations.
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Background:
Took it to Stateline Challenge where I hear a knocking. Got it home and tore it apart only to find the crank balancer was out of time and contacting the end of the connecting rod every time they came around. The timing gear on the crank was not in the right position, it had either spun somehow or it was installed incorrectly.
So I took the crank to our local engine shop who does GREAT work. They stripped down the crank, inspected it, and it checked out. So it went back together, welded and balanced. The gear was pressed back in the proper position, aligned with the small hole using a pin. then it was welded to the crank. (Just two small beads to allow future crank rebuild.)
I then assembled the engine and put it back in the bike. I have verified the timing many times, checked for spark, and as far as I can tell Im getting fuel. Over the course of this, I have changed ignition and the wiring harness, but that didnt change anything. The bike will crank over and if I hold the starter, it almost sounds like its trying to idle, but stops as soon as I cut the starter. If I give it a little throttle it almost seems like its helping but still doesnt to anything. If I give too much throttle, it kind of bogs (its not running but sounds boggy as it tries to start, if I give too much throttle.)

Timeline for changing ignition and harness.
Way before Stateline- Running street harness, and 510 stator/ignition. Bike running great.

Just Before stateline- Swapped to an offroad harness due to some questionable wires on the street harness that could pose problem at upcoming race. Running 250 ignition/stator. Bike still running.

After stateline and after crank rebuild- still running offroad harness, 250 ignition/stator. Bike NOT running. Swapped back to 510 stator/ignition. Still NOT RUNNING.

Today- put a new O-ring on the fuel screw. The old one was torn so I figured what the hell, maybe its making it waaay too rich. No luck. NOT RUNNNNING****************************************
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I really hope this is something stupid. I cant see what the hell would pose a problem. I'll upload a video of trying to start. Maybe someone will recognize the way it sounds as "such and such" problem. Any help is appreciated. Thanks...
 
Havent worked on it much. I got tired of checking and rechecking everything else so I stripped it apart only to find just what I expected: Nothing visibly wrong...
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I have the same thread on SMJ, and everyone asked the obvious but also a couple other questions, which didnt seem to bring about any answers..
 
J.R. said:
Havent worked on it much. I got tired of checking and rechecking everything else so I stripped it apart only to find just what I expected: Nothing visibly wrong... :banghead:

I have the same thread on SMJ, and everyone asked the obvious but also a couple other questions, which didnt seem to bring about any answers..
Click to expand...

Seems the off-road harness is the only obvious component still remaining after the changes? Otherwise I'd be tempted to strip the carb. It might be unrelated to the changes you've made.
 
The offroad harness was running the 530 at and a little before the Stateline raceA and I forgot to mention. The bike has been running my 250 engine recently, with the same offroad harness, etc.. so all the elec. is ok. I was even using the 250 stator and ignition on the 530 before but now its on the 250 and in the bike running..
 
Sounds similar to what im going thru at the moment - i swapped rotors and stators from my 250 & 450. Now neither run. If you swap CDIs with applicable rotors and ignition pick ups, it may help. (havent tried that myself as one bike is at home, the other in another city - both with wrong stators and rotors)
 
Whenever I swapped ignitions, I swapped the whole setup as is required to make the bike run. The stator, flywheel, and CDI.. I assume this is what you mean?
 
J.R. said:
Whenever I swapped ignitions, I swapped the whole setup as is required to make the bike run. The stator, flywheel, and CDI.. I assume this is what you mean?
Click to expand...

Yup, thats what i mean. I DIDNT swap CDIs, hence my issues.
Re-reading your thread - how did they weld the balancer gear on? did they de-magnetize crank after mig/tig welding? (not sure if arc welding introduces a magnetic field). Wiring from your ignition pick up ok?
 
Not sure about the welding, tho slowpoke doesnt think its an issue. I will add, this shop is well known for their engine work, including crank rebuilds/welding, etc
 
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