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 The previous version was outdated and no longer supported.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

Broken Shifter Shaft TC450

HuskyT

HuskyT

Moderator
Staff member
Well it finally happened.. my first major breakdown
banghead.gif
my 2005 TC450 has over 300 hours on it now... was riding a very fun and newly Jumpy Vet Track at Milestone MX on Saturday... 12 laps in and having a serious amount of fun holding off a new 2011 Yammie 450 and another CRF 450 and the shifter just disappeared on me...

Could not find it to get my toe under it... pulled off the track and I can see that it is in the all the way down position.... head back to the pits in what I assume is third gear... I'm assuming that the bolt has sheared that holds it on and I have sheared the splines or something...

This did not happen while shifting.... I was approaching a step down table and shifted into third to get more speed for it and then when I landed, I had no shifter....

Back at the pits I lay the bike over and find that the shifter shaft is just rotating freeely up and down with the shifter....shaft must be broken inside...

Any thoughts guys on what I should start checking for and can I pull the shifter shaft by pulling off the right side case cover.... have spoken breifly with George and Robertaccio... may not have to split the case (crossing fingers now) but anyone else have this happen?

Anyone walk me through this?

T
 
hammer said:
Take right side cover off and slide it out, just that easy.
Click to expand...
Thanks Hammer...
thumbsup.gif



after looking up these tonight in my 2005 Parts PDF it does actually look that easy...

Parts Identifier:
TC450trannypartspage-2.jpg


Parts Numbers ( page 2 of 3)
TC450Huskytrannypartsidentifierpage.jpg


Hopefully will get some time after coaching Girls softball tomorrow night to strip it down... if not I have an Easter weekend project!

T
 
Ok here is the damage inside....just a sheared shifter shaft!
may42011065.jpg


Found a missing bushing on the shifter pin??? if you don't realize this is there you could miss it very easily...

Fishing out the shifter ratchet pin flanged bushing spacer... found this in one of the bottom oil drain ports
may42011059.jpg


Putting bushing spacer in under the sift shaft foot ( on the shifter ratchet pin first)
may42011060.jpg


Put new Shifter shaft in place and slide thru to other side of the case:
may42011062.jpg


Back in place align pin spacer bushing and shift shaft foot:
may42011063.jpg


Ensure shifter return spring is located properly:
may42011064.jpg


Button it all back up , fresh oil and it now works fine....
 
Glad to see it was a relatively easy fix for you, man. Is the broken shift shaft a pretty common issue on the older bikes?
 
You got me on that... my first serious breakdown ... first broken shift shaft that I have heard or seen on the forums since 2005 on both CH and TT....

This was a quick easy fix once I discovered the missing spacer floating around in the bottom...

T
 
An other happy ending story:D glad this was easy for you and not end up with a major catastrophic failure
 
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