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 The previous version was outdated and no longer supported.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

Need some Clutch help

jkm

jkm

Husqvarna
AA Class
2007 TE450.
At 3000 miles, I lost the clutch - while riding in snow.

Replaced stock slave piston with 7602 piston and seal. Problem solved.

At 4000 miles, I lost the clutch again. This time during a Fall Dual Sport ride. The master cylinder was empty. I was able to bleed it and get it to work well enough to finish that 2 day DS ride.
During and after that DS ride, when the bike was parked overnight or longer, there would be clutch until the cold bike was started. As soon as it started, the clutch would go away. As long as there was fluid in the master cyl, it would come back after pumping of lever few times. Over the next couple weeks, I checked the mc and it always had min oil in it. But, I bled the system a number of times during this time period, thinking my problem might still be air in the system. So, I was putting m oil in the system, and that made it was hard to tell if it was going down or not. I could ride the bike as far as I wanted once the clutch came back after the cold start up, and it would not go away.... until the bike sat overnight again.

I could not find any leaks.....but I

Rebuilt the master cylinder anyway. Rode the bike 50-100 miles or so and the clutch worked fine.... until the bike sat overnight. Cold start up, lose clutch. Pull lever a few times, clutch came back. Ride all day, no problem.

Looking the bike over for outward leaks, I was pretty sure that I could see some sort of 'film' on the inside of the sight glass. I imagined this to be mineral oil which was not mixing with the motor oil.

I'd read stories of the slave cylinder being 'out of round', so.....

I ordered and installed a slave cylinder from Zip-Ty.
When re-installing the 7602 piston and seal, the system lost fluid. But, along with the new slave cylinder, Zip-Ty had sent an extra seal for the stock piston, so the stock piston and new seal were used. The leak stopped.

Rode 50 miles in the snow. The clutch worked fine. After the ride, the Bike sat in an un-heated garage for a week. Walking past the bike, I reached out and gave the clutch lever a pull and there was no clutch! Looked at MC and it was about 1/3 full of Min oil. I'd lost m oil again. I filled it about 1/2 full and rode the bike. The clutch doesn't feel right, but I'm guessing it was actually too low and needs bled.

I had a machinist mic all the parts. Stock slave cylinder is a bit out of round in one area by 1/1000". 7602 piston is not out. The seal on the 7602 piston was well worn (Thanks to Clay for sending me another!)

I'm at a loss. I have not replaced the clutch line because I can't find any outside leaks and I'm still sure that I was seeing mineral oil on the inside of the sight glass.

But with all the new parts, I'm still losing the clutch. Anyone got anything? Thanks.....jkm
 
i would suggest you spend the money for a brand new slave assy.the line should be fine.the oil loss is probably going in to the motor.dan
 
husky sells the slave assy complete.which is a new body ,piston, oring and all.chasing these kinds of things is enough to drive you crazy.i would simplify it and install a new husky slave assy as that seems to be why you are losing clutch pressure.hope that helps.dan
 
Ahhhh... I feel your pain. When I first got my new to me 06 TE450, I was having enough clutch issues to make me want to actually consider converting it to a cable and scrapping the hydralic system :banghead: I would lose pressure after hot and multiple uses on the trail.

It took a bit of time and parts, but eventually I was able fix it and its been good for two years. I tried George's x ring, a new slave, multiple bleeds (piston/slave should filled and then bled bottoum up ie pumping from slave to the master). Ultimately it was my master. FYI, I have heard that even rebuilding the master wont work if there was any flaking or pitting in the master. Lucky, there is only 2 or 3 potential solutions (MC, Slave, O ring). Dan is the man.
 
I had a problem like that after installing a new piston. It was air in the cylinder! I had to unbolt the slave cylinder & then compress the piston to get the air to bleed out.
 
2005 TE450.

I showed up for a dual sport ride and had no clutch. Pulled lever and nothing. Loaded bike back up and went home.

Checked fluid and it was low. I refilled and went for a ride the next weekend. No clutch 2 hours into ride. Fluid was gone.

Found a crack in the hose behind a zip tie that tied wiring to the hose. Replaced hose for I think $100 (?). Problem solved.
 
Here's an update: Since the clutch wasn't working, I decided I should bleed it. I topped off the mc and while the top was off, worked the lever. As I did, air bubbles came up into the mc. I started to look around and thought I may have seen a small bubble coming up out of the bleeder too. I hadn't loosened the bleeder yet, so I thought maybe the shop where I'd had the clutch work done had not tightened it enough. Well, it felt plenty snug to me, but I tightened it even more - scarey tight. Then I cleaned that area real good with carb cleaner, and took the bike for a short spin. During the ride, I lost the lever completely and there was min oil all over the bleeder area.
Clay (7602) has been real helpful thru all this, so I gave him a call to tell him what I'd found. He advised that I should put a fuel line on the bleeder to see if the fluid would come up into the hose or if the bleeder was leaking around the threads. So, I cleaned the bleeder out good and attached a fuel line. I was unable to ride the bike due to 'white-out' conditions at the time, but I did run it a couple minutes, while working the lever. So far, the threads are dry, and there is nothing showing in the fuel line hose yet.
 
By putting a piece of fuel line on the bleeder, I was able to confirm that the fluid is coming up thru the bleeder hole, not around the threads. Up until now, I've never heard of a bleeder failing. I've put a new bleeder on the system. I'll update if anything new comes up.....Thanks to all who've helped.......jkm
 
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