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 The previous version was outdated and no longer supported.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

Question about Engine Cases 450-510SMR

tls25rs

tls25rs

Husqvarna
AA Class
Kind of an odd situation I have a question about.

I am building a 510 motor out of a couple of parts motors, both of the 06-07 vintage, and it was my understanding that there isn't any difference between the 450 and 510 cases other than the length of the head studs. This thought is supported by looking through the parts fiches where the 450 and 510 are listed together in all situations, finding that there is only one clutch cover part for both the 450 and 510 and the associated gasket only has one available part number.

In 06 there are two available crankcases and in 07 there are three available choices but again they all use the same covers and gaskets on the clutch side.

The problem I have is, the clutch cover and gasket from the broken 510 motor do not fit onto the good 450 cases. It's not a big deal because I have the clutch cover and gasket from the 450 to use but it doesn't make any sense according to the parts fiche.

The difference is in the area around where the kickstarter would be if the bike had one. All the other areas are identical. It looks as though on the 510 cases that area of the cases is larger to accomodate a larger gear on the kick start. Also on the 510 case there is a slot that would allow oil down onto the kick start shaft as well as a boss with two threaded holes in it which I am sure is used to hold part of the kick start assembly. The 450 cases have neither of these two things.

My question comes down to, does anyone know why the 450 cases I have are smaller in this area and also possibly what fiche I would locate the correct right side crankcase/clutch cover and associated gasket in case I need one in the future.

If I have to I can take a picture and post it up but the lower part of the motor is together now so I would have to disassemble it to do so.

Thanks

Joel
 
George,

What are the chances that one of the smaller case motors made into an 06 or 07? The guy I bought the motor from had an 06 or 07 (don't know the exact year but it looked exactly the same as my 06, plastics, frame, electronics, forks etc.) bike that he parted out.

Thanks

Joel
 
Everything is the same only thing that is different is clutch cover, gasket,kick start gears and shaft. Engine mounting points are the same.
Later George
 
Thanks George!

Before I used the cases in question I checked everything else to see that they were the same, only thing that I missed was the smaller kickstart area. Figured that out when I went to put the larger clutch cover on and wound up scratching my proverbial head a little. Grabbed the smaller clutch cover that was originally on this motor and everything went smooth from there.

Here is a list of RH cover and Gasket part numbers for the various years:

04, 05

Gasket 8000 99854
RH Cover 80A0 99172

06,07

Gasket 8000 A5906
RH Cover 80A0 A5905

08, 09

Gasket 8000 A5906
RH Cover 80B0 B0388

Hope it's helpful if someone does a search later on.

Thanks

Joel
 
There was a guy that goes by the name jimj525 or something like that that put a couple of hybrid bikes together in your area IIRC.
 
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