TE 250/310 xlite starter issues...

[R_Little]

This sounds confusing ... What hangs open? The valve?

Yes, for some reason all the other valves are measured found maybe .001 too tight and you slap a one size smaller shim in there and they measure .001 into the spec like they should.

For whatever reason the valve under the decompressor seems to be all over the place when I measured it.
for example I may read .003 too tight so put a 2 size smaller shim (.004) in and measure and it comes out .003 too loose. What? Measure it again and it reads correct. Button it back up.

Use the bike for a 6 months and the estart struggles....check valve and find all the others are in spec but this one is now .004 too loose....put the original valve shim in and all is good.

I think cam orientation on that valve is critical to make sure the decompressor is not holding the valve open causing a false tight valve reading.

I think if the valve is too loose the decompression doesn't quite open it enough.....why you can still kickstart it I can't really explain.....maybe it's just a bit too much for the E-start but not enough for your leg.

 

[glangston]

I've got 36 hours (800 miles) on my 2012 TE310 and no issues. Changing out the 40 rear sprocket to a 45 seems about right for me. Bike is idling smoother and the 2500 -3000 rpm issue just isn't noticeable up here in Mammoth @ 7500 ft-9000 ft. Definitely no starting issues. Still some lean pops on deceleration but not bad. Has not died on slow downhill either, which was a concern for awhile.

 

[Tessier]

According to my dealer when the pulled the bike apart the keyway on the flywheel was stripped. I have yet to see what it look's like in there because all this was under "warranty" but could someone post pictures if they have any. I'd love to see how this happen's since everything in the starting system was just replaced.

This weekend I am planning 120 mile ride so hopefully everything goes well and we can put all these issues behind me finally.

 

[Phoenix]

Here are some pics I took when I replaced my sprag clutch. I had the flywheel-stuck-to-the-ring-gear problem. You can see the spring on the sprag clutch was pretty worn out. There are also a couple of pics of my mangled flywheel key. Unfortunately I think I did this myself by overtorquing the flywheel nut. The bike has been working pretty well since I got a new sprag clutch.

Here are some things I have decided are key to pay attention to on this bike:

Torque torque torque - I have bought two very nice torque wrenches since owning the bike. Especially on the cam cap bolts!
Battery strength - If the bike even starts to struggle, I yank out the kicker. It doesn't seem to take much juice to fire the fuel pump, but it needs a little, its best to conserve it.
Starter motor - Again, if the bike is struggling to start, I pull out the kicker and do it the old fashion way. No need to tax this underwhelming estart system.

The last one is kind of silly. It shouldn't be this way, but I've learned to live with it.

 

[Tessier]

Well I completed 120 miles this weekend and for whatever reason when I started the ride my battery was completely dead I just put it in before bringing it back to my dealer and the deal said they don't have a charger for lithium ion but unfortunately did use a booster pack to start the bike with the battery connected hopefully that didn't do any damage. I figured it was new so it just wasn't completely charged but as the day went on I figured it would charge up. Well look's like I was wrong because for the whole 120 miles every time we stopped to regroup I had to kick start the bike. Either way at this point I was just glad to be out and enjoying the bike!

My only other issue was everyone kept complaining that when I would pass them my bike would suddenly kick up a huge roost and start chucking rock's directly at them and no matter what they did there bikes just could keep pace. Not sure what that's about but I liked it! Now I just need to figure out this charging issue.

 

[Indorider]

Inspected my flywheel key and it appears intact.
I have never done shims before, need some pointers.
How do shims come?
Do you stack them to get the right clearance?
Do you have to buy a kit or can you find loose ones for sale?

This is a really good thread on valve adjustment
http://www.cafehusky.com/threads/2010-txc-250-valve-adjustment.17407/

 

[glangston]

Well I completed 120 miles this weekend and for whatever reason when I started the ride my battery was completely dead I just put it in before bringing it back to my dealer and the deal said they don't have a charger for lithium ion but unfortunately did use a booster pack to start the bike with the battery connected hopefully that didn't do any damage. I figured it was new so it just wasn't completely charged but as the day went on I figured it would charge up. Well look's like I was wrong because for the whole 120 miles every time we stopped to regroup I had to kick start the bike. Either way at this point I was just glad to be out and enjoying the bike!

My only other issue was everyone kept complaining that when I would pass them my bike would suddenly kick up a huge roost and start chucking rock's directly at them and no matter what they did there bikes just could keep pace. Not sure what that's about but I liked it! Now I just need to figure out this charging issue.

I've heard the LiOn batteries are damaged by letting them get too far discharged....IOW it could be dead/broken. Some only need to discharge to 10 volts or so and they're toast, others can go down to 8 volts before the damage is done. This info was related to me by a dealer who talked with Earth-X battery rep over the phone over a warranty.....he got a new battery from them.

 

[Tinken]

10.5 volts is basically the generic limit for lithium ion batteries. Shorai batteries; do not allow the voltage below 12.86. If you use one, I recommend getting the powerwerx and setting it to 12.86. There is an emergency override too.

http://www.powerwerx.com/batteries-chargers/dc-low-voltage-disconnect-lvd.html

 

[RailwayRog]

Been away from the board since my bike has been in the shop since July.
Here is an update since I got my bike back a few weeks ago and i'll do an abbreviated recap.
Was having numerous E start issues I couldn't remedy myself like replacing starter motor, ring gear, placing the decomp exhaust valve at .05 clearance. In addition I had fuel pump issues which I fixed myself by replacing the fuel pump with the California one. So I wrote a letter to the president of Husky USA explaining the problems and how I felt about the situation.
He instructed me to bring it to the nearest authorized dealer to be looked at. At this point the kick start sprag was jammed into the flywheel which I had previously unjammed and what a hassle it was to get the pieces apart.
The bike was in the shop for a couple of months while I waited for a new designed ring gear and worm/pinion replacement parts to come from Italy. They also replace the flywheel and sprag that was jamming up.
Got my bike back for an Oct 7th dual sport ride. The ride started out in technical 1st gear terrain so another issue reared its ugly head and that's flame outs. So right away it flamed out a number of times, about the fourth time using the
E start which was working great I heard just a winding sound and the engine would not turn over nor fire when kick starting. Day is over a .03 miles from the start. Bring the bike back to the dealer, it had sheared the flywheel key. I also informed the dealer about the flame out issue so he did some tuning with the software (tuned it with the O2 sensor in).
Yesterday I rode an 80 mile enduro and the bike performed flawlessly, I didn't win any trophies but I didn't need to, I think I have my bike back.
A note about the flywheel key, when they replaced the key they also applied red loctite to the crankshaft where the flywheel mates to it.
And in the end (I hope this is the end to this saga) Husky responded and took care of the problem and that should be noted. The letter I received back from the president was one of concern and wanting to do the right thing and this was for a bike well out of warranty.
I also want to mention the repair facility I used in Medford, NY. Fun Wheels http://www.funwheels.com/
The owner/mechanic took the pains to explain all that was going on behind the scenes and never gave me the bums rush. I would highly recommend Funwheels to anyone looking for repairs or purchasing a new bike. And if Husky comes out with that 2 stroke road legal bike I know where I'm going to purchase at.

 

[bigbugberg]

Well after waiting 6 weeks to get parts from Italy, I got the bike out of the dealership. 2010 TE250 was in for the dreaded starter issue. They replaced the worm gear, starter, and a couple bushings. When I picked up the bike the chain was waaaaaay too tight. It creaked when I sat on the bike. I brought the bike home and looked at it hard. I figured if the dealer can't adjust the chain properly, what else can they not do? Well they also can't put oil back in the engine and they can't put back bolts previously removed. Now I had to go over this thing top to bottom. It ran so bad it was basically unrideable, gasping, backfiring, stalling, etc. I figured I had to get everything in spec before troubleshooting. I started with the valves, left exhaust too loose, right exhaust too tight (perhaps the reason for the starter to go?), swapped the shims between sides, all good. Intake in spec. Mix screw 1.75 out, sanded the grounds, add oil. Bike runs again, not good, but rideable. The bike still has (like another orange brand I own) a bad off idle hit, some call it a snatchy throttle, I call it poor performance. I don't really want to shell out more $$$ just to get the thing to run like it should. 12 port injectors, new ECUs, iBeats, all that crap is unfortunately required. The combination of the poor dealer support, poor parts availability, and the extra BS to get the bike to run right is waaaaay too much suffering. Shouldn't we all be reading about great rides and sharing places we've been rather than reading the latest false hope of a "Solution" for a poor performing bike?
In conclusion, no more Huskys in the corral.
Ever.

 

[Coffee]

..Shouldn't we all be reading about great rides and sharing places we've been rather than reading the latest false hope of a "Solution" for a poor performing bike?...

Yes I do, and you seem pretty patient about the things you have been through.

But for the casual readers, how prevalent these types of things are is difficult to ascertain. Most people generally only log in and type their thoughts when they have a problem - as opposed to logging in and letting the world know that their starter is working great. That said, the problem seems statistically significant to me.

 

[Phoenix]

Well after waiting 6 weeks to get parts from Italy, I got the bike out of the dealership. 2010 TE250 was in for the dreaded starter issue. They replaced the worm gear, starter, and a couple bushings. When I picked up the bike the chain was waaaaaay too tight. It creaked when I sat on the bike. I brought the bike home and looked at it hard. I figured if the dealer can't adjust the chain properly, what else can they not do? Well they also can't put oil back in the engine and they can't put back bolts previously removed. Now I had to go over this thing top to bottom. It ran so bad it was basically unrideable, gasping, backfiring, stalling, etc. I figured I had to get everything in spec before troubleshooting. I started with the valves, left exhaust too loose, right exhaust too tight (perhaps the reason for the starter to go?), swapped the shims between sides, all good. Intake in spec. Mix screw 1.75 out, sanded the grounds, add oil. Bike runs again, not good, but rideable. The bike still has (like another orange brand I own) a bad off idle hit, some call it a snatchy throttle, I call it poor performance. I don't really want to shell out more $$$ just to get the thing to run like it should. 12 port injectors, new ECUs, iBeats, all that crap is unfortunately required. The combination of the poor dealer support, poor parts availability, and the extra BS to get the bike to run right is waaaaay too much suffering. Shouldn't we all be reading about great rides and sharing places we've been rather than reading the latest false hope of a "Solution" for a poor performing bike?
In conclusion, no more Huskys in the corral.
Ever.

I'm surprised it took that long. I ordered a ring gear, worm gear and at a separate time a sprag clutch from Halls and they had them in stock. The only thing I've ever had to wait on was a cam and that was about 2 weeks. My bike has had every gremlin in the book, but I still love my Husky.

 

[twmtatenrost]

As my thread states elsewhere 8 wks without a brand new te310 2012 bike with 35 hrs use. Husky parts'' not available'' until W/c 29th Oct 2012.

still no sign of parts

still no bike


Husky £6k better off

what about the customer?

golden buisness rule- world wide---- if you dont take care of the customer, somebody else will.

opinions please.

 

[Coffee]

As my thread states elsewhere 8 wks without a brand new te310 2012 bike with 35 hrs use. Husky parts'' not available'' until W/c 29th Oct 2012.

still no sign of parts

still no bike


Husky £6k better off

what about the customer?

golden buisness rule- world wide---- if you dont take care of the customer, somebody else will.

opinions please.

It appears to me the xlite starter issues are statistically significant, but not systemic.

You list your location as Wales. If it were me, and you have not done so, I would contact Husky Sport and see if they could shed any light on the situation... assuming you have not done that already.

I could tell you what I would do, but that really does not matter. You have to decide what is best for you.

I can say that when I was last deciding what bike to buy, I *really* thought about what things were important to me and I decided stone cold reliability and fun to ride (for me, I've no idea what 'fun' is to you) was near the top of the list, and small quirks, less than ideal bike weight, and other things like that were much lower in priority.

 

[RailwayRog]

As my thread states elsewhere 8 wks without a brand new te310 2012 bike with 35 hrs use. Husky parts'' not available'' until W/c 29th Oct 2012.

still no sign of parts

still no bike


Husky £6k better off

what about the customer?

golden buisness rule- world wide---- if you dont take care of the customer, somebody else will.

opinions please.

Like Coffee states contact Husky via letter form stating your problems. I experienced the same problems so they are aware of the starter problems.
I wrote a letter to Husky USA stating the problem and how I felt about the whole situation. They where a little reluctant at first to cover it because the bike was way out of warranty. But in the end they covered all the cost of the repairs. I did have to wait a couple of months for the parts to come from Italy, they where supposedly one of a kind or beta parts they are working on to fix the starter problem.
I believe in most cases if you want to get your point across or let them know how you feel a letter is the best way to go. And I am not a letter writer but I was really upset and pissed about the number of issues I had with this bike.
In the end I can say they satisfied me, but I'm sure if I didn't write the letter I would have gotten no satisfaction and would have went away angry at Husky.
Roger

 

[Coffee]

Like Coffee states contact Husky via letter form stating your problems. I experienced the same problems so they are aware of the starter problems.
I wrote a letter to Husky USA stating the problem and how I felt about the whole situation. They where a little reluctant at first to cover it because the bike was way out of warranty. But in the end they covered all the cost of the repairs. I did have to wait a couple of months for the parts to come from Italy, they where supposedly one of a kind or beta parts they are working on to fix the starter problem.
I believe in most cases if you want to get your point across or let them know how you feel a letter is the best way to go. And I am not a letter writer but I was really upset and pissed about the number of issues I had with this bike.
In the end I can say they satisfied me, but I'm sure if I didn't write the letter I would have gotten no satisfaction and would have went away angry at Husky.
Roger

The only other thing I could add, is to ask Husqvarna NA (USA), or whatever your local importer is - to pass the email onto Italy so they are aware of the magnitude of the situation. The more feedback the better.

 

[twmtatenrost]

All
thanks for the advice and comments. I have been in touch with the Dealer who has liaised with Husky Uk who are liaising with Husky Italy.
Just extremely frustrated that this problem is taking time. to be fair to the dealer and Husky they are daeling with it and hopefully I will get a solution this week
Twm

 

[twmtatenrost]

All
thanks for the advice and comments. I have been in touch with the Dealer who has liaised with Husky Uk who are liaising with Husky Italy.
Just extremely frustrated that this problem is taking time. to be fair to the dealer and Husky they are daeling with it and hopefully I will get a solution this week
Twm

 

[TE in RC]

Shorai battery Do not allow voltage below 12.86!

 

[robertk61]

Have a look at this thread:

http://www.dirtbikeworld.net/forum/showthread.php?t=97948