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 The previous version was outdated and no longer supported.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

TE 449 Stripped gear lever

Cannot see why its so difficult to tighten the bolt, just take the sump guard off, if that is such a pain what else are you not doing to your bike ?
 
If the skid plate is stock, it would be easy and there is no need to remove it anyway. If it is aluminum, forget it, serious pita to remove.
 
I have a alloy one, four easy bolts to get to off, done in a few minutes !! Do you have a strange aftermarket one then ?
 
That plate could do with a few holes in it, after a long muddy ride you would be carrying lots of extra weight around plus the engine will get a lot hotter.
 
Mud? I am unfamiliar with that term?
Haha, yea, not much mud here, mostly sand. I do plan on adding some holes to this plate, I just haven't gotten to it yet. :D
 
Doug Piper said:
Cannot see why its so difficult to tighten the bolt, just take the sump guard off, if that is such a pain what else are you not doing to your bike ?
Click to expand...

Apparently you have not tried to access this bolt.
Either that, or you have some pretty fancy tools ...

The frame is in the way for a conventional, in-line approach to the bolt as a driver (or allen wrench using the long side)would offer.
And there is not enough room to fit a 1/4 drive socket and wrench in there - and no, you can't fit a flex end in either.
only a 8mm box end fit for me, and I could only turn less than 1/8th of a turn each time. I actually found a 2nd 8mm wrench that had a little different offset and alternated them.

World class pain in the ass. just a really poorly thought out design here (if someone actually put it into testing at all).
Now, I carry an extra lever, and those 2 little 8mm box ends with me on every ride.

PS did I mention red lock-tite ???

I also found it apparent to remove both the skid plate, and the chain as it offered more, yet still minimal room.

Last,

Good luck using a longer bolt with a lock nut on the far end. There is no room for that either.
Been there, thought of that, and found it just wouldn't work ...
Some here have said you can,

To that I say, pictures, or it didn't happen ...

But yes, from your comment, it is quite apparent you have not been down there on a 449/511 shifter "overhaul" ...
 
SloChicken said:
Apparently you have not tried to access this bolt.
Either that, or you have some pretty fancy tools ...

The frame is in the way for a conventional, in-line approach to the bolt as a driver (or allen wrench using the long side)would offer.
And there is not enough room to fit a 1/4 drive socket and wrench in there - and no, you can't fit a flex end in either.
only a 8mm box end fit for me, and I could only turn less than 1/8th of a turn each time. I actually found a 2nd 8mm wrench that had a little different offset and alternated them.

World class pain in the ass. just a really poorly thought out design here (if someone actually put it into testing at all).
Now, I carry an extra lever, and those 2 little 8mm box ends with me on every ride.

PS did I mention red lock-tite ???

I also found it apparent to remove both the skid plate, and the chain as it offered more, yet still minimal room.

Last,

Good luck using a longer bolt with a lock nut on the far end. There is no room for that either.
Been there, thought of that, and found it just wouldn't work ...
Some here have said you can,

To that I say, pictures, or it didn't happen ...

But yes, from your comment, it is quite apparent you have not been down there on a 449/511 shifter "overhaul" ...
Click to expand...
Totally agree, I even removed the swingarm and that didn't help much...
 
Doug Piper said:
Have you tried a 8mm x 7mm offset spanner ? that worked for me.

View attachment 23935
Click to expand...

Box end wrench is effectively the same thing. Yes, that is what I used. One can only turn the wrench about 1/8th of a turn at a time. Just a ridiculous pain.

I am done here. explained it 3 times now. Kind of pissing me off just thinking about it ...

here is a link to the wrench type I used. And no, it didn't work worth shit. Unless you like putting a wrench on a nut 100 times just to tighten it once ...

http://www.google.com/imgres?imgurl...E6UdjQEuXr2QWKvoCIBw&ved=0CFMQ9QEwCg&dur=7738
 
I did not mean to offend you capabilites, i am considering passing this problem onto a very good friend who has some machining tools where we could remove some of the alloy near the bolt haed to gain better access, will update this thread in the future.
 
Londin said:
Guys guys guys......the middle of the bolt is an Allan key - takes a minute to get to!!
Click to expand...

Yep, that was a revelation for me, mucked around trying to get in there with a little socket, bending spanners to try and get in there, then discovered it was a socket head too.....doh
 
schoops said:
Yep, that was a revelation for me, mucked around trying to get in there with a little socket, bending spanners to try and get in there, then discovered it was a socket head too.....doh
Click to expand...
Yes, some do accept an allen key (my replacements were 1 with, and 1 without an allen keyway.
Still, that is beside the point, an allen key won't fit well enough to be of use. Clearances from frame are too tight to turn enough to torque the bolt effectively.

Damn, talking about this is like having to get a divorce from the same crazy lady over and over ...
 
Doug Piper said:
I did not mean to offend you capabilites, i am considering passing this problem onto a very good friend who has some machining tools where we could remove some of the alloy near the bolt haed to gain better access, will update this thread in the future.
Click to expand...
No offence taken bud - just a really frustrating job that on virtually any other job would be a 5 minute fix.
 
Thanks to this thread, and Bill at Cameron Cycle in Peterborough, Ontario......

My TE449 is back in business within 48 hrs of stripping the shift lever. Stripped the lever this weekend, had a frustrating ride out of the woods,
and resigned myself to a few weeks trying to track down a lever. Amazingly Bill had not one, but two in stock!

Took a about an hour tonight to replace the lever.

- Removed the skid plate, loosened the chain by taking off the rear wheel, used a long round head allen key to loosen the bolt, popped the old shift level off.
- Cleaned the spline shaft, cleaned the allen bolt (the replacement did not come with a bolt).
- Red Loctite on the lever threads, put the new lever on, which was a little trickier than taking the old one off, adjusted height as I went. I had to use a tire iron to
properly seat the new one.
- Coated the old bolt with red loctite, tightened into new lever.
- Replaced skid plate, put the rear wheel back on.

Now I'll cross my fingers and hope that it holds. I would have bought both levers tonight, but Bill apparently bent his riding the Corduroy Enduro this past weekend.

Has anyone actually located an after market source for improved shifters? (a source with then in stock).
 
well my 511 has stripped its lever too,
Im in australia and new one is costing my $125
kind of pissed of about this , im sure guys riding wr450f dont have this problem
i even rang zip ty racing this morning about there coming soon shift lever
there answer was vague ,
" not something we have done "
havent taken that off the website
ring back in a month ?? so no help there ..
 
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