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kleualle

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About kleualle

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    Colorado
  1. kleualle

    2004 TE510 Engine Failure

    Does anyone have or know of a 2004 TE 250/450/510 scrap engine I could salvage transmission and clutch parts from cheap? ktl...
  2. kleualle

    2004 TE510 Engine Failure

    What is your understanding on how they addressed the problem? I looked at the '05 and '06 parts manuals and they still use 8 rivets to attach the clutch basket to the gear. The rivets are the same part number across the 3 years. Seems to me the parts are pretty much the same with no improvements. Maybe they improved their process of putting the parts together so the rivets are less likely to break later? ktl...
  3. 86 hours / 2200 miles on the bike primary failure: clutch basket rivets, secondary failure: transmission repair cost: ~$2000 total, 1600 in parts, 400 on labor 3 rivets from the clutch basket failed, breaking and coming loose and ground through the transmission gears destroying the transmission. Broken gear teeth, split one gear in half, bent main output shaft by .03". Clutch basket rivets - poor design? Too weak for application? Bound to fail on every bike made that way? Anyone have this issue? Was Husqvarna USA able to help? So far they've said no to me. What is everyone's thoughts? I'm terribly bummed. Still have 3 yrs of payments left on the bike. I don't feel I can trust the bike after putting the same stock parts (rivets) back into it. Hall's Husky checking on billet clutch basket that uses bolts to mount to gear rather than rivets. They said it was made for '05-06 bikes but may fit '04. Any help or advice would be appreciated. ktl...
  4. kleualle

    rear tire, cut the mudguard

    My 2004 stock TE510 rubbed a hold in the mud guard the first time I rode it. After that tire was used up, I've put a Maxxis 120 IT Dessert on it. The chain has been adjusted 2-3 times since the bike was new. The tire just rubs the new mud guard while riding but doesn't rub a hole in it like previous. The clearances in that area a pretty tight. ktl...
  5. kleualle

    04 te 510 your veiws please

    I love my 04 TE510. I've got around 60 hrs / 1550 miles on it and it has been holding up well. One concern I have is with the clutch basket rivets. See my post at: http://www.thumpertalk.com/forum/showthread.php?t=286828 My understanding is that in reality, the TE510 is the same bike from head to tail as the TE450 with the only difference being the stroke of the piston (the con rod is longer). So all the 04's (250,450,510) may have the possibility of a clutch basket rivet working loose. I tweaked the jetting just after I bought it and it seems to be spot on. It always starts easy. It has loads of low end and is so easy to bring the front end up when you need it to glide over rough stuff. The power rolls on very strong but smooth. I can't say enough good about this bike. ktl...
  6. kleualle

    Alloy Flakes in my TE510 Oil

    Found the probable cause of the metal flake problem on the magnetic tip of the oil plug during my most recent oil change. I put 10 hrs on the engine since I discovered the initial flaking. It does appear to be a rivet from the clutch basket as mentioned by woody2's quote above. I'll post a pic of the rivet when I get a chance. Hope the remaining rivets in the clutch basket hold up and don't come loose over time. ktl...
  7. kleualle

    Alloy Flakes in my TE510 Oil

    Here are some more email quotes from some various dealers regarding the alloy flakes. From: mtnsports1@yahoo.com "I forwarded this on to Cagiva....so maybe they can give us an answer. I'm a little late ...so let me know if you have found anything out. I'm thinking that the cam chain is hitting an engine case (cylinder.?? head ?) and making the shavings. Usualy there is a knocking noise when that happens though (loose chain). Russ" From: brian@halls-cycles.com "In one other instance I have seen the rivets on the outter clutch hub (basket) rub the bottom of the inner hub. as the clutch bearing wears, it allows a slight amount of movement (wobble) of the outter hub, causing intermitant contact with the inner hub." I'll be interested to hear what Cagiva thinks of the problem. Seems like each responce has a slightly different theory as to what the problem could be. More info to come as I get it. ktl...
  8. kleualle

    Alloy Flakes in my TE510 Oil

    Here are some more email quotes from some various dealers regarding the alloy flakes. From: mtnsports1@yahoo.com "I forwarded this on to Cagiva....so maybe they can give us an answer. I'm a little late ...so let me know if you have found anything out. I'm thinking that the cam chain is hitting an engine case (cylinder.?? head ?) and making the shavings. Usualy there is a knocking noise when that happens though (loose chain). Russ" From: brian@halls-cycles.com "In one other instance I have seen the rivets on the outter clutch hub (basket) rub the bottom of the inner hub. as the clutch bearing wears, it allows a slight amount of movement (wobble) of the outter hub, causing intermitant contact with the inner hub." I'll be interested to hear what Cagiva thinks of the problem. Seems like each responce has a slightly different theory as to what the problem could be. More info to come as I get it. ktl...
  9. kleualle

    rear tyre

    I just installed a Maxxis IT-Dessert on my 510 and it looks and rides great. It is 120/100x18 which is equal to the 140/80x18. The first number is the width of the tire. The second number is the ratio/percentage of the height to the width. The third number is the rim diameter. There is a conversion chart and details you can see at the following link: http://motorcycleinfo.calsci.com/Tires.html ktl...
  10. kleualle

    Alloy Flakes in my TE510 Oil

    Sorry, the link you saw in the post is his email address. What he wrote to me was in quotes below it. I did copy and paste it into the post. Also, I'm running the stock clutch. My bike ran fine today. I might be psycing myself out trying to listen for a problem or knocking. I usually listen to music while I ride and just try to feel the bike. I can still hear the motor though in case some wild sound starts happening. Kelly...
  11. kleualle

    Alloy Flakes in my TE510 Oil

    Here is a reply from George Erl at Uptite. uptite@sbcglobal.net "Kelly; This is a tough one, from what you've said a couple thing's come to mind . 1 possible thought is they were in the motor from factory machining chips stuck in a corner or oil galley that didn't get cleaned out very unlikely but anything is possible. I would carefully look at the chips under a microscope looking for machining marks on the chips? That is a lot of chip fragmentation, have never seen this much without an accompening noise, vibration,or running issue this is why i think possibility #1. #2 if the flakes are silver not aluminum then it is the silver plating comeing of the big end rod bearing, some times the hard surfacing on the inside of the rod or pin can flake off from being shattered caused by detonation or wwhen the case hardening was not deep enough, whereas the softer core material is moving and resulting of the flaking of the hard surfacing material. If this happens this hard material gets between the cyl and piston cuts into the niksil looking like you took a razor blade on edge making up and down cuts into the cylinder and piston. As some one said possible bearing seated, this would be a first as far as I've seen with amount of fragments going on. Did you cut the paper oil filter apart , easy way is to band saw top and bottom off and streach it out lookin in the botton of pleats. Heads or tails on splitting cases if it seems to have cleaned itself up change the oil very often . if it starts to make any noises get in side see whats going on sorry can't tell you what's going on but will say it's very unusual please feel free to ask more questions if I can help I'll try. later george" I'm going for another ride this morning and not worry about it. ktl...
  12. kleualle

    Alloy Flakes in my TE510 Oil

    Today, I sent an email to several nation wide Husky dealers and I'll feed their responses into this thread as I get them. This is from Dan at MotoXotica. "the only time we had a situation of excessive metal being in the oil was on a tc 450 with about 30 hours of use.motor was getting noisy also.shortly after the rod had excessive play needing replacement.seemed as tho the motor was not getting adequete lubrication.dan." This relates to an earlier mention of the needle bearings in the crank/connecting rod assembly. Something to think about. Kelly...
  13. kleualle

    Shifting problem

    BCRider - I recently posted a thread regarding alloy flakes in my TE510 oil. I've been trying to understand the source and if it will be a problem for the long run. I was suprised to see the extent of metal flakes in my bike's oil. Check out my post and photos and let me know what you think. Were the flakes you saw in your bike's engine similar to what I'm seeing? Thanks... The thread: http://www.thumpertalk.com/forum/showthread.php?t=286828 Some pics I posted: http://img.photobucket.com/albums/v...le/DCP_5278.jpg http://img.photobucket.com/albums/v...le/DCP_5279.jpg http://img.photobucket.com/albums/v...le/DCP_5282.jpg http://img.photobucket.com/albums/v...le/DCP_5285.jpg
  14. kleualle

    Alloy Flakes in my TE510 Oil

    *** Alloy Flaking Update *** I road the TE510 hard for 2.25 hrs / 53 miles. The bike ran & performed great as it always has. Afterward, I dumped the oil and there were no additional flakes. There were some flakes that I believe were left over from the earlier flaking event. I think the event is over and the production of the flakes is tapering off. Here are some pictures so you can see the extent of what I'm experiencing. The flakes will not stick to a magnet and, to me, are a bright shinny silver color and very thin like plating. I placed a dime and a 6 inch ruler in the box as a reference for size and scale. Thanks in advance for your comments and thoughts. Kelly... Check out these photos. (Sorry, the date stamp on my camera needs setting)
  15. Greetings, I wanted to run this past everyone for your thoughts. Recently I changed the oil on my 2004 TE510 and to my surprise found hundreds of silver alloy flakes in the oil that dropped into the pan and in the filter screens. Some remained in the openings of the engine block and I fished as many as I could out with my finger. The flakes are not nuggets but flakes that vary in diameter from 1 - 4 mm and are non magnetic. They are very thin and look like they are shavings or chips from an alloy case. If you put them all together there is probably 1/4 to 1/3 of a teaspoon. The bike has 52 hours of run time on it and I change the oil and filter on a regular basis as well as other maintenance items. I've never had any problems with the bike and it continues to run strong with no noticeable or incorrect noises. It starts easily and reliably. I've had what I view as normal fine metal shavings on the magnetic oil plug from the gears. The kick starter mod had been installed by the dealer shortly after I purchased the bike last August. I've never used the kick starter, just the electric start. I put fresh oil in the engine, warmed it up for 5 minutes. Ran it through the gears for a minute or so. I then dumped the oil and checked for additional flakes. I didn't see any substantial quantity of new flakes, only a few that I think were pre-existing and flushed out from the oil change. Earlier, I had pulled the clutch side cover and carefully looked for flakes and could not see any on the clutch assembly or in the gears inside. I pulled the spark plug and cranked the kick starter through its motion by hand and all was smooth as well as the spring return back to the resting position. Nothing felt like it was scraping or rubbing. I spoke with one mechanic who thought maybe a bearing had seated in which cause a minor clearance issue that basically resolved itself. Has anyone experienced anything like this before? What are your recommendations? Do you think a clearance problem developed and resolved itself by way of the metal flakes? Are there more problems on the way? Should I continue to ride it and monitor the flaking by checking the oil after each ride or pay to have the case split and inspected? Thanks in advance for your thoughts. Kelly...
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