Wild Dog Adventure Riding

Technical Section => Make / Model Specific Discussions => Husqvarna => Topic started by: adv on November 03, 2013, 10:06:45 pm

Title: TE 610 General Maintenance
Post by: adv on November 03, 2013, 10:06:45 pm
Can we have a dedicated thread for 610 Maintenance and DIY Mods?

EDIT:

YES IT IS NOW ONE!  :biggrin:

BiG Dom
Title: Re: 610 General Maintenance & Mods
Post by: adv on November 03, 2013, 10:07:46 pm
What is the brake fluid change intervals? Mine is rather dark and I feel it needs changing.

Title: Re: 610 General Maintenance & Mods
Post by: BiG DoM on November 03, 2013, 10:08:32 pm
What is the brake fluid change intervals? Mine is rather dark and I feel it needs changing.

Normally 5000km/yearly or when it looks like that!!
Title: Re: 610 General Maintenance & Mods
Post by: adv on November 03, 2013, 10:09:23 pm
What is the brake fluid change intervals? Mine is rather dark and I feel it needs changing.

Normally yearly or when it looks like that!!

AHAHAHA  :imaposer:

 :thumleft:

Bleed it out with DOT5?
Title: Re: 610 General Maintenance & Mods
Post by: BiG DoM on November 03, 2013, 10:19:41 pm
I think DOT4 or 5 would be fine. If lazy I often just take a syringe and remove the BF from the reservoir and top up with fresh - usually before it starts getting bad.
Title: Re: 610 General Maintenance & Mods
Post by: BiG DoM on November 03, 2013, 10:31:00 pm
Can we have a dedicated thread for 610 Maintenance and DIY Mods?



OK I HAVE MADE THIS THREAD A STICKY - ie will appear in bold at the top of the Husky Model Specific Discussion section.

Please add your inputs - lets keep then specific to maintenance and I will dedicate a separate one to mods.
Title: Re: TE 610 General Maintenance
Post by: adv on November 03, 2013, 10:44:07 pm
Thanks Dom

Im on 4800KM with the spanner light notification illuminated on the dash.


I would like to do an oil dump and change the filters

Questions

1. How many liters does the 610 hold.

2. How many oil filters?

3. Im assuming the plugs are CR8/9E's?
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on November 03, 2013, 11:20:11 pm
Thanks Dom

Im on 4800KM with the spanner light notification illuminated on the dash.


I would like to do an oil dump and change the filters

Questions

1. How many liters does the 610 hold.

2. How many oil filters?

3. Im assuming the plugs are CR8/9E's?

Do you have an Owners Manual? If not you need one for some of these basics - 60 pages in english. Should be online as I found the parts catalogue.

1) Oil is 2 litres with filter change and 1.8 without
2) Main oil filter - paper/mesh replaceable type and two stailnless steel basket reusable ones.
3) Plugs are NGK CPR8E - I have fitted the Iridium CR8EIA-10
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on November 03, 2013, 11:53:01 pm
OK for those that have not discovered Cafe Husky - get over there as it is THE site for Husky owners.
Here is a link to some useful technical fixes:

 
http://www.cafehusky.com/forums/technical-reference.61/ (http://www.cafehusky.com/forums/technical-reference.61/)
Title: Re: TE 610 General Maintenance
Post by: Straatkat on November 14, 2013, 09:36:10 am
What oil are you guys using for the 610?
I like to use Motul 300V as I heard very good things about it, but I could not get it in 10w60, only 15W60.
I would like to hear what you guys are using, as I have an oil change looming.
Title: Re: TE 610 General Maintenance
Post by: adv on November 14, 2013, 10:48:12 am
Just service and replaced with actyvo. Should be fine.
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on November 14, 2013, 11:19:26 am
What oil are you guys using for the 610?
I like to use Motul 300V as I heard very good things about it, but I could not get it in 10w60, only 15W60.
I would like to hear what you guys are using, as I have an oil change looming.



15W60 should be fine and Motul top rate. I have been using Castrol Edge Sport 10W60 as I get a good deal on it. Liqui Moly also excellent. Basically I would advise use the best synth you can get and afford, and change at more regular intervals than specified (especially if used long and hard). Money well spent in the bigger scheme of things.  :thumleft:
Title: Re: TE 610 General Maintenance
Post by: Straatkat on November 14, 2013, 12:46:37 pm
Thanks Dom, will do 15W60 Motul, and I'm going to do the clutch washers as well, whether they need it or not. I'm on 10k now. Maybe after Alan's ordeal I should also check all internal nuts for tightness while I am in there. last time, 5k, my chain tensioner was on 6 clicks....so it should still be fine.
Title: Re: TE 610 General Maintenance
Post by: Straatkat on December 12, 2013, 12:29:09 pm
Saw my rear sprocket is looking decidedly shark toothed, have a cover over the front one so haven't checked it yet. Now is the ideal time to make some ratio changes...
I'm going to go with a 47 rear (45 is std) and 13/14/15 in front (15 is std)
My ratios will be as follows:
Standard ratio 15-45--------3        130km/h (just to compare speeds at the same rpm)
13-47--------3.615  (20% slower)  104km/h Pulls like a horse, but runs out of steam quickly, good for very technical stuff
14-47--------3.36    (12% slower)  114km/h
15-47--------3.133  (4,5% slower)  124km/h Probably a good all rounder ratio, but would still prefer a taller ratio for tar stretches.
16-47--------2.94    (2% faster) Should be good for slabbing some distance, nice relaxed revs at 130.


My thinking is that it is easy to change front sprockets, and getting the tension on the chain adjusted is not a massive deal, so it will give me more versatility.
Might end up liking one particular ratio and just leave it on that.
Thought long and hard about a faster ratio for long tar sections, but I hardly ever do those, and have a concern about power not being enough, and of course then the hooligan in me will want to go too fast...on a bike that was not designed to be high speed vehicle.

Title: Re: TE 610 General Maintenance
Post by: BiG DoM on December 12, 2013, 12:36:53 pm
I run 15/47 and very happy with it.  :thumleft:  The 15/45 is in fact not a good wear combo either as there is not enough variation in tooth chain contact pattern.
Title: Re: TE 610 General Maintenance
Post by: Straatkat on December 12, 2013, 08:40:45 pm
Yes the std ratio is exactly 3, so the chain runs the same links over the same teeth all the time. Never thought about it like that, but I suppose it could have an effect. By the way I am getting all the sprockets from Chaintech, biggest variety and also cheapest. Bought the DID VX2 X-ring chain elsewhere but their price on that is also keen.
Title: Re: TE 610 General Maintenance
Post by: alanB on December 12, 2013, 09:42:15 pm
I use Castrol Power 1 4T racing synthetic oil - thats what the guys at Primrose recommended - seemed like a good enough oil.  Used that all along.

Its quite expensive in the bike shops but a lot cheaper at Midas  :thumleft:
Title: Re: 610 General Maintenance & Mods
Post by: alanB on December 12, 2013, 09:43:58 pm
I think DOT4 or 5 would be fine. If lazy I often just take a syringe and remove the BF from the reservoir and top up with fresh - usually before it starts getting bad.

The manual says DOT4

My rear brake fluid looked a but dodgy so I just tipped it out and filled it up, I was expecting air bubble issues but it seems OK.
Title: Re: TE 610 General Maintenance
Post by: alanB on December 12, 2013, 09:52:31 pm
If you need the workshop manual you can download from my website.

www.abolton.co.za/upload/2008SM-TE610IE (http://www.abolton.co.za/upload/2008SM-TE610IE) Repair.pdf
Title: Re: TE 610 General Maintenance
Post by: Straatkat on December 13, 2013, 08:28:58 am
I think DOT4 or 5 would be fine. If lazy I often just take a syringe and remove the BF from the reservoir and top up with fresh - usually before it starts getting bad.

The manual says DOT4

My rear brake fluid looked a but dodgy so I just tipped it out and filled it up, I was expecting air bubble issues but it seems OK.


It is really easy to just bleed it through, the place where the old fluid can cause corrosion is in the caliper, and if you only change the fluid in the reservoir it kinda leaves the bad stuff where it can cause damage.
I just sneak a plastic pipe over the nipple, and bleed it through untill no more dark stuff comes out. (pump the lever and open the nipple a little to let the pressure out and close again) Also clean that rubber boot thinghy, and don't leave the reservoir or brake fluid bottle open for too long, the stuff is horribly hydroscopic.
Title: Re: TE 610 General Maintenance
Post by: Straatkat on December 13, 2013, 08:37:30 am
I use Castrol Power 1 4T racing synthetic oil - thats what the guys at Primrose recommended - seemed like a good enough oil.  Used that all along.

Its quite expensive in the bike shops but a lot cheaper at Midas  :thumleft:

Got 4 Liters of Motul 300v but it is 15w50,all they had, now that is going out of spec both ways as the manual says 10w60, not sure if I want to use it in my Husky, and it will be about R450 for an oil change...a bit steep.
Maybe I should use it in another bike and get some Castrol like Alan suggests. :3some:

Alan, thanks for the manual, will definitely download it. ;)
Title: Re: TE 610 General Maintenance
Post by: alanB on December 13, 2013, 09:24:22 am
I think the Castrol Power1 was R89 per litre at the local Midas.
Title: Re: TE 610 General Maintenance
Post by: sidetrack on December 14, 2013, 09:51:24 pm
15-47 gearing and Castrol Actevo. Used Actevo even in my CRF with zero problems. The 610 motor is not the same as the modern racing 4 t's so I believe fully synthetic is a waste of money imho.
Title: Re: TE 610 General Maintenance
Post by: Straatkat on December 15, 2013, 07:52:13 pm
Oil is cheap insurance to keep you motor healthy, the cost of which pales against the cost of a motor rebuild, so I don't like to skimp in this department. Most synthetic oils are probably much better than needed, but then that would be additional insurance for when we run the motors hot in difficult conditions.
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on December 15, 2013, 07:58:45 pm
Must say I subscribe to the same philosophy as Streetcat  :3some:
Title: Re: TE 610 General Maintenance
Post by: sidetrack on December 15, 2013, 08:10:14 pm
I ran my DRZ400 on Actevo only, sold it at 68000km. At 50 000km I opened the top end and the bore was good as new. There is no way I'm paying double for fully synthetic when it's not needed (ie racing). More important is to service at regular inervals and keep the air filter clean. Previous owner of my bike ran high spec Motul and I had to repair alot of worn items with less than 15000km on the clock, I won't say it was the oil as Motul is top class but you can not guarantee 100% running even at R150 / L. Oil debates will always be a hot topic, whatever gives you piece of mind  :biggrin:
Title: Re: TE 610 General Maintenance
Post by: alanB on December 16, 2013, 09:35:16 am
I agree with both arguments actually - if that's possible  :-[

Can't see the point of skimping on oil to save a few rand - but you don't need to go ballistic either.  Just get a good enough quality oil that meets or exceeds the manufacturer's specs.

Primrose recommended The Castrol Power 1 4t synthetic saying that's what they use in all their Huskies, I checked its specs and didn't see any reason to argue.  And I have stuck to that since, especially since finding that's it quite cheap at Midas.

But I agree with Sidetrack, frequent maintenance is the key, clean the air filter after every dusty ride, keep it properly oiled, change the oil and oil filter frequently.   

You need to do that with any bike/car if you want it to last.
Title: Re: TE 610 General Maintenance
Post by: adv on December 16, 2013, 01:36:59 pm
My rear brakes seem to bind when standing in the sun. Any ideas?
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on December 16, 2013, 01:51:10 pm
When did you last clean the callipers and lube the pins? Could just be the disc and pads expanding and binding on the pin?
Title: Re: TE 610 General Maintenance
Post by: adv on December 16, 2013, 02:54:15 pm
When did you last clean the callipers and lube the pins? Could just be the disc and pads expanding and binding on the pin?

I have not. Good idea.

Ill tear them open when I have a moment.  :thumleft:
Title: Re: TE 610 General Maintenance
Post by: Straatkat on December 16, 2013, 03:36:16 pm
Sidetrack definitely have a point and regular maintenance is probably the best solution, question is, is 5000km old Motul as good as 2000km cheaper oil, I doubt it very much. Think fresh oil will win hands down. Just drained my oil after 5000km (10k service) and it is very black, definitely not gpoing to wait this long next time, probably 2500km a better change interval.
Title: Re: TE 610 General Maintenance
Post by: sidetrack on December 16, 2013, 05:40:28 pm
Sidetrack definitely have a point and regular maintenance is probably the best solution, question is, is 5000km old Motul as good as 2000km cheaper oil, I doubt it very much. Think fresh oil will win hands down. Just drained my oil after 5000km (10k service) and it is very black, definitely not gpoing to wait this long next time, probably 2500km a better change interval.
Yip I also service at about 2000-2500km.
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on December 20, 2013, 01:02:26 pm
Please note this is a dedicated thread for 610 Maintenance and DIY Mods :3some:.
Title: Re: TE 610 General Maintenance
Post by: Straatkat on December 20, 2013, 08:59:20 pm
Servicing my bike, 10k , and decided to do the clutch washers as preventitive maintenance, found only very small pieces of debris in the LH screen, probably the size of pin heads, so made the special tool to hold and loosen the clutch basket, and found some destruction. The washers are worn but not as bad as some of the pics I saw on forums, but the plate that sits over the springs is worn badly on some wings. Found an interesting phenomenon, some washers are still 100% fine while others are worn almost through. Then I examined the faces on the gear (the oblong holes that the spring-washer combo work in) and saw they are punched and the shear faces are left rough, and they are eating up the washers. Some of the faces are smoother than others and those washers were actually fine. I have now polished those faces to avoid them eating my newly made washers for breakfast!
Now, what to do with the plate that holds the washers? Are they available as a loose part or only as a complete clutch basket assembly?
Title: Re: TE 610 General Maintenance
Post by: sidetrack on December 21, 2013, 10:33:59 am
I guess you could file them down but you will have less metal than before. Contact Blazes he might have the part for you  ;)
Title: Re: TE 610 General Maintenance
Post by: Straatkat on December 22, 2013, 08:24:19 am
I mig welded the plate and filed it down again, probably not the best solution, but should work. First prize would be a new plate, will have to see what can be done in the new year.
Title: Re: TE 610 General Maintenance
Post by: alanB on December 22, 2013, 10:50:54 am
I mig welded the plate and filed it down again, probably not the best solution, but should work. First prize would be a new plate, will have to see what can be done in the new year.

Hi Bertie

Nice work!

I think I see why they are wearing, the slot at the top for the washer seems off centre in the photo?  Which would make the spring sit up against the one side maybe?
Title: Re: TE 610 General Maintenance
Post by: sidetrack on December 22, 2013, 11:39:34 am
Never seen so much wear on the plate caused by the spring before. The spring must have been really loose !
Title: Re: TE 610 General Maintenance
Post by: sidetrack on December 22, 2013, 11:40:37 am
I think the Castrol Power1 was R89 per litre at the local Midas.
Yep I saw it's only about R20 a liter more expensive than Actevo so I bought some and put it in my bike, it sounds the same  :biggrin:
Title: Re: TE 610 General Maintenance
Post by: alanB on December 22, 2013, 11:44:16 am
I think the Castrol Power1 was R89 per litre at the local Midas.
Yep I saw it's only about R20 a liter more expensive than Actevo so I bought some and put it in my bike, it sounds the same  :biggrin:

Is that a bad thing? :biggrin:
Title: Re: TE 610 General Maintenance
Post by: sidetrack on December 22, 2013, 12:58:43 pm
I think the Castrol Power1 was R89 per litre at the local Midas.
Yep I saw it's only about R20 a liter more expensive than Actevo so I bought some and put it in my bike, it sounds the same  :biggrin:

Is that a bad thing? :biggrin:
Secretly hoping to get the motor quieter, it has always had the irritating ticking noise I want to get rid off. From reading it sounds like a Husky thing but I want it gone.
Title: Re: TE 610 General Maintenance
Post by: Straatkat on December 22, 2013, 01:41:18 pm
Jaques, you can do even better than that, Autozone is only R85 for Castrol Power1, or you can do much worse and buy some from Chaintech @R165!!!
Title: Re: TE 610 General Maintenance
Post by: alanB on December 22, 2013, 02:13:23 pm
I think the Castrol Power1 was R89 per litre at the local Midas.
Yep I saw it's only about R20 a liter more expensive than Actevo so I bought some and put it in my bike, it sounds the same  :biggrin:

Is that a bad thing? :biggrin:
Secretly hoping to get the motor quieter, it has always had the irritating ticking noise I want to get rid off. From reading it sounds like a Husky thing but I want it gone.

Ja look I think they have a certain agricultural aspect that I don't think can be denied  :biggrin:
Title: Re: TE 610 General Maintenance
Post by: sidetrack on December 22, 2013, 02:21:06 pm
I think the Castrol Power1 was R89 per litre at the local Midas.
Yep I saw it's only about R20 a liter more expensive than Actevo so I bought some and put it in my bike, it sounds the same  :biggrin:

Is that a bad thing? :biggrin:
Secretly hoping to get the motor quieter, it has always had the irritating ticking noise I want to get rid off. From reading it sounds like a Husky thing but I want it gone.

Ja look I think they have a certain agricultural aspect that I don't think can be denied  :biggrin:

Well at least if I ride I can't hear it  :ricky:
Title: Front caliper pin
Post by: sidetrack on December 22, 2013, 02:22:25 pm
Check your pin holding the front brake pads in the caliper. Mine lost it's circlip and the pin was about 1mm away from making contact with the spokes !
Title: Re: TE 610 General Maintenance
Post by: wolf skaap on December 22, 2013, 03:58:10 pm
Ja look I think they have a certain agricultural aspect that I don't think can be denied  :biggrin:

It's only after owning a precision engineered motor like the crf that you have these niggles. As they said, its never gonna sound like a Honda!

Remember how noisy the 525 and that 550 was!
Just go ride your bike and be happy!  :ricky:
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on December 22, 2013, 05:43:38 pm
... and who might "they" be?  ::) ... sounds like the royal "we"... as far as I am concerned "they" can piss off as I do not want my Husky to look or sounds like a Japcrap Honda, thank you very much. Now lets get back to the dedicated subject of this thread = Husky TE 610 General Maintenance.

Straat kat I have never seen wear from the spring like that  :o  And Alan's observation is good about the off-centirc cutout? Did you check the brass bushing for play?
Title: Re: TE 610 General Maintenance
Post by: Straatkat on December 22, 2013, 08:48:51 pm
The bent tabs on the plate that I fixed are equal, just the photo that was taken from an angle then it looks like one is bigger than the other, but the plate is a Husky part, and the tabs are equal.
The bush has some play, but really not much, ever so slight movement in the clutch basket. Also remember the bush is loose in both the clutch side and on the shaft, so you need to add the tolerances of the 2 sliding surfaces together and that will give double the play, was thinking about putting loctite on one of the sides, will measure and loctite the biggest tolerance.

The washers were worn down quite thin and then the springs can move about some,  I have 2 washers that are still as new, all the others are farked, go figure.
Title: Re: TE 610 General Maintenance
Post by: wolf skaap on December 22, 2013, 11:15:49 pm
... and who might "they" be?  ::)
You asked the question, here's your answer: anybody listening to a 610 idling next to a crf. 

Now go.. delete my post again, as you seem to do with posts that do not support your product  ::)
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on December 23, 2013, 06:05:53 am
... and who might "they" be?  ::)
You asked the question, here's your answer: anybody listening to a 610 idling next to a crf.  

Now go.. delete my post again, as you seem to do with posts that do not support your product  ::)

Firstly Husky is not my "product" - I own one and am passionate about it - I do not sell the product! I have owned two Hondas and while I 'liked' them I was not passionate about them. As I have indicated before this is a dedicated thread for Husky TE610 owners and other interested WD's who have positive contributions or questions to post on General Maintenance - it is not here for puerile trolling, hijacking and brand bashing bullying by naysayers (which has reared its ugly head recently). There is nothing stopping anyone from taking these opinions and prejudices and airing them under Jou Ma - it is just not appropriate here on a dedicated technical thread - and yes they will get deleted if necessary. This is not to protect the brand which after all people buy and ride by choice - but to retain the integrity and purpose of this thread.  :thumleft:

Title: Re: TE 610 General Maintenance
Post by: Rough Rider on December 23, 2013, 09:08:38 am
... and who might "they" be?  ::)
You asked the question, here's your answer: anybody listening to a 610 idling next to a crf.  

Now go.. delete my post again, as you seem to do with posts that do not support your product  ::)

Firstly Husky is not my "product" - I own one and am passionate about it - I do not sell the product! I have owned two Hondas and while I 'liked' them I was not passionate about them. As I have indicated before this is a dedicated thread for Husky TE610 owners and other interested WD's who have positive contributions or questions to post on General Maintenance - it is not here for puerile trolling, hijacking and brand bashing bullying by naysayers (which has reared its ugly head recently). There is nothing stopping anyone from taking these opinions and prejudices and airing them under Jou Ma - it is just not appropriate here on a dedicated technical thread - and yes they will get deleted if necessary. This is not to protect the brand which after all people buy and ride by choice - but to retain the integrity and purpose of this thread.  :thumleft:



I agree with you Dom
Title: Re: TE 610 General Maintenance
Post by: alanB on December 23, 2013, 09:21:12 am
The bent tabs on the plate that I fixed are equal, just the photo that was taken from an angle then it looks like one is bigger than the other, but the plate is a Husky part, and the tabs are equal.
The bush has some play, but really not much, ever so slight movement in the clutch basket. Also remember the bush is loose in both the clutch side and on the shaft, so you need to add the tolerances of the 2 sliding surfaces together and that will give double the play, was thinking about putting loctite on one of the sides, will measure and loctite the biggest tolerance.

The washers were worn down quite thin and then the springs can move about some,  I have 2 washers that are still as new, all the others are farked, go figure.

Ok so it was just the photo making it look off centre :thumleft:

Regarding that clutch bush.  I could move mine quite a lot (I thought) by grabing the basket and wiggling it - but Conrad of Offroad cycles wasnt worried about that at all, after checking it out himself after I asked him to, he said he didnt think it needed replacement.  So I deferred to his experience.
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on December 23, 2013, 11:52:12 am
The bent tabs on the plate that I fixed are equal, just the photo that was taken from an angle then it looks like one is bigger than the other, but the plate is a Husky part, and the tabs are equal.
The bush has some play, but really not much, ever so slight movement in the clutch basket. Also remember the bush is loose in both the clutch side and on the shaft, so you need to add the tolerances of the 2 sliding surfaces together and that will give double the play, was thinking about putting loctite on one of the sides, will measure and loctite the biggest tolerance.

The washers were worn down quite thin and then the springs can move about some,  I have 2 washers that are still as new, all the others are farked, go figure.

Ok so it was just the photo making it look off centre :thumleft:

Regarding that clutch bush.  I could move mine quite a lot (I thought) by grabing the basket and wiggling it - but Conrad of Offroad cycles wasnt worried about that at all, after checking it out himself after I asked him to, he said he didnt think it needed replacement.  So I deferred to his experience.

Good to know. Mine had a very little play when I did the washers but also thought it pretty negligible.  :thumleft:
Title: Re: TE 610 General Maintenance
Post by: Straatkat on December 24, 2013, 11:26:44 am
Check your pin holding the front brake pads in the caliper. Mine lost it's circlip and the pin was about 1mm away from making contact with the spokes !

Checked mine and the wire clip is also missing, but the pin is still in place, going to put some wire through the hole and tie it on properly.
Title: Re: TE 610 General Maintenance
Post by: sidetrack on December 24, 2013, 12:22:17 pm
Check your pin holding the front brake pads in the caliper. Mine lost it's circlip and the pin was about 1mm away from making contact with the spokes !

Checked mine and the wire clip is also missing, but the pin is still in place, going to put some wire through the hole and tie it on properly.

Reckon it gets knock off when riding through the bush, threaded unit may have been a safer bet.
Title: Re: TE 610 General Maintenance
Post by: Straatkat on December 24, 2013, 03:45:12 pm
The bent tabs on the plate that I fixed are equal, just the photo that was taken from an angle then it looks like one is bigger than the other, but the plate is a Husky part, and the tabs are equal.
The bush has some play, but really not much, ever so slight movement in the clutch basket. Also remember the bush is loose in both the clutch side and on the shaft, so you need to add the tolerances of the 2 sliding surfaces together and that will give double the play, was thinking about putting loctite on one of the sides, will measure and loctite the biggest tolerance.

The washers were worn down quite thin and then the springs can move about some,  I have 2 washers that are still as new, all the others are farked, go figure.

Ok so it was just the photo making it look off centre :thumleft:

Regarding that clutch bush.  I could move mine quite a lot (I thought) by grabing the basket and wiggling it - but Conrad of Offroad cycles wasnt worried about that at all, after checking it out himself after I asked him to, he said he didnt think it needed replacement.  So I deferred to his experience.


OK I measured my bush on the clutch basket and between the basket and the bush it has 0.04mm clearance and between the bush and the shaft it has 0.1mm play, which is a sloppy 0.14 total. Think I'll be turning another.
Title: Re: TE 610 General Maintenance
Post by: Straatkat on December 26, 2013, 10:22:44 pm
Got my bike together today, new clutch bush, new washers, and repaired spring retention plate, works great. no untoward noises. Just for the record I fitted a 47 back sprocket and 13 front, it feels like I fitted a turbo, but runs out of steam quite fast.
7000 revs sees 130km/h and at 110 it revs 5800. Seems this ratio is a bit extreme for allround ability, will fit the 14 front next and see if I can live with that on the road. (the 13 is going to destroy my back tyre in no time, spins ALL the time)
Title: Make your own gaskets
Post by: BiG DoM on January 04, 2014, 06:04:54 pm
Well while I wait for a few parts for my Airboxectomy project I started going over the Husky = I want to do a service, check the front steering head bearings, and I wanted to do the valve clearances. So pulled the tank and radiators aside etc to get at the valve covers ... which still leak!!  :'(  I am determined to fix it this time - now the existing gaskets had been reused a few times and last time I also used silicone gasket sealer to try and get a good seal ... but of course the oil comes out the bolts!!! Long story short the gaskets were a bit fooked when I got them off and did not really want to use them again OR wait for new ones. I had a half sheet of gasket paper from Autozone that I had used for a clutch cover gasket on the KDX and so promptly traced two valve cover gasket and cut them with a scalpel and punched the holes with a leather punch. Total cost R1.50 for two! (The whole sheet had cost me just over R3.00 and had used half already). Now there is a bargain.  :3some:  So just to say - make your own if you need to, is so simple. Oh and the (hopefully) oil leak fix = copper washers (thanks alanB for suggestion) and silicone gasket fix on the top part of the bolts. There is not thread at the top of the cover so it does not gravitate on the thread just weeps through at the bolt head IMO.
Title: Re: Make your own gaskets
Post by: sidetrack on January 04, 2014, 08:50:37 pm
I have read some just forego the paper gaskets and put some silicone sealant only. I'm not a big fan however as it always seems to squeeze out the sides and could land up in the oil pump.
Title: Re: Make your own gaskets
Post by: BiG DoM on January 04, 2014, 09:01:24 pm
I have read some just forego the paper gaskets and put some silicone sealant only. I'm not a big fan however as it always seems to squeeze out the sides and could land up in the oil pump.

Yeah also read that somewhere but like you not a fan of the stuff if I can help it. Also really most of it gets squeezed out ... and inside too!
I find a gasket just makes more sense. Also if you have ever had to scrape that kak off a machined surface without scratching it and stripping your m@4r you will avoid it... especially if it is every time you do the valve lash!
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on January 05, 2014, 09:07:56 pm
Did the valve lash again yesterday - jirre but those tolerances are small and the space in there is tight. Just as well the feeler is so thin otherwise you would struggle to get it in! I bought two Wurth ones from Welsh some time back and have trimmed the one a bit narrower and it now has developed an nice little curve at the end ... works sweet  :thumleft:  

Also got to the steering head bearings ... mission yes to drop forks etc but had been on my mind. I was actually very impressed by the bearings - both condition and appearance. They are well made (did not notice a brand) and have very good dust covers. Have washed them out and repacked. Only very very slight wear on the race at the bottom on the rear side where they always get the most wear on bikes. So good to go.

Thinking maybe while all apart up front of getting 'sidetracked' and doing an alanB type instrument plate.  ::)
Title: Re: TE 610 General Maintenance
Post by: Straatkat on January 07, 2014, 12:27:06 pm
I have read some just forego the paper gaskets and put some silicone sealant only. I'm not a big fan however as it always seems to squeeze out the sides and could land up in the oil pump.

Yeah also read that somewhere but like you not a fan of the stuff if I can help it. Also really most of it gets squeezed out ... and inside too!
I find a gasket just makes more sense. Also if you have ever had to scrape that kak off a machined surface without scratching it and stripping your m@4r you will avoid it... especially if it is every time you do the valve lash!

Silicone make a very good seal, some car manufacturers assemble their engines without gaskets at all, but each to his own, I also detest getting the sh#t off when you have to take a cover off. Doesn't leak oil though! If you use silicone on one side and lightly oil the other face it comes off easily and you don't have to scrape it off, just put the cover back afterwards.
If you want to make your own gaskets, another method is to use a hardwood mallet and tap the gasket out on the actual casing by just lightly tapping at an angle inside and out. Works really cool with thinnish gasket paper.
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on January 07, 2014, 02:56:02 pm
Ja I have used silly cone before - I have generally not torqued it at first and let it sit over night to cure before putting final pressure on ... seems to allow a slightly thicker coating. Still I like a gasket - old school works.
Title: Re: TE 610 General Maintenance
Post by: adv on January 08, 2014, 02:39:54 am
Sm flooded today after I switch off after a stoppie.

Would not start... not even running start.

Eventually started after a bit of a fiddle here and there. Is it common for it to flood so quickly?
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on January 08, 2014, 06:38:29 am
Sm flooded today after I switch off after a stoppie.

Would not start... not even running start.

Eventually started after a bit of a fiddle here and there. Is it common for it to flood so quickly?

stuck float?
Title: Re: TE 610 General Maintenance
Post by: sidetrack on January 08, 2014, 08:15:44 am
Sm flooded today after I switch off after a stoppie.

Would not start... not even running start.

Eventually started after a bit of a fiddle here and there. Is it common for it to flood so quickly?
No mine has been on it's side a couple of times and through some mean offroad terrain and no flooding  ???
Title: Re: TE 610 General Maintenance
Post by: adv on January 09, 2014, 12:11:41 am
i did smell a lot of fuel. closed the tap and swung away. eventually she fired up after 2 running attempts.
Title: Re: TE 610 General Maintenance
Post by: Rough Rider on January 09, 2014, 09:09:20 am
i did smell a lot of fuel. closed the tap and swung away. eventually she fired up after 2 running attempts.

Next time open the throttle 100% and give it 3 or 4 swings and then start it normally with the throttle closed.
Title: Re: TE 610 General Maintenance
Post by: saklx650c on June 17, 2014, 08:26:17 pm
Hi, anyone got info on timing chains and adjustments.  Reading the manual says adjustment required after 10000km and 20000km.  Mine seem to be making a bit of noise at the moment.
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on June 17, 2014, 10:21:56 pm
Lots of info on Cafe Husky and Thumpertalk. Sounds like yours does not have the auto adjust tensioner unless they are just saying check at 10 and 20k? Many end up replacing the auto adjust CCT on the later models with a manual adjust anyway(APE is the preferred brand). What model is yours? If it is the ACCT you pull it and count the clicks out on the shaft to determine how stretched the chain is 10-11 clicks is time to replace chain. Remember these bikes are naturally a bit noisy by some standards.
Title: Re: TE 610 General Maintenance
Post by: saklx650c on June 18, 2014, 10:00:48 am
Lots of info on Cafe Husky and Thumpertalk. Sounds like yours does not have the auto adjust tensioner unless they are just saying check at 10 and 20k? Many end up replacing the auto adjust CCT on the later models with a manual adjust anyway(APE is the preferred brand). What model is yours? If it is the ACCT you pull it and count the clicks out on the shaft to determine how stretched the chain is 10-11 clicks is time to replace chain. Remember these bikes are naturally a bit noisy by some standards.
Hi Dom, thanks for info will check this evening and see if adjustment is required. When are you riding in the  EL area. I would also like to see the airboxotomy. 
Title: Re: TE 610 General Maintenance
Post by: lj111 on January 27, 2016, 10:37:26 pm
If you need the workshop manual you can download from my website.

www.abolton.co.za/upload/2008SM-TE610IE (http://www.abolton.co.za/upload/2008SM-TE610IE) Repair.pdf

Hi Alan

Does your website still work? I would love to get my hands on a workshop manual for a TE610.

Thanks

Louwrens :thumleft:

Title: Re: TE 610 General Maintenance
Post by: Crossed-up on January 27, 2016, 10:45:51 pm
Try

http://www.wilddog.za.net/forum/index.php?topic=151482.0 (http://www.wilddog.za.net/forum/index.php?topic=151482.0)

http://www.bikechatforums.com/viewtopic.php?t=140295 (http://www.bikechatforums.com/viewtopic.php?t=140295)
Title: Re: TE 610 General Maintenance
Post by: lj111 on January 28, 2016, 07:15:54 am
Try

http://www.wilddog.za.net/forum/index.php?topic=151482.0 (http://www.wilddog.za.net/forum/index.php?topic=151482.0)

http://www.bikechatforums.com/viewtopic.php?t=140295 (http://www.bikechatforums.com/viewtopic.php?t=140295)

Thanks Crossed-up :thumleft:
Title: Re: TE 610 General Maintenance
Post by: lj111 on February 24, 2016, 02:10:28 pm
I think the Castrol Power1 was R89 per litre at the local Midas.

Do you get it in 15w60? Or is the 10w50 OK?

Thanks  :thumleft:
Title: Re: TE 610 General Maintenance
Post by: alanB on February 24, 2016, 08:35:20 pm
If you need the workshop manual you can download from my website.

www.abolton.co.za/upload/2008SM-TE610IE (http://www.abolton.co.za/upload/2008SM-TE610IE) Repair.pdf

Hi Alan

Does your website still work? I would love to get my hands on a workshop manual for a TE610.

Thanks

Louwrens :thumleft:



Sorry only saw this now

The link should be www.abolton.co.za/upload/2008SM-TE610IERepair.pdf (http://www.abolton.co.za/upload/2008SM-TE610IERepair.pdf)
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on February 24, 2016, 08:39:40 pm
Sub!😉


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Title: Re: TE 610 General Maintenance
Post by: lj111 on February 25, 2016, 06:34:18 am
If you need the workshop manual you can download from my website.

www.abolton.co.za/upload/2008SM-TE610IE (http://www.abolton.co.za/upload/2008SM-TE610IE) Repair.pdf

Hi Alan

Does your website still work? I would love to get my hands on a workshop manual for a TE610.

Thanks

Louwrens :thumleft:



Sorry only saw this now

The link should be www.abolton.co.za/upload/2008SM-TE610IERepair.pdf (http://www.abolton.co.za/upload/2008SM-TE610IERepair.pdf)

Thanks Alan

 :thumleft:
Title: Re: TE 610 General Maintenance
Post by: lj111 on February 25, 2016, 06:39:38 am
Sub!😉


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Hi Chopper pilot

Saw your bike at Rough Rider when I went to look at his KDX. All I can say is  :drif:.
Have you got your bike yet?
Title: Re: TE 610 General Maintenance
Post by: lj111 on February 25, 2016, 06:40:58 am
I think the Castrol Power1 was R89 per litre at the local Midas.

Do you get it in 15w60? Or is the 10w50 OK?

Thanks  :thumleft:

 :sip:
Title: Re: TE 610 General Maintenance
Post by: alanB on February 25, 2016, 07:54:49 am
Don't use Castrol Power 1!

Sidetrack posted a video some time ago showing its actually crap oil!

I've actually settled on Caltex Delo 400.  I use it in my car and a while ago decided to try in in the bike.  My bike runs much smoother on it I think, plus its quite cheap!  And the Husky top end clatter is much more subdued  :biggrin:

One of business acquaintances used to do oil analysis on mining equipment, and when we were driving along one day he asked what oil I used in my car.  When I told him Delo 400, he was very pleased.  He said that was one of the few oils that consistently gave good results on heavy equipment like Caterpillar's etc they used to monitor.

I know its not a bike oil, but I'm happy with it so far.
Title: Re: TE 610 General Maintenance
Post by: lj111 on February 25, 2016, 08:11:44 am
Don't use Castrol Power 1!

Sidetrack posted a video some time ago showing its actually crap oil!

I've actually settled on Caltex Delo 400.  I use it in my car and a while ago decided to try in in the bike.  My bike runs much smoother on it I think, plus its quite cheap!  And the Husky top end clatter is much more subdued  :biggrin:

One of business acquaintances used to do oil analysis on mining equipment, and when we were driving along one day he asked what oil I used in my car.  When I told him Delo 400, he was very pleased.  He said that was one of the few oils that consistently gave good results on heavy equipment like Caterpillar's etc they used to monitor.

I know its not a bike oil, but I'm happy with it so far.

Thanks Alan :thumleft:

I am learning a lot from you guys :thumleft:
Just want to give my Husky some love, in exchange for the smiles she give me :ricky:
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on February 25, 2016, 10:30:57 am
Am I right that  Delo 400 is generally specced for diesel engines? I did use it once in my HP2 in Lesotho when I holed my sump!
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on February 25, 2016, 12:10:24 pm
In motor vehicles, and specifically VWs, Castrol is a no go. Plenty of sludge build-up. I use Shell oils in my vehicles.

Motorex in the KTM. Bel-Ray EXP or ELP in the DR 650. Have also used Motul.

The 4 x 4 fraternity rave about Caltex Delo 400 in their diesels.


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Title: Re: TE 610 General Maintenance
Post by: alanB on February 25, 2016, 02:30:27 pm
Ja Delo 400 is meant for diesels, but it says on the label its can be used in all vehicles.

What convinced me about it was my business acquaintance telling me how well it performed (their service was to take periodic oil samples of each major vehicle on the mine and then advise on oil changes and engine overhauls  based on what they found in the oil etc.

He said it was the only commercially available oil (ie available to the common motorist) which they used/recommended - all the other oils they used/recommended were not available to you and I.

But any discussion on oil soon becomes a bit like religion!

So who knows?  All I do know is my bike seems much smoother and the top end doesn't clatter as much as it used to, and its much cheaper and easier to get hold of than the purpose spec bike oils.

So use it - dont use it  8)
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on February 25, 2016, 05:01:27 pm
What is the SAE rating Alan?

How many kms on the Delo 400?

And I'm sure no clutch slipping issues!


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Title: Re: TE 610 General Maintenance
Post by: alanB on February 25, 2016, 06:54:44 pm
Its 15W40

Herewith a link to the spec. http://www.caltex.com.au/FPL%20PDS/Delo%20400%20Multigrade.pdf (http://www.caltex.com.au/FPL%20PDS/Delo%20400%20Multigrade.pdf)

They say about half way through that its not recommended for motorcycle engines ???

So maybe you shouldn't listen to me on this one?

I've been through two changes so far and like the way the bike runs on it so I think I'm going stick with it until I find a reason not to.
Title: Re: TE 610 General Maintenance
Post by: ChrisL - DUSTRIDERS on February 25, 2016, 10:12:53 pm
alanb if your bike likes Delo 400 you can use Fuchs 15w40 Truckplus too. A very good oil. All new John Deere tractors are sold and serviced with it.
Title: Re: TE 610 General Maintenance
Post by: lj111 on February 26, 2016, 09:46:53 am
I can get Liqui Moly 10w60 in Bellville for R180 a liter. Think I will go with the Liqui Moly. Expensive, but hope its worth it?
Title: Re: TE 610 General Maintenance
Post by: lj111 on February 26, 2016, 04:49:30 pm
Can get Motul10w60 at Track Mac for R480 a 4liter. Works out R120 a liter. What will you guys recommend between Liquid Moly and Motul?
Title: Re: TE 610 General Maintenance
Post by: alanB on February 26, 2016, 10:13:13 pm
Motul is very good as far as I know.
Title: Re: TE 610 General Maintenance
Post by: lj111 on February 27, 2016, 07:10:01 am
Thanks Alan.

The price ain't bad comparing with the other makes. 10w60 is also in spec.  :thumleft:
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on February 27, 2016, 11:04:53 am
Motul is JASO MA-2 spec. Doubt if Liqui Moly will be, but it might not have a single additive which could be harmfull to your clutch.

My main objective is the best protection for the metal to metal sections of the engine.




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Title: Re: TE 610 General Maintenance
Post by: lj111 on February 27, 2016, 06:06:53 pm
Good to know. Thanks CP :thumleft:

Liqui Moly will only be a R120 more a service. Not bad for more peace of mind.





Title: Re: TE 610 General Maintenance
Post by: Straatkat on February 29, 2016, 10:28:54 pm
I like to use Motul V300 in my 610 because sometimes I ask a hell of a lot of the oil, like the time my bike fell over on a mine dump, completely upside down, and I was rolling some distance down and had to scramble back up to the bike to kill the motor as it was still idling! There is no way it could have picked up the oil in the sump, so all of a minute or more it ran without oil and then you rely on the film of oil that is in the bearing shells....I will rather pay a little(or much) more for that piece of mind. Engine rebuilds are expensive!
Like Alan said, oil is like religion. Whatever gets you to heaven!
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on March 01, 2016, 03:41:45 pm
Question regarding the oil filter. Is there a Hi Flo one available?


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Title: Re: TE 610 General Maintenance
Post by: BiG DoM on March 01, 2016, 04:15:57 pm
Question regarding the oil filter. Is there a Hi Flo one available?


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Must be - but there is also a very good serviceable solution from Zipty.
Title: Re: TE 610 General Maintenance
Post by: Straatkat on March 01, 2016, 06:42:13 pm
Yip, Hi Flo HF563
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on March 01, 2016, 07:47:22 pm
Yip, Hi Flo HF563
Dankie Bertie!




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Title: Re: TE 610 General Maintenance
Post by: sidetrack on March 01, 2016, 09:31:57 pm
I believe the premium price you pay for Motorex is KTM hype, Liqui Moly is good and avaliable from most auto parts shops at good prices. Must say that I used Castrol Actevo with great success in my DRZ 400.
Title: Re: TE 610 General Maintenance
Post by: Kykdaar on March 01, 2016, 09:59:49 pm
Also use Castrol Actevo in the SM
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on March 02, 2016, 06:22:54 am
Sub!😉


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Hi Chopper pilot

Saw your bike at Rough Rider when I went to look at his KDX. All I can say is  :drif:.
Have you got your bike yet?
That's good to hear!👍

Was planning to ride it back to Nelspruit, TK is going down to CT, and has offered to bring it back!😃

Very excited!👍


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Title: Re: TE 610 General Maintenance
Post by: lj111 on March 02, 2016, 03:20:40 pm
Sub!😉


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Hi Chopper pilot

Saw your bike at Rough Rider when I went to look at his KDX. All I can say is  :drif:.
Have you got your bike yet?
That's good to hear!👍

Was planning to ride it back to Nelspruit, TK is going down to CT, and has offered to bring it back!😃

Very excited!👍


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I'm sure you will be very happy. :thumleft:

Enjoy :ricky:
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on March 02, 2016, 06:46:59 pm
Sub!😉


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Hi Chopper pilot

Saw your bike at Rough Rider when I went to look at his KDX. All I can say is  :drif:.
Have you got your bike yet?
That's good to hear!👍

Was planning to ride it back to Nelspruit, TK is going down to CT, and has offered to bring it back!😃

Very excited!👍


Sent from my iPad using Tapatalk

I'm sure you will be very happy. :thumleft:

Enjoy :ricky:
I will surely do!👍


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Title: TE 610 General Maintenance
Post by: chopperpilot on April 08, 2016, 10:26:37 am
Collected my 610 TE this past weekend from Kykdaar in Pta, who brought it up from CT. It belonged to Rough Rider.

(http://uploads.tapatalk-cdn.com/20160408/9fb3a1d16639b0aef865081fedb89208.jpg)
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on April 08, 2016, 11:13:26 am
The previous pic was taken when it was still in CT.

The bike has various extras, is in overall good condition, with hardly a scratch on it, and just over 8k on the clock.

Although it's in good condition, I'll be stripping the bike, checking and servicing it. Getting to know it in the process.

I've been riding DRs for a long time, and my approach to maintenance has resulted in many an enjoyable excursion in Swaziland.

I will not be doing to much to the TE, it is after all not a project bike, so will share what I do on this thread.

The plastics were covered in clear vinyl, which was looking tatty. I could remove it without damage to the graphics.

Cleaned the glue of with benzene, which left the plastics slightly dull. Applied some silicon, but will use some polish once the bike is stripped, to bring the shine back.

I noticed that although the exhaust cannister is a free flow, it was restricted when comparing the header's inlet diameter to the can, with the baffle.

We have a talented fabricator on the plots here in Nelspruit, who opened the can up nicely, polished it, and applied his logo.

Sounds great, but still need to test it on the road.

At R 1500, I'm chuffed with the result!

(http://uploads.tapatalk-cdn.com/20160408/623c3cf8db2888fca891463a01a3a829.jpg)




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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on April 08, 2016, 11:20:43 am
I considered an aftermarket FMF I had lying around. The Husky exhaust has no support for the long mid-pipe. It hangs on the headers and cannister. The OEM can has 2 attachment points to the rear subframe. One reason for keeping the OEM can. The OEM can is also much longer than an aftermarket, which will make the 50mm baffle quiter.

A pic of the end piece.

(http://uploads.tapatalk-cdn.com/20160408/d59723c7ba4eabc790bd5971af23e3e2.jpg)


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Title: Re: TE 610 General Maintenance
Post by: BiG DoM on April 08, 2016, 11:25:28 am
Great buy.  :thumleft:
Not sure that I would have been happy with someone applying his logo to a piece of refined Italian sculpture (notice who manufactured it and that fine integrated  logo on the design of the tailpiece). R1500 for a spit and polish and his branding??   :o ::)  
Anyway you should have looked inside that zorst - one of the best things you can do is de-restrict it ... which it sounds like may have been done already if "free flow"? Essentially with the decat one removes alot of weight at the same time. Oh and I did shorten mine slightly at the same time - really for aesthetics. I have also had the header ceramic coated inside and out. Has it had the power-up plug done?

Title: Re: TE 610 General Maintenance
Post by: Kykdaar on April 08, 2016, 11:29:42 am
I really like the standard can with the Husky "H" intact, so I am glad you could retain and modify it.

Looks great :thumleft: :thumleft: but I must agree with BigDom on the "Havoc" thing - maybe good enough for a KLR/DR rider but you stepping up in life now :biggrin:
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on April 08, 2016, 11:30:56 am
OK - I now see with this later pic where the cost has come in... with the enlarged tailpiece outlet pipe. Looks like it was done very neatly.  :thumleft:
I would even consider sending him mine to do likewise - ask him what he would charge just for that end-piece work please.
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on April 08, 2016, 12:07:07 pm
I actually requested the can not to be polished, when he asked me, when dropping the pipe off. The logo came as a surprise too! :o (I'm sure all can be removed though. Maybe some bead blasting, or a rub with some scotch brite? ???)

I could also buff the logo out, and have the Husky logo sand blasted on? ???

The can was gutted before (free flow), but the perforated pipe's diameter was much less than the inlet pipe. ;)

A new 50mm perforated pipe was used, and new packing inserted. :thumleft:

A slightly tapered aluminium pipe was welded to the Husky end can, after the square outlet was opened up. The new perforated pipe slips over this tapered pipe. :thumleft:

I bought the bike with the power-up module fitted, as well as a JD Tuner fitted. (Have the booklet, still need to study it. ;))

He said he could make me new headers if they are restrictive. How do the engine's exhaust port diameter compare with the headers ID? ???
 
Title: Re: TE 610 General Maintenance
Post by: Kykdaar on April 08, 2016, 12:15:03 pm
If you look at the way the headers fit onto the cylinder, round groove slip-on fit and the fact that they are constructed of relatively thin high-quality stainless steel then I would say there is only a very slight difference and that they are, therefore, not restrictive.
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on April 08, 2016, 12:23:11 pm
BD

Let me know what you exactly want done, or I can PM his number to you.

My late friend, Dries Pienaar, refered to Juan as "Geraas op die Plaas"!

Biker, staying on a plot, beer boep, pony tail, wheelie king, but a magician with metal work.

Even done decats for some GP BMW dealer.

He gutted the pipes on my 990 S. His welding as good as the factory.


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Title: Re: TE 610 General Maintenance
Post by: BiG DoM on April 08, 2016, 12:25:57 pm
I would not worry too much about the silencer logo - looks like it has been sandblasted and depending how deep could be waterpapered and then buffed out.  The JD Tuner is a VERY nice addition and compliments the exhaust benefit.
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on April 08, 2016, 12:26:49 pm
BD

Let me know what you exactly want done, or I can PM his number to you.

My late friend, Dries Pienaar, refered to Juan as "Geraas op die Plaas"!

Biker, staying on a plot, beer boep, pony tail, wheelie king, but a magician with metal work.

Even done decats for some GP BMW dealer.

He gutted the pipes on my 990 S. His welding as good as the factory.


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Like that geraas op die plaas  :imaposer:

Essentially I would like to send him just the end piece that he has made round and large for the same work - I would take it off. (I have also seen someone in USA who retained the squarish shape of the OEM outlet and enlarged it - not sure if he could do that but the round would also be fine)
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on April 08, 2016, 12:51:20 pm
I'm sure he could do anything you wish!

The round pipe on my end can, was first cut, tapered and welded, before welded to the end can.

What diameter perforated pipe do you have? Would you like him to square a round tapered pipe, that would fit in your perforated pipe?


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Title: Re: TE 610 General Maintenance
Post by: BiG DoM on April 08, 2016, 01:55:56 pm
I'm sure he could do anything you wish!

The round pipe on my end can, was first cut, tapered and welded, before welded to the end can.

What diameter perforated pipe do you have? Would you like him to square a round tapered pipe, that would fit in your perforated pipe?


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I will let you know - will have a look and think this weekend  :thumleft:
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on April 08, 2016, 02:00:12 pm
I'm sure he could do anything you wish!

The round pipe on my end can, was first cut, tapered and welded, before welded to the end can.

What diameter perforated pipe do you have? Would you like him to square a round tapered pipe, that would fit in your perforated pipe?


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:thumleft:

I will let you know - will have a look and think this weekend  :thumleft:
Title: Re: TE 610 General Maintenance
Post by: lj111 on April 08, 2016, 09:18:27 pm
Collected my 610 TE this past weekend from Kykdaar in Pta, who brought it up from CT. It belonged to Rough Rider.

(http://uploads.tapatalk-cdn.com/20160408/9fb3a1d16639b0aef865081fedb89208.jpg)

Happy times!!

Congratulations on a great bike. Now its just smiles and miles waiting.
 I wil keep a close eye on this thread. What you guys have forgotten, I still need to learn.

Enjoy :thumleft:
Title: Re: TE 610 General Maintenance
Post by: Straatkat on April 08, 2016, 11:54:28 pm
Henk, the way your exhaust was done is exactly how I did mine, removed the Cat, fitted a 50mm perforated pipe all the way through the exhaust and welded it to the tailpiece, but I shortened my canister to 380mm, looks good and saves some weight.
you were VERY lucky to get that bike, low km's and almost everything already done to it. Swaziland is calling!
Title: TE 610 General Maintenance
Post by: chopperpilot on April 09, 2016, 06:54:12 am
Thank you Bertie!

While at Kykdaar's place all the bikes were ridden around the block. My TE, his DR, his SM.

I was mighty impressed by the "crispness" and pulling power of his carbed SM, which was sold this week.

He shared with me that your TE is the strongest pulling 610 he has ridden.

Regarding the JD Tuner. I have the booklet and will study it, and adjust if necessary. Rough Rider did mention he adjusted it slightly rich, which will be even worse at my 3000' above sea level.

I only re-fitted the exhaust can, warmed it up, and gave it a few good revs.

To scared to ride it without proper ATGATT.

I still need to reinforce the subframe, and the battery bracket appears to have completely broken off. I fortunately have a good welder in town.

I will start stripping and servicing next week.


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Title: Re: TE 610 General Maintenance
Post by: Rough Rider on April 09, 2016, 01:26:57 pm
The previous pic was taken when it was still in CT.

The bike has various extras, is in overall good condition, with hardly a scratch on it, and just over 8k on the clock.

Although it's in good condition, I'll be stripping the bike, checking and servicing it. Getting to know it in the process.

I've been riding DRs for a long time, and my approach to maintenance has resulted in many an enjoyable excursion in Swaziland.

I will not be doing to much to the TE, it is after all not a project bike, so will share what I do on this thread.

The plastics were covered in clear vinyl, which was looking tatty. I could remove it without damage to the graphics.

Cleaned the glue of with benzene, which left the plastics slightly dull. Applied some silicon, but will use some polish once the bike is stripped, to bring the shine back.

I noticed that although the exhaust cannister is a free flow, it was restricted when comparing the header's inlet diameter to the can, with the baffle.

We have a talented fabricator on the plots here in Nelspruit, who opened the can up nicely, polished it, and applied his logo.

Sounds great, but still need to test it on the road.

At R 1500, I'm chuffed with the result!

(http://uploads.tapatalk-cdn.com/20160408/623c3cf8db2888fca891463a01a3a829.jpg)




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That pipe looks really great and I am sure will add to the performance.

Oh by the way I found the Lambda sensor I removed from the exhaust, when I fitted the power up plug. If you want it give me a shout. 
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on April 09, 2016, 03:01:29 pm
Thank you Rough Rider!

I'm really chuffed with this bike! Can not let a day go by without peeping in the garage it's parked in!

Can't wait for the first ride!

Regarding the lambda sensor. Even though I might not need it, I'm also one of those guys that keep everything that came off a bike. I will PM my PO address, if you don't mind sending it.


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Title: Re: TE 610 General Maintenance
Post by: BiG DoM on April 09, 2016, 03:39:22 pm
That battery cradle failure is a known weakness one of the documented TE idiosyncrasies. I also replaced the OEM battery with a lighter Lithium ion Ultrabatt. While you are fixing the battery cradle check the wiring in that area - it is known to be poorly routed on some bikes and chafes through right there.  :thumleft:
Title: Re: TE 610 General Maintenance
Post by: Kykdaar on April 09, 2016, 04:09:33 pm
That battery cradle failure is a known weakness one of the documented TE idiosyncrasies. I also replaced the OEM battery with a lighter Lithium ion Ultrabatt. While you are fixing the battery cradle check the wiring in that area - it is known to be poorly routed on some bikes and chafes through right there.  :thumleft:

Ja, also told Chopperpilot about the weak battery tray - they are more often broken than not. On a TE some dense foam and an Ultrabatt is a requirement.
Title: Re: TE 610 General Maintenance
Post by: alanB on April 09, 2016, 09:01:19 pm
The problem with the battery tray is actually just due to the battery not being properly tied down.

The standard restraint is a silly rubber band.  That allows the battery to jack hammer up and down as you ride.  That will break any tray, especially if you ride hard over rough terrain.

All that you need to do is toss the rubber band and get some heavy duty cable ties and crank the battery down really hard onto its mount.  This will stop the battery jack-hammering the welds and the problem will be solved IMO.
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on April 09, 2016, 09:05:01 pm
I am sure Alan is right. This is how we tie batteries on enduro bikes. I also always put a few strips of draught exclusion tape underneath and on contact surfaces to help cushion.  :thumleft:
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on April 10, 2016, 05:37:15 pm
Advice noted for the battery! Thanks!


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Title: Re: TE 610 General Maintenance
Post by: Crossed-up on April 26, 2016, 09:01:49 am
Very useful thread on cam-chain replacement.

http://www.supermotojunkie.com/showthread.php?60551-A-HOW-TO-610-Cam-Chain-Replacement (http://www.supermotojunkie.com/showthread.php?60551-A-HOW-TO-610-Cam-Chain-Replacement)
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on April 26, 2016, 06:17:47 pm
Very useful thread on cam-chain replacement.

http://www.supermotojunkie.com/showthread.php?60551-A-HOW-TO-610-Cam-Chain-Replacement (http://www.supermotojunkie.com/showthread.php?60551-A-HOW-TO-610-Cam-Chain-Replacement)
Thanks!👍


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Title: Re: TE 610 General Maintenance
Post by: BiG DoM on April 28, 2016, 11:08:38 am
HELP - Having a brain fart!  >:D  I have the front counter sprocket off my 610 for replacement ... am I right in saying that the collar side faces inward?  ::)
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on April 30, 2016, 09:11:12 am
HELP - Having a brain fart!  >:D  I have the front counter sprocket off my 610 for replacement ... am I right in saying that the collar side faces inward?  ::)
(http://uploads.tapatalk-cdn.com/20160430/249eaf12242c823788bb3ebbd5a03e72.jpg)


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on April 30, 2016, 09:19:16 am
I'm busy with some TLC/maintenance on the TE.

Stripping the rear sub frame to add some gussets/reinforcements.

The 2 thinner sections at the rear of the sub frame, appear to be slighty bent.

Are they suppose to be in line with front/square section, of the frame? I reckon so. (Quick repair while the sub frame is at my welder!)

(http://uploads.tapatalk-cdn.com/20160430/a2ee895e5bcc7586e10632d8fa471efa.jpg)(http://uploads.tapatalk-cdn.com/20160430/2dba7923e31ea4662d04d24b63465b15.jpg)


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on April 30, 2016, 09:20:46 am
More pics.

(http://uploads.tapatalk-cdn.com/20160430/555e916b4391902848d2e9ea1f747287.jpg)(http://uploads.tapatalk-cdn.com/20160430/ac6136abb7ec6aa431b7fe6a1741d584.jpg)


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on April 30, 2016, 09:27:18 am
The left frame extension appears to be bent down and inward, slightly more than the right one.

The right extension only slightly down and inward.


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Title: Re: TE 610 General Maintenance
Post by: Kykdaar on April 30, 2016, 11:40:18 am
You putting some good effort in there :thumleft:
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on April 30, 2016, 02:20:25 pm
You putting some good effort in there :thumleft:
It's an awesome machine! Need to now everything is perfect, before taking it to the dirt!

Did a tar commute to work. Wow! This beast pulls super strong!


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Title: Re: TE 610 General Maintenance
Post by: Kykdaar on April 30, 2016, 06:20:10 pm
You are well on your way to becoming a Husky enthusiast :thumleft:
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on April 30, 2016, 11:15:43 pm
Yes that rear subframe is compromised. Some gentle heating and leverage should get it straight (yes in line horizontal and with mainframe) before the gusseting. Have you checked Cafe Husky threads on that for pics? I also braced mine across the two spars.
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on April 30, 2016, 11:16:32 pm
HELP - Having a brain fart!  >:D  I have the front counter sprocket off my 610 for replacement ... am I right in saying that the collar side faces inward?  ::)
(http://uploads.tapatalk-cdn.com/20160430/249eaf12242c823788bb3ebbd5a03e72.jpg)


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Thanks as I suspected - spacing collar inward.  :thumleft:
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on May 02, 2016, 08:55:33 pm
Yes that rear subframe is compromised. Some gentle heating and leverage should get it straight (yes in line horizontal and with mainframe) before the gusseting. Have you checked Cafe Husky threads on that for pics? I also braced mine across the two spars.
Thanks BD!

I'll check on Cafe Husky.👍


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Title: Re: TE 610 General Maintenance
Post by: BiG DoM on May 03, 2016, 11:32:16 am
Where does this tube normally connect? I have fitted a 630 tank to the 610 having lost the OEM in a fire. The 610 fuel pump as I recall has a return feed for overfueling but the 630 does not. Is that what this is or where does it go? Or is it a vent? Sorry had bike apart for awhile and now scratching my head!
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on May 03, 2016, 12:40:43 pm
Eish BD, I'm still in the process of striping, cleaning, servicing and learning!😧

Do you have a pic of the bracing on the sub frame ends?

Mine came with a stainless bent plate, that bolts on the sub frame, onto which the luggage plate is bolted.

I'll post a pic, as soon as I'm home in 2 weeks time.


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Title: Re: TE 610 General Maintenance
Post by: BiG DoM on May 03, 2016, 01:26:43 pm
Eish BD, I'm still in the process of striping, cleaning, servicing and learning!😧

Do you have a pic of the bracing on the sub frame ends?

Mine came with a stainless bent plate, that bolts on the sub frame, onto which the luggage plate is bolted.

I'll post a pic, as soon as I'm home in 2 weeks time.


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Ok I have worked out that that pipe is a fuel return pipe from the pressure regulator and has a male coupling pressure fitting. I know they changed the TB on the 630 to a 45mm unit and maybe has a different pressure regulator. In fact I think the pressure regulator and fuel return are part of the 630 fuel pump and as such dumps the fuel back right where it is in the tank. I will then have to figure out what to do with this fuel return maybe T - in to the cross over pipe?
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on May 04, 2016, 05:47:34 am
Eish BD, I'm still in the process of striping, cleaning, servicing and learning!😧

Do you have a pic of the bracing on the sub frame ends?

Mine came with a stainless bent plate, that bolts on the sub frame, onto which the luggage plate is bolted.

I'll post a pic, as soon as I'm home in 2 weeks time.


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Look on the Cafe Husky site under 610/630. There is a sticky thread on the 630 frame braces - basically the same. Can also search for the 610 ones. I reinforced my rear luggage plate underneath but do not load the rear frame as I use a Giant Loop Coyote or Mojave that rests mostly on back of seat.
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 09:58:39 am
This past weeked I had the privilege of riding the TE for 3 days in Swaziland, joining TK and Straatkat on their 610s, with Xpat on his 630.

The Swazi Hard Core rides are arranged by Just Blip It, who rides a 990, and a fellow rider Steelimage on his 690 also joined the group.

I will do a seperate riding impression post of the TE.

As mentioned before, I prefer to maintain my bikes well, normally resulting in incident free trips.

I stripped the Husky, till only the frame with engine and front forks remained.

The swingarm's links and bearings where completely stripped, cleaned, checked and lubricated.

All bearings where fine. The swingarm main pivot bearings don't have a grease nipple, and required some grease, although they were not dry.

Pic with swingarm refitted.

(http://uploads.tapatalk-cdn.com/20160717/6022e31613723bff2eabd37368e8f143.jpg)


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 10:03:48 am
The suspension linkages have 2 grease nipples. I however found that the shock's bottom bearing was bone dry, but not damaged. It doesn't seem to be "fed" by the grease nipple. Applied some Bel Ray Waterproof grease, which resulted in the slight play I felt before stripping completely gone.

(http://uploads.tapatalk-cdn.com/20160717/49524dcf424c00baa31228dff658f136.jpg)


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 10:08:31 am
If the top mounting bolt of the shock is removed, the bottom bolt will drop below the level of the dog bones, with the bike lifted slightly, allowing easy spanner access to the bottom bolt. I turned the "bearing" through 90 degrees, and pushed grease in by hand.


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 10:13:43 am
The bearings and seals of the wheels were checked, and the seals greased. Bearings still perfect!

Also took them to my local bike shop, to have the tubes and spokes checked.

Spokes were tightened, one new HD tube fitted, as the old one had been patched before, new inner nipple tape fitted to both rims, and a new rim lock fitted.

Ready for fitment!

(http://uploads.tapatalk-cdn.com/20160717/9029b2c4baa120794350bfbb72504c28.jpg)


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 10:19:23 am
Fitted a new spark plug. Bought it at Yamaha, and told it was specifically designed for boat and jetski engines?

Will it be more resilient to water? Straatkat?

Old plug colour looks fine to me from a tuning perspective.

(http://uploads.tapatalk-cdn.com/20160717/f7f001da2224b0f23afb4f0e4f278eb9.jpg)(http://uploads.tapatalk-cdn.com/20160717/ace7541e28a7bf22a156c1c78b824d9d.jpg)(http://uploads.tapatalk-cdn.com/20160717/30634627818883d0b79f37e8d498a2d7.jpg)


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 10:22:05 am
Lubed the rear brake lever pivot. It has 2 o-rings keeping water out. The pivot of the master cylinder to lever was also greased.

(http://uploads.tapatalk-cdn.com/20160717/0e170d3225d93075c34eece522a3f58f.jpg)


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 10:27:42 am
The rear subframe was handed to my local fabricator, to have the subframe ends straightened and gussets welded as support.

The battery support was welded and reinforced. I manufactured and fitted a aluminium base that covers the complete battery's base, and added 3mm weather strip as shock absorber.

(http://uploads.tapatalk-cdn.com/20160717/acef88f41b6507c31e1c5ab90a048148.jpg)(http://uploads.tapatalk-cdn.com/20160717/e00f3f597c4a0d736007a7bf6a35721d.jpg)(http://uploads.tapatalk-cdn.com/20160717/aa2a36c34fd4834cc2fc314992341224.jpg)


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Title: Re: TE 610 General Maintenance
Post by: BiG DoM on July 17, 2016, 10:27:58 am
See my posts on Cafe Husky re the swing arm and linkage bearings that I did a complete replacement on. The extra seals route I went on the swing arm is the answer (I was thinking of fitting a grease nipple at one stage). Do not underestimate what these bearings can actually look like! I was astounded how shagged mine were and the bike had never been abused or really done many water crossings etc. and I am careful with pressure washing. The peace of mind having gone right through and replaced and improved the setup was worth it.


http://www.cafehusky.com/threads/rear-linkage-bearings-bushes.39776/page-3 (http://www.cafehusky.com/threads/rear-linkage-bearings-bushes.39776/page-3)

http://www.cafehusky.com/threads/swingarm-bearings.39835/ (http://www.cafehusky.com/threads/swingarm-bearings.39835/)
Title: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 10:28:49 am
My fabricator made the gussets slightly smaller and shorter than I requested.

He's more knowledgeable on metal than me, so I'll be leaving them as is for now.

I pack quite light for my trips, with the slightly heavier items on the back of the seat's edge.

(http://uploads.tapatalk-cdn.com/20160717/aa4e8b9bffb7f5094a5e78dfed168baa.jpg)(http://uploads.tapatalk-cdn.com/20160717/4dcdbbb7af7ecc5369cf1ee3a45d2b0d.jpg)


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Title: Re: TE 610 General Maintenance
Post by: BiG DoM on July 17, 2016, 10:32:58 am
I see you still have the original side stand this is going to let you down they are made of spaghetti. Look at getting the cast alu one from a 630 or have it reinforced.  :thumleft:
Title: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 10:35:48 am
Thanks BD.

I'll have a look at your links.

I specifically mentioned the swingarm and linkage bearings, as my Husky has only 8200 kms on the clock.

Fortunately no damaged bearings!

I'm used to taking my DR 650s linkages apart, as it has no grease nipples!


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 10:43:04 am
I see you still have the original side stand this is going to let you down they are made of spaghetti. Look at getting the cast alu one from a 630 or have it reinforced.  :thumleft:
I've read that they are problematic.

Where is/are the weak point/s?

I actually had it reinforced, by having a half pipe welded on from the swivel joint to about halfway down. (On the inside.)

Also had a plate welded to the foot.

I don't climb on the bike, by stepping on the footpeg. Hopefully the side stand will hold for while! Next will be the alu one!

(http://uploads.tapatalk-cdn.com/20160717/8a08208f911991e77ad89d6d26fe2232.jpg)(http://uploads.tapatalk-cdn.com/20160717/3f92e7659b0bf4e30318935f7765c35a.jpg)


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Title: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 10:54:49 am
I checked all cooling system hose clamps.

The clamps at the top of the radiators I turned, as they were rubbing against the fuel tank. (The screw part.)

Coolant level needed to be topped up slightly. Had some Motorex.

(http://uploads.tapatalk-cdn.com/20160717/be7828ead3d98ab4fb94e494e2ff5eae.jpg)(http://uploads.tapatalk-cdn.com/20160717/f4089f882744f1d22ac96a101aaeadfa.jpg)


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 10:59:28 am
The cluch lever was slightly worn at the top of the swivel part, which resulted in a lot of vertical movement. (The plastic insert was perfect.)

Sanded, applied Pratley Steel, filed, sanded, lubed, and now as good as new again!


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Title: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 11:03:38 am
The accelarator and clutch cables were lubricated with Q20. Sprayed the cables at the top, till the fluid ran out the bottom of each cable. Applied a bit of grease to both ends of the clutch cable. Operation is very light.

Removed the throttle cable cover on the Fi unit, and cleaned the dust, before lubing the cables. Throttle tube cleaned and lubed.

New grips fitted and stainless locking wire done on the grips. Used clear rattle can for grip glue.

(http://uploads.tapatalk-cdn.com/20160717/639158822c27cf8f50ff7b01ec847eb9.jpg)


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 11:12:24 am
See my posts on Cafe Husky re the swing arm and linkage bearings that I did a complete replacement on. The extra seals route I went on the swing arm is the answer (I was thinking of fitting a grease nipple at one stage). Do not underestimate what these bearings can actually look like! I was astounded how shagged mine were and the bike had never been abused or really done many water crossings etc. and I am careful with pressure washing. The peace of mind having gone right through and replaced and improved the setup was worth it.


http://www.cafehusky.com/threads/rear-linkage-bearings-bushes.39776/page-3 (http://www.cafehusky.com/threads/rear-linkage-bearings-bushes.39776/page-3)

http://www.cafehusky.com/threads/swingarm-bearings.39835/ (http://www.cafehusky.com/threads/swingarm-bearings.39835/)
For now I'll open and grease the spherical bearing after every serious ride.

Maybe obtain some proper seals from Bearing Man.

Is this bearing suppose to be greased by the grease nipple, together with the 2 needle bearings? I experienced grease reaching the 2 needle bearings only.


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Title: Re: TE 610 General Maintenance
Post by: BiG DoM on July 17, 2016, 12:18:25 pm
If you referring to the linkage then yes there is a small transfer port between the two sets of bearings.
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on July 17, 2016, 12:50:56 pm
I see you still have the original side stand this is going to let you down they are made of spaghetti. Look at getting the cast alu one from a 630 or have it reinforced.  :thumleft:
I've read that they are problematic.

Where is/are the weak point/s?

I actually had it reinforced, by having a half pipe welded on from the swivel joint to about halfway down. (On the inside.)

Also had a plate welded to the foot.

I don't climb on the bike, by stepping on the footpeg. Hopefully the side stand will hold for while! Next will be the alu one!

(http://uploads.tapatalk-cdn.com/20160717/8a08208f911991e77ad89d6d26fe2232.jpg)(http://uploads.tapatalk-cdn.com/20160717/3f92e7659b0bf4e30318935f7765c35a.jpg)


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If it has been reinforced then should be fine - they normally break just below the cast hinge. Problem is that the reinforcing and welding also makes the stand heavier. It has always amazed me that on most bikes the kickstand seems to be the last thing they design and make as an after thought! Inevitably the bushing wears and slop develops (even if the stand itself does not buckle) - why does no-one put a simple sealed bearing in there?
Title: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 03:45:43 pm
If you referring to the linkage then yes there is a small transfer port between the two sets of bearings.
Yes, the linkage.

Confirm the grease transfer port doesn't connect to the bottom shock spherical bearing? It has to be greased by hand?


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 04:06:17 pm
Removed the "bling" from the exhaust cannister. 👍

(http://uploads.tapatalk-cdn.com/20160717/4e38ed65b534544c1bd68cf4b721014e.jpg)


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Title: Re: TE 610 General Maintenance
Post by: BiG DoM on July 17, 2016, 05:42:00 pm
If you referring to the linkage then yes there is a small transfer port between the two sets of bearings.
Yes, the linkage.

Confirm the grease transfer port doesn't connect to the bottom shock spherical bearing? It has to be greased by hand?


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No it does not grease that one. Grease by hand, good seals and should be ok.
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 06:02:02 pm
If you referring to the linkage then yes there is a small transfer port between the two sets of bearings.
Yes, the linkage.

Confirm the grease transfer port doesn't connect to the bottom shock spherical bearing? It has to be greased by hand?


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No it does not grease that one. Grease by hand, good seals and should be ok.
Thank you BD!

Did you mention the OD and ID of the seals you used?

Confirm 4mm thickness, as you couldn't find 3mm?


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Title: Re: TE 610 General Maintenance
Post by: BiG DoM on July 17, 2016, 06:50:12 pm
If you referring to the linkage then yes there is a small transfer port between the two sets of bearings.
Yes, the linkage.

Confirm the grease transfer port doesn't connect to the bottom shock spherical bearing? It has to be greased by hand?


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No it does not grease that one. Grease by hand, good seals and should be ok.
Thank you BD!

Did you mention the OD and ID of the seals you used?

Confirm 4mm thickness, as you couldn't find 3mm?


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For the Heim Joint (lower shock bearing) the replacement was complete in the kit with seals. For the swing arm I ended up using 3mm seals and one of the bearings slightly narrower if I remember correctly. I really wanted to know that they were sealed.
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on July 17, 2016, 08:00:33 pm
If you referring to the linkage then yes there is a small transfer port between the two sets of bearings.
Yes, the linkage.

Confirm the grease transfer port doesn't connect to the bottom shock spherical bearing? It has to be greased by hand?


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No it does not grease that one. Grease by hand, good seals and should be ok.
Thank you BD!

Did you mention the OD and ID of the seals you used?

Confirm 4mm thickness, as you couldn't find 3mm?


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For the Heim Joint (lower shock bearing) the replacement was complete in the kit with seals. For the swing arm I ended up using 3mm seals and one of the bearings slightly narrower if I remember correctly. I really wanted to know that they were sealed.
Thank you!👍


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Title: Re: TE 610 General Maintenance
Post by: Archangel on August 05, 2016, 04:22:28 pm
The more I read this thread, the more I worry about the amount of time I'm supposed to spend on my bike!   :peepwall:

Half the stuff on here, I never even knew existed...
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on August 05, 2016, 06:52:54 pm
The more I read this thread, the more I worry about the amount of time I'm supposed to spend on my bike!   :peepwall:

Half the stuff on here, I never even knew existed...
Yes, quite a bit to be done!

I have done a 3 day ride in Swazi, as well as a 1 day red & black route in the Lowveld, after the comprehensive maintenance.

Stripped most plastics and tank for a good clean.

After my next 3 day Swazi ride I'll do some intensive maintenance again.

Oil will be done now. Motul full-syn, 10W60.

Rough Rider had the damping and rebound suspension settings set up at half the factory recommended settings. Front 6 clicks out. Now 12 clicks out. Rear at 20 clicks oit now. Was at 10 clicks. More plush, but not bottoming out when taking the "speed humps" on the Kruger fence section.

Might tweak the rear about 2 clicks in.

Softer suspension should have less impact on the subframe and battery base.

At some stage I will service the front forks myself, and maybe have the rear shock serviced.


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Title: Re: TE 610 General Maintenance
Post by: Archangel on August 05, 2016, 08:10:51 pm
I'm not sure I know my bike well enough to go on a long trip yet. Here's to hoping I can just get on and ride until such point when I have time to do all these checks...  :snorting:
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on August 23, 2016, 10:47:53 am
I do a lot of riding in Swaziland with the 610 TE. :biggrin:

My fellow riders, mostly on 690 KTMs, swear by their steering dampers in the rocks and deep sand. :thumleft:

I have no experience with steering dampers, but it seems one can only benefit from fitting it. :)

Google brings up a few pics, and the name MotoSportz also comes up, but doesn't link with their website. ???

Any info on a steering damper for the Husky? ???
Title: Re: TE 610 General Maintenance
Post by: Rough Rider on August 23, 2016, 10:51:53 am
The 610 is so stable, it does not require a steering damper. I found it a bit too stable and the turning ability was compromised as a result.
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on August 23, 2016, 11:17:38 am
The 610 is so stable, it does not require a steering damper. I found it a bit too stable and the turning ability was compromised as a result.
Thank you RR! :thumleft:

It will be lots of $$$, so appreciate your advice! ;)


The electrics (lights, indicators & horn) died on this weekend's trip in Swaziland. No issue with starting and the FI though. ;)

Have not checked anything yet. Any such previous experience? ???

Suspecting a fuse or wiring.
Title: Re: TE 610 General Maintenance
Post by: BiG DoM on August 23, 2016, 03:18:37 pm
I have a Scotts on mine - saved my ass a good few times. Is not a virtual must like on the KTM but a very nice 'nice to have' imho. In fact a steering damper on any offroad bike is money well spent and better off first spending it on a damper than spending it on other farkles like exhausts, bling etc. Great for sand, marbly rocks, wind etc. Does not compromise turning at all on my bike and you can set the release points on a Scotts/Ohlins. 
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on August 23, 2016, 03:25:59 pm
I have a Scotts on mine - saved my ass a good few times. Is not a virtual must like on the KTM but a very nice 'nice to have' imho. In fact a steering damper on any offroad bike is money well spent and better off first spending it on a damper than spending it on other farkles like exhausts, bling etc. Great for sand, marbly rocks, wind etc. Does not compromise turning at all on my bike and you can set the release points on a Scotts/Ohlins. 
Thank you BD! :thumleft:

Any leads where to find one, specifically the mount for the TE, and the cost thereof? ???
Title: Re: TE 610 General Maintenance
Post by: Tony the Boney on August 23, 2016, 05:54:30 pm
I have a Scotts on mine - saved my ass a good few times. Is not a virtual must like on the KTM but a very nice 'nice to have' imho. In fact a steering damper on any offroad bike is money well spent and better off first spending it on a damper than spending it on other farkles like exhausts, bling etc. Great for sand, marbly rocks, wind etc. Does not compromise turning at all on my bike and you can set the release points on a Scotts/Ohlins. 
Thank you BD! :thumleft:

Any leads where to find one, specifically the mount for the TE, and the cost thereof? ???

sorry...hijack....would be nice to get a mount for the TR as well  :biggrin:
Title: Re: TE 610 General Maintenance
Post by: Rough Rider on August 23, 2016, 09:16:18 pm
The 610 is so stable, it does not require a steering damper. I found it a bit too stable and the turning ability was compromised as a result.
Thank you RR! :thumleft:

It will be lots of $$$, so appreciate your advice! ;)


The electrics (lights, indicators & horn) died on this weekend's trip in Swaziland. No issue with starting and the FI though. ;)

Have not checked anything yet. Any such previous experience? ???

Suspecting a fuse or wiring.


Sounds like one of the fuses under the right hand number board. I had one go once before. The fuse holders are not the best quality.
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on August 23, 2016, 10:17:15 pm
The 610 is so stable, it does not require a steering damper. I found it a bit too stable and the turning ability was compromised as a result.
Thank you RR! :thumleft:

It will be lots of $$$, so appreciate your advice! ;)


The electrics (lights, indicators & horn) died on this weekend's trip in Swaziland. No issue with starting and the FI though. ;)

Have not checked anything yet. Any such previous experience? ???

Suspecting a fuse or wiring.


Sounds like one of the fuses under the right hand number board. I had one go once before. The fuse holders are not the best quality.
👍


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on August 24, 2016, 08:43:54 pm
The 610 is so stable, it does not require a steering damper. I found it a bit too stable and the turning ability was compromised as a result.
Thank you RR! :thumleft:

It will be lots of $$$, so appreciate your advice! ;)


The electrics (lights, indicators & horn) died on this weekend's trip in Swaziland. No issue with starting and the FI though. ;)

Have not checked anything yet. Any such previous experience? ???

Suspecting a fuse or wiring.


Sounds like one of the fuses under the right hand number board. I had one go once before. The fuse holders are not the best quality.
Correct. The front one, 20 A, is fused. Wonder why?

Nothing than the standard consumers on the bike.


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on August 24, 2016, 08:45:20 pm
Gave the seat some more padding.

(http://uploads.tapatalk-cdn.com/20160824/fa31a220de0432b18e8c12c34a6636cd.jpg)


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on August 24, 2016, 08:47:00 pm
Had a custom tail pack made.(http://uploads.tapatalk-cdn.com/20160824/b06d21f7a351d8b10d13abdbe9050ba7.jpg)(http://uploads.tapatalk-cdn.com/20160824/b647a399a2ac4aff5ea284fe7eafb681.jpg)


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on August 24, 2016, 08:49:47 pm
And a handle bar bag. Passport and Leatherman in small front pouch and snacks for the day in the larger pouch.

(http://uploads.tapatalk-cdn.com/20160824/c256b80373d080d1c9145fb953991e2a.jpg)(http://uploads.tapatalk-cdn.com/20160824/8cdbfc6c53be689fdfa501945634e435.jpg)


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Title: Re: TE 610 General Maintenance
Post by: chopperpilot on August 24, 2016, 08:51:12 pm
Having some fun in Swaziland!

(http://uploads.tapatalk-cdn.com/20160824/5ed8a5ee00fd181f1d4617439238d036.jpg)


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Title: Re: TE 610 General Maintenance
Post by: Tony the Boney on August 25, 2016, 08:20:23 pm
Nice tailpack! The bike looks good!!
Title: Re: TE 610 General Maintenance
Post by: chopperpilot on August 25, 2016, 10:46:57 pm
Nice tailpack! The bike looks good!!
Thanks Tony. Works a charm!


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Title: Re: TE 610 General Maintenance
Post by: Aprilian on August 24, 2018, 02:44:18 pm
Can someone please post a pic of the standard battery with leads connected (from top) My XTZ14BS seems too tall and terminals are up against frame with cable running over the battery. Is this the standard setup?