Year 2000 era Husqvarna TE-610 Info Thread

Discussion in 'Thumpers' started by Muggins, Nov 13, 2008.

  1. rockaholic

    rockaholic Adventurer

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    Hey Dr.Stomp.

    Sorry for such a delay, been very busy lately. Anyway, the exhaust system I have on my husky I've bought off ebay several years ago. It uses the original headers to a 2-into1 pipe and into a light sporty muffler, which uses the original muffler mounting holes on one side. Back when I bought it, the seller in the ad specified that it's to fit a 2000 TE610 and it did perfectly. It was made by FP-racing, but it is not a very well known brand and I'm not sure if they were making there set-ups specificaly for huskies like ours, or it was made custom to fit. But I'm just really happy I got my hands on mine, as it sounds really sweet, seems well made and is tons lighter than the original set-up. I made a few very bad pictures in my very dark garage last night, and I'll try to make more decent ones when I have the time.
  2. alfred jorgensen

    alfred jorgensen Adventurer

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    Not sure if the Italian motorcycle manufacturer's outsource their manuals to a non-Italian speaking country? I worked in Italy for a while in a former life and got to the point where I could (somewhat) comprehend a technical manual. I also know German fairly well so when I scratch my head looking at the English language translation (in an Italian manual), I turn to the German language version and if that also looks like `gobbledygook` I try to understand the original Italian language section.

    Having said that, I believe that what is going on is that the Italian manufacturers understandably do write the original manual in the Italian language. The `screw-up` than happens because they then hand that original Italian version to somebody who translates `word for word` using a dictionary (or software) into whatever languages that they decide to include in the manual and then it often comes out as `gobbledygook`. That is why most international businesses use `interpreters` instead of `translators` when they conduct business, interpreters are fluent in both the language that they are translating from and also the language they are translating into and have often lived in countries that speaks both languages so they understand the different `interpretation` of of words or phrases.

    On a lighter note, I used to work in countries that have a lot of goats but I have never seen anybody ride them (except maybe for kids), they are too small for that purpose :-)

    Why did I change forks? That is a long story indeed but it probably comes down to that the suspension tuner I used for years (including on the original TE 610 E forks) turned out to not understand Marzocchi forks and `butchered` them making me believed the original forks were no good. I went through a few different `trials` before settling on a set of Marzocchi Shivers (USD 45 mm forks modified by LT Racing). I have a set of forks that are the same `family` of Marzocchi forks as those originally on the TE 610 E (45 mm standard forks) on a Moto Guzzi Quota and they work just fine, I also had a similar set on an AC 900 Cagiva Elefant (a.k.a. Ducati E900) for a while and they worked great on that bike so I should probably have kept them and changed suspension tuner, oh well!
  3. Seekanddestroy

    Seekanddestroy n00b

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    I just did my first oil change and filter change. I pulled 2.8 quarts out of the damn thing! So i got ahold of the old owner and he thought it took 3 quarts and he only rode it for three weeks after the oil change about 2 miles to and from work 3 to 4 times a week, so 60ish miles total. My question is other than a couple of seals leaking that i already found do you think it could have caused any other damage? Bikes got alot more power now with the oil at the recommended level, valves are louder but nothing crazy, they were really quiet with it overfilled. Heres a pic of my ride and the old rotten air filter it had. Also my bike came with that aserbis Husqvarna extended range tank and 82db te410 cans installed and my carb is a mikuni t40 flat side! This thing rips! 20170926_171819.jpg 1506558431146-920198109.jpg
  4. alfred jorgensen

    alfred jorgensen Adventurer

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    Other than `blowing` seals, you probably do not have any lasting damage. By the way, be aware that the larger 4.2 U.S. Gallon Acerbis tank holds some of the fuel lower than the petcock so it`s not usable. My recollection is that you can burn about 3.5 - 3.6 Galllon before running the out of usable fuel (on level ground).
    Seekanddestroy likes this.
  5. Seekanddestroy

    Seekanddestroy n00b

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    Thanks for the input alfred, i rode it some more yesterday and it does seem like its running well. As for the tank i can see the petcock is a little higher so it might not be worth the extra weight to run the big tank unless i plan on doing longer rides.

    Anyone else on here have any experience with the mikuni t40 flatside on this bike?
  6. fritzcoinc

    fritzcoinc Enjoying my last V8

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    Too much oil won't hurt. If the valves are less noisy now its because he used a heavy weight oil.
    Did you clean the screens?
    One is under the clutch cover, the other by the shifter:

    [​IMG]
    Here are the skid plate clamps I made. Also, you will want to make a hole in the skid pan for the front drain plug.:
    [​IMG]
    When you adjust the valves, replace the fiber bolt seal washers ( at left ) with these rubber seal type washers ( shown on and by bolts )
    McMaster Carr # 93786A125 ( 6MM )

    [​IMG]
  7. fritzcoinc

    fritzcoinc Enjoying my last V8

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    Look for air leaks as the Mikuni may not fit the Husky intake that was designed for the Dellorto carb.
  8. Seekanddestroy

    Seekanddestroy n00b

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    Fritz your the man! Thanks for all the info. I cleaned both of the screens with some gas and checked for leaks on both sides of the carb. It seems like they fitted it with an adapter ring that is gasketed. Hese a shot, the white plastic is the adapter ring. I sprayed starting fluid around both sides and didn't hear any leaking.

    I just ordered a full athena gasket kit for under 100 and got those pressure sealing bonded washers.

    I also noticed that the bike has this makeshift rocker bolt with copper washer instead of the special flathead one. Think i should buy a new oem one with the bushing?

    Attached Files:

  9. fritzcoinc

    fritzcoinc Enjoying my last V8

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    Not sure bout rocker bolt. OEM may be best.
    I was thinking about what you posted about the bike now seems to not run as good, I'm guessing but maybe you over oiled the air filter and its just not breathing????
  10. Seekanddestroy

    Seekanddestroy n00b

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    I think it was the old gas, i drained the tank and filled it with premium chevron and threw 2oz of sea foam in and now it runs like a champ. I read an old reply where you mentioned to take apart the rear shock linkage and front headset bearings and clean and re-grease. Im gonna get started on that tonight after i mount that skid.

    Forks feel like shite though, any recommendations as far as oil goes and amount to put in? Im gonna drain em and clean the seals ( they aren't leaking).
  11. fritzcoinc

    fritzcoinc Enjoying my last V8

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    Just follow the setup instructions in the manual ( adjustments and air gap ). Also, check the preload. The previous owner of my bike took out the preload spring spacers leaving slack in the stack up. I made new ones from 1" SCH 80 PVC pipe from Lowes and set 10mm preload in both legs ( I'm 240 pounds and ride moderately ) . I've had a problem with the fork seals leaking and I believe the previous owner did as well. When I got my bike, besides the above, there was only 12" of oil in one fork leg and 6" in the other. I filled to the recommended air gap of 140MM and the seals started leaking. I used the recommended 7.5 WT oil. I replaced the standard seals twice and again with the USD seals that seem to have lasted longer, but the jury is still out. I've been told these forks are rubbish but I have the same forks on another bike and they haven't leaked a drop.
    Did you get a manual and parts list? PM if you don't have these.

    While you are suspended, check the rear shock: http://advrider.com/index.php?threa...-610-info-thread.406358/page-39#post-32596280

    Redneck air gap setting tool, vac type. Set suction tube to air gap dimension, set on top of the collapsed fork tube without spring, then use the hand pump to draw off extra oil. This will make both forks very close to the same.:
    [​IMG]
    Make something like this to handle the forks:
    [​IMG]
  12. Seekanddestroy

    Seekanddestroy n00b

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    Yup, first thing i did after buying the bike was download the service manual and parts diagram manual.

    Great ingenuity on the the air gapping tool. I was starting to wonder how i was gonna get that gap on both sides. And yes the rear shock will be next, its a bit clapped out as well. So using air is ok in the rear? I've got a nice pump i use on my mountain bikes shocks which should do the trick. And once again thanks for all the great info, helps me tremendously!
  13. fritzcoinc

    fritzcoinc Enjoying my last V8

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    N2 is best, but hard to find a place that can get the pressure you need in one MC shocks. So I usually get the max. N2 PSI I can then hand pump air for the balance. I've used straight air too with no issues, yet.

    Thanks on the Air Gap tool. It also has a million and one uses around the shop like removing old brake fluid from master cylinders. If you don't have a hand vac pump for the suction part, try to get help from one of your girlfriends.
    LOL
  14. overlandr

    overlandr Dystopist

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  15. Greco

    Greco Braap!

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    Greetings All! Just found this gem of a thread. I found a 99 TE610 this summer and have been racing vintage MX on it all season. I put a NOS Big Gun single exhaust on it and Holy BeJeebus its loud! I ran it in the parking lot and switched straight back to the stock duals. Now that the season is over (won my class!), I'm going to shorten the stock cans and remove the spark arrestors. Mainly to save a bit of weight, but also gain a bit of sound. We did that back in 92 on my 350 wxe and it really helped.
  16. Greco

    Greco Braap!

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    When I bought my bike, its starting was hit or miss. Sometimes it would fire right up, sometimes the only way to get it going was to grab some friends and push start it. We did all the usual items, new plug, checked valves, pulled the air filter, adjusted the throttle cable, even replaced the flywheel. Still hit or miss. It seemed like it was flooding very easily. I went through the Dellorto carb, cleaned it, adjusted the floats, and checked as much as I could. I even listed it for sale. I was cruising fleabay and found a guy selling a Mikuni complete with the throttle and cable. I picked it up, along with a complete set of plastic he had. It arrived the day before I was to race the last MX of our vintage season. My son and I replaced the carb in about an hour in my garage at about 10pm. We put it all back together and it started in 3 kicks. The next morning, it started from cold, no choke, 2 kicks. All day, from practice to all motos, it was a one kick starter. The Mikuni pulls harder than the Dellorto ever did and it will pull top gear now. Before I had to be on flat ground with a tail wind or it wouldn't pull 6th. Now it just pulls and pulls. I've been mid pack on the starts of all my motos all season. With the Mikuni, I've pulled the last 4 holeshots. My class is 1999 or older, over 250cc. My main competition is a guy on a KTM 540 2 stroke. I pulled him down the start straight in both motos this past weekend. Can't say enough good things about the new carb.
  17. alfred jorgensen

    alfred jorgensen Adventurer

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    This does look like the Acerbis tank that Husqvarna sold as an aftermarket option back then, however, the fairing looks like nothing I have seen before. There were `privater` efforts in the Dakar with the TE 610 E (some bikes were supposedly built by CH Racing who at the time ran Husqvarna`s World Enduro and Moto Cross teams (CH Racing also build the Cagiva factory Dakar team Elefant`s from 1985 - 1996).

    That tank will fit all 1991 through 2003 (maybe 2004) 610 models. The earlier larger Acerbis tank (25 L) will fit the same bikes if you remove the cooling fan on the TE E models.
  18. alfred jorgensen

    alfred jorgensen Adventurer

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    BTW, that tank (19 liters I believe) was fitted as standard in OZ but nowhere else. I have this tank and I have warned earlier that it in reality does not have the rated capacity since quite a bit of fuel is trapped in the wings below the petcock level unless you can hold a really long wheelie!