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Old 04-25-2013, 10:58 PM   #3631
chevmekanik
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Joined: Mar 2012
Location: West Kootenays
Oddometer: 52
I have seen the black wire plague before, it can be frustrating to diagnose, if left long enough I have found the wire corrode bad enough to create an open, while still leaving the insulation on the wire pristine looking.Thankfully I have not encountered this on my 630, although I have used dielectric grease on all connections after hearing of this issue with others.
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Old 04-26-2013, 04:55 AM   #3632
WILL_S
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Location: goodly satisfactory place, qld
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Quote:
Originally Posted by DYNOBOB View Post
Will, Speaking as a bystander, it seems to me the dealer should have found the problem after the second "bad" tps. No one else has had one bad tps, much less two (or three). I wouldn't be surprised if none of the tps' have actually been bad. I can believe water got into the plug causing corrosion/resistance and improper tps values going to the computer. I could also believe you've had an intermittent short in the wire harness and may have some burned wires. My point would be, the dealer should have been digging deeper after the first replacement tps didn't fix the problem.

It's pretty common in all types of vehicle repair to throw parts at the problem instead of making the effort to pinpoint the problem. I wouldn't be surprised if the distributor/warranty people feel like this is whats happening and are reluctant to keep playing. It is hard though to manage the relationship w/ a dealer and not alienate them.

Hope they get if figured out this time but I sure wouldn't blame you gave up on the 630. Keep us updated and get some pics of the "black" wire harness if you can, it may help someone else.


.
I agree with what you are saying.The thing is a warranty claim for a new loom was denied originally. The distrib has only fronted one tb,the dealer the rest. Now the ball game has changed.They are supplying a 610 loom which will need repinning at the ecu and another sensor,all they have at short notice.I will try to get some pics .The wire is corroded the full length inside the sheath.Luckily i've had a mate clued up on this sort of stuff that convinced them to look further into wiring/plug this time.
Not giving up but not sure i could trust the bike this time for the ride.Bit of a shame.
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Old 04-29-2013, 06:08 AM   #3633
onetravdown
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Joined: Jul 2007
Location: The garbage state
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Have a few parts for sale (center stand, cargo rack, exhaust, etc.) if anyone is interested.

http://www.advrider.com/forums/showthread.php?t=882909
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Old 05-06-2013, 10:10 AM   #3634
The Letter J
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Location: Santa Maria, CA
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Another one bites the dust. That's 2 blown Husky engines within 2 weeks of each other! While neither of them are my bikes, they are owned by the only 2 guys I ride dual-sport with . I'm rebuilding the TE250:

Quote:
Originally Posted by The Letter J View Post
Does anyone know of an engine builder/ shop that specializes in Husky's who's brain I could pick before ordering parts?

BTW I did finally find a source for online parts diagrams here: http://www.husqvarnaoutlet.com/oem_parts




The 630 (pictured below) blew the head gasket going down the highway. It wasn't acting up or making funny noises, it just started losing power and 5 seconds later (while he got to the side of the road) it was done. The 630 is still under warranty so we trucked it down to the dealer ~3 hours away and they jumped right on it. Tri County Powersports in Moorpark CA http://www.tri-countypowersports.com/ has been great. The mechanic there sent these pictures:



melted side of cylinder:



melted edge of head:



chewed up piston:



Warranty coverage has already been approved for a new cylinder/ piston/ head, they are going to take a deeper look into the bottom end just incase. Looks like a few parts are on back order, hopefully that is not a sign of things to come from Husky!
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Old 05-06-2013, 12:13 PM   #3635
DYNOBOB
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Once repaired, I'd recommend someone verify the bike isn't running lean. When stock mine was very lean on the big end, even with the PU kit. If he mistakenly got regular octane fuel/bad fuel it would be even worse. Did it have a fuel programmer?


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Old 05-06-2013, 12:42 PM   #3636
The Letter J
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Location: Santa Maria, CA
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No programmer, just a power-up kit and de-catted stock muffler (custom single exhaust collector, left side only) The JD tuner was the next purchase on his list!
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Old 05-06-2013, 07:56 PM   #3637
johngil
Reseda, CA
 
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I think I ate a head gasket last weekend as well. Over 8,000 trouble free miles to date.
Bike will be going in to Tri-Valley in the next week or so. Husky warranty is up, but for some reason I bought an extended plan. Hope that pays off..
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Old 05-06-2013, 10:13 PM   #3638
DYNOBOB
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What were your symptoms John?



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Old 05-07-2013, 02:33 AM   #3639
johngil
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Bike got was down on power and would overheat under load. Puked coolant and oil looks like shit, although I haven't drained it yet. Running the bike with the radiator cap removed showed some pretty big bubbles coming up through the coolant (which is pretty dark).

We'll see...
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Old 05-07-2013, 02:04 PM   #3640
Fast1
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Quote:
Originally Posted by johngil View Post
Bike got was down on power and would overheat under load. Puked coolant and oil looks like shit, although I haven't drained it yet. Running the bike with the radiator cap removed showed some pretty big bubbles coming up through the coolant (which is pretty dark).

We'll see...

running just the power up kit or do you have the JD programmer also?
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Old 05-07-2013, 02:27 PM   #3641
johngil
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Quote:
Originally Posted by Fast1 View Post
running just the power up kit or do you have the JD programmer also?
JD and no lean spots.
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Old 05-08-2013, 07:52 AM   #3642
BaronVonDarrin
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Joined: Mar 2011
Location: Philadelphia, and at times Western Maryland
Oddometer: 638
anyone here ever ground down their steering stops and tapped it? i am thinking about doing that to mine, unsure how hard or possible it might be
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Old 05-08-2013, 08:19 AM   #3643
larryboy
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Joined: Jan 2005
Location: On a set of 50,000 mile tires.
Oddometer: 15,031
Quote:
Originally Posted by johngil View Post
JD and no lean spots.

I forget the specs...is the 630 almost 13:1 compression like the 610? Might be worth it on the rebuild to use a thicker head gasket to drop the compression a bit.
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Old 05-09-2013, 09:24 AM   #3644
larryboy
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Location: On a set of 50,000 mile tires.
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Quote:
Originally Posted by 955616846 View Post
The 630 head has quench decks so a thicker head gasket is not the best way.

Ok then, base gasket it is.

Just looked it up, 12.4 to 1 for the 630. The 610 was 12.8 to 1. They're both in race gas territory and really need 100 octane, I'd try to get it down to 10 to 1 on a rebuild so it will live.
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Old 05-09-2013, 09:43 AM   #3645
browneye
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Location: Orange County, CA
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Quote:
Originally Posted by larryboy View Post
Ok then, base gasket it is.

Just looked it up, 12.4 to 1 for the 630. The 610 was 12.8 to 1. They're both in race gas territory and really need 100 octane, I'd try to get it down to 10 to 1 on a rebuild so it will live.
Maybe that's why mine pings at higher rpm mid-throttle.
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