Has anybody had this problem with the 250? or is it only the 450 that is breaking the case.

Is this the outer case #80AD 99172 and where did it break, I broke mine at the bolt hole just below the kick starter, was putting the case on and kick starter kept binding, finally got it to go on (I thought) bolts were screwing in fine when I heard a pop. The cause for binding was the spacer inside the return spring on the kick shaft was not seating all the way.

TE450
Thanks to Dan & Ann at Motoxotica for all you help & support.

Kraig

I would like to know if this is a manufacturing problem or an installation issue. I want to install mine for backup on long rides but want it to be reliable. I have talk to others who have run them and used them with no issues. What's the scoop?

Anyone out there using the kicker a lot and have no issues?

Thanks,
K

I've got an official, by Husky, Kickstarter Installation PDF file if you want it.   PM me and I'll email it to you if you want it.

Flame on

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OK, so it is an installation issue?

I don't really know if it was an installation problem or not.  All I know is my kick starter was installed as per the PDF file I referred to and mine works fine.  There is a long thread on this issue here on TT.  If I remember correctly as per the thread, the paper installation instructions included with the kick starters when they first arrived in the US were not quite clear???

Do a search and find the thread, it is quite long with lots of questions??

I'm going to have the dealer install mine when I go back for the 1st service....That way if there is some bizarre issue, they'll hopefully deal with the problem. I asked the dealer aboutthe problem today and he said they had one guy with a 450 have this issue pop up.

You Bet this is a problem.
I had mine installed and it broke the outer case first ride out.
The stop for the mechanism on the inner case is a problem, it breaks off. Take out your kicker shaft, and on the stop were it hits the inner case I had cut and welded a piece the same size. that way you have double the contact area. Or bend it inwards.The stop on the inner case is too soft,and the shaft barely touch's the edge. it breaks forcing the shaft outward, it either wrecks the outer or both cases or worse. With the extra contact area, I have not seen the issue again.
I have a thread  here on TT and other (at least 2) members have the problem.
My dealer admits the issue, most don't see it because very few people us the kicker.  

Hello people.
My name is Márcio and I have just just bought a new 04 TE 450 on the 22nd of may, down here in Brazil. In my country Huskies are imported through AGRALE ( www.agrale.com.br )- a company who produces farm tractors and agricultural implements. In the past they used to build their own motorcycles, but nowadays they import all the brands from Cagiva - Italy (thanks God).
Here in Brazil, all huskies have been delivered to the dealers with the kick starter already mounted, and many of them have broken the RH engine cover. I bought mine from Motostreet ( www.motostreet.com.br) and I was told that my bike had a modified version of the kick starter. I asked them to explain me what was happening, and I was told that the cover was breaking only when the bike backfired while being kick started. It seems the problem is that when the engine backfires, the idle gear engages together with the other one, and as their ratios are different, the gears jump and break the engine cases.
The same problem has broken three Yamahas WR 450 RH engine covers in Brasília, the city in which I live. Those bikes used to chew their eletric starters, and when the owners began using the kick starter, if it backfired - bad luck.
I have been told by the people at Motostreet that the problem was solved by changing the two gears that operate the kick starter, but I really ain't planning on using it, because here in Brazil people never tells you the truth. I don't know if the gears have been changed or if the dealer has machined then to prevent them from engaging together, creating a domestic solution that I do not trust. I am waiting to go to a race, so that I can talk to other owners who have had their system modified to check if the problem is over. Untill that happens, I am going to use only the eletric starter, which easily fires the bike. As soon as I learn some more, I will keep you informed.

Márcio Vargas - from Brazil.

03 YZ250F (for sale)
THE INCREDIBLE HUSKY 04 TE 450!

Back to original question, Has anybody had this happen to a 250?

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I believe the case and all other parts are shared so i would think if it is happing to any of them they all have the potential to have this issue.

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As said earlier, the covers, and all internals are identical. Possibly less compression may not bring this problem on as early? But ultimately, use the kicker only when necessary, it is still an AWESOME bike!

I have always heard to avoid buying a first year model of anything, be it a car,truck, bike etc. I'm sure Husqvarna will work this problem out. And if this is the worst problem they have going, then that's not too bad at all.

Well crap, it looks like mine is shot now too. I have at least 300 miles after the kick starter was installed. It just exploded and it looks like it broke the cover, and one of the case halves. What a BUMMER. I don't know where to go from here. I guess I will at least remove the cover to see what else may be damaged. HELP!!!! I will call me dealer tomorrow to see if he will help me. It is devastating though I do tell ya. It broke when it backfired, though I was using the button that time.  I had kicked it previously that day, but I worked just fine. Any help WOULD be appreciated. Thanks.

I had mine fitted by the dealer afterreading the original thread on this topic. It cost £300 but for peace of mind it was worth it.

I've had problems with the electric start and the kickstart has bailed me out every time without a problem. (Now i've said it!)