Hi all,
Just picked up an 07 TE610 yesterday for use on the RV and hitting some trails. Worried about the size and weight but after riding yesterday at Carnegie for a bit, I am really liking this beast. Except for one minor problem I think. Hit a jump, got serious air and when I came down the engine died. Took a minute to get her started but she started back up and ran fine until we went down in the crack and had to climb out. Made it about half way up a monster hill and the bike started to stutter and lost power. I tried again but the same thing happened about the same place. Could it be the float? Runs great most everywhere else, stutters at top end also. Any suggestions from the experts?

Anyone know where I can buy plastics, can't find anything for the 610. Found what I needed on Ebay but in yellow, ehh. Not matching the red and black.

Is the motor stock? If it is then I would recommend getting a JD Jett kit and an
aftermarket muffler. If the smog crap hasn't been removed I'd do that as well. If
you're going to be riding at Carnegie or similar places with hilly terrain I'd consider
lowering the gearing. I put a 14 c/s on mine and it made it a lot better for mountain
trails without giving up too much top speed. I wouldn't recommend jumping the 610
as it's just too big and heavy for that as I'm sure you've probably figured out. I had
a blast last time I was at Carnegie. Made it up all the steep hills but ended up seperating my shoulder on a very steep downhill. Got going to fast and hit a bump where the trail traverses the hill, flew over my bars and landed on my shoulder.

Sounds to me like the float level is to low. So far as getting air with the 610 the one thing I would suggest is that you pay particularly close attention to the footpeg mounts. More than a couple of people have sheard the mounting bolts. To make them better the thing you have to do is remove the peg assemblies and make sure that the mounting pads on the frame and the peg assemblies are flat. All you have to do is run a smooth file over them a few times (maybe quite a few times), then bolt them back up with locktite on the bolts.

Mine is an 08 with FI but I work on KTM's with the same carb you have. Carb is the best piece made but the emission stuff they have to do for import export guys usually screw them up. I would start with follow the vent hose from the gas cap. Does it go down to a jucktion box at the back of the engine? 2008 has a carbon canister at the right front corner of the engine but I do not see that on yours. If a previous owner removed that where is the hose routed to? Tank MUST be vented to atmosphere to run right.
Next the carb has 4 vent hoses that come from the upper part of the carb body and hang off the back of the engine? Do yours go to a black box, or hang free?
If you want to get into jetting, my 2005 TE450 came with a 52 pilot jet, way too big! 42 fixed all stalling issues on it

I believe the motor is stock except for the Uptite slip on exhaust. Definitely have to gear it down some as I never left 2nd gear at all less I was on a fireroad. Jumping is fun on the beast, she handles great, soft smooth landing. I think it is the incline that is the problem, when I got air, I was veritical in the air and came down smoothly. Will check the smog stuff.

JoePass said:

I read about the footpeg problem and will fix that ASAP. I am thinking float level also but will have to read up on that subject. Thanks for the advise.

rajobigguy said:

Since there is no vent hose on the gas tank, I am not sure if I can follow but I will look for any smog stuff.
Aftermarket exhaust by Uptite (slip-on). Not sure about the jetting, will have to take her apart when I get the chance. I will check the 4 vent hoses and add the filter from Uptite, I have one on my TC450 and love it.

Thanks for the jetting info, I am thinking that is where I will look first. Thanks for all the advise.

Dave Hopkins said:

Those are some pretty chunky handguards you've got there. :thumbsup:
Did you remove the headlight and blinkers for the Carnegie ride ?

Haha, those are Maier handguards and they look ugly but appear to function well. The Husky stalled coming out of the crack half way up the side of a big hill, she fell in the dirt hard. I looked, nothing damaged.
The headlight was taken off at purchase time, he had a Baja Designs 8" headlight. He is sending me the stock one next week. Will need to remount one rear blinker as the pipe melts it in it's current position. Front ones are still operational. Will need to fabricate a mounting plate for the speedo and ignition as he took the old one off and I didn't get it.
Still checking on replacement plastics, only have found the side panels and rear fender. I will order the UFO fender with lights and see if that works.
New clutch cable on order, need a hydraulic upgrade but don't see one out there.
Can't wait to ride again, need to get a trailer so I can bring both Huskies:banana:

JoePass said:

FlyLikeABandit said:

In addition to the footpegs, you will also need to brace the battery tray on the subframe. It is very weak and prone to breaking (especially if you enjoy jumping the beast). While you're at it, check the bracket that holds the clutch cable on the motor. It sometimes needs tweaking to ensure the clutch cable doesn't kink (& then break) there.

aebbern said:

thanks aebbern,
Will check out the battery box when I take her apart this weekend. Thanks for the advise,

Just thought of one more "must do" item for you... replace the two bolts that attach the bottom of the subframe to the main frame. They break pretty easy (mine and many others) and are simple to replace with a higher grade bolt.

This seems to be the biggest issue with the TE610 - the factory used some weak fasteners in places they shouldn't have... but at least it's an easy fix.

Cheers,
Andy

Thanks, keep those suggestions coming. If I get enough data, I would compile it into a nice format and post it some wheres for others to use next time.

R the valves the same to check as other 4 strokes, I have a 04 TC450 and check the vavles there, same procedure?

Started her up in the garage last night, it was a little cold in there, and i heard a knocking sound, it only happened for about a minute till it warmed up a bit. I read that could be sloppy tolerances when cold due to the enlargement of the piston when heated up. I hope there is no issue, there are about 16K miles on the bike. I will keep an eye on it and make a video of the noise next time I start it cold.

Thanks all,


PS, a few of us are taking the day off and going to Carnegie tomorrow, all skill levels will be there, come one come all. Play hookie.:banana:

FlyLikeABandit said:

The noise you heard was probably the autodecompress, They sometimes hang up until you hit the throttle a couple of times. Nothing to worry about.

rajobigguy said:

Thanks, I hope that is all it is. I will video it so I can post the sound later.
Thanks again,

Sounds like a little piston slap (like you read about). Common on big four singles after they've had some miles. 16K certainly qualifies. As long as it's not ugly sounding and it fades away once the bike warms up I wouldn't worry about it.