Project Husqvarna TE610 Part 3: Dual Sport Adventure Bike Nut and Bolt

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I marked the gear and the bent-tab lock washer before torquing the nut to see exactly how far it moved and was happily surprised to see that it didn't.

You'll have to find a way to keep the gears from turning while you apply torque. Some people jam a penny between them, others have used a screwdriver and broken gear teeth as a result. Motion Pro makes this tool called a “GearJammer” specifically for locking gears without damaging them. It was originally designed for slightly smaller gears, but I liked the way it fit here a lot better than a penny.

If you're in there, you've drained the oil already, so it's a good time to replace the oil filter and check the tubular screen to the left. (Called a bag filter, it should have little or no visible debris in it, as it is designed to catch big chunks and prevent collateral damage if something starts coming apart.)

Be careful replacing the side cover, as the slot in the end of the oil pump drive must be aligned correctly. There's another bag filter on the left side of the engine, under its own cover rearward of the timing cover. Be very careful with that cover's two bolts, as they have a reputation for stripping the threads in the case.

I've used Motul products for years on many different vehicles and always been pleased with the results – the three shown here were used on Project TE610. The 300V oil made a noticeable improvement in operation of the transmission immediately. Long-term engine durability will take long-term riding to show.

I refilled the engine with Motul 300V 4T Factory Line 15W-60 Off Road oil. It is a 100-percent synthetic lubricant designed for people really beating the stuffing out of their off-road bikes. Perhaps overkill for this application, perhaps perfect.

Husqvarna's factory recommendation is 10W-60. I'm okay with the slightly higher cold viscosity of the Motul, as I'm not planning to cold start in snow on this oil change. Some Husky experts recommend 20W-50, but I am more comfortable maintaining the hot viscosity recommended by the factory. Of all the choices with appropriate viscosity range, Motul is by far the easiest to find at motorcycle parts retailers in Southern California.

On initial shakedown rides prior to changing the oil, I experienced a common TE610 problem, difficulty finding neutral with the bike running once it's warmed up. With a fresh fill of Motul 300V, finding neutral is easy. Shifting may be a little easier, too, though I had no complaints before.

From the factory, the left rear turn signal is in the line of fire of the TE610's exhaust, which is extra-hot due to the presence of a catalytic converter. The one on this bike was already melted when I bought it.