Husqvarna TE610: Fork Swap

The Husqvarna TE610 gets new forks...

The Husqvarna TE610 gets new forks…

During the holiday season, I made a HUGE mistake while doing repairs on the Husqvarna TE610.  Tightening while texting!  That’s right, the age-old flub of allowing yourself to be distracted while wrenching, by of all things, the digital-mosquitoesque annoyance of texting.   While tightening a small 5mm fork bolt that secures the front axle, and simultaneously wishing my friend a cyber ‘happy-holidays,’ I snapped the bolt off deep in the threads.  Good grief!  

Husqvarna TE610 suffers a fork mishap…

After a massive extraction effort that involved breaking multiple screw-extractors (they almost never work for me!), a few mill bits, and some marathon cursing, I ended up with a slightly damaged right fork lower.  A quick check online highlighted the pitfalls of owning a bike like the Husqvarna TE610 (and upside down fork in general), with a replacement cost of $467 for just the fork lower.

While I was able to finally get the bolt out, and retap the hole for a replacement, the damage had been done.  I rode the bike like that for a month, but there was always the nagging fear in the back of my mind that the thing might break loose, leaving me curled in a ball on the side of the road after the axle let loose.

I began researching a set of replacement forks.  A common complaint with the Fuel Injected Husqvarna TE610 (starting in 2008) had always been that they were shipped without fully adjustable forks.  The ire of the enthusiast community had been stirred when the bikes arrived without the adjustability, which had been present in all the marketing literature.  The crowd went wild, and there are numerous threads online about the disappointment in this omission, as well as common fixes for the ailment.  Seemed like I was given the perfect excuse to upgrade to a set of fully adjustable forks…

I felt that I should be able to find a complete set – for less than the cost of the replacement part.  Fairly quickly I came across Jeff, owner of Toxic Moto Racing, an online shop that specializes in Supermotard parts.  After a few emails, I was awaiting a pair of Marzocchi Shiver 45mm forks that came from a 2006 Husqvarna TC250.  Same size, with the fully adjustable compression and rebound, all for $170 shipped!  Perfect.

Stay tuned to part 2, for a rundown on rebuilding the Shiver 45mm upside down forks on the Husqvarna TE610…

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