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July 2nd, 2009, 01:04 AM   #1
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Cracked primary gear

Hi!

My engine make loud noise. I open left side and primary gear nut open by fingers, there´s also crack on primary gear.


I need your help what else I should do or check. And what cost new primary gear?
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July 2nd, 2009, 01:17 AM   #2
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RE: Cracked primary gear

Check the mains too
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July 2nd, 2009, 03:20 AM   #3
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RE: Cracked primary gear

check the crankshaft where the key fits.It often cracks the end of the crank..from the pic you supply things look that way.
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July 2nd, 2009, 08:09 AM   #4
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From the look your picture the key and keyway look ok. Remove the gear and check them both, as nsman says the crank end can fracture around the keyway. As long as the key is still a snug fit then you may be able to get away with just a new primary drive gear and key, around Ł85 from Taffy I think. The gear needs to be heated in the oven for half hour then it will slide on, use bearing lock on the gear and thredlock on a new nut.

Whilst we're on the subject of primary drive gears...friend of mine has an 08 FE650, bought May last year, to cut a long story short basically the bike got nosier up to the 22 hours it was run, then locked up whilst on tick over. I took the clutch cover off and the primary drive nut was nearly off the end of the thread and the gear was cracked, the key was sheared and the keyway was twice the size it should be due to the gear chattering around on the crank for 22 hours, end of the crank also fractured badly.
So, bike needs new crank, gear etc plus whatever damage may have occurred up the top end due to the gear spinning 45 degrees on the crank, expensive to say the least.
The nut was obviously never torqued from the factory and there was no evidence of any threadlock. So, he was just on the verge of sending the engine off to be repaired when he thought, lets make a call to Husaberg and see what they say, not being hopeful after all, it is only a 30 day warranty and the bike is over a year old. It turned out to be a worth while call, they are paying for all the parts, inc crank, as long as he takes it to a Husaberg or KTM dealer he just has to pay labour, approx Ł300. They would have paid for the labour too if he had it serviced by a Husaberg dealer.
Now that's what I call a good service, well done Husaberg.
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July 2nd, 2009, 02:58 PM   #5
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Thanks! I will remove gear and check crank end. At the same time I´m gonna put the engine on table, open it and check all.
The guy I bought this, did rebuild at 80h and I´m running now about 60h.
Let you know then what I found and can take some pics.
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July 2nd, 2009, 04:01 PM   #6
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check JBSracings gallery for a lock washer fix to the crank primary drive gear and intermediate shaft nuts.

Took about 40 min to make the washers and machine the gears.
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July 6th, 2009, 11:05 PM   #7
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I take couple pictures, more is in my gallery



There´s no crack but not look good.. Can this fix?
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July 7th, 2009, 07:54 AM   #8
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You crank seal is fitted wrong!
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July 7th, 2009, 08:12 AM   #9
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Originally Posted by ElSnorro
You crank seal is fitted wrong!
What you mean?
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July 7th, 2009, 08:42 AM   #10
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Originally Posted by Huspee
Originally Posted by ElSnorro
You crank seal is fitted wrong!
What you mean?
Your crankshaft seal should be the other way inside
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