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December 17th, 2014, 12:53 PM   #1
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05 650 Timing Question

I had to remove my clutch basket in order to fix the kick start ratchet return.

After putting the basket back in, and rolling the motor over a few times with the kick start, I attempted to set the engine to TDC. This is when I noticed that my alignment point on the idle gear and pinion gear do not align with one another (not sure if one of my Grunions spun the the gear while it was open).

I removed the basket again and aligned the three marks. I think I might not be on the compression stroke since I can rotate the crank by hand with the sparky still installed. I think I might be in the overlap area on the cam.

Before I light this sucker off, I wanted to know a fail safe way of checking that my cam/crank timing are correct as to not smack my valves on the piston (I've done this before on a DRZ and bent all the valves and broke 3 guides.

Seeing how replacement parts are little harder to find for this, I would like to avoid another "trophy". I took the smashed bits from the DRZ and welded together a trophy that sits on my wall as a constant reminder.

Thanks in advance gents.
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December 17th, 2014, 01:28 PM   #2
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Remove the rocker adjustment covers and watch your valves open ...you can see what stroke it is on that way. Just for your peace of mind.
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December 17th, 2014, 08:40 PM   #3
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its in the manual found here Service Manuals - Husaberg Forum


all you need to do is align all the marks at TDC and make sure the cam sprocket marks align with the top of the head which it will be if you haven't taken the cam chain off. compression stroke or exhaust doesn't matter

the marks won't align perfectly but if you check what they look like one tooth off either side you get the idea.

if you remove the pulse coil (#5) there is a crank locking bolt underneath it

take out the hex bolt and replace it with a longer one to lock the crank at TDC both my 650 cranks were spot on tdc when locked in the 08 cases

can use a straw down the sparkplug hole to get it about right then shine a light into the hole and line up the small indent in the crank with the locking hole

if you put the timing strip in this position its also about right for tdc
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05 650 Timing Question-tdc.jpg  

Last edited by bushmechanic; December 18th, 2014 at 05:03 PM.
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December 18th, 2014, 12:09 AM   #4
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if you have the 2 dots on one gear dissecting the one dot on the other. place a ruler between the two gear centres and close one eye. if it looks right then go for it.

you should be alright for starting it one tooth out but if it doesn't sound right then stop...you made a mistake and you'll have to do it the slow way and have the rocker cover off?

regards

Taffy
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December 18th, 2014, 09:52 PM   #5
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Thank you all!

Turns out I'm on the scavenge stroke, but like Bushy says, it doesn't matter.

Cheers again gents!
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