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June 6th, 2005, 08:02 PM   #1
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Snapped Countershaft - Under Warranty



Would you beleive that I have somehow managed to encounter a snapped countershaft on my '04 FE650. The bike has done almost 4000km since Nov (Purchase) and has been serviced oil/air etc every ride. It is religiously checked over as per handbook requirements.

Riding has been brilliant (awsome power) until I suddenly noticed no drive !!! countshaft snapped at intenal Circlip groove and looks to my untrained eyes like a material failure. 3/4 clean break 1/4 twist off.

Very uncommon, or so I am told. And to top it off I am bikeless for the next 3-4 weeks waiting for bits.

Don't Husaberg know that there is Air travel and Air Freight? Any ideas why my parts can't come from the manufacturer in Sweden/Austria (wherever they are !!) in under a week ? I bought some Doc Marten Shoes last month from UK which arrived in 4 days

Not sure what to do now. I ride every weekend without fail.

Might have to ask the factory to extend the warranty by the time the bike is out of service because they don't have the parts
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June 6th, 2005, 09:09 PM   #2
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In Belgium we have the needed parts within a week tops.
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June 6th, 2005, 09:18 PM   #3
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Originally Posted by madero
In Belgium we have the needed parts within a week tops.
My Point exactly. Three to four weeks is not acceptable, my dealer was even surprised !

Would be curious if it is the same countershaft as on the '05. ie current production. Maybe someone has an '05 650 parts manual and can check it for me ?
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June 6th, 2005, 10:50 PM   #4
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i know that you don't want to hear this but perhaps you could volunteer to pay the extra for air freight. this will either shame them into volunteering to do it instead or-well-you get the bike done quicker with a little money out of your pocket!

regards

Taffy
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June 6th, 2005, 11:03 PM   #5
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Air Freight

Might be the go...

Might stir them up enough to get some action I hope !!!
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June 7th, 2005, 08:33 PM   #6
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Consider having the part cryogenically treated before installation for a little extra insurance.
Cryo Science website
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June 7th, 2005, 08:41 PM   #7
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Cry-Oh

Originally Posted by husabutt
Consider having the part cryogenically treated before installation for a little extra insurance.
Cryo Science website
Cry-Oh - I did a bit of that when I found out that I'd be bench racing for the next month !!!! Can't do it as it would probably void the warranty.

Isn't that what was done to Walt Disney ???
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June 8th, 2005, 07:12 AM   #8
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Countershaft failure

U2slow, your fracture description is typical for a fatigued part. Cyclical fatigue takes time. It takes time for a crack to start, and it takes time for the crack to progress. Considering the riding time on your bike, you probably had a very quick crack initiation, which would indicate either a surface defect of some type on the shaft, or a significant stress raiser. You mentioned failure at a clip groove or machining detail? That would constitute a stress raiser. The other significant observation was the 3/4 clean versus 1/4 rough fracture. The fatigue is the smooth portion, the final "rapid" failure is the rough surface area. This ratio would indicate significant but not excessive loading to the shaft. Think of it as 1/4 of the shaft area having the ability to carry the stresses just before final fracture. Perhaps the heat treatment was not right, or the groove bottom had sharp corners that were under tension even before the bike was ever ridden. None of these questions can be answered without a closer look, but shaft failures should be few and far between when proper maintenance is performed, as you have apparently done. I would push this issue with Husaberg since there is no evidence of neglect to account for the premature failure. In fact, the evidence of early fatigue initiation suggests a defect early on. Best of luck and hope you get it back together soon. BD
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June 8th, 2005, 05:06 PM   #9
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Countershaft failure - unique ?

Originally Posted by BD
U2slow, your fracture description is typical for a fatigued part. Cyclical fatigue takes time. It takes time for a crack to start, and it takes time for the crack to progress. Considering the riding time on your bike, you probably had a very quick crack initiation, which would indicate either a surface defect of some type on the shaft, or a significant stress raiser. You mentioned failure at a clip groove or machining detail? That would constitute a stress raiser. The other significant observation was the 3/4 clean versus 1/4 rough fracture. The fatigue is the smooth portion, the final "rapid" failure is the rough surface area. This ratio would indicate significant but not excessive loading to the shaft. Think of it as 1/4 of the shaft area having the ability to carry the stresses just before final fracture. Perhaps the heat treatment was not right, or the groove bottom had sharp corners that were under tension even before the bike was ever ridden. None of these questions can be answered without a closer look, but shaft failures should be few and far between when proper maintenance is performed, as you have apparently done. I would push this issue with Husaberg since there is no evidence of neglect to account for the premature failure. In fact, the evidence of early fatigue initiation suggests a defect early on. Best of luck and hope you get it back together soon. BD
My Sentiments exactly BD. Definately looks like a fatigued part which is covered under the warranty. The 1/4 twisted is definately where the shaft attempted to hang on. I suspect that either a material quality or heat treating were substandard and that this is a one off occurrence.

Maintenance is a religion for me. Oil change every ride, filter every second. The rest of the engine is spotless, in fact the piston, bore and head all look new, ring gap is as original also, must be due to my soft riding style. Will get on the phone today to dealer (who has been fantastic ) and distributor and see what the hold up is with the parts.

Thanks for the great post - if I can I will get some pics of the shaft. And post them.

I'd really like to know if anyone else has had this happen ?
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June 13th, 2005, 08:55 PM   #10
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I was in a bad situation with my 2005 bike and waited over two months for parts. I blame the Dealer for not following up and the Distributor for misplacing paperwork. After a call to BMG (very nice people) they got everything straight and parts arrived UPS in 5 days. Stories I hear is the parts will sit in Customs for days or weeks before being passed thru. If it is flown in by UPS or FedEx they must go through Customs.

The swede's may be going through difficult times. The 2005 Volvo is own part by Ford Motors and their new V-8 engine and drive train is made by Yamaha.
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