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December 31st, 2016, 07:59 AM   #1
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I Ride: Husaberg Fc550, Fe650, Husqvarna TE450, Kawasaki KX250, KTM MX500, Montesa 310.
Changing gearbox and crank case. What to expect?

Hi.
I have a FC550 2001, 4 speed, with cracked case!

It was quite ok for a while, but now the oil leak is gettig bad. Sooo......I am planning to change to a new (used) crank case, and at the same time, put in 5'th and 6'th gear....
Of course I will totally rebuild the engine with all bearings and seals.

I see a 2004 crank case for sale, from a FE550, and some complete gearboxes as well. What do I have to keep in mind when I want to purschase parts from other years of make. If I want to just switch crank cases and put in my old parts? Please!
This will cost some money either way, but if I start to buy wrong parts this will make me unhappy!

Last edited by Highflyer; January 1st, 2017 at 04:15 AM.
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December 31st, 2016, 08:24 AM   #2
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you must NOT contaminate your balancer assembly, clutch, intermediate, crank gears or the intermediate (known to some as the waterpump shaft) shaft with any other year. 2001 must work alone.

you can fit everything straight over BUT the ignition. this can't be swopped with any ease.

best to keep it simple, use 2001-2003 cases, change everything straight over to them. 501 or 550 cases will do.

I'm surprised you can't repair yours, I repair cases and they are fine afterwards. another home mechanic mistake????

the 2001-2008 gearbox are a straight swop. all the gears and shafts are the same for all 8 years BUT in 2003 the clutch drum fitment was changed so all you need for 2003-2008 box is the later drum, clutch steels, a washer or two. I do it as a kit.

Taffy
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January 4th, 2017, 02:35 PM   #3
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Thanks for info.....again, Taffy!
Yes, maybe the crack can be welded. It's no home mechanical mistake.......yet. Thats why I ask a lot of questions; so I might not make such mistakes. The Norwegian dealer, for many years, have told me that this has been done with several similar cases, with luck. But I recently recieved a message that his is serious ill, and might not be able to help me. So, I think I will be loooking for a new crank case, just in case. But of course, If I start the job, and I dont have a spare crank case at that date, I'll have to check on a repair.
But, then I will get hold of a 6 speed gearbox.
Do I need another fork, or is it only the gears that I need? It looks like there is 2 forks in a 4 speed box, and 3 in a 6 speeder?
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February 14th, 2018, 01:16 AM   #4
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I Ride: Husaberg Fc550, Fe650, Husqvarna TE450, Kawasaki KX250, KTM MX500, Montesa 310.
Finally, the job is almost done.
The crank case is welded AND reinforced. Looking good! All bearings replaced, new conrod, new piston, and new seals.
I had some problem getting the gearing drum to run free, after I knocked the crankcase together, but after I knocked it out a bit, it's ok. BUT.......It feels like the gearbox jams!?
I can spin it some, and suddely it jams..?
I'm sure the forks is ok, with it's cups, and are in the right groove. I have also tried to knock with a plastic hammer on the shafts, from right and left, but no.....
I'm also quite sure the gears are stacked right.
Any ideas what might be wrong?
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February 14th, 2018, 01:57 AM   #5
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I was at a show a year ago this weekend and a norwegiasn customer told me the importer had just recently died from cancer. very sad.............

anyway, not sure what is wrong with gearbox but the technique is always to ISOLATE.

so clutch off, selector off. take selector drum and forks out. just leave the two sets of clusters and start up from there.

the mistake is usually washer wrong side of circlip and the other is the 5th and 6th gears on the output. these two must hold the fork. they must be infield of the gears towards the centreline of the bike.

Taffy
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February 14th, 2018, 04:55 AM   #6
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Jupp!
I think I just have to do as you say, Taffy.
Take it all down again, and start all over.

And yes, Morstad has passed away. It's sad, because he had a lot of experience with Husaberg.
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February 14th, 2018, 09:31 AM   #7
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yes his son phoned me a few years ago fr parts and we had a good chat. they didn't know any of the modifications but hopefully he took a few ideas on board.

Taffy
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February 15th, 2018, 05:50 AM   #8
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It's all apart again. I think there was the gear selector drum, that was'nt in the right possition. The shafts and the gears runs like in butter, and shifts smooth now, when the engine is open. I'll try to put it together again now, but I'll save my silicone. I'll take it apart again and apply silicone sealant when I know everything runs right.
You'll recieve a order for some minor stuff for my topp end, Taffy!
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March 6th, 2018, 03:57 AM   #9
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Hi Taffy!
You've got a couple of PM's from me, and I've tried a couple of ways trough you web-site to contact you lately, about my order. But............completely silence! Why?
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March 6th, 2018, 04:09 AM   #10
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I have answered you but I come to UHE via a link onto the opening page. it then tells me three ways that I have a PM but I dismiss this 'for later'. I answer threads heer etc and then it is my dinner and I maybe forget that I have a PM? PMs don't have a counter on the screen which would be handy..... sorry about that!

taffy
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