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December 31st, 2016, 06:59 AM   #1
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From: Norway

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I Ride: Husaberg FC550
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 03:15 AM.
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December 31st, 2016, 07:24 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, 01:35 PM   #3
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From: Norway

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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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