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January 16th, 2019, 04:15 PM   #1
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2008 Husaberg FE550 engine noise

Hey guys, having a little trouble getting much feedback around my friend group with the 'Berg and figured I'd try the forum.

Just finished putting the bike back together after I broke the first gear pin off the shift drum. I've followed the repair manual closely to repair but I am still getting some sort of noise coming from the engine (maybe from the valvetrain?)

The noise/symptoms can be heard here:

I will note a few things:

-I wasn't entirely confident setting the tension on the timing chain per the instructions in the book (says push to slight resistance then one more click)... how much is "slight resistance?"

-I did find the #1 shift drum pin floating around at the bottom of the side cover, it looked as though it got chewed up a little bit.

-I don't see anything visibly wrong with any of the gears in the side cover, nor is there any apparent damage to the valves.

-IIRC the bike DID make this noise after it had lost 1st gear and before I started the repair. I shut the bike down the instant it started to make this noise and walked a good couple miles haha...

-bike is relatively low mileage

-spark plug looks fowled right now (although that kinda makes sense)

I just got done checking the valve clearance and I took the valve cover back off for another inspection. The valves appear to be properly adjusted and I've removed the cam tensioner for another inspection which looks good to me personally. Moves back and forth and the gears look fine and lock in nicely. I did install the tensioner with a vert soft push on the toothed rod against the chain guide, and then put the spring in to press on the toothed rod. Didn't hear any additional clicking at this point from the spring pressure.

I would really appreciate it if someone could give me an idea of what they would look into more thoroughly. Perhaps I'm overlooking something simple that could have been damaged by the broken shift drum pin causing the noise in the first place.

Thank you.
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January 17th, 2019, 10:53 AM   #2
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Perhaps try a mechanics stethoscope
to help narrow down the general area where the noise is originating from. You can also use a long screwdriver and place the plastic handle end to your ear.

Its hard to tell from the video but it sounds a bit like a ratcheting noise. You may want to inspect the kickstart mechanism if the noise is coming from that area.

Take a look at this video
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January 18th, 2019, 12:26 AM   #3
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run her with the valve covers off for a a minute.

I reckon it's from the left cover?

like eric, i just can't be sure though....

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January 18th, 2019, 04:04 AM   #4
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Check your timing chain rollers,they divide in halves
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January 19th, 2019, 11:36 AM   #5
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Husabutt and Taffy, Thank you for the recommendations. I have ordered a stethoscope (might be a couple days) as I think you are both correct that I need to better locate where the sound is coming from. In the meantime I will try taking the oval-shaped adjustment covers off the top of the valve cover and try running the bike like you suggested. Although the bike does have a hard time running as well.

Husaberg 644, You're speaking of the drum-shaped individual pins inside the timing chain, correct? So I would likely need to pull back off the timing chain and inspect the individual links for cracks or wear?
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