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July 1st, 2020, 02:11 PM   #1
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I Ride: Husaberg 400 FE
400FE 1997 - restart after bottom engine replacement

Dear community

I finished the assembly of the engine. I replaced every parts of the carb. Identical to origin except main jet which was not available at 185 but 190.
I have check the clearance of the valve to 1/6 turn méthods.
The ignition plate set up is controlled as described in the photo below :

But my Zab refuse to start
So I removed the upper part of the cam tu check the position of the shaft versus the piston. Screw alignment was perpendicular to the horizontal border of the head when piston is at tdc.
What I dunno is : Is there a spark at every turn of the engine ? Or only 2 turn ? Is it possible to be misalign from 180deg with the cam shaft ? How to be sure that the distribution is well set ?

Other question : this cam on picture hereunder just move around freely. And the little spring on the other side of the gear doesn’t have any use/effect. Can you inform me of it is normal please ?

Do anyone have the 1997 service or/and owner manual please ?

Last edited by JulienN; July 1st, 2020 at 02:25 PM.
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July 1st, 2020, 02:43 PM   #2
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I Ride: 99 FE501e, FX600e, FC501
You need to remove the decomp and either replace or rewind the spring, when installed properly it will stay against the cam ledge and snap back when pulled
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July 2nd, 2020, 01:08 AM   #3
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Your cam still has a very thick shoulder coming through the middle of the cam sprocket. get the shoulder machined flat to the cam sprocket by an engineer. then fit the later auto decomp and spring.

you get a spark everytime up. sticking a strraw or something through the plug hole is not a good way to get TDC.

I use a T-bar and 17mm socket on the crank and I'm very slow and careful. I use a long threaded stud I have here. 20cm long. I dome the end. I then push into the hole and lock over to the side with one hand. use a rubber band to keep it there.

then turn the engine each way and where the piston stops mark the flywheel. you can move the stud one thread up or down. you want to be marking 25mm left and right of centre and then measure the 50mm between them and mark TDC.

you want a wet plug/piston from the fuel.
you weant a spark.
you are halfway there!

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July 2nd, 2020, 09:57 AM   #4
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Taffy is referring to the "Dead Stop Method" or "Positive Stop Method of finding TDC. Taffy has made his own tool that fits into the spark plug hole. I got this one from Hayabusazone - Cylinder Heads
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400FE 1997 - restart after bottom engine replacement-tdc.jpg  
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July 2nd, 2020, 09:58 PM   #5
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Contactes moi par mp je te donnes mon numéro de téléphone afin de t'expliquer ce qui ne fonctionne pas.
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  Husaberg Forum > Mechanical and Technical > Mechanical

1997, 400fe, bottom, engine, replacement, restart

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