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June 24th, 2007, 09:04 AM   #1
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Cam gear position vs main gear after kick mechanism change

Hi!

I have changed the kick axle and I am now not sure how to engage the clutch in order to get the exact cam position vs piston position. Se picture. The obvious answer is to place the dot on cam gear in between two dots on main gear.

The kick axle retaining the arm engaging kick gear is a really weak construction and an expensive part.

Best Regards
Patrik
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Cam gear position vs main gear after kick mechanism change-main_cam_gears.jpg   Cam gear position vs main gear after kick mechanism change-kick_axle.jpg  
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June 24th, 2007, 11:26 AM   #2
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RE: Cam gear position vs main gear after kick mechanism chan

ok

we have details of how to get the cam timing right in the doc. there is a technical drawing there showing you how to get it right.

as for the kickstart gear well, that is described as well in 'engine rebuild'. well i think it is! i will now check.

Kickstart fitment: the diagram in the parts manual shows the spring the wrong way around. Remove the outer gear for now. Fit the straight part of the spring into the centre of the kickstart mechanism and then fit the hooked end into the engine case feeding it all in as one. Fit the kickstart and wind the unit 180 degrees clockwise until the 'keyhole' shaped ratchet piece goes past the high point of the crescent shaped plate. Now press unit down into the case and release. The unit will turn counter-clockwise and rest against the shoulder of the crescent. Now remove the kickstart and you're ready to fit the gear.

i hope this answers your question but if it doesn't - please come back to me.

regards

Taffy
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June 24th, 2007, 09:59 PM   #3
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RE: Cam gear position vs main gear after kick mechanism chan

Thanx a lot for your answer. Assembled kick mechanism yesterday. Your description worked a lot better than Husaberg doc. Just put it in, klockwise engagement and push in untill fit. But still dont seem like the best construction.

I briefly checked the doc but couldnt find the right info on cam positioning. Maybe some document Ive missed ?
Anyway I turned the motor a few times and it seems good. One thing I wonder though is if the cam wheel could be on the wrong stroke. What I mean is if I put the cam wheel one turn off should the ignition be able to ignite on the wrong stroke ?

Regards
Patrik
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June 24th, 2007, 11:12 PM   #4
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RE: Cam gear position vs main gear after kick mechanism chan

if when the piston is at TDC you have the cam lobes pointing either up or pointing down - it doesn't matter. there is a spark everytime the engine goes around so one is always going to be for the non-compression stroke. you'll be ok.

my advice is to fit the cam with the lobes up and then rotate the engine 360 degrees until the lobes are down. NOW FIT THE ROCKER COVER!

regards

Taffy
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June 25th, 2007, 06:45 AM   #5
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The kick mechanism may seem like a weak part when it is taken apart, but if you take your time, you can put it back together without a lot of strain, and once it's all torqued in, it should not budge.

As for the gears, they seem to be misaligned.
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June 25th, 2007, 09:44 AM   #6
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Just seems odd that the "thingy" holding the arm engaging kick wheel could be bent/snatched, but I guess I have to give in on this one

I never removed rocker cover, looked at the valves etc. The only thing Ive done is remove clutch and therefore misaligned main and cam gear.
The gears in the picture are misaligned due to spring tension and piston tdc. When fitted with clutch wheel the cam gear dot is placed in between the two dots on the main gear. Correct ?

Thanx for all your answers. It helps a lot.
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June 25th, 2007, 02:03 PM   #7
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Remove clutch assembly, realign dots, put clutch assembly back.
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June 25th, 2007, 05:04 PM   #8
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What LeFrog said. It is a bit of a pain to line everything up. I used a socket wrench to hold the crankshaft in position. Check the tappets. If the valves are moving, then you are 360 degrees out. Rotate the crank and try again. You will have to wiggle the clutch basket back and forth and use a finger to align the other two gears as well. When the single dot on the valve drive gear is inbetween the two dots on the crankshaft, you have it!
Here's Taffy's file: http://www.husaberg.org/modules/gallery ... C02816.jpg
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June 25th, 2007, 09:10 PM   #9
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It's also in the repair manual. You can turn the big gear with a big crescent wrench.
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June 26th, 2007, 12:22 PM   #10
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Thanks for all your help. it started on the first kick. perfect...

But after a few seconds of running the oil went milky and my mood got worse.
Apparently I replaced the old gasket with a new one that doesnt fit exact. Just bought a gasket that should fit from a husaberg dealer and on put on the cover side and mounted it. Didnt double check that it fitted over the coolant hole (which it aparently didnt) on the engine side.

My limited experience says that coolant (glycol) is a nightmare for any bearing... So this is what it feels like to be a moron.
I will jump on a new thread to see what can be done with an engine filled with coolant.
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cam, change, gear, kick, main, mechanism, position



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