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September 29th, 2008, 09:11 AM   #1
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timing gear nut loose

a friend just traded for 07 450 and it sounded like a thrashing machine. everyone kept saying husaberg sounds like that, but seemed to me to be getting louder from clutch cover side. i had a 03 ktm 525 once sound like that and intermediate shaft nut came loose and sounded just like this husaberg so we pulled clutch cover last night and sure enough it was loose (could turn with fingers). so we removed it, cleaned threads and applied loc tite, and reinstalled. as i was tightening nut up when i got to rough place in threads where it had been run loose, something make loud pop. prior to this i dont think motor had turned backwards at all and then it did, of course nut was getting tighter to the point where it would start turning. my worry is that its not suppose to turn backwards at all and i may have broke something? starter gear maybe? i couldnt see anything and was wondering if anyone had any experience with this and if something is broke where i should look? is this nut backing off common in these bikes as it was in a few years of ktms? any advise would be greatly appreciated thanks -jamie
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September 29th, 2008, 09:23 AM   #2
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RE: timing gear nut loose

welcome to UHE jamdze

hope you enjoy it here, have a look in the doc to the left of screen and under red and amber for other little nuances etc.

i'm going to catiously laugh because i think i know what it is and if it is i hope you'll see ther funny side too!

the sprague bearing housing has teeth as you know and they can catch the cam chain tensioner blade on all the 450s!!!!, going forwards doesn't matter but backwards it does so have a look!

rarely are these nuts found to be loose. sometimes they are lose and snap the end of the crank off because someone has tightened the nut with an air gun and then the next man uses a ball pane hammer for summink!

regards

Taffy
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September 29th, 2008, 09:32 AM   #3
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RE: timing gear nut loose

thanks taffy, maybe i should pull cover back off and check it out. i wished i would have found this site and done a little research 1st because someone had been in the clutch cover before. i read somewhere if nut is put on backwards it will not tighten up as it should. i put it back like i found it but now i am not sure if it was right to begin with. thanks -jamie
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September 29th, 2008, 11:29 AM   #4
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Re: RE: timing gear nut loose

Originally Posted by jamdrz
thanks taffy, maybe i should pull cover back off and check it out. i wished i would have found this site and done a little research 1st because someone had been in the clutch cover before. i read somewhere if nut is put on backwards it will not tighten up as it should. i put it back like i found it but now i am not sure if it was right to begin with. thanks -jamie
Hi there,

If you did not follow page E10 of the Factory service Manual, then you should open it up and redo your work. Using the correct Loctite and nut torque is VERY important.

Here is page E10....

Joe
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File Type: pdf Page E10 from RA_Husaberg_2004_E.pdf (138.6 KB, 150 views)
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September 29th, 2008, 11:54 AM   #5
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RE: Re: RE: timing gear nut loose

yes i did torque to 85 ft/lbs and used red loctite -jamie
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September 30th, 2008, 01:06 PM   #6
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RE: Re: RE: timing gear nut loose

Jamie - I am sorry but I am going to hijack your post. What the guys have said above is no doubt right for your engine so don't let what I am going to say worry you, you won't need to do it.

Taffy & others - I have had a lot of problems with my nuts falling off. We followed the book Loctite everything, even other stronger Loctites, more torque, spring washers everything. In Sidecar they still come loose. In my gallery is pictures of what we now do which is 100% succesful. Basically we grind a flat on the gears, turn 1mm off the nuts (which only takes away the chamfer not any threads) and install a washer and bend up as shown in gallery and as in OEM clutch. Shown in gallery is an early attempt using home made washers we now have them laser'd with tabs etc like the OEM clutch.
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September 30th, 2008, 05:35 PM   #7
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RE: Re: RE: timing gear nut loose

thanks, i am going to keep eye on it and if it comes loose again i may try that. -jamie
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October 2nd, 2008, 06:24 AM   #8
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RE: Re: RE: timing gear nut loose

well i found the culprit. we went to use kickstarter and found it locked up. upon disassembly and inspection looks like kickstarter mechanism and gear popped out of place. sure wish i would have tried it before putting everything back together. thanks for all the advise though. -jamie
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October 2nd, 2008, 10:04 AM   #9
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RE: Re: RE: timing gear nut loose

ok so look at the sledge key and note how it has to stick it's arse out the back to stop against the sledge (crescent) stop. if the face you can see of it is recessed by say more than 1mm when this happens it's worth putting some weld on the end so that the key always sits as deep in the kickstart mechanism as possible.

i think i've done a photo of it in the doc.

regards

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October 2nd, 2008, 01:35 PM   #10
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RE: Re: RE: timing gear nut loose

thanks taffy
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