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October 3rd, 2008, 12:24 PM   #1
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I Ride: 99 ktm 200exc, 96 CR265, 77 xs650 bobber, 2000 honda superhawk
96 fc501

i am looking for a gearbox/case breakdown for reassembly. anyone have one lounging around their harddrive?
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October 3rd, 2008, 12:42 PM   #2
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From the "Downloads" section of the main menu on the left, download the 1999 Workshop manual.

http://www.husaberg.org/index.php?mo...&cid=1&start=0
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October 8th, 2008, 04:13 PM   #3
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gracias evidently i downloaded the wrong one a couple years ago. lol i lost two teeth on first gear and one in the main shaft gear.... no wonder things weren't working as they should! just hope i can get it back together as its the first time splitting any case.
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October 8th, 2008, 04:27 PM   #4
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This may come in handy, from Taffy's gallery, not sure if it applies to your model exactly but a nice exploded diagram anyway:

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October 9th, 2008, 09:15 AM   #5
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not sure if it applies to your model exactly but a nice exploded diagram anyway:
doesn't apply to the early model engine. cam chain driven off the crank.
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January 6th, 2009, 04:16 PM   #6
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I Ride: 99 ktm 200exc, 96 CR265, 77 xs650 bobber, 2000 honda superhawk
Been a while on this one. anyone seen any used parts available? i can get mine from boss for about 300, but seeing my luck with transmissions (just had to rebuild the truck trans to the tune of $2000) i dont have quite that much laying around.
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January 6th, 2009, 06:43 PM   #7
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Keep an eye on the eBays around the world. A complete set of internals for your box sold here in Oz less than 12 months ago. With the Yankee dollar so high at the moment it might be worth your while bringing bits in from overseas.

Does your bike have the oil filter housing on the RHS just behind the cylinder? If not the nearest workshop manuals available ('98 & '99) for download might show differences to your bike.

Also, don't forget to download the parts manuals from the "Former Files" section at the bottom of here. The exploded views in them are excellent at showing the order in which the bits go together. If you download them all through to 2001 you will likey find most of the parts you are after were used in later years as well. Certainly widens your options when chasing them up.
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January 6th, 2009, 11:41 PM   #8
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Re: 96 fc501

Originally Posted by Bucklee
i am looking for a gearbox/case breakdown for reassembly. anyone have one lounging around their harddrive?
there is a gear in the 2002 box that is shown the wrong way around. please quadruple check this!!!!! if you go into the doc, it is mentioned there.

i know it's not your year but these gearboxes are the same back to 1997 for sure.

regards

Taffy
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January 7th, 2009, 11:54 AM   #9
oyk
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hello,
when you find some spare parts for your tranny, make sure they are from 1997 and on models. except from minor but effective changes in the clutch pressure plate which reduces completely the drag, they also changed the supplier for the gearbox gears because untill 1996 there were some times producing parts for the transmition with bad quality control that resulted in some decimals of a millimeter in the parts.

hence many problems in gearboxes up to 1996.

this included also my 1994 that back to 2000 the tranny exploded and rebuilted with newer parts.

by the way, ebay.com now i think has many gearbox parts for you.
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January 8th, 2009, 10:03 AM   #10
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what were the minor clutch mods exactly? how can i tell one from the other? sorry to interupt by the way!
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