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May 16th, 2017, 12:14 PM   #11
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Something to consider from post I did a few years ago:

The transmission was modified with a different tooth profile between 2001 and 2002. The easiest way to determine how the engine was built is to look at the counter balancers' drive shaft. The early shaft has a straight surface and the later one has a diameter change between the position for the timing sprocket and the drive gear (tapered).

The following gears are not interchangeable between 2001 and 2002/2003: Counter balancer, balance drive shaft, drive gears on balancer drive shaft and crank shaft and also the outer clutch basket.

This is a direct quote from the 03 workshop manual. The difference in tooth profile may be subtle. Many have replaced their 01-02 counter balancer with the factory updated part (double row bearings), did not check the tooth profile and ordered the mid 02 and up part or just ordered the 03 part thinking it was the updated part they needed. The result was a loud gear whine. Husaberg makes a special updated double row bearing counter balancer specifically for the 01 and early 02 models. You could probably find a good used clutch basket from a 01, hopefully from a 400. The 01's had a defective torque limiter which would damage the clutch basket if a backfire occurred during starting. Mostly the 650's were affected. A warranty replacement torque limiter was given to all 01 model purchasers.
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May 16th, 2017, 12:39 PM   #12
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If you were unlucky enough to have a 01 or 02 motor built with 01 transmission parts then you may want to consider finding a used 02-03 Counter balancer, balance drive shaft, drive gears on balancer drive shaft and crank shaft and the outer clutch basket if you are interested in trying to make it e-start.

I believe that the reason for the profile tooth change is that it caused too much drag on the motor for which the e-start components were just not up to the task.

2001 was the first year for the GEN 2 motor and it had its fair share of teething issues.
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May 22nd, 2017, 05:53 AM   #13
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Stripped down a bit more



Head stock bearing race not good lol

Few frame repairs needed

Then she will be off for powder coating


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May 22nd, 2017, 12:45 PM   #14
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see if you can't weld up the bracket really nice and properly/

then fit the sidestand WITH a later 2004 bolt OK?
then judge the angle from photos of how high it comes up when up? will it hit the exhaust for instance?

cut, weld, grind, drill NOW and not later OK?

you need to know whether it will come up too high (and hit the exhaust) and also: will it roll around far enough and not too far to take the weight of the bike?

also, with the sidestand down, would it ideally be twisted around a little to sit on the pad/

if we did a survey here: 50-60% possess Husabergs that don't actually sit on the pad!

Taffy
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May 25th, 2017, 07:50 AM   #15
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Flywheel puller arrived today, cheers taffy
We now have this left Fc550 project-img_6244.jpg


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May 25th, 2017, 07:52 AM   #16
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Will this flywheel run lights? Fc550 project-img_6243.jpg


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May 25th, 2017, 09:02 AM   #17
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I think it's the stator that has two coils? One for lights etc the other for ignition.


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May 30th, 2017, 03:47 AM   #18
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Originally Posted by husabutt View Post
Something to consider from post I did a few years ago:

The transmission was modified with a different tooth profile between 2001 and 2002. The easiest way to determine how the engine was built is to look at the counter balancers' drive shaft. The early shaft has a straight surface and the later one has a diameter change between the position for the timing sprocket and the drive gear (tapered).

The following gears are not interchangeable between 2001 and 2002/2003: Counter balancer, balance drive shaft, drive gears on balancer drive shaft and crank shaft and also the outer clutch basket.

This is a direct quote from the 03 workshop manual. The difference in tooth profile may be subtle. Many have replaced their 01-02 counter balancer with the factory updated part (double row bearings), did not check the tooth profile and ordered the mid 02 and up part or just ordered the 03 part thinking it was the updated part they needed. The result was a loud gear whine. Husaberg makes a special updated double row bearing counter balancer specifically for the 01 and early 02 models. You could probably find a good used clutch basket from a 01, hopefully from a 400. The 01's had a defective torque limiter which would damage the clutch basket if a backfire occurred during starting. Mostly the 650's were affected. A warranty replacement torque limiter was given to all 01 model purchasers.
thanks for the info, cross checking what parts i have with 01-02 parts lists i appear to have 02 parts, drive shaft gear numbers match to 02, and i have bearings on the outer clutch basket as apposed to bushes?
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July 4th, 2017, 12:23 AM   #19
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thought i may aswell replace some of the bearings...then i read the main bearing threads and got totally confused.. i have a 02' fc550, its current main bearings are NSK 6206 c4 ball(9) race bearings, whats the recommended replacement?
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July 4th, 2017, 12:42 AM   #20
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just stick a pair of roller mains in, don't worry about ball. remove all the shims so the crank is as narrow as possible.

get the OEM parts as they are worth the extra. SKFs are fine although Bushie has a ereal hatred of them, swears everyone's bike will lunch next week. we've never had one single mains failure and I've done a couple of hundred.

Taffy
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