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July 10th, 2017, 11:46 AM   #1
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I Ride: 2008 FE 550
Question Transmission issues on 2008 FE550

Hi,

My recently purchased 2008 FE550 has a bit of weirdness with the transmission. I can find neutral fine with the engine off. When I start, then put in gear, no problems. But while engine running,

1) can't shift back into neutral. And

2) when running, in gear and clutch in, it feels like bike is not fully "clutched" - meaning I can't roll it backwards. It doesn't "walk" forward per se, but I can't roll it back.

Remedies I've taken:

1) rebuilt both master and slave cylinders with new gaskets and cylinders all round.
2) Bled and refilled with mineral oil. Normally use Magura, but since I'm still in "troubleshooting" mode with multiple bleeds/refills, I'd like to sort the issue out before finishing with Magura.

Clutch doesn't slip, or misbehave in any other fashion other than the above two issues.

Any help would be most appreciated.

cheers from Canada,

CM
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July 10th, 2017, 12:01 PM   #2
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I Ride: 7 Husabergs two FE570S,FS570 FE390/450,07 FE650,05 FE550,2 Husqvarna's 86 WR400,87 510,09 Buell
Also look at the clutch both plates and lining discs. Warped uneven. Might have to replace them. With huskys to Husaberg's Neutral has always been a bitch. Adjust your clutch at the lever as tight as your comfortable with. Some people look for neutral as there rolling to a stop other roll the bike back and forth not to work with You though... if no one responds try looking around the forum for your answer. Good luck
Thanks from canadius

Last edited by Rainerio; July 10th, 2017 at 04:35 PM.
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July 10th, 2017, 12:38 PM   #3
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Its common with Husabergs.
Yeah there are few things you can look into with cover off with worn plates, warped/grooved discs.
Taffy sells a clutch pill that helps get better separation. He also has special thickness discs I believe. But you will need to confirm with him. I have just heard and have not got some myself yet.

pollo
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July 10th, 2017, 02:31 PM   #4
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Thanks Rain and Chicken (Yes, Spanish is one of the three languages I speak).

Regrettably, I'm not as fluent in mechanish, but I'm slowly getting there.

Have never taken the clutch side off any bike - but I've got the full manual - will study tonight.

cm
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July 10th, 2017, 06:06 PM   #5
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Originally Posted by canadius View Post
Thanks Rain and Chicken (Yes, Spanish is one of the three languages I speak).

Regrettably, I'm not as fluent in mechanish, but I'm slowly getting there.

Have never taken the clutch side off any bike - but I've got the full manual - will study tonight.

cm
My name is Paul and my Italian boss started calling me paolo and then it started sounding like pollo. And it stuck.
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July 11th, 2017, 12:36 AM   #6
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yup, clutch steels IMHO.

cheers

taffy
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November 5th, 2017, 10:59 PM   #7
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Just picking this up as the whole point of the clutch exploration was to look at the clutch plates / steels.

So now that all replacement parts have arrived, I've noticed something odd - and am wondering if it may have a bearing on my initial symptom of clutch not being fully engaged.

The manual refers to a #17 - support washer 25 x 35 x 1 as the first part to insert in the assembly.

But looking at the assembly on my bike, it looks like it was never there. When I put the needle bearings and half washers on, look at the gap - a good 2-3mm of play.

I'm concluding that part was missing, and am wondering if that resulting offset is contributing to the no first to neutral at stop, no roll back in gear with clutch in symptoms. The clutch plates looked perfect - hardly worn.

Thoughts?
Attached Thumbnails
Transmission issues on 2008 FE550-img_6265.jpg   Transmission issues on 2008 FE550-img_6268.jpg   Transmission issues on 2008 FE550-img_6264.jpg   Transmission issues on 2008 FE550-img_6266.jpg  

Last edited by canadius; November 5th, 2017 at 11:06 PM.
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November 6th, 2017, 01:44 AM   #8
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yep, you're right!

slap it together and ride!

Taffy
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November 6th, 2017, 08:37 AM   #9
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Originally Posted by Taffy View Post
yep, you're right!

slap it together and ride!

Taffy
so you're saying yes, I'm missing the support washer (59032017000)?

As far as I can tell, the only thing further aft of the two needle bearings is the main clutch shaft bearing, so that's where that support washer is supposed to be.

Another part to order .... lol

cm

Last edited by canadius; November 6th, 2017 at 08:39 AM.
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November 6th, 2017, 09:02 AM   #10
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yes you need the washer. yes you are right

taffy
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