Is it a shift drum?

etcbrown · Jan 14, 2012

My 2001 fe501 has been spotty on shifting for the past 8-10 rides. Generally speaking it would not up shift until it warmed up.

But today near the end of a tough ride in sand washes it became stuck in first gear and would not shift out, not even to neutral. Had to limp back to the truck, about 10 miles in first.

It has never made any noises to suggest it was tearing up any gearing. So does this sound like a shift drum issue, or perhaps worse?

Taffy · Jan 15, 2012

NO

you have two problems that can easily be addressed.

firstly, grind all the bludgeoned edges off the gear selector.

second, the screw in the middle will be loose. loctite it back in.

regards

Taffy

etcbrown · Jan 15, 2012

Taffy, I aplolgize but since we don't speak proper english over here I am at a bit of a loss when attempting to interpret your response.

On the one hand it looks as if you are being sarcastic. But then again you may be being genuine and I just don't have enough knowledge to follow along easily. So for my sake could you put it in a bit more detail, and in terms a relative Husaberg newbie can understand?

Thanks in advance!

kli · Jan 15, 2012

I had the same problem.

Like Taffy says, the screw of recoil of gear shift mechanism come lose, in my case I had little more bad luck.
Recoil has sprung out of the screw, go under clutch hub and wear gears of it, so I need to change it, I also change complete gear shift mechanism, with new from 2004,it's thicker, so the selector it's much harder and accurate.

Regards

kli · Jan 16, 2012

Open clutch cover and you will bellow clutch gear shift mechanism with recoil.
Just for inspection you even don't need to dismount the clutch.[attachment=0:alwwnid6]Gear shift mec.PNG[/attachment:alwwnid6]

DuaneB · Jan 16, 2012

etcbrown... all of the advice above is on the right track, I had the same problems. The shift mechanism that Taffy mentions and is highlighted in the last picture by kli is likely your problem. It consists of two metal plates that slide back and forth on each other to rotate the shift drum as you shift up and down. The edges of these metal plates get beat up from the "star" on the end of the shift drum which prevents them from sliding properly and the end result is getting stuck in gear. Like Taffy suggested, just take it apart, file the burrs from the edges of these two plates, loctite the screw back in when you put it together and you should be good. Cheap fix.. only cost will be the gaskets for the clutch cover and water pump.

Also.. they changed this part (I think in 2004) to use a harder steel to prevent this problem, I think it's also thicker because I had to do a little bit of modifying to make the 2004 part fit in my 2002 550.

Hope this helps make it clearer.

Taffy · Jan 16, 2012

yep that's triangulated help for you Browny. Doesn't get any better than that! 8) 8) 8) 8)

regards

Taffy

etcbrown · Jan 16, 2012

Thanks for the help to all!

Will give her a look as soon as I get a few hours.

Oh, and now Taffy's response is perfectly clear; when placed in context. :cheers:

etcbrown · Mar 23, 2012

OK, broke her down and just as Taffy predicted it was rough edges on the sliding shift plates. Filed the rough spots off and they now slide nicely again.

Now for the new problem :angry: :cuss:

I partially re-assembled placing the shifting star thingy with the shortened prong (neutral I presume?) on the post with the flat or smooth top, (I think, it is tough to really tell for certain) and now when in neutral I can shift up one gear and then it tops out, but I can shift down 4 or 5 gears from neutral?????? Seems backwards to me. How do you align the shifting star on the shift drum?

Taffy · Mar 24, 2012

so you didn't mark where the star went..... :roll: :roll: :roll:

what can we say......... :| :| :|

my best advice is to remove the sprung wheel and then keep spinning the backwheel with your right hand and cogging the drum clockwise till it stops. then come back that lil bit and that'll be neutral won't it! then put the star plate back on and the neutral under the sprung wheel. you should still be in neutral right? check the box through once for luck and then the jobs a good un.

regards

Taffy

Is it a shift drum?

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