Help ! - 2001 FC engine issues

awilksch · Nov 9, 2012

Gidday all me old buddies on UHE - its been a fairly long absence from the site, but pleased to report that the happy little family of 2 Bergs (and me) have been running relatively smoothly.

I was just dropping back to look for a fix for a sticky / jammed gear shift - and of course found some background reading, which I'm sure will get me into the picture (when Taff sounds sure of something, its gotta be ya first port o call)... Also its worth highlighting the importance of reporting back on your tech posts and giving everyone the benefit of your experience - did the fix work? was it something else? what did you observe?

Anyway, thanks again guys !!

Whats the feeling on here about the falling of the 70 degree Bergs?? felt like a pretty sad day to me...

Azza.

awilksch · Nov 13, 2012

Re: Gidday !! - gear shift claw

Hi again all,
can someone please point me to an image of the maintenance work that one does on the gearshift claw when having shifting issues - the link in the doc http://www.husaberg.org/modules/gallery ... .sized.jpg from in the 'wear items amber alert won't load up.

Cheers!

Azza.

awilksch · Nov 13, 2012

Re: Gidday !!

Okay, so for the record - and anyone else's benefit - this is what the shift fork is meant to look like (from another post on the site)

download/file.php?id=1678

and (attached) is what mine looked like when I opened the side up - its clearly jammed, and not driving the selector around on each shift.

so its time for me to de-burr the fork plates.

Azza.

awilksch · Nov 14, 2012

Okay, so this has officially turned into a call for help -

After sorting my gearshift issue out and re assembling the clutch, I tried to turn the engine over through a couple of cycles by hand, but found it jammed up tight. I think that the synchronisation between the primary crankshaft gear and the balancer & timing drive gear has shifted.

The 2001 - 03 workshop manual says to align the marks on the primary crankshaft gear (I have these) with the mark on the countershaft drive gear (I dont have any marks on this) before torquing the nuts.

I have not had any of this apart - so the relationship between the timing chain and the balancer has not altered.

The manual tells me how to align the primary gear (thus the crank), which is fine - but I am not sure how to properly re set the countershaft drive gear before reinstalling the clutch basket.

I am also assuming the lock up I experienced while trying to turn the motor over by hand is likely to be the counter balancer coliding with the piston?

Please help

Cheers!
Azza.

Taffy · Nov 15, 2012

yes your right azza

firstly, the intermediate shaft gear should have dots on it whatever happens? yet yours hasn't? mmmm? strange?

I suppose it could be on the wrong way around I suppose? want to check?

the other guaranteed way is as follows.

remove the rocker cover
remove flywheel cover and get the flywheel to 12 o clock: have you heard about the third line? if you have it, line it up with the screw hole at 12 o clock.
remove the clutch basket
then turn the intermediate gear nut until the two cam lobes are symetrical to the top of the head
refit the clutch basket and it should still be; third line under the screw and cam lobes symetrically pointing up and out at 11 and 1 o clock.
mark the Intermediate gear any which way for the next time.
turn crank 360d xo lobes are down
refit rocker cover

regards

Taffy

ned37 · Nov 15, 2012

i would think having it out of time would not lock it up. hard to believe there's no dots on the gears.???
sure your kickstart pawl didn't slip off? was the cover a bit tight at the back when tightening the screws?

Taffy · Nov 15, 2012

the counterbalancer will hit the piston IF the piston is at BDC as the CB is at 12 o clock Ned.

regards

Taffy

ned37 · Nov 16, 2012

true, but that won't lock it up until you hit the piston. :cheers:

awilksch · Nov 16, 2012

It was either piston / counterbalancer or piston / valves - I was working on re timing and got a distinctive clunk at the valves, so I am sure it was piston and counterbalancer the first time.

I have positioned crank for TDC (using maks on the primary crank gear) and positioned the cam and balancer according to the valvetrain as there are no marks on the balancer primary.

I am yet to pull the balancer primary retaining nut off and do the 14 tooth countback to be sure and then will mark that gear for future reference.

I will update (or yell for help again) as I go on..

Thanks Ned & Taffy.

Cheers!

awilksch · Nov 28, 2012

Well... the 14 tooth countback didnt work, but using known points of reference, I have re established the synchronisity between the crank, the balancer and the valve train.

The timing mark tooth for my counterbalancer primary is a long way past 14 teeth, however, I assume that it has been rebuilt in the past and that the installation of the counterbalancer drive shaft was not aligned to the marks, thus the keyway was not in the position referenced in the '14 tooth countback method'...

hopefully when I kick it again, it goes brum.... not bang...

Azza.

awilksch · Dec 13, 2012

Okay - She is alive !! :cheers:
Notes to remember -

* mark everything with a paint pen before you pull it apart !!
* dont take for granted that there will be timing dots (if they werent there when you pulled it apart, they wont be there when you put it back together).
* if the counterbalancer drive isnt aligned inside the cases (more dot to dots) then dont expect the keyway on the outside of the centrecase to represent anything !
* get the kickstart shaft right before gak-ing the gasket and fiting the side cover... :cuss:
* keep the basics in mind - TDC is always TDC
* shed time is cheap - compared to bent valves and other broken bits... best to work through confidently and thoroughly...

Azza.

ned37 · Dec 14, 2012

i think you got it right! :cheers:

Kye · Dec 19, 2012

awilksch said:
* get the kickstart shaft right before gak-ing the gasket and fiting the side cover... :cuss:

Its a real ******* isnt it?! I had my gasket surfaces mickey mouse spotless, a nice thin even smear of three bond, and after a hour of swearing, finally reverted to the forum and discovered to joys of the kickshaft anomoly. i finally got my 650 back together last night, a week after starting to put the clutch / sidecover on, and it still took three goes.

Help ! - 2001 FC engine issues

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