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Husaberg 04-08 gear dog wear

Joined Jan 2022
33 Posts | 4+
France
Hi guys,

I'm rebuilding a 04 650 FSE and found flakes on the oil drain magnet.
So I took the engine apart for a full rebuild and found the gear dogs pretty worn. I suppose the metallic flakes come from there.

I don't have much experience with these parts, the gears are expensive so I don't want to replace if this wear is still ok.

What do you think? For the straights dogs I will try to machine them to avoid them further degrading.

Thanks!
 

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Last edited:
Hi Samuel, I can find complete gearbox in good condition and fair price for you. DPD shipping from Poland should take 3-4 days so you will be able to fix your bike next week:D
 
Samuel

those slivers of steel will be the main bearings. all that gearbox wear is from 15 years and not last week!

Taffy
 
Hi guys,

Thanks for the inputs! Undercutting might be a solution but if I can find a used gear set I would rather go for that time saving option.
Yes trust the flakes might come from the main bearing, they did not look too bad but they will be replace anyway.
 
I've seen far worse gear sets. just look at the gear selector fork and you'll see bad binding across all generations. 4 places in total, two on each plate. the 1989-2003 are the worst.

Taffy
 
Those gears look pretty good to me, when more than 20% of the dog is affected or you are missing shifts you have a problem. Undercutting can be problematic, as you can go through the hardening of the metal.
 

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