'02 FC550 stuck in third gear...

sandskipper · Sep 8, 2006

Hello gents,

This past weekend I had a three day trip up to the cinder OHV area in northern Arizona to do some high altitude (8000ft) Forest riding. The bike ran pretty good seeing as I didn't re-jet from my 2000ft elevation. Last day of riding and about 5 miles from camp I lost all ability to shift, I was in third gear at the time. I was able to bring her home in third gear but after much fidgeting I was still not able to get my steed out of third. I did a search and found this, http://www.husaberg.org/index.php?name= ... hift#19676 , thread from last year and will pull the side cover off this weekend for examination. Anyone have any useful comments or recommendations while I have the bike apart?
Also while I was returning to camp my bike started to sputter and cut out for a few moments before it regained its composure.... Does this sound like a possible fouled plug due to the excessively rich A/F mixture or signs of a dying stator? I was making my way down some long declines with the bike idling just prior to the coughing and choking the bike started exhibiting and I have not touched anything since Monday evening when I arrived back home in the Phx valley. I plan to pull the plug and replace, as well as remove the side cover and inspect my shift plates for burrs this weekend. I will post up any finds when I get a chance.

Regards,

Taffy · Sep 9, 2006

RE:

well, well, well keith

you're still alive then!

if you're familiar with delving into the left of the engine you'll have no problems with this. otherwise you need to watch the valve timing when you pull the clutch hub.

it'll be at your gear change mechanism and you'll be ok.

it'll be one of the following;

the post into the case through the middle of the selector arm coming loose
the tensioned roller wheel that keeps it in gear coming loose and falling off the star.
burring and chaffing as you say.

just have plenty of loctite around and do those two up tight.

regards

Taffy

sandskipper · Sep 14, 2006

Thanks for the comments Taff.

I pulled the side cover and clutch from the bike and the problem was apparent, the gear selector claw was stuck in the "back" position and the little spring was not pulling it back into the returned position for the next shift. Also noted that the large "X" screw that returns the gear selector into the horizontal position was loose and backing itself out of the case. I pulled the selector and filed the burred edges and took some fine grit sand paper to the whole mechanism to smooth all the actions and then refitted the selector back on the bike after oiling it up. I replaced the "X" screw with a good snug fit after lock-tite ing the threads and the action is great now.... hell, I might even be able to find neutral while the bike is idling! I have enclosed a picture of the finished selector after de-burring and sanding, glides nicely! I have also tore down the carby and did a thorough cleaning while the bike is apart, will refit later this weekend. Will set valve lash and reassemble and see how it goes, more to post when I finish this weekend. Thanks again for the comments taff, take care mate.

Regards,

schwim · Sep 14, 2006

So that's the problematic shift fork, eh?

Keith, when pulling it apart, did you have to do anything other than removing the KS and shifter? I guess what I mean is does anything need to be watched for when removing the cover? Does the KS shaft stay where it should or is there something that needs to be set in place before reassembly?

I'll be needing to do this soon, and you're pics make my inner mechanic smile inside. Thanks for them!

thanks,
json

LeFrog · Sep 14, 2006

So Keith when do we go ride? If you're game, stepson and I have our 1st ride of the season this week-end, it's going to be easy trails in the back end of the Rolls or Sickamore, around the time when the quadders are still sleeping or eating. You game???

Taffy · Sep 14, 2006

meatloaf said it "two outta three ain't bad...."!!!

well done mate

Taffy

sandskipper · Sep 14, 2006

I will type later..... I just spent the last hour typing a descriptive of this job and when I went to add pics....... my internect connection errored and closed w/o warning loosing everything. :x

Regards,

DaleEO · Sep 15, 2006

Wow Skip!!

That motor looks like new, your bike is well taken care of. Awesome pics, text, and arrows.

Schwim, when taking the clutch basket off there is one thing that you really need to be careful of and that is the fact that the clutch drive gear acts as an intermediate gear between the primary or crank gear and the cam chain/counter balancer drive gear. My 01 did not have any marks on these gears, and I was not paying attention the first time I took it off and the cam/counter balancer gear jumped when I pulled the clutch basket. I ended up having to take it to the mechanic to have it re-timed and he marked the gears for me.

Make sure the motor is at TDC on the COMPRESSION stroke before beginning the dis assembly of the clutch et al. AND! use a marker of some kind that will stay and put some marks on those gears before you pull the clutch basket so you can get everything lined back up again when you go to re-assemble.

LeFrog · Sep 15, 2006

Keith those are nice photos, bro.

We need more like that.

Let me know when you're ready to rock and roll.

LeFrog · Nov 2, 2006

Resurrecting Skipper's bad gear fork thread

OK, so I am having the same problem.

I removed the gear box and everything else and worked on the gear selector assembly. The fork was stuck badly. Used the Dremel and the metal brush to debur all the friction points. It seems to be working a bit better, now, but the fork is not coming out all the way on its own. I have to push it manually if I want that to happen.

It is not stuck and pushes the "star" up and down, but it will only make it turn a couple times, and not always the same number of times. Sometimes it will push it once up, sometimes twice.

I guess this is normal, due to the fact that the gear box is disinstalled and the bike is not running, but I need confirmation before I reassemble the bike.

Also how do I make sure the star is installed properly? I made sure to put it back the exact way I found it (position of the missing tooth) but now I wonder. How do I make 100% sure?

Thanks in advance!

LeFrog · Nov 4, 2006

Alright, I read the service workshop manual and fixed it properly. It's always harder the first time. Well, that's what she said.

Here is a video I made showing how it works: 1st, 2nd, 1st, 2nd, 1st, neutral.

Little MPEG

It's a good this to see, for who has no clue how it works. It also explains how the selector finds neutral.

Also on these gear selectors, sometimes neutral can only be found if one moves the bike forward a bit.

JoeUSA · Nov 5, 2006

LeFrog said:
Alright, I read the service workshop manual and fixed it properly. It's always harder the first time. Well, that's what she said.

Here is a video I made showing how it works: 1st, 2nd, 1st, 2nd, 1st, neutral.

Little MPEG

It's a good this to see, for who has no clue how it works. It also explains how the selector finds neutral.

Also on these gear selectors, sometimes neutral can only be found if one moves the bike forward a bit.

Was that the mechanic talking in the background?

Joe

LeFrog · Nov 5, 2006

Yes, young ones

2Dogs · Jun 8, 2009

LeFrog said:
Alright, I read the service workshop manual and fixed it properly. It's always harder the first time. Well, that's what she said.

Here is a video I made showing how it works: 1st, 2nd, 1st, 2nd, 1st, neutral.

Little MPEG

It's a good this to see, for who has no clue how it works. It also explains how the selector finds neutral.

Also on these gear selectors, sometimes neutral can only be found if one moves the bike forward a bit.

Hello,
Do you still have your MPEG? I think I need this....

Had the lockup/can not change gears thing happen this past weekend, have not torn it apart yet.

Thanks,
Dave

Taffy · Jun 9, 2009

you'll find 90% of the problems with gears are in your left cover. get this off and the clutch out the way.

the selector fork burrs
the central bolt through the selector comes loose.

pretty sure it's one of those two.

regards

Taffy

2Dogs · Jun 9, 2009

Taffy said:
you'll find 90% of the problems with gears are in your left cover. get this off and the clutch out the way.

the selector fork burrs
the central bolt through the selector comes loose.

pretty sure it's one of those two.

regards

Taffy

It is at least partly selector fork burrs - got it torn down to where I can see it. Now its back to work, will finish and update this evening.

Thanks!

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