04-08 Mounting The Timing Chain

Taffy · Mar 24, 2015

husabutt said:
Would you recommend using the dead stop method of finding TDC or is the engine lock up tool / bolt right on the money?

it's not that anything is right or wrong, more like quick or slow. I have to do it right and I have to be quick. time is money.

so, I went up to my first 04-08 engine and did the dead stop method AND also WITH a protractor on the flywheel face.

when the engine is at TDC:
"the leading edge of the staple is in a line between
A) the centre of the crank
and
B) the bottom edge of the ignition cover bolt hole situated at 9 o clock"

cheers

Taffy

bushmechanic · Mar 24, 2015

easy way to peen the rivet links:

get the link on as orientated in pic with arrow #3

after you're happy with the cam timing rotate the chain and or engine/crank till the link is in the position shown at #2 (the soft ends of the rivet link will face out, not like the pic)

then put a small block of steel between the crank case and the chain and peen the pins.

only need to visually check if you have peened enough (compare to the rest of the chain) and that the chain is still flexible at the peened joint (again compare it to the other links)

bushmechanic · Mar 24, 2015

some more references

http://husaberg.org/mechanical/1187-locking-bolt-size.html

http://husaberg.org/mechanical/19419-05-650-timing-question.html

the locking bolt is hiding in the 628 engines

bushmechanic said:
its in the manual found here Service Manuals - Husaberg Forum

all you need to do is align all the marks at TDC and make sure the cam sprocket marks align with the top of the head which it will be if you haven't taken the cam chain off. compression stroke or exhaust doesn't matter

the marks won't align perfectly but if you check what they look like one tooth off either side you get the idea.

if you remove the pulse coil (#5) there is a crank locking bolt underneath it

take out the hex bolt and replace it with a longer one to lock the crank at TDC both my 650 cranks were spot on tdc when locked in the 08 cases

can use a straw down the sparkplug hole to get it about right then shine a light into the hole and line up the small indent in the crank with the locking hole

if you put the timing strip in this position (as shown in pic below) its also about right for tdc

Vandor501 · Jun 30, 2021

Reviving this thread a bit..

Pulled the head to change gasket and change the chain and bearings in the process. I did manage to do it all with the clutch still in but when I adjusted for the timing I had another issue..

The flywheel seized and now I can only turn the flywheel a bit back and forth.. What direction is the flywheel supposed to be turned looking at it from the RH side?

I believe that I may have turned it a bit too much the wrong way without thinking and locked the Kickstarter gear against the clutch basked but what else can cause this?

Note: when I do turn it, it's really smooth and nothing seems to be wrong with the crank. Also I removed the connecting gear from the starter motor and still the same. Everything was absolutely fine right before I started to adjust the chain/cam for timing..

I might be able to link a video of it tomorrow.

Skickat från min iPhone med Tapatalk

Taffy · Jul 1, 2021

your starter sprague is one way so you still need the left cover off. pull the starter clutch out and it'll turn both ways again.

regards

Taffy

04-08 Mounting The Timing Chain

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