1998 FC501 Stopped Dead

Hey Allister,

In my short experience with Husaberg motors of this era, I have opened up 3 ('96 350, '98 400 and '96 501)and in all of them there were serious or potentially serious issues with the kickstart sledge, the half moon shaped piece of metal on which the kickstart keys slides until it engages with the kickstarter gearwheel.

The two countersunk screws that hold the sledge in place tend to work there way out, have their tops ground off by the back of the gear wheel, or worse, snap off and then find their way into gears etc. On the 350 one of the screws had sheared off and had taken two teeth off the clutch hub, which in turn had rattled around and taken teeth off the crankshaft gearwheel. On the 400 and the 501, the screws were finger loose and well worn and the sledges were very worn.

I wonder if in your case something similar has happened. Seems odd that the kickstart lever won't move, as even if the motor was locked up, it should still move down until the kickstart key engages in the back of the kickstarter gearwheel.

Unfortunately the only way to check the kickstart sledge/screws is to pop off the clutch cover, remove the clutch and kickstart gearwheel. Worth checking one day anyway, not a major, a couple of hours work and can be done with the motor in the frame.

I replaced the kickstart sledges - Nigel Bevin in Taupo has them but they may need to be milled thinner, as the later ones he has are thicker than these earlier ones and don't allow the kickstart gearwheel to slide in properly (rubs on the sledge). I replaced the screws with stainless steel hex head countersunk screws, torqued in and Loctited.

Where in NZ are you?

Cheers, Tony.

Titirangi, Auckland
New Zealand

1996 - FE 501
1998 - FC 400
1996 - FE 350 and 600 (motors only)
1989 - ATK 250

I would pull the clutch cover off and inspect the kickstart mechanism and gears. I would suspect that the gear broke and a piece fell in and locked the clutch and primary gears.

Hi Tony.

Down here in the Deep South. Mosgiel actually.

A few local guys down here have them, and I joined the list of guys a couple of years ago.

Have enjoyed the hugh lumps of power these things generate, compared to the older DR440!!!

I'll try and take a look over the course of this coming weekend.

Thanks for your reply. Very helpful.

Keep in touch.

Allister

Hey Allister,

Good luck with that, certainly sounds like a tooth/screw or something is jamming up the kickstart/clutch/primary gears. You will soon know when you get the cover off and clutch hub out and see what moves (or not !!).

Give me a call (021 689 092) if you want to have a chat about it.

I have a copy (electronic file/pdf) of the 1999 Shop Manual which covers all the steps to a motor/clutch/fuel system tear down/re-build, which could be handy. PM (not sure how you do that) or phone me and let me know your email address and I can send you a copy.

Call me over the weekend if you discover you need a part (gear, kickstart sledge etc.) as I am catching up with Nigel Bevin in Taupo, who has parts for the earlier Bergs.

Cheers, Tony P.

get that left cover off and remove the clutch. from that you can check if the crank will rotate or the gearbox kickstart will rotate.

camchain might be another one = snapped. kickstart is a good one as well.

it's very do-able even for a novice mechanic so i would say: go for it.

regards

Taffy

Hi guy's.

Thanks for the response. I'll get that cover off this weekend and keep you posted on what I find out.

Cheers,

Allister

HI boys. just thort i would say hi from a fellow kiwiberger as i scanned on through.

mine did that yesterday, rode it to my garage, then stripped the carb tried to restart it turned free for a sec the locked up,
turned out to be the decomp on the kick start, i just roled the bike backwards while in gear, sorted it

it may not be the right thing to do here, worth ago ???????

sms