Engine rebuilt - set up issue- HELP needed!

Tempest · Apr 22, 2015

Hello Guys

once again I have to ask you for help and advice regarding my Husaberg 501 '97.
Engine is now after a nearly coplete rebuilt but it did not start at all.
Seems to be an issue either with parts or set up. It kicks back while using kickstarter and does not start. The obvious issues triple checked and no ideas how to proceed further.

Below I place a picture with two marks on SEM module. At this point is Upper Dead Point of piston. insert on crankshaft is then on 15:00 hours, valve sfaft
is set on marks as well and in this posision cams are 180 degres versus ,,pushers'' means engine is in working position.
In reality only ignition setup should be done and this seems to be an issue (if above description is right - which I hope is).
So here comes the trouble -we fight with this for several days with no positive result.

One more thing is bothering us as well there is no mark on stator as shown in owners manual ?

Does anoone have idea what to do to make this machine running.

I hope you guys have some ideas.

Thanks in advance

jmscrttndn · Apr 22, 2015

First thing that comes to mind is whether the timing is correct (on cam chain). You said you triple checked all the normal stuff, so hopefully you looked here.

Next, maybe the kickstarter itself is messed up. If the 97 is anything like the 05, the kickstarter shaft is very easy to unseat when installing the side case.

tourist · Apr 22, 2015

is the stator orientable at all? and thus timing?

berglsmerg · Apr 22, 2015

Is the stator working and is the Flywheel key intact ?

husabutt · Apr 22, 2015

This looks like the timing mark on the stator to me?

husabutt · Apr 22, 2015

These look like the timing marks on the flywheel.

As yours is the kick start model align the mark on the left with the mark on the stator.

jampe · Apr 22, 2015

-99

It`s a -99 engine on your picture. do you have the right coil to it?

Regards
Jampe

husabutt · Apr 22, 2015

If you put the stator on the cover in the middle of the adjustment range it probably should have at least started.

Check your stator with an ohmmeter:

Red and black 3000 ohms
Green and black 168 ohms
Both yellow wires to blue less than 1 ohm

If the stator values are O.K. and the ignition timing is set correctly then your cam timing is off. One tooth off can cause problems.

How did you determine that the piston was at top dead center?

Did you purchase a steel 04-08 cam sprocket or did you end up drilling the aluminum one of unknow origin that you had?

I recommend using the dead stop method of finding TDC. Its very easy to use and you don't have to rely on marks somewhere that may not be correct or eyeballing a zip tie or screwdriver sticking out the spark plug hole (although many do this successfully).

Before you take your motor apart you can use the dead stop method to help determine what marks are what on your flywheel.

To use the tool insert it into the spark plug hole while the piston is on the compression stroke. Slowly turn the motor over until it stops against the TDC tool. Use a felt marker pen and mark the flywheel and case at about the 10 o'clock position. Turn the motor around in the opposite direction until it stops again against the tool. Mark the case only where the flywheel mark is. Use a straight edge, ruler or wooden paint paddle (sketchy but I have used one) to guide your marks from the flywheel to the engine case. Remove the tool. Then simply split the difference between the two marks and that's where TDC is when the flywheel mark is right in the middle.

I used this method just this weekend on my wifes Yamaha YFZ 450 Quad. It had no flywheel marks because I installed an aftermarket flywheel and the cam timing came out right on the money after I removed the cams to do a valve adjustment.

So yes I am really sold on this tool as it raises the accuracy bar a notch or two.

APE - TOOLS

husabutt · Apr 22, 2015

jampe said:
It`s a -99 engine on your picture. do you have the right coil to it?
Regards
Jampe

I agree. Its a 99 or 2000 not a 1997. The blue tank and frame lead me to believe its a 2000. Hard to tell from the avatar. Same ignition on both. 97 had a different ignition.

In the 98 and earlier pdf does anyone notice something that does not belong?

jampe · Apr 23, 2015

The -00 have hydraulic clutch so it is maybe an mix of parts from different bikes.

husabutt said:
I agree. Its a 99 or 2000 not a 1997. The blue tank and frame lead me to believe its a 2000. Hard to tell from the avatar. Same ignition on both. 97 had a different ignition.

In the 98 and earlier pdf does anyone notice something that does not belong?

Tempest · Apr 23, 2015

Hi Guys

thanks for some tips and hints so far. We are going to check them tommorow on the bike.

Just to explain my engine should be '97 but some elements on the bike are newer- Frankenberg I'm afraid.

So far we are confused as the ignition in hole range does not give any good set up. Engine works but it has no power and it just does not sound right.

This lead us to idea that perhaps we have ,,one tooth'' timing issue.
Sounds to us that ignition is way too early.

If you have any more advice for us I would really apreciate.

Thanks

Tempest · May 7, 2015

Hello Gents

Investigation continues.
We have managed to start up engine - rinning quite smooth but....

Yet we have an issue.

As I've mentioned in previous post we had no luck with standard set up of the ignition equipment.

Using the whole range of regulation we could not manage to find satisfying set up to start the engine no matter what we tried.

According to our observation ignition was happening too early therefore firend came up with idea to increase ,,range of set up'' by turning the outer cover around 45degree towords front of bike. Cover was fixed to engine case using some ,,special'' fixture and it started immidiatelly and was running smooth.
This indicates to us that either the whole thing is not from Husa or there is something else wrong.
Our suspicious is that a flywheel has a cut out in wrong orientation. Are we right? Anyone has any idea what can I do to make it works?

Please see pict one with sketch how my unit looks like.
Second picture - how the engine inside - no mounts for coils

Tempest · May 7, 2015

Please find what I have currently on my engine.

As stated above - in ,,normal'' seting no luck to get it started
While turning the whole ouside cover 45 degrees front - engine runs perfect but of course you can't ri de it like this as there is no chance to mount cover into desired holes in the engine.

Can someone tell me what I have it wrong?
We thing that flywheel is from LC4 KTM
If this is right is ,,orginal'' husaberg flywheel different regarding ,,marks'' vs. cut out which could explain this phenomenum of 45 degree rotation ?

PLease help.

Thanks

Tempest · May 7, 2015

and the cover picture for the end.

husabutt · May 7, 2015

The engine seems to be a 1999. You may have a 89-98 stator or a 01-03 stator. I don't know what the differences are in the stators but I think I think that you may be finding out first hand. Can you post some pictures of the wiring coming out of the stator (unplugged)? This may help identify which stator you have.

bushmechanic · May 7, 2015

is it possible for you to attach new tabs or mounting points in the required position ?

that is what I would do.

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