FC600 Service manual (wont start)

Trickyrich77 · May 16, 2011

Hi, I'm new to the site. I've got a '92 model FC600 (since Christmas) and can't find a service manual anywhere. I need to check the timing and valves as the Hussy wont start. It stalled last time out while green laneing and would not start again.
I've checked there's a spark, made sure the flywheel woodruff key is OK and rebuilt the carb but it still refuses to start. Any ideas?
Thanks, Richard.

RDP501 · May 16, 2011

Check here - http://www.husaberg.com/Downloads.33.8.html

I didn't see any service manuals for ones of your vintage but the motors stayed pretty much the same from '89-'00 with the '97 models getting an oil pump and the '99s getting a reversed ignition. I used to have a service manual for the early models but it went away with my '96 FE501 when I sold it. The owner's manuals should have timing specs. The valve clearance is checked at TDC compression stroke and should be .004"/.1mm (I still have the feeler guage I bent to fit the '96 501). It may not be a bad idea to put a new spark plug in it (NGK C8E or CR8E). Also, check the grounding of the ignition. I once had the voltage regulator come loose a bit (the ignition was grounded through it) on a FE650 and the bike would not start. Paritially clogged pilot jets can also be a problem and I usually replace them.

Taffy · May 17, 2011

ditto that also see a thread running on a 96 400 that won't start.

regards

Taffy

Trickyrich77 · May 17, 2011

Hi, Thanks for the info. I've looked through the manuals but I'd like to know how to check the cam timing.
The flywheel marks on my bike seem a bit odd. When the piston is at TDC with the valves closed, the two marks on the flywheel are about 70 and 80 degrees anti-clockwise of the mark towards the top of the crankcase. Is this normal?
What I'd like to do is check that when the piston is at TDC, the marks on the cam sprocket (assuming it has marks) are lined up correctly. Can I check this? The coolant pipe runs into the left side of the engine just where the cam sprocket is hiding. Is it just a case of draining the coolant then removing the top cover? This is why I was looking for a service manual. None of the ones I've found go into this sort of detail.

By the way, the bike is supposed to be an ex- Craig Pratley motocrosser. When she was running, everything seemed perfect. I've replaced the fork seals and oil, rebuilt the brakes and all of the bearings etc. seem perfect so it rode spot-on.
Is a purple frame normal? I thought they were all blue.

RDP501 · May 17, 2011

You will need to drain the coolant to remove the cam cover (if I remember right - it had been a long time since I've even looked at a motor of this vintage) and, if I remember right, there should be 2 marks on the cam sprocket to line up with the top of the head. Either that or the 2 bolts that fasten the cam sprocket onto the cam will line up. I use a dial indicator to determine TDC and don't always rely on the flywheel marks. These motors are very simple to work on compared DOHC motors of later KTMs and the Japanese bikes. They are basically a 2-stoke motor design with a 4-sroke top end.

It sounds like the frame on your bike has been re-painted as a friend of mine bought a new '92 FE350 and it seems like the frame on it was black but I haven't seen it for years.

Trickyrich77 · May 17, 2011

Thanks RDP and Taffy.
I'll let you know if the cam timing is OK when I get chance to work on it.
Does a TDC dial work on pressure? I put a screwdriver (not sharp) in the plug hole so I can see when it's at its highest point - being careful it's properly upright as you don't want it to fall and damage the piston if the piston falls then rises too quickly. Crude, but it works. Maybe I ought to invest in a guage

RDP501 · May 17, 2011

A dial indicator probe (for lack of a better word) inserts through the spark plug hole and is connected to a dial guage which indicates how much the object it is measuring moves vertically (in this case the piston, I used to use this to set the timing on my 2 stroke Husqvarnas with Motoplat ignition by adjusting the firing point x mm btdc - the 500s were 2.8mm btdc) and originally my dad bought it to time his Rokon back in the mid '70s. Dial indicators are used in machine shops, etc.

http://www.globalindustrial.com/p/tools ... gwodXna0DA

The one I have came with an adaptor to screw into the spark plug hole of 2 strokes but with the Husabergs and other 4 strokes I've used it on I have to carefully hold it in place by hand as I don't have the correct adaptor.

Randy

Taffy · May 18, 2011

RDP501 said:
if I remember right, there should be 2 marks on the cam sprocket to line up with the top of the head. Either that or the 2 bolts that fasten the cam sprocket onto the cam will line up.

No, neither. the early bikes have alloy sprockets with no marks and there is nothing about two vertical bolts that you can use for lining things up.

There's no need for a DTI, just put something smooth in the hole that locks it going either way compared to a screw in the top hole that holds the ignition cover. then as the engine gets stopped either way you mark it and halfway is your TDC.

cam timing can be done from here. just make sure the lobes look even and balanced and use a ruler across them to exaggerate any leaning. a slight forward tilt is OK on the 600.

regards

Taffy

Trickyrich77 · Jun 13, 2011

It starts!
I couldn't find anything wrong, so re-assembled, adjusted the tappets to 0.1mm, and started on about the 3rd kick.
Thanks for the help but I'm still not entirely sure what caused it although thinking about it, when I was on my last ride, the carb balance pipe snapped so I wonder if it was taking on water in the carb aswell?
Anyway, all sorted now. Cheers.

Search

Search

FC600 Service manual (wont start)

Trickyrich77

RDP501

Taffy

Trickyrich77

RDP501

Trickyrich77

RDP501

Taffy

Trickyrich77

Similar threads

Register CTA

Recent Discussions