FE400E 2001 Set-up

1. Rockers - from what I've read it seems that the 01 cam follower bearings were undersized and doomed to early failure. Solution - they need to be replaced with the 03 onwards rockers. Correct?

YES

2. Cam, the cam profile is too aggressive and results in rapid tuliping of the valves. Solution - It should be replaced by a lineweaver or later model cam? Which Lineweaver cam for the 400?

THE LX1 FOR TORQUE AND THE LX2 FOR MORE TOP END. GET THE TORQUER CAM. HE'LL NEED YEARS TO WELD IT UP. ALL LATER CAMS ARE THE SAME I BELIEVE SO PERHAPS THE ONE FROM THE 450 TO BE SAFE.

3. Balancer - Single row bearing prone to failure on larger motors but should be OK on 400. Solution - replace with later model double row bearing?

WASN'T A BIG PROBLEM BUT YES.

4. Electric starter - The starter is undersized and the cables to it likely to have poor connections. The starter gears and mechanism are prone to failure. Solution - Modify cables for better current carrying, replace gears and mechanism with later version from 07?

PROBABLY NOT A LOT WRONG WITH THE CABLES. YES.

5. Main bearings - Prone to failure. Solution - replace bearing with different type which is less critical for clearance. Ensure bearing seat is correct size. This problem seems more likely to occur on later models?

DIDN'T HAPPEN TO THE 400 AT ALL. SO I WOULD LEAVE

6.Ignition - SEM stator is affected by heat and moisture. Solution - keep stator dry. Has anyone tried connecting hoses to the stator cover so that the stators rotation sucks clean, cool dry air from the air box? Husky did this in the 80s with Jacky Mertens race bikes to increase stator longevity.

SOMEONE MAY HAVE DONE IT BUT A DRILLED HOLE UNDERNEATH WILL SUFFICE AS PER DOC.

7. Cam chain Tensioner - The tensioner runs out of travel very quickly. Solution - Replace the tensioner guide with an 03 on part. Weld an extension on to the tensioner shaft or replace with a KTM RFS tensioner?

CORRECT ABOUT THE BLADE BUT YOU DON'T WELD ANYTHING ON TO THE TENSIONER - YOU BREAK THE ALUMINIUM DOME OFF THE END.

8. Camchain sprocket - It is aluminium and wears quickly. Solution replace with steel sprocket. Has Husaberg updated the camchain sprocket lake KTM with a built in weight for the auto decompessor stop rather than a screw? If so what year model or part number?

NOT 100% HERE BUT OTHERS WILL HELP. NOT CLEAR TO ME WHAT YOU MEAN?

OK if someone could confirm those I would be grateful.

Some other questions.
Why is there a kick start activated decompressor when there is also an auto decompressor? Can I get rid of it since it has no seal on the shaft and leaks oil? YES YOU CAN. BUT USE A NUT N BOLT AS ANYTHING BONDED IN THE HOLE WILL FALL OUT.
What is the deal with the stupid o-ring on the kick start shaft? surely it will leak oil as well? NO IT DOESN'T!
Has any one machined out the cover and installed a proper seal? YES AND THEY LEAK!

I've downloaded the workshop manual bu the photo showing the setting of the camshaft/ counter balancer timing is crap, does anyone have any decent photos showing how it is done?

Sorry for the long winded post. Hopefully I'll get my questions answered and in the future I can be of assistance especially when it comes to interchangeability of KTM and Husaberg parts as I have quite a few RFS parts still and will be comparing them to see what will swap.

So far I have noticed that RFS cam should fit if you remove the water pump drive but the cam sprocket is different as the camchain has a different pitch. I think one of the rockers will interchange but I haven't measure it up yet. I also think most of the clutch will exchange and hope to update mine to the later model inner basket with the steel tubes.

WILL BE VERY INTERESTED TO HEAR ABOUT THAT

regards

Taffy

RE: Re: FE400E 2001 Set-up

we've heard nothing of a change in pitch of the chain craigy.

your '#8' is a little clearer now and it's worth pointing out that we've not heard of a single case of the nylon locknut coming undone.....

good luck

regards

Taffy

Craigy said:

3. Balancer - Single row bearing prone to failure on larger motors but should be OK on 400. Solution - replace with later model double row bearing?

Click to expand...

Do not replace with a mere later model balancer. There is a specific update part number especially for an 01.

From the Doc (I wrote this part )




Counterbalancer Update for 2001 and early 2002 models
The single bearing counterbalancer was replaced with a double bearing counterbalancer in late 2002. Counterbalancer failures were experienced on some 650's and on a lesser amount of smaller displacement engines. A counterbalancer assembly is available to upgrade to the double bearing version. Included are: Counterbalancer, bearings, circlip and shim. The 2003 counterbalancer cannot be used, as teeth on the counterbalancer sprocket have a different mesh.

470/501/550/650-2001 use update part # 201 257-01
470/501/550/650-2002 use update part # 210 243-01

More good 2001 info from the doc:


Husaberg 470/501 Models



Counterbalancer Update for 2001 and early 2002 models
The single bearing counterbalancer was replaced with a double bearing counterbalancer in late 2002. Counterbalancer failures were experienced on some 650's and on a lesser amount of smaller displacement engines. A counterbalancer assembly is available to upgrade to the double bearing version. Included are: Counterbalancer, bearings, circlip and shim. The 2003 counterbalancer cannot be used, as teeth on the counterbalancer sprocket have a different mesh.

470/501/550/650-2001 use update part # 201 257-01
470/501/550/650-2002 use update part # 210 243-01



Complete counterbalancer removal
Since the counterbalancer can be a potential source of engine failure, serious racers sometimes remove the counterbalancer completely to eliminate the hazard. This does result in more vibration at idle and at very low RPM. In place of the counterbalancer a 7.4mm spacer ring should be used. The balancer drive shaft gear teeth can be ground off. Set crankshaft axial freeplay to 0.6mm-0.8mm. Use main bearings SFK NJ206ECP/C3. The crankshaft can be rebalanced if desired.






Main Bearings
The crankshaft has ball bearings for models 2001-2002 and roller bearings for model 2003. Use same as 2003, (2) SFK NJ206ECP/C3. Option, substitute left side bearing with SKF 6206C3/TN9. Heat the crankcase half to 200 degrees centigrade to facilitate bearing removal




Connecting Rod
Check for cracks on early 2001 models.




Rockerarms
2001 and 2002 Rockerarm roller bearings are subject to premature wear and failure. The 2003 Rockerarm assemblies are of a slightly different design and last longer. Replace the entire rockerarm assembly with that of the 2003 version. Future roller bearing changes can be made without replacing the entire assembly.

Rockerarm intake complete 2003 P.N. 200 330-01
Rockerarm exhaust complete 2003 470/501/550/650 P.N. 200 331-02
Rockerarm exhaust complete 2003 400 only P.N. 200 331-01



Starter Gear Warranty Issue Early 2001
The very first 2001 engines produced came with a very weak electric start Slip Clutch Gear Wheel. During e-starting, if the engine backfires, there is a good chance the gear will break and sometimes damage the Free Wheel Outer Part. If the engine stalls it can try to run backwards for a moment breaking the starter gear. A updated starter gear was produced and covered under a warranty program. Most early 2001 models were updated at the dealership level or by the motorcycle owner as they all would eventually break. The upated part number 250 283-01 supercedes the retired faulty part number. Reports of the updated warranty part breaking are almost nonexistant. There are potentially a few bikes out there that did not receive the update in the U.S. as the importer discontinued its affiliation with Husaberg during this period leaving a void for quite some time. Cryogenically treating the gear will add an extra margin of strength.




Transmission
The transmission was modified with a different tooth profile between 2001 and 2002. The easiest way to determine how the engine was built is to look at the counter balancers' drive shaft. The early shaft has a straight surface and the later one has a diameter change between the position for the timing sprocket and the drive gear (tapered).

The following gears are not interchangeable between 2001 and 2002/2003: Counter balancer, balance drive shaft, drive gears on balancer drive shaft and crank shaft and also the outer clutch basket.