Help ! - 2001 FC engine issues

Gidday all me old buddies on UHE - its been a fairly long absence from the site, but pleased to report that the happy little family of 2 Bergs (and me) have been running relatively smoothly.

I was just dropping back to look for a fix for a sticky / jammed gear shift - and of course found some background reading, which I'm sure will get me into the picture (when Taff sounds sure of something, its gotta be ya first port o call)... Also its worth highlighting the importance of reporting back on your tech posts and giving everyone the benefit of your experience - did the fix work? was it something else? what did you observe?

Anyway, thanks again guys !!

Whats the feeling on here about the falling of the 70 degree Bergs?? felt like a pretty sad day to me...

Azza.

Re: Gidday !! - gear shift claw

Hi again all,
can someone please point me to an image of the maintenance work that one does on the gearshift claw when having shifting issues - the link in the doc http://www.husaberg.org/modules/gallery ... .sized.jpg from in the 'wear items amber alert won't load up.

Cheers!

Azza.

Re: Gidday !!

Okay, so for the record - and anyone else's benefit - this is what the shift fork is meant to look like (from another post on the site)

download/file.php?id=1678

and (attached) is what mine looked like when I opened the side up - its clearly jammed, and not driving the selector around on each shift.

so its time for me to de-burr the fork plates.

Azza.

Okay, so this has officially turned into a call for help -

After sorting my gearshift issue out and re assembling the clutch, I tried to turn the engine over through a couple of cycles by hand, but found it jammed up tight. I think that the synchronisation between the primary crankshaft gear and the balancer & timing drive gear has shifted.

The 2001 - 03 workshop manual says to align the marks on the primary crankshaft gear (I have these) with the mark on the countershaft drive gear (I dont have any marks on this) before torquing the nuts.

I have not had any of this apart - so the relationship between the timing chain and the balancer has not altered.

The manual tells me how to align the primary gear (thus the crank), which is fine - but I am not sure how to properly re set the countershaft drive gear before reinstalling the clutch basket.

I am also assuming the lock up I experienced while trying to turn the motor over by hand is likely to be the counter balancer coliding with the piston?

Please help

Cheers!
Azza.

It was either piston / counterbalancer or piston / valves - I was working on re timing and got a distinctive clunk at the valves, so I am sure it was piston and counterbalancer the first time.

I have positioned crank for TDC (using maks on the primary crank gear) and positioned the cam and balancer according to the valvetrain as there are no marks on the balancer primary.

I am yet to pull the balancer primary retaining nut off and do the 14 tooth countback to be sure and then will mark that gear for future reference.

I will update (or yell for help again) as I go on..

Thanks Ned & Taffy.

Cheers!

Well... the 14 tooth countback didnt work, but using known points of reference, I have re established the synchronisity between the crank, the balancer and the valve train.

The timing mark tooth for my counterbalancer primary is a long way past 14 teeth, however, I assume that it has been rebuilt in the past and that the installation of the counterbalancer drive shaft was not aligned to the marks, thus the keyway was not in the position referenced in the '14 tooth countback method'...

hopefully when I kick it again, it goes brum.... not bang...

Azza.

Okay - She is alive !! :cheers:
Notes to remember -

* mark everything with a paint pen before you pull it apart !!
* dont take for granted that there will be timing dots (if they werent there when you pulled it apart, they wont be there when you put it back together).
* if the counterbalancer drive isnt aligned inside the cases (more dot to dots) then dont expect the keyway on the outside of the centrecase to represent anything !
* get the kickstart shaft right before gak-ing the gasket and fiting the side cover... :cuss:
* keep the basics in mind - TDC is always TDC
* shed time is cheap - compared to bent valves and other broken bits... best to work through confidently and thoroughly...

Azza.