Husaberg 600fe 1993 stuck in gear. ?

happier · Jun 20, 2015

Hi all had first break down with berg today ;( gears started getting stuff then stuck in 3rd gear drained oil looks okay took clutch cover off can see selector fork it's moving but selector barrel seems seized any ideas before I go further in and I change oil ever time out so not lack of maintince

huscan · Jun 20, 2015

I have had this happen twice on my 1995.
In my case I took off the gear selector mechanism spring loaded doomahicky and literally played around with it for an hour while I was watching Tv and noticed it would stick about once in every 100 or more movements. I then filed down some edges smooth and it is now 100% fixed.
I think there is info on this website somewhere regarding this.

happier · Jun 20, 2015

Hi pal thanks for that just Gina go take clutch basket off and have a look at the mech nisam
It looks jammed up when shine torch in i have clutch casing off is there any thing I need to watch out for take clutch basket off ?

bushmechanic · Jun 20, 2015

gotta make sure the kickstart shaft doesn't move outwards at any stage or needs to reset the kicktart return spring (get a helper to push it in as you work on the case removal)

I had the same problem in my 02 but since i know the parts were nice and smooth I put a stiffer spring on the plate instead

post #159

http://husaberg.org/mechanical/17998-bushmechanic-mongrel-628-trailbike-16.html

happier · Jun 21, 2015

Hi thanks for advice had a look at I tonight and it defo needs to come apart the engine I mean. took of gear slector mech And try moving barrel by hand it too a bit to get it moving but it keeps going tight about 3rd 4th so think it's termina gearbox prob

bushmechanic · Jun 21, 2015

nasty.. 3rd and 4th are the main weakpoints in the gearbox

be sure to try everything a few times before taking the engine apart though

check with orangeberg for parts if needed (see links in my signature)

happier · Jun 21, 2015

Thanks again mate I'll tread carefully don't think gears are damaged think there is some thing like a bearing or shaft gone as was still driving in all gears just when I parked it up it stuck in 3rd gear ? Also I'll need to mark the timing on Tdc any tips for striping it witch side would I leave gears in when split ie left or right casing

clad its out now as I never built the motor and always weary of other people's work so I can get good look inside and gone paint up the motor

bushmechanic · Jun 21, 2015

the RHS case can be removed while the box stays in the LHS .. tap the shafts back in as the rhs case comes off, selector fork shafts may move but thats OK

factory manuals can be found here

Service Manuals - Husaberg Forum

happier · Jun 23, 2015

Hi does any one know were I can get flywheel puller or know the thread size cheers

Taffy · Jun 24, 2015

here fella

Taffy

happier · Jun 25, 2015

Hi guys got it apart a friend came and took fly wheel off for me with a puller this is all I could find wrong the selector barrel seams to be binding up on the casing and has left a ring on the barrel

Taffy · Jun 25, 2015

have a look at the selectro fork. where the sliding plate and the rocking base plate keep hitting the selector drum pins they bludgeon the noses left and right making the claws wider than the rest of the plate at those 4 points. you need to file the bludgeoned sides off so the plates pass each other.

if the selector drum has two circlip grooves then get another sirclip for the second groove. this will hold the drum still all the time. make sure the ball bearing can't move in and out. there used to be a location screw there somewhere if I recall?

regards

Taffy

happier · Jun 26, 2015

Hi Taff have looked at drum there is no circlip groves at all ? It sits in needle roller bearing on clutch side and just sits in bare aluminium on out out shaft side only thing I have noticed is that some one has held coiled the oil drain plug and it comes in next to the barrel on right hand casing I'll post pic when I get home is there an updated barrel off newer model I could fit or are they different

Taffy · Jun 26, 2015

they are different later. none of this is insurmountable. stay cool!

Taffy

happier · Jun 26, 2015

Here is pick of what has caused the problem

bushmechanic · Jun 26, 2015

rens found the oil strainer had buckled and was pressing on the drum = shift issues

the thread in your lower LH corner looks a bit dodgy and very close to the drum bore

happier · Jun 27, 2015

Yeah it's because they have striped oil drian plug and have ree sleeved the hole with overvsized thread it's a balls up do u know any one who might have second hand casing ? Right side ?

if not was Gina get a sim washer on end of barrel were the line is and get barrel turned down the thickness of shim then it won't be runing on that thread

bushmechanic · Jun 27, 2015

sounds good, that ought to fix it nicely

Orangeberg had older cases maybe check with him .. link in my signature

happier · Jul 1, 2015

Hi all got barrel machined and sim for it planing rebuild at weekend any one know the torque settings in nm for the head /barrel nuts

bushmechanic · Jul 1, 2015

Service Manuals - Husaberg Forum

http://husaberg.org/service-manuals/20310-1999-pre2000-husaberg-engine-repair-manual.html

44N.m

50-60 should be Ok .. i use 100 on my 08 with HT studs and 60 on the 02

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