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Removing the clutch basket, timing...

S

SuperMotoMike

Joined Aug 2007
202 Posts | 1+
Maryland - USA
When replacing the stupid water pump seal (again) the kickstart shaft popped out of place (again). I marked the clutch basket, crankshaft gear and top timing gear with a sharpie so I when I put it back together I could get everything aligned and timed correctly.

When I pulled the clutch basket the top timing gear spun about a quarter turn. What is the best way to get it back into the proper place to reinstall the clutch basket? The timing mark is pointing straight down towards the crankshaft gear.

Can I simply move the crankshaft gear into the proper TDC alignment without damaging the valves or do I somehow have to move the valve train back a quarter turn? I'm a little confused...

Oh, also.. I found the little E-Clip that hold the oil pump gear on the shaft mangled on my oil drain magnet! Anyone know what size that is? Its item #8 on page 59 of the 06 parts manual. I can buy those little clips locally if I know what size I need.

Thanks in advance!

Mike
 
Just align gears as per below drawing. Therer is also good info in the Docs's under "strip & rebuild"

You cam probably spun cause it was pressing on a valve when you removed basket. Dont worry, just align them marks as per drawing and put basket back in.

The kickshaft can be a bit tricky to get back in, explaining how to do it even more tricky.

Anders, DK
 

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Thats what I thought but didn't want to damage the valves by turning the crank. I know all about the kicksart shaft, I've been down that road before!

Thanks!

Mike
 
Good.

If your camgear moves by hand, the valved are closed, so no danger. I think the piston will not hit them even if they where open, but I don't know for sure. Someone else will know.

Anders, DK
 
Good.

If your camgear moves by hand, the valved are closed, so no danger. I think the piston will not hit them even if they where open, but I don't know for sure. Someone else will know.

Anders, DK
 
When I pulled the clutch basket the top timing gear spun about a quarter turn. What is the best way to get it back into the proper place to reinstall the clutch basket
Click to expand...
i would just put a wrench on the cam gear and with the clutch and crank gears at your marks, turn it and plop it in
 
SuperMotoMike said:
Oh, also.. I found the little E-Clip that hold the oil pump gear on the shaft mangled on my oil drain magnet! Anyone know what size that is? Its item #8 on page 59 of the 06 parts manual. I can buy those little clips locally if I know what size I need.

Thanks in advance!

Mike
Click to expand...
Are you sure that the e-clip is from the oil pump?
When the camchain gets old it might rub against the side wall and make the e-clip come loose.

http://www.husaberg.org/index.php?name= ... highlight=


/Nick
 
Ghost said:
SuperMotoMike said:
Oh, also.. I found the little E-Clip that hold the oil pump gear on the shaft mangled on my oil drain magnet! Anyone know what size that is? Its item #8 on page 59 of the 06 parts manual. I can buy those little clips locally if I know what size I need.

Thanks in advance!

Mike
Click to expand...
Are you sure that the e-clip is from the oil pump?

/Nick
Click to expand...

Yeah, I'm sure.

Thanks,

Mike
 
The way to do this is to have the marks lined up at TDC on the comp stroke before taking the clutch basket off, so there should be no tension in the cam gear train cos both valves are closed. You were some where off TDC on the comp stroke with a valve open and the compresion of the valve spring closed the valve and turned the cam.

You say the cam gear mark is pointing down toward the crank. So your valves are closed and the cam gear mark is where it should be (roughly). Now you need to move the crank to align the crank gear marks with the cam gear mark.

Question is; are you at TDC on the comp or exhaust stroke when you re-align the marks and does this matter for the ignition timing?

http://www.husaberg.org/index.php?full= ... _photo.php
 
Yeah, I was thinking I should have put it at TDC before taking the basket out... So now how do I tell if its on the compression or exhaust stroke? My top gear looks just like your pic, with the dot pointing down.
 
There is only 1 TDC when cam is not in the equation (Basket off). So with the basket off, dots aligned, and you turn the engine 1 rev, that dot is then aligned again..... same same. So the answer is just to put the basket in.

Anders, DK
 
And for the ignition, you question makes sence now. But this engine does not care, it sparks at every TDC. Waste of perfect sparks isn't it ??

Anders, DK
 
OK, got it! I'm just going to align the dots and put the basket back in. After I get that stupid kickstart shaft back in place :wall: ...
 
SuperMotoMike, put the kickstarter lever back on and crank it down about 1/4 turn. It should pop straight back in. Had the same problem with my 07 FE550. Just push on the end of the shaft when you go to re-install the clutch cover & all good.
 
Got it, thanks! I'm getting to be an expert at it... Two things I LOVE about my berg: 1. Water pump seal 2. Kickstart shaft NOT!!!
 

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