Sprocket spline stripped :( :(

I'm about to order all gaskets and tools I need to split my engine. If you can wait a few days I can share the list as I have to look through the workshop manual and do the job on paper first to make sure I have everything before I start.
There is a complete gasket set, but that is not necessary for you so you can save some money.

For your information you will more or less take apart the whole bike.... To get the engine out you need to disassemble everything but the steering head with forks. So if you want to get started while you wait for my list you can start with that job. When you know how to do it you can do it in one hour, but it takes more time the first time.
I suggest you really pay attention to how the loom is routed, specially under and around the battery box. Take pictures. Also when you have the loom out spend some time with it and look for damaged cables and corroded connections.

Google this and you will find. ktm 81730099000

There is no gasket between the engine cases, Loctite 5910 is to be used.

I have one kit already home. It's a full kit and OEM. I have opened up the side cases a few times and removed the cylinder on one of my engines. But now I am about to split the cases on one.

This is a good site. It's a swedish site (store is 1 h from me) but the parts names are in english and you can find part numbers. HUSABERGSHOP.se - Reservdelskatalog - FE 570 AUS 2012 (2012)

I guess what you need is 78033010000, "COUNTERSHAFT 08"?

Stay away from super hardened sprockets tham claim twice the life. They are harder than the shaft. Would rather replace a 20 dollar sprocket.

octopusenvy said:

nice when shop is 1hr away in the home country! I will hunt the countershaft 08 as i believe u are correct, thank you. Just have to get one to me, and then split cases. I would very much like a list of what you do on paper (or in an email or pdf)...this would help me a lot and earn the best swedish beer when i visit or our finest NZ drink if u ever come here.

Click to expand...

If you go to the owners docs you will find good info under strip and rebuild.

Did you use the JT series or the MX series front sprocket ? Just so the viewers know what to stay away from. It really sucks knowing you used a great product only to have it damage another part.

This is what I figured out, and is partly based on a discussion with a good Husaberg mechanic.

I attached parts of the workshop manual. I zipped the folders and renamed them to .pdf to be able to attach them. Rename them to .zip or just open them with winzip, 7z or similar.
Below are my notes after reading through the workshop manual. As I never done the job yet I might have overlooked or missed something. But it should hopefully make your job a bit easier. If any other guys have some input/experience it would be nice to know. Regarding special tools, there are many ways and other tools that can be used, but sometimes special tools are just more convenient. I will do this job in the future too.

View attachment 20 DISASSEMBLING THE ENGINE.zip.pdf
Page 129. Engine work stand (61229001000) - Not worth it I guess
Page 129. Fitting for work stand (81229002000) - Not worth it I guess
Page 131. Crankshaft locking bolt (113080802) - Not needed, remove the copper washer from the existing bolt and screw it back in.
Page 133. Extractor (58012009000) - I will purchase one
Page 135. Gear quadrant (80029004000) - Unless you have a cog to sacrifice to make your own tool I guess it can be handy to buy one. But a copper coin might as well work?
Page 136. Clutch holder (51129003000) - Not an impressive tool. Make your own. (I will sacrifice two clutch disks and screw them together so they lock everything)
Page 136. Extractor (75029021000) - I will purchase one
Page 139. Puller (75029048100) - I will purchase one

View attachment 21 ENGINE - WORK ON INDIVIDUAL PARTS.zip.pdf
Page 154. Preparing the timing chain tensioner
Page 163. Work on the countershaft

View attachment 22 ASSEMBLING THE ENGINE.zip.pdf
Page 167. Mounting sleeve (78029005100) - Not needed unless you removed the crankshaft
Page 172. Use new lock washer. Retaining plate (77332018000)
Page 174. Use new lock washer. Tab washer 08 (78030068000)
Page 178. Release device for timing chain tensioner (77329051000) - Use whatever, no need to buy

Two other parts that can be of use for you:
View attachment 31 TECHNICAL DATA - ENGINE TIGHTENING TORQUES.zip.pdf
View attachment 42 SPECIAL TOOLS.zip.pdf

I been adviced to use Loctite 2701 instead of 243 inside the engine. Not worth the risk having loose parts inside..

Tools I will buy:
Extractor (58012009000)
Gear quadrant (80029004000)
Extractor (75029021000)
Puller (75029048100)
Mounting sleeve (78029005100)

Parts I will buy:
Gasket kit Husaberg (81730099000)
Retaining plate (77332018000)
Tab washer 08 (78030068000)

Hope this help. I will try to upload the complete workshop manual somewhere.

jon andersson said:

This is what I figured out, and is partly based on a discussion with a good Husaberg mechanic.

...

Click to expand...

YES! Thank you!!!

Oh! Hey - The '09 shop manual is here: https://drive.google.com/drive/folders/0B_X2MDkeGC0hNDRubmdrOEV2Rms

Get a file and see just how hard the shaft is.

I might do that, could be fun to document the process. A lot of work so no promise but I will for sure consider it.

tourist thank you for that link! I had some memory about that but wasn't sure. Btw, didn't you split your engine or do I remember wrong?

Not yet

OCTOBRO.... there is a bloke in Waiuku by the name of Gurnad Giesler (not sure of his shop name) who has Plenty of knowledge and experience on earlier Bergs. May be of some help to you.