Are you trying to split the main cases ?

single track, on 21 April 2012 - 12:56 AM, said:

That is correct. The LHS to be specific.

I've got a feeling that the timing chain sproket will need to come off. It's the only thing I can see that would prevent the cover from coming away. It looks like there is a bearing or something behind the sproket that must be on a tapered spline.

Before it gets ugly I suggest downloading the 2009 workshop manual from http://husqvarnaoutl.../repair_manuals - I don't think the motor changed much (if at all) for 2010.

Oh, the nut on the primary drive gear (which you haven't got to yet) is a left hand thread.

Good luck mate!

Edited by 7point62, 21 April 2012 - 05:41 AM.

Are you trying to remove the clutch cover assy, the case with the oil filler and oil window in it? Or are you trying to split the main cases to get to the bottom end? If you are going for the bottom end you will need to remove the clutch basket, gear shifting mech, primary drive gear plus some other stuff.

Yeah, it looks like the O.P. is trying to split the cases without disassembling the clutch side. That's why I recommended the workshop manual.

7point62, on 22 April 2012 - 06:11 AM, said:

You don't actually need to remove anything from the clutch side to split the case on the gearbox side (LHS). I found that what was stopping me was infact the timing chain gear/sproket.

Anyway, after splitting the case I inspected all the oil channels to see where the mysterious washer could have come from. Of course in typical fashion I couldn't find anything so had to keep searching.

With my workshop manual in hand I decided to completely strip the engine to the last piece and find the missing puzzle.

3 hours later and I could not find ANYTHING missing. The gearbox was perfect, no missing washers there (which was the most logical explanation). I then moved onto the clutch side and again, found NO missing parts.

Totally baffled I am now in the process of reassembling the engine. While I had the cases off, I turned the engine while in gear to check for any unusual play; could not find anything what so ever.

Only thing I can think of is that by some fluke of nature, a washer fell into the engine durring production and it was just floating around until one day, a perfect storm event caused the washer to be mangled. Honestly I wouldn't expect a piece like that to last very long in there, but it all depends on where it was wedged. It is only a hypothesis but I have no other explanation. Every part on the engine was checked against the manual drawings with no missing parts to be found.

The cylinder and piston are in perfect condition with no scouring or damage. I cannot find ANY damage internally other than the17mm bolt on the crankshaft as shown in my previous pictures. Maybe a washer was placed there and it got damaged, it's the only place I can see that kind of damage. According to the manual, there should be no washer there.

Anyway....I will report once I've got the engine together ang back on the bike. Will be a few days at least.

Wish me luck.

Edited by crazynuts, 22 April 2012 - 03:58 PM.

oh......   I  didnt see that one coming........
I thought it was the race off of a bearing ....... this book just keeps
getting better ....
please keep us informed  

kim

honda4oo, on 22 April 2012 - 05:15 PM, said:

Well Kim, this is the last page of the book and the mystery remains unsolved.

I put the engine back together and mounted it to the bike, reconnected all the plugs, cables, cooling system etc and filled the engine with oil. Last bit to go on was the fuel tank; I was ready to start the bike. Connected the fuel line, put the key in the ignition followed by a mumble of "you better start ya bastard". Turn the key and........

....not enough fuel in the tank. Pump dry.

Trip down to the local servo and 5L jerry can in tow I came back and repeated my good luck dance.

I was kind of crapping my pants at this stage as it was a moment of truth. This was either going to be a success and my theory of a washer floating around is sound, or this will end up with me taking the whole bike to a mechanic with my behind lubed up ready for the ramming (cost).

So anyway, turned the key, clutch lever in and pressed the red go button.

bwop bwop bwop.....bwop bwop bwop.....Braaaaaaaaaaaap pa pa pa pa pa pa pa pa pap.

YOU BLOODY BEAUTY!!!!!!

I am now left with a feeling of great relief but filled with a wealth of knowledge. I now know the bike inside out (quite literarly) and it was a good time to conduct a yearly clean of all the suspension components and tightening of the bolts.

So in essence, this is one of those "movies" where it goes to black just before the ending, and you are left wondering what the heck all of that was about. For me it's a happy ending if a little lackluster in a conclusion to the issue. Either way I'll be back on the saddle in the near future with hopefully nothing but good news to report.

hey husky (BMW) take note of this post...... and take it up with the q&a- q&c people at the next pep talk
meeting at the beginning of the shift .
thank you for the post ,I'm sure that you will get a ton of miles on your ride now before you will
need to tear it down again  

kim

Wow, amazing, I feel good for your result, did you ever get a look at the crankshaft bearings?  Keep us updated on this thread.  BTW, you are not the only one to find weird stuff coming out of your bike.  I found this stuck to my drain magnet on my FIRST oil change over a year ago.  I decided against tearing it down and just rode it.  8000 miles later, all is good and I still don't know what the piece is, although it looks like the end piece from an oil pump strainer tube.