Wear items amber alert

From Owner's Document

All items are generally accepted for all Husaberg models.

To confirm speciffic differences check out your bike's sector at the bottom.

Light yellow for 400/450, light blue for 470/501, yellow for 550/650.

Husaberg generic info

Alloy dowels in louvers

Loctite into frame. Otherwise they spin out with radiator sidepanel bolt. Drill louver/dowel together. Fit a small self tapper just ahead of the radiator sidepanel screw.

Weak and failing electric starter '00 - '02

For three years owners struggled with weak starters that were classified as 'restarters' and only to be used after the engine was warm. Typically the starter would spin through and not quite 'catch' the engine and batteries went flat quickly.

There was an error in the '03 parts manual whereby they simply failed to realise that the whole set up had been upgraded for that year. The parts book was corrected in '04 when Husaberg went to the present Parts # system.

WAS IN '02

9 250 247-01....Free wheel outer part 01- (outter)

10 250 245-01...Clutch mechanism free wheel 01- (sprague)

11 360 035-01...Needle bearing free wheel 01-

12 250 248-01...Free wheel inner part 01- (inner). Changed to part No.250273 for '03.

BECAME IN '04

20 800.40.020.000 .......03 FREE WHEEL GEAR 03 (outter)

24 0405 101310............02 NEEDLE BEARING K 10X13X10 02

25 800.40.025.000 ........03 FREE WHEEL HUB 03 (inner)

26 800.40.026.000........ 03 FREE WHEEL 03 (sprague)

Don't mix the 'sets' of parts! (read Engine whining ....below).

By matching the old and new, it should be very easy to get the right parts. But remember, the sprague was only 40% of the problem for owners wishing to have good electric starts! The battery needs beefing, the starter motor wants beefing and with the new starter, owners need a new mounting bracket. Then we have the modified decomp which matches a later ('03) camshaft.

Engine whines badly all the time

Mainly a '00 - '02 problem and easily fixed. whining noise Many engines will have had several new sprague clutches but some made a terrible racket! This is due to fitting the later starter free wheel hub into the earlier sprague bearing or vice-versa. The answer is simply to order the correct part to go with the rest of the set-up.

Counterbalancer Update for 2001 and early 2002 models

The single bearing counterbalancer was replaced with a double bearing counterbalancer in late 2002. Counterbalancer failures were experienced on some 650's and on a lesser amount of smaller displacement engines. A counterbalancer assembly is available to upgrade to the double bearing version. Included are: Counterbalancer, bearings, circlip and shim. The 2003 counterbalancer cannot be used as teeth on the counterbalancer sprocket have a different mesh. </p>

• 470/501/550/650-2001 use update part # 201 257-01
• 470/501/550/650-2002 use update part # 210 243-01

Starter Gear Warranty Issue Early 2001

The very first 2001 engines produced came with a very weak electric start Slip Clutch Gear Wheel. During e-starting, if the engine backfires, there is a good chance the gear will break and sometimes damage the Free Wheel Outer Part. If the engine stalls it can try to run backwards for a moment breaking the starter gear. A updated starter gear was produced and covered under a warranty programme. Most early 2001 models were updated at the dealership level or by the motorcycle owner as they all would eventually break. The upated part number 250 283-01 supercedes the retired faulty part number. Reports of the updated warranty part breaking are almost nonexistant. There are potentially a few bikes out there that did not receive the update in the U.S. as the importer discontinued its affiliation with Husaberg during this period leaving a void for quite some time. Cryogenically treating the gear will add an extra margin of strength.

Counter balance bearing

The bearing can fail on the 501/650 engines whereas the 400 gets away with it's single row because the actual balance weight is smaller and lighter giving the bearing an easier life. But there is now a solution and that is the single bearing that contains two rows of ball bearings: a kind of 'duplex bearing'. Check out the '07 parts book for this upgrade.

2006 counter balancer, one piece bearing with two ball races	also close-up. (Dr C)

This bearing is very expensive to replace, however, Ausberg has discovered that the two bearings are infact standard bearings machined down by 1mm each side to get the desired total width.

Exhaust valves on 400/470

Unfortunately when they get a bit older the exhaust valve has been known to lose it's head!

Fuse "box"

Poor quality. Find a stronger one that uses spade fuses.

Ignition wires

May break or loosen. Need to be supported at headstock or will twist and break eventually.

Clutch pipe

Knuckle will leak near cylinder. Fit braided hose variety. Standard KTM 250F fits - braided from '03+

Seat "dzus" screw

Very loose from new. The problem is that the 'dzus' screw's thread is undersize.

Brake calipers

Seizing-don't slide laterally. Pull rubbers back and copper slip 1-2 times per season.

Rear suspension

Lower heim bearing. Needs to be stripped and greased mid season or expensive to replace.

Swing arm pivot

Shaft and bearings together. Clean and use a mixture of grease and oil mid-season. Replace everything together and not peicemeal. The '04+ pin is prettier and lookout for the rubber seals, these should always be on the outside. The pins appear to be as much as .010" undersize and must be a major cause for concern in supermotard...

Stuck in gear

The selector "claw" metal is too soft. Separate the "claw" from the plate, rub away edges and burrs. '04+ is made from hardened steel and has a darker colour (Dsducati). See old and new together below:

Note the two tiny screws, the newer spring makes the shifter taller, initial attempts to fit show the longer screw and the brass collar supplied (on the right in the photo) are too tall and hit the underside/outer edge of the clutch gear teeth. So keep the original screw, narrow the head down to just the width of the dowel and re-use.

Positive HT leads

Split open in red. Replace with '03+ plasticoated clear wiring.

Grooved clutch drum

Clutch drum gets grooved badly. This stops the plates moving apart and 'free' from friction plates. The '03 had steel dowels and different 'steels. The '01 and '02s can be cheaply upgraded at replacement time.

Sidestand spring crow's "claw"

Made shorter by 10mm. Sidestand bouncing over bumps smashes into underside of tailpipe. Stronger tension on spring now increases wear at pivot bolt though.

Sidestand plates

Hole wears oval. Weld thicker steel. Shouldered bush. Right through both plates and sidestand, also bush sidestand. Whole unit is more rigid and wear area is larger and more successful.

Thick plates on the side, a bushed stand using a shouldered dowel. The hook was shortened because the stand bounced up and down while racing. Still need to do something about that eye for the spring though.

Rear brake pipe

Zip-tie to front plastic mount. Otherwise will jump out and weld to exhaust.

One cam bolt loosens

The decomp weight hits this one. Peen over the threaded bit of the bolt to secure. (Ausberg)

Camshaft profile

All cams up to '03 had aa viscious ramp that made the valves bounce as well as tulip. The cam was changed for '03. Always rebuild with the later Cam coded '000' in the parts manual.

Kickstart boss bends

Not too many of these on the little 400.

Left cover/cases wear

'02 Model: Centre exhaust section sits on the joint. Raise exhaust with a jemmy bar and pinch tight.

Broken valve spring

This can be a rare problem on machines prior to 2004. The bike is difficult to start, MAY make a slight tick-tick noise and can give the same or similar symptoms as the SEM ignition or carb troubles. This thread gives you an idea of what to look for

Broken valve spring (can be seen on the lower left) with guide seal wrecked!

Inlet valves pull/tulip

The '01 and '02s again! Seats hammer, valves pull through the seats. It will show in the tappets needing slackening all the time. You will need new valves and to have the seats "kissed". Improvements in material have stopped this completely with the help of the new cam design.

Radiator filler

Counter hold nipple when installing hose! Nipple that is pushed in will cause cap to
release pressure prematurely which causes unexplained overheating (Viking).

[edit] Husaberg 400/450 specific info

[edit] Husaberg 470/501 specific info

[edit] Husaberg 550/650 specific info