FIRST...... Im the only one who has taken this engine apart since new. I bought it new, sold it to a friend and bought it back. The bearing behind the drive sprocket went up in pieces so therefore I am doing a complete restoration.
The first two times I disassembled the engine I did it without service manual. I just used good old mecanic skills. This time I used the service manual and I ran over two things that are not similar between my engine and the manual.
1. The clutch page H36 in the manual: The manual shows 7 actuator plate, 8 thrust bearing, 9 thrust washer. My engine has 7 actuator plate + a trustwasher, 8 thrust bearing, 9 thrustwasher + a 0,4mm shim in the same size as the trustwashers. I have now removed the shim but I still use the extra trustwasher. Just want to mention it but the real issues comes now.
2. Freewheel page H38 in the manual: I have never separated the flywheel from the freewheel. I have always removed them together as a unit. Now when putting it back I can see in the service manual that there should be a needle bearing and a thrust ring behind the freewheel. I dont have any of those. It has worked flawless since it was new (180 hours) but this cant be right? The freewheel can be moved back and forth aprox 4-5mm behind the flywheel (Thickness of the missing thrust ring). Its still engaged with the bigger outer needle bearing but sooner or later this will get damaged. Did Husqvarna change something during the xlite years. Did they just ditched a thrust ring and a bearing because it wasnt needed or did they threw spare parts together in the last minute before going KTM? I can understand that the smaller inner bearing is not as important as the bigger outer one takes all force, but the thrust ring??? Do anyone know the parts numbers for the bearing and the thrust washer?
Ola
The first two times I disassembled the engine I did it without service manual. I just used good old mecanic skills. This time I used the service manual and I ran over two things that are not similar between my engine and the manual.
1. The clutch page H36 in the manual: The manual shows 7 actuator plate, 8 thrust bearing, 9 thrust washer. My engine has 7 actuator plate + a trustwasher, 8 thrust bearing, 9 thrustwasher + a 0,4mm shim in the same size as the trustwashers. I have now removed the shim but I still use the extra trustwasher. Just want to mention it but the real issues comes now.
2. Freewheel page H38 in the manual: I have never separated the flywheel from the freewheel. I have always removed them together as a unit. Now when putting it back I can see in the service manual that there should be a needle bearing and a thrust ring behind the freewheel. I dont have any of those. It has worked flawless since it was new (180 hours) but this cant be right? The freewheel can be moved back and forth aprox 4-5mm behind the flywheel (Thickness of the missing thrust ring). Its still engaged with the bigger outer needle bearing but sooner or later this will get damaged. Did Husqvarna change something during the xlite years. Did they just ditched a thrust ring and a bearing because it wasnt needed or did they threw spare parts together in the last minute before going KTM? I can understand that the smaller inner bearing is not as important as the bigger outer one takes all force, but the thrust ring??? Do anyone know the parts numbers for the bearing and the thrust washer?
Ola