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June 28th, 2020, 08:46 AM   #1
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Piston 650 to high?

Hello guys.

Got a 650 from 2002 with a later model engine.
The previous owner did put a new piston in but could not get it running.
I did by cleaning carb but under throttle cooling fluid came out.
So retorq the headbolts and then piston started hitting The head.

Is this piston to long? Can anyone help me?

https://ibb.co/C71NRp1
https://ibb.co/r32nLxt
https://ibb.co/7RYnZf6

Also there is goo on the drainplug. What could that be.
Planning on opening the engine anyway.


https://ibb.co/y0BgBm7


Thanks in advance
Sander from the Netherlands

Last edited by SandurRx; June 28th, 2020 at 08:50 AM.
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June 28th, 2020, 01:26 PM   #2
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How do you know the piston is hitting the head?
The goo on the drain plug if you rub it between your finger tips can you feel anything bigger than a grain of salt?
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June 28th, 2020, 07:14 PM   #3
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It looks like the piston is too long to me. I would venture a guess and say the goo is probably fiber clutch plate material and that the oil was not changed and proper intervals. Even if not worn out the fiber clutch plates tend to lose their friction material with age. I think your fiber clutch plates are either very old, very worn or of low quality.
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June 30th, 2020, 10:19 AM   #4
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if the piston is only 0.9mm over the top it is not touching the head because a head gasket is 1.3mm crushed. BUT, a piston shouldn't be more than 0.4-0.5 over the top to allow for the 'throw' when revving. it certainly shouldn't be stopping the enginbe from turning over.

it is a blessing though.

what about the valves hitting the pockets?

I don't think you're being honest? why the secrecy with the camera and the cloth?

Taffy
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July 1st, 2020, 12:29 PM   #5
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So the goo could be clutch. Thanx for the tip.

Piston must be to high then. Its 1mm for sure.
Cant see marks from valves tho.

Look at the new pics. You can see the piston hits the head on throw.

https://ibb.co/KFx15cc
https://ibb.co/QvYZtpP
https://ibb.co/p21F8mz
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July 2nd, 2020, 01:17 AM   #6
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hello

you need to find out 'why'?

it could be that you have the earlier long stroke crankshaft in the engine but with a longer rod?

maybe someone has machined the cases? this one is easy to answer because the cam chain will be very slack even when new.

you need to be very accurate NOW about how much the piston is ove the top. normally Husberg pistons lean over (sadly) so 0.9-1.1mm left and right would be typical.

let me know and I'll do a real compression calculation for you.

regards

Taffy
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July 2nd, 2020, 10:42 AM   #7
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Your casing serial nr. seems odd.
They came with a printed /lasered serial nr.
Yours is stamped in.
I have never seen a 2-820 up to this point.
As they started them 04.
So
4-820 (2004)
5-820 (2005)

And so on.

Maybe a rebought new one. These came without serial nrs.


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July 5th, 2020, 06:51 AM   #8
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Thanks for your help Taffy.
Bought a new chain off you that needs to be fitted.
Donít think the Engine is machined though.

I will check how the piston sticks out when then engine is out off the frame.
Little time to spend on the bike at the moment.
You mean left and right when standing on the left side of the bike right?

They did not put a new rod or crank in the engine when the new piston was placed.
Could the piston just be to high? The previous owner did tell me the new one was higher.
I then just thought it would be a high compression one.

About the case id. I think itís a rebought 2004 one
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July 5th, 2020, 11:23 PM   #9
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No, a piston is only measured across the gudgeon pin (american english; wrist pin) otherwise it would wobble back-n-front!!!!!

when stripping an engine ALWAYS check the crank float before you strip and if seekinga blueprinted rebuild; the squish. your case may serve as a warninks (sorry!) to others that there are idiots out there.

when you stip it you'll need to measure the following.
pull the GP out as much as you dare until a vernier can sit on it and the edge of the piston. this distance would normally be 13.8mm (says he without looking in his book!).

let us know.

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July 7th, 2020, 04:57 AM   #10
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Are there no markings on the piston crown?
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