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July 10th, 2009, 02:28 PM   #1
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blown FE400 :( pics added

Hi,

I am rebuilding my FE400 because of the chronic top end problems and other issues after 9 months I got it second hand. Actually I have not been able to drive it for long due to recurring mechanical problems. Recently I take the cylinder head off and the picture was depressing. You can shake the piston in its sleeve almost 0.8mm(I didn't make measurements yet) in each directions. I think this is due to stuck oil pump because of shavings through the oil line before filter. There was no oil screen on the oil drain plug when I got it. Previous owner was a complete idiot. I had fixed the oil pump after I reliazed it in weeks since I got it but it was too late..Thus the story ended up with blown engine long before I got it I think. I still wonder how it held and still was running nice. To cut it short, I fortunately managed to find a parted out FC470 auction on ebay and got 100mm piston sleeve BV head and valve cover with rockers for BV head. So I had to convert it to 470 but I don't have the crank and counter balancer for 470. I think I can reuse my crank and balancer although there is slight difference as Taffy has mentioned before on the forum. My question is whether it is possible or not? I will change the bush on little end. I wish big end is fine at least..
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July 11th, 2009, 03:32 AM   #2
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RE: blown FE400 :(

No comments?
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July 11th, 2009, 08:18 AM   #3
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RE: blown FE400 :(

thats a tough one to answer for anybody that hasn't done it already. i'm sure its possible, just don't know how much work will be necessary to make it happen. the c/b will prolly be ok, but you need to make a list comparing all the dimensions of the two and compare them. GET TO WORK
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July 29th, 2009, 05:45 AM   #4
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RE: blown FE400 :(

I have a ten point question.Is it normal that I can shake the piston in its bore slightly?does it really have that much tolerance?bore seems ok and the lathe traces on the piston is still clearly recognisable..
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July 29th, 2009, 06:06 AM   #5
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RE: blown FE400 :(

yes the top of the piston is loose. the bottom of the piston should be quite tight though.

your crank and balancer will do a good job. the balance will be a little out. if you wanted to rebalance it that is all you need to do. i would go ahead and try it....

didn't see this thread originally or i would have answered you faust.

regards

Taffy
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August 14th, 2009, 02:49 AM   #6
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Here are the pics of the scored sleeve, piston and other bits inside the engine
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blown FE400 :( pics added-img728.jpg   blown FE400 :( pics added-img726.jpg   blown FE400 :( pics added-img724.jpg  
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August 14th, 2009, 02:54 AM   #7
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another pic
2003 model bike with 2002-2003 transition engine with parts from both year inside with cylindrical roller main bearings stock.
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blown FE400 :( pics added-img729.jpg  
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August 22nd, 2009, 02:31 PM   #8
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I finally rebuilded my engine with 470 head 37mm inlet 30mm ex. 100mm piston.new bearings,some mods etc..everything is perfect starts at first button!
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