Husaberg
Go Back   Husaberg Forum > Mechanical and Technical > Mechanical

Mechanical Mechanical Forum - spinning bits and gyrating bobs


Thanks Tree171Thanks
Reply
 
LinkBack Thread Tools Display Modes
July 22nd, 2014, 07:43 PM   #11
Senior Member
 
Goose916's Avatar
 
Joined: May 2010
From: San Francisco, California

Posts: 517
Thanks: 223

I Ride: 2 2005 FS650C; 2 2004 FS450C; 1993 Honda F2; 1972 Triumph Daytona; 1969 Ducati 450 Jupiter; 1974 rd
I envy your skills. Can't wait to see the finished product!
Thanks from bushmechanic
Goose916 is offline  
 
July 23rd, 2014, 02:42 AM   #12
Senior Member
 
bushmechanic's Avatar
 
Joined: Jun 2007
From: south east WA Australia

Posts: 3,775
Thanks: 1072

I Ride: 2008 700FK, 2002 628FST
crank endfloat

Thanks Goose, there are heaps of way more talented people out there, im just a dirty ol engineer

made a spacer and set the end float at 0.1mm for the 22206 spherical rollers



gearbox stuff.

Bulletproof Gearbox "Upgrades"

my engine and Tyre choice have a habit of destroying rear hubs, rear spokes and ripping the gearbox in half. (105mm bore and bolted paddles)

Ive had 6 gearbox failures In Total, about half of those with the 100mm bore and knobbies but none in the last 150 hrs with a bolted paddle, 75rwhp and a few tricks.

first time it broke was at 160hrs as built from the factory, i screwed up and landed a big bastard flat jump with a bit too much throttle on then on landing the G force on the lever shifted into 3rd .. bang. this happened a second time after a tiny stick flicked up off the front wheel and hit the shift lever

so I looked into the shift star and detent arm. ours is different to almost every other bike. the spring is softer and the shift star is very pointy without the traditional double curve.

that will make more sense when I add more pics tomorrow

tapped a 5mm thread into this hole for a 5mm CSK bolt and used a 2010 KTM 450SX detent arm spring. approx doubles the force on the arm



reprofiling the shift star more in line with other bikes



more pics to come plus circlip upgrades and hardness testing/retempering of the 3rd and 4th sliders

this shows the basic difference, other bikes have a double profile on the star





when you shift gears your input does not actually slide the gears into place, what you do is put the detent arm over the top of one of the points.

the actual shift is done by the detent arm spring so when you have a double profile it can wait for the "right" moment to slide

the berg star just slams it straight in... it is faster.

another issue is the circlips being too pissweak

these are the 08 clips from my bike after the first failure.



the 08 clips are much tougher than the pre 08 clips

tip from KTM talk via craigy was both are crap compared to the kawasaki clips (92033172)



there is an opportunity to use one of these locking stop discs I made on the output shaft, can only install one of them.

I still have one left from back in 2008 to go in my 628







so with the shift star and detent arm fixed (in 2008-9) there were no more failures from the bike shifting itself into gear at the wrong time and the upgraded clips have not been a problem.

but about this time I put the 105mm piston in and started running bolted paddle tyres.





now the gears would just rip in half under load, I sent one box away to be shot peened crack tested hardness tested and cryogenically treated. seemed good but the hard facing flaked off 5th .. it was an old gear, maybe was due to go anyway.

the last mod was just take a standard box (no cryo) and re-temper one of the gears (4th slider) in an oven for 1 hr at 250 deg C

with all those mods Ive had a good run of 150 hrs with the big engine and the paddle tyre although i mostly run in 5th gear

I picked out a set of gears today for the 628 build Bushmechanic Mongrel 628 Trailbike

and re tempered some of them in the same way, will be changing gears more often so did 3rd and 4th sliders and the gears that engage into their teeth , 5th and 6th.

they tested 63-65 HRC before and 58 HRC after. polished one side before they went in .. the flash is deceiving, the color we are chasing is dark purple.






oil pump mods Oil pump upgrade 15mm wide









testing the cracking pressure of the valve



put the oil pump cover on and used compressed air

OEM was 13-15 psi, i have it set at 35 psi, a bit over 3 lbs force from the spring is about right

Last edited by bushmechanic; July 23rd, 2014 at 05:01 PM.
bushmechanic is offline  
July 23rd, 2014, 02:45 AM   #13
Senior Member
 
bushmechanic's Avatar
 
Joined: Jun 2007
From: south east WA Australia

Posts: 3,775
Thanks: 1072

I Ride: 2008 700FK, 2002 628FST
Pro X piston

got my pro-x piston from jawzys ebay shop .. good service

it weighs about the same as the elko but is 0.1mm taller .. bonus





pin is heavier than they speced


bushmechanic is offline  
July 23rd, 2014, 02:52 AM   #14
Senior Member
 
bushmechanic's Avatar
 
Joined: Jun 2007
From: south east WA Australia

Posts: 3,775
Thanks: 1072

I Ride: 2008 700FK, 2002 628FST
Trick Titanium wrist pin

I had trick titanium make me this Titanium pin in 2009

decided I didn't want to use it with the 105mm piston

it is very very well made .. T17 with DLC and c33 hardened end caps, should have the same fatigue life as a steel pin if subjected to the same deflection

since its not as stiff its about 1/2 the life expectancy of a steel pin .. 1/2 of forever sounds OK

due to the greater deflection it needs a larger clearance in the little end of the rod and inside the piston.





weight is 40 gm.. apparently the wossner pin is only 60 gm which (if true) makes the Ti pin a bit overpriced. mine was about $100 but i think they want 200 now.
bushmechanic is offline  
July 23rd, 2014, 01:39 PM   #15
Senior Member
 
tourist's Avatar
 
Joined: Nov 2012
From: Iceland

Posts: 2,133
Thanks: 647

I Ride: 1 Berg, 1 Zook
Keep 'em coming!!

Looking forward to seeing what you're doing about the suspension especially.
Thanks from bushmechanic
tourist is offline  
July 23rd, 2014, 04:25 PM   #16
Senior Member
 
bushmechanic's Avatar
 
Joined: Jun 2007
From: south east WA Australia

Posts: 3,775
Thanks: 1072

I Ride: 2008 700FK, 2002 628FST
Originally Posted by tourist View Post
Keep 'em coming!!

Looking forward to seeing what you're doing about the suspension especially.
actually im not looking forward to that bit much .. the WP shock is off a 2002 model .. I have an elka quad shock that will probably be more fun to make work.
bushmechanic is offline  
July 25th, 2014, 03:07 AM   #17
Senior Member
 
bushmechanic's Avatar
 
Joined: Jun 2007
From: south east WA Australia

Posts: 3,775
Thanks: 1072

I Ride: 2008 700FK, 2002 628FST
finding true TDC



made a tiny TDC locating screw setup to speed up assembly ,




Last edited by bushmechanic; July 25th, 2014 at 03:15 AM.
bushmechanic is offline  
July 25th, 2014, 07:03 AM   #18
Senior Member
 
berglsmerg's Avatar
 
Joined: Aug 2009
From: Charters Towers, Australia

Posts: 1,292
Thanks: 339

I Ride: FE 610 oh yea
Nice work on the oil pump/cover Damon, a much more practical and elegant solution compared to the rusty spam tin cover. Flows more too, woo hoo, headroom for a plain big end.

Spherical bearings and inserts are just showing off/fancypants etc. I had a 97 husky tc 610 with spherical bearings and no oil pump, had a few big ends fail but those mains soaked up the crank flex. That thing vibrated like a jackhammer, drank like George Best and went like the clappers.

Is that a tiny bit of crown you have poking up above the deck ? Static C.R ? And what was your choice for big end bearing or have you solved the inertia vs friction woes of that poor over worked thing.

10 psi relief vent ?

Yoghurt in the shed ??

Outstanding as always.
Thanks from bushmechanic

Last edited by berglsmerg; July 25th, 2014 at 07:15 AM.
berglsmerg is offline  
July 25th, 2014, 09:49 AM   #19
Senior Member
 
Goose916's Avatar
 
Joined: May 2010
From: San Francisco, California

Posts: 517
Thanks: 223

I Ride: 2 2005 FS650C; 2 2004 FS450C; 1993 Honda F2; 1972 Triumph Daytona; 1969 Ducati 450 Jupiter; 1974 rd
and here I thought the "Greek style" was bearing grease. I've lived in SF too long
Goose916 is offline  
July 25th, 2014, 03:50 PM   #20
Senior Member
 
berglsmerg's Avatar
 
Joined: Aug 2009
From: Charters Towers, Australia

Posts: 1,292
Thanks: 339

I Ride: FE 610 oh yea
Originally Posted by Goose916 View Post
and here I thought the "Greek style" was bearing grease. I've lived in SF too long
Yeah well I'm hoping it's just yoghurt.....
berglsmerg is offline  
Reply

  Husaberg Forum > Mechanical and Technical > Mechanical

Tags
628, bushmechanic, mongrel, trailbike



Search tags for this page
Click on a term to search for related topics.
Thread Tools
Display Modes


Similar Threads
Thread Thread Starter Forum Replies Last Post
Bushmechanic frame Build pics and Stuff bushmechanic Suspension 159 May 16th, 2014 04:18 PM
Bushmechanic, please read grasstrackpete Mechanical 6 June 15th, 2009 07:51 PM
mongrel tail light ferret Electrical 7 January 8th, 2007 03:34 PM


Facebook Twitter Google+ RSS Feed