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August 17th, 2015, 10:30 AM   #1
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650 Rebuild!

Hey kids

The time is upon us. Some horrible bottom end clunking noise from the berg the other day, and Ive been itching to tear into it for a while. Oil showing flakes for the last few changes. Hoping to return it to a much better state than what I got it in, inside and out!

at 170hrs on a full rebuild.

Ill use this thread for advice and updates for those doing something similar.
Wouldnt be possible without the teachings of bush mechanic, Dr.c and a few others, you guys are golden.

So I was hoping to find something obviously wrong, but so far Ive only got some tired looking mains, a dead output bearing and a sneaking suspicion that the balancer bearings are cactus. I havent ripped the left side off the shafts yet, but ill do that in the next few days.

Edit: apologies for the huge photos, computers arent my strong point!

Rotor be gone!



New engine upgrade?



Cases came apart without a splitter! Just gentle taps with a plastic hammer on the crank and output shaft.



Heres the right side main, SKF. I think I know where some of the flakes have come from!



And my liner from a few different sides, Its actually in good shape so I dont think Ill bother replacing- probably a hone and the next size piston.



And heres the Wossner piston- the wrist pin journal is toast!
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Last edited by LemoneyF; August 17th, 2015 at 07:30 PM.
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August 17th, 2015, 10:59 AM   #2
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keep it coming!
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August 17th, 2015, 07:20 PM   #3
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Resized the pictures!

Gearbox output bearing, feels super sloppy and is banged up to hell.


Wossner piston at 170hrs. Never used much oil, but the oil control ring doesnt have much life left. Also scratched up on both skirts. As you saw before, the wrist pin journal is worn badly. New piston in the works. Wossner is cheapest by a mile but I suspect theres a reason for that.



Onwards!
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August 17th, 2015, 07:58 PM   #4
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nice pics

the cheapest piston is pro X .. approx 100hr life im not using any of their stuff in a berg again LOL

your wossner skirt looks pretty good really

your liner is in good nick and prolly won't get much bigger from the hone check clearences in manual or from piston mnfr before ordering the piston sizing

Last edited by bushmechanic; August 17th, 2015 at 08:15 PM.
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August 18th, 2015, 07:14 AM   #5
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Originally Posted by bushmechanic View Post
nice pics

the cheapest piston is pro X .. approx 100hr life im not using any of their stuff in a berg again LOL

your wossner skirt looks pretty good really

your liner is in good nick and prolly won't get much bigger from the hone check clearences in manual or from piston mnfr before ordering the piston sizing
Indeed, that piston skirt looks pretty damn good compared to the pistions I have pulled outta my 650. Keep up the good work and you may want to take a good long look at Bushmechanic's 628 Mongrel thread. If you're inclined to modify the motor for additional reliability - that thread contains great advice. While you're in there, it's the time to do so!
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August 18th, 2015, 08:20 AM   #6
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Ive actually heard good things about ProX and they seem quite expensive? a good $50 on what the Wossners cost, Ill hunt around now youve told me something different.

Quick question, can I reuse the inner main bearing race if it looks like its in good nic?

And Goose, ive had a solid read of that thread, its all great info. I had to tear myself away from his 710 thread, my plans were running wild haha!
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August 18th, 2015, 04:15 PM   #7
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hi lemony

the prox piston part# for the 80mm crank is 01.6606.A B or C they are 20-40 usd cheaper than wossners and a dimensional copy of the oem 628 elko but i would not use one again.

wossner don't have a piston for the 80mm crank, theirs is for the 82mm crank whats the number on top of yours ?

Im using a wossner 8737 570 piston this time, its not exactly the same as oem 628 elko or the prox listed above, you would have to check exhaust valve to piston clearance (should be just ok)

the other option is to get a wossner 8583 listed as for a ktm 540 or 560 piston and machine out the top to your requirements.

you could re use a bearing inner but i wouldn't, leave it on for now to determine crank axial play if you haven't already measured it

then remove the inner race with a die grinder cut nearly through and cold chisel to split it open or can hold crank up in the air and use oxy torch to quickly head the race, will drop off, or there is a tool you can make or buy .. see makazaikas four stroke force 450 build.

then make required adjustments to the shims and install the new race.

I prefer to use the cut method as you then have a dummy inner race you can use to get the axial play right
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August 19th, 2015, 12:30 AM   #8
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So definitely a wossner 650, but im not sure of the size (A,B,C).

And Ive learnt that Ebay isnt the place to be comparing prices haha.

Im a big fan of using oxy torches so that method seems the goods.

Ive been using a small copper plumbing bolt to jam into the gears which worked perfectly last night- the entire motor is now in bits. For the clutch basket inner I threw the motor back into the bike, got 6th gear and stood on the back brake. Cracked the centre nut off perfectly.

My balancer is a bit of a concern. It doesnt have any up-down play, but its happy to wiggle side to side a tiny amount. Maybe half a mm measured at the end of the balancer. I cant find any measure of how much play is too much!

Im looking forward to baking my cases, as a chef I am super experienced with tasty baked goods.
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August 19th, 2015, 01:21 AM   #9
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I was disappointed to only see a tin of beer in some of the pictures... not all!
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August 19th, 2015, 04:30 AM   #10
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Hi, the piston you should use is the wossner. From '01 to '03 husaberg used as oem piston the wossner which is flat on top but 1.5mm shorter(not good). The '04 husabergs used the wossner but it was the same as elko. From '05 to '08 they use the elko. If you download the '04 650 service manual you will see what i mean, the part number is listed there(for the '04 wossner). Check for prices and buy the cheaper(wossner or elko). The prox piston is cheaper but don't last as wossner or elko.
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