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December 1st, 2017, 07:24 AM   #11
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Yeah, if it seems like things are going slow, this is why. They're absolutely swamped.
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January 10th, 2018, 05:58 PM   #12
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Another update:
Piston - Apparently I did a poor job of measuring parts when I took the engine apart. Once assembled on the rod, the piston I selected was 2mm below the deck according to Travis. We've switched to using a KTM 560 SMR piston from Wossner. Having it sent out for Microblue.

Custom rod - Upon fitup, Travis discovered that the rod was contacting the cases. He had to do some trenching.

Carb - I got a Christmas bonus at work so I've decided to pull the trigger on boring the carb out.

Cam sprocket - We decided to switch to the steel cam sprocket that Bushie supplied the part number for in my hybrid engine thread.

Progress - As it stands right now, the bottom end is together, the head work is complete, the carb work is complete and all Travis is waiting for is the cam sprocket to arrive and the piston to come back from Microblue.

Jetting - Travis's website mentions that the carb overbore comes with custom jetting so I'm hoping this'll get me in the ballpark. I do feel that it's necessary to mention, as an indication of how cool Travis and the folks at Thumper Racing are, that he offered to weld up a sensor bung on my exhaust and provide a wideband to help get it dialed in so long as I decide to do the break-in near his shop. And, since his shop is near some of the best motorcycling in Nevada, I think that I'll take him up on it.

Pictures to come once I get the engine back.
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February 9th, 2018, 05:03 PM   #13
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I just received an email from Travis saying that the engine's done. We're going to talk on Monday to square up the finances. That gives me the weekend to find a buyer for my spare kidney as I expect this to be expensive.
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February 9th, 2018, 06:09 PM   #14
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I Ride: '07Exc 525 & '07 FS 550.Just sold ' 08 Ktm 450 sxf.
I can't wait to read your ride review/report. I'm also collecting funds for Travis to do his magic to turn my blown 650 into a jewel 700. I estimated 10K Canadian. So far got only 4😞
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March 14th, 2018, 12:55 PM   #15
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I can't even imagine what a Husaberg 700 must be like.
Sitting at home recovering from a cold and keeping an eye on my vomiting 6-year-old. It's killing me that I can't work on the bike. At least the old engine is out.

Working on replacing the swingarm bearings before getting the 660 in place.

A few pics (with the old and dirty not quite out yet...but I assure you that it is now).

By the way, can anyone give me some advice on the procedure to adjust a manual cam chain tensioner? Travis installed one (presumably from an RFS engine) and I imagine it'll need some fussing in the not so distant future.



Thanks from brucifer, tourist and Alan
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March 15th, 2018, 06:29 AM   #16
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https://youtu.be/56WhyUxGMhE
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April 18th, 2018, 05:04 PM   #17
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Well...the engine is in now. There's been a bunch of drama with a wet stator conversion that Thumper Racing urged me to do and both exhaust header bolt holes ended up getting stripped out when I went to torque everything up.

I did some of the heat cycles recommed by TR in the few hours that I had available last week and I can report great results. With the weight reduction from balancing the crank, the engine has definitely gotten more responsive. It didn't really lose any part throttle bottom end or mid range despite the larger valves and head porting. I can't talk to the top end and full throttle yet as I'm trying to adhere myself to the TR break-in recommendations that advise working your way up to 100% pace (full throttle riding) slowly in 10 minute sessions with 30 minute cool-downs in between. I was hoping to get there while riding at the Hangtown motocross track on Sunday but she up and quit!!!!

I was coming into a choppy right-hander with lots of braking bumps and the engine suddenly lost power. It didn't lock up and exhibited plenty of compression when trying to restart it so I'm doubtful anything went wrong inside the engine. My guess is fuel or ignition. Going to tear her apart tomorrow and check my stator connections as the spade connectors I used on the wire ends left a lot to be desired. Hoping that one of them has come loose. The other thing I'm going to check is the needle in the carb. I've had the needle clip come off in a Keihin FCR before which resulted in the needle dropping down into the needle jet. She would give me a "thump" every now and then while kicking so, whatever the cause is, it's potentially intermittent.

Wish me luck.
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April 19th, 2018, 02:59 AM   #18
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oh no! alllmost there though!!
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April 19th, 2018, 05:15 PM   #19
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I looked into it a bit more today and everything seems to be in order. I pulled the spark plug and the jetting appears to be a smidgen on the rich side of spot on if the plug color is to be believed. What I'm really happy about is that I don't see any aluminum stuck to the plug. That's a relief!

The needle clip is still in position so no problem there.

It's at this point that I ran out of time and had to go to work where I'll probably spend all evening distracted by thoughts of what else could have gone wrong.

The sad part is that I have too many projects and won't be able to get back to this one until Sunday.

I promise, when this is all sorted out, I'll post a video of it running. In the meantime, Here's a video from last summer. Same bike but with the old paintshaker FC600 engine that I just removed.

https://photos.smugmug.com/photos/i-...QBd5f-1280.mp4
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April 24th, 2018, 06:19 AM   #20
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Hmm...what have we here?! The woodruff key for the flywheel isn't supposed to be 2-piece!



That would explain why I was getting spark only once in a while.
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