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November 15th, 2017, 05:51 PM   #1
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I Ride: fc550 kx500 kdx200 wr450
01' 550fc roller rockers, bearings

Having learned of the shortfalls for the 01 550 top end I started with the roller rockers. There seems to be two types installed. Don't know which of two prior owners may have upgraded or replaced when failed the roller bearings.

Please chime in and share what you identify. The issue being specifically, neither bearing conforms to the other and one has been sticken to hold it in place. Maybe the entire roller was replaced given there is no strike marks along the lip/bearing edge.
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01' 550fc roller rockers, bearings-rockerbearings3.jpg  
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November 16th, 2017, 03:45 AM   #2
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it is really tough to know which it is because 7.6 and 7.8mm are so close. I often read 7.7 on the workshop vernier. it is a nightmare.

you are still best getting the pin out and trying to measure it. on a good day they will say 7.8 or 7.6mm

I have them both in stock,

Taffy
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November 16th, 2017, 09:15 AM   #3
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The 01-03 rocker arms were pressure fed.

In 03 the rocker rollers were updated with 7.8mm pins as Taffy has described.

It was a common upgrade to use the 03 rocker assemblies in 01 and 02 models to increase longevity of the bearing. A probably larger contributing factor to premature roller rocker failure was the aggressive profile of the camshaft. In 2004 the cam was mellowed out and didnít beat the rollers to an early death. The 2004 Cam, Cam Sprocket and
Autodecompression Device would be a nice upgrade for your 01 (with or without the 03 rockers). This may allow you to remove the kickstart activated Decomperssion parts as the 04-08 ADC system works very well.

It appears that one of your rollers was replaced. The peening done, to fasten it to the arm, should have been done in the center of the pin and not on the arm itself I believe.

Before you sink a ton of money into a 01 it would behoove you to read every post ever written regarding a 01 and also the Wiki.

On the bright side, yours is a FC and you will not have to contend with trying to get it (a 01) to e-start. That in itself SIGNIFICANTLY reduces the number of issues you will be presented with and may make for a worthy endeavor (fixing the old girl up).

Eric
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November 16th, 2017, 09:24 AM   #4
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all rockers up to and including 2002 had 7.8mm pins
2003-2008 had the 7.6mm pins.

I hope I got that right!

Taffy
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November 16th, 2017, 09:48 AM   #5
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Originally Posted by Taffy View Post
all rockers up to and including 2002 had 7.8mm pins
2003-2008 had the 7.6mm pins.

I hope I got that right!

Taffy
Ahh, so the pin got smaller so that the bearing could get bigger.

I seem to have had it bass ackwards..................
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November 17th, 2017, 12:29 AM   #6
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if it IS confusing;
what he wants is a shop that will let him buy both and return one!

regards

Taffy
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November 18th, 2017, 10:09 AM   #7
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Originally Posted by husabutt View Post
The 01-03 rocker arms were pressure fed.

In 03 the rocker rollers were updated with 7.8mm pins as Taffy has described.

It was a common upgrade to use the 03 rocker assemblies in 01 and 02 models to increase longevity of the bearing. A probably larger contributing factor to premature roller rocker failure was the aggressive profile of the camshaft. In 2004 the cam was mellowed out and didn’t beat the rollers to an early death. The 2004 Cam, Cam Sprocket and
Autodecompression Device would be a nice upgrade for your 01 (with or without the 03 rockers). This may allow you to remove the kickstart activated Decomperssion parts as the 04-08 ADC system works very well.

It appears that one of your rollers was replaced. The peening done, to fasten it to the arm, should have been done in the center of the pin and not on the arm itself I believe.

Before you sink a ton of money into a 01 it would behoove you to read every post ever written regarding a 01 and also the Wiki.

On the bright side, yours is a FC and you will not have to contend with trying to get it (a 01) to e-start. That in itself SIGNIFICANTLY reduces the number of issues you will be presented with and may make for a worthy endeavor (fixing the old girl up).

Eric
In order of your reference:

Pressure fed rockers: I might be in trouble now (jumping the gun on preventative failure); having seen Taff's video on drilling top side of rocker arm with funnel type catch cavity to increase oiling (did I sabotage oil pressuring ability w/ 1mm final drip hole)?

Rocker Bearing: Now knowing one was replaced (peened in error) shouldn't the issue w/ remainder be simply the outside diameter of the new replacement bearing (presuming updated needed size within same)?

Rockers: Depending if I ruined current w/ drilling hole or not, prefer to keep rockers, avoiding 03, replace remaining bearing.

2001 investment and overall scheme: Received bike via defaulted loan, repo if you will. Non running, failed stator. New stator, got it running w/ rough timing, kid tried to start, kicked back which broke both ankle bones. Bad start, sat for a while, all in now. Removed kickstart decomp system, fixed starting prob. Bike runs good missing power only prob. Plan was to update known issues, sell it. Now might keep it if reliability and failure avoidance can be managed. Low hours, AAA condition.

Research sourced intended fixes: Either change cam and updated rockers (and bearings therein) or dual valve springs. Go to steel cam gear, new chain, updated tensioner, replace remaining rocker bearing, new cam bearings. 01 parts failure risks identified XXX fingers I have an exception or keep use to minimal (have kx500 and wr450 also, only 1 rider to use all), Photos next

Last edited by Markafc; November 18th, 2017 at 10:14 AM. Reason: minor, spelling errors, ref to photos
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November 18th, 2017, 10:18 AM   #8
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Pics

Pre upgrade pic and son's kickstart kickback result
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01' 550fc roller rockers, bearings-preupgrade-photo.jpg   01' 550fc roller rockers, bearings-kickstarter-kickback-caused.jpg  
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November 18th, 2017, 09:57 PM   #9
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Originally Posted by Taffy View Post
it is really tough to know which it is because 7.6 and 7.8mm are so close. I often read 7.7 on the workshop vernier. it is a nightmare.

you are still best getting the pin out and trying to measure it. on a good day they will say 7.8 or 7.6mm

I have them both in stock,

Taffy
I had to know what I was dealing with, oem rocker or updated, same with bearings. Husaberg cited the peened one was a replaced bearing. I'll pull the pin and mic it in preparation of parts order. Thanks!
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November 18th, 2017, 10:10 PM   #10
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I don't think that you will have any issues due to drilling the rocker arms as all of the other Husaberg's from 89-2000 and 04-08 were splash fed.

I am not exactly sure what you mean by: Rocker Bearing: Now knowing one was replaced (peened in error) shouldn't the issue w/ remainder be simply the outside diameter of the new replacement bearing (presuming updated needed size within same)?

The outside diameter of the bearing is the same only the inner needle bearing pin size was changed in 03. These are actually pretty easy to replace. I would just stick with the original size and replace every 40-50 hours of use.
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