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October 9th, 2018, 03:15 AM   #1
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how to rebuild/assembly a 2004 fs650 engine

hi guys,

i'm a new user.
i'm buying my second FS650.
i already have a 628cc and i'm buying a 644cc.

the problem is that the ex-owner has disassembled the engine.
i've never done before. but i would like to assemble the engine by my self.
(i probably have all the tools)

is there a tutorial? a video?
i've the instruction (PDF) meda by Husaberg, but i'm not sure they are enought.

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October 9th, 2018, 04:46 AM   #2
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You can do it!

Husaberg motors are rather minimal, which is good, and lightweight and there's only really one of everything (as opposed to a multi-cylinder engine), so it's very manageable at home.

As for videos, there are probably going to be bits and pieces of the process on Youtube. KTM motors are somewhat similar, and in general all dirt bike motors as well.

Do you have the Husaberg "Repair Manual" handbook? The cover looks like the attached picture. They're quite good and clear imo. I as a beginner would also find some challenge in using only that book. Forum members have collected almost every single manual there is - there's a Manuals subforum, and a Google Drive collection here:

The Four Stroke Dirt Bike Engine Building Handbook is very good! By Paul Olesen, available on
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Last edited by tourist; October 9th, 2018 at 04:50 AM.
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October 9th, 2018, 06:14 AM   #3
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there used to be a video on youtube of someone splitting a 400, the same age.


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2004, engine, fs650, rebuild or assembly

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