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February 9th, 2019, 07:10 PM   #1
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I Ride: 2007 FS550E Supermotard
Bottom end rebuild - what parts do I need?

Hello everyone. I'm hoping those more knowledgeable than me can help me out here please.

My 2007 FS550E has just clicked over to 12,500km. It's running very well and I've no complaints, pulls nice and strong and starts easy on the boot. Such a fun bike.

However, I see the manual calls for the following work to be done at the 120-hour/800-litre mark (which I calculate to be approximately 12,000km):

A. Replace the conrod bearings
B. Check piston pin bearing
C. Replace the balancer shaft bearings
D. Replace the crankshaft main bearings

I've been looking at the parts fiche on AOMC.mx and I'm now left with a few questions which in a nutshell is basically: what parts do I need for this work? I'll get a local shop to do the work for me but they'll need me to source the parts.

The specific questions I have are:

1. Is my only option for A and B above the 'Conrod Rep Kit 501/550 800.30.015.000' or is there some way to get the individual bearings without the conrod itself? Or is it worth just replacing the conrod while I'm at it?

2. Are there 1 or 2 bearings on the balancer shaft? The fiche indicates 1 but the manual says replace bearings, hence my question.

3. What other parts would I need to source for the workshop to have on hand all the parts required to complete this work? Presumably I would need to get the 'Engine case gasket kit 800.30.099.000' but what else? Base gasket? New timing chain and connecting link? All the seals and thrust washers in the 'Crankshaft, Piston' section of the fiche?

Thanks in advance for the guidance!

Of course the other option is just not bother with any of this and just keep riding it as is (and doing regular oil changes and valve checks) until something goes wrong...
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February 10th, 2019, 10:48 AM   #2
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So, first of all I'd keep riding The service intervals in the manuals are mostly a guideline / cover-your-ass statement by the manufacturer. Just change the oil regularly and check the filters for particles and stuff. And stay on top of valve adjustment.

For when the time does come: Do you have a copy of the service manual? There's a manuals section on the site and a Google Drive that's a little easier to navigate imo. E.g. here: https://goo.gl/Fa65bn

In general, most engine bearings can be sourced from a general bearing supply.

Re. the 550 rod: The 550 rods are getting hard to come by. Some members of here have had CP Carillo build a custom, carburised, rebuildable rod. I think that's probably the way to go. There are some posts on here on how to go about it.
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February 10th, 2019, 12:00 PM   #3
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Agree with Tourist, its just a number.
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February 10th, 2019, 01:56 PM   #4
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You could measure the axial play of your crank with a dial guage by taking the ignition cover off.

If it's less than 0.4mm I'd think about replacing the mains sooner than if it was 0.6 plus.

Easy test of the most important spec regarding the most common failure (main bearing)

I would not worry about anything else. Just ride it
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April 12th, 2019, 04:15 PM   #5
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Thanks everyone for the insights. Always appreciate the collective wisdom of this place!
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April 13th, 2019, 06:50 AM   #6
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the rod kit is NLA. I do a pin and bearing kit for that rod. I'd say the first thing to show will be your piston and a bit of smoking. till then keep riding. there's no base gasket on your engine. You can't get balancer bearings as they are only made to those dimensions under license to KTM and KTM won't sell them, indeed it was last month that they even stopped selling the balancer assembly full stop!

regards

Taffy
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April 13th, 2019, 10:51 PM   #7
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Originally Posted by Taffy View Post
the rod kit is NLA. I do a pin and bearing kit for that rod. I'd say the first thing to show will be your piston and a bit of smoking. till then keep riding. there's no base gasket on your engine. You can't get balancer bearings as they are only made to those dimensions under license to KTM and KTM won't sell them, indeed it was last month that they even stopped selling the balancer assembly full stop!

regards

Taffy
That's no good re the bearing but I did a quick Google and it looks to be the same bearing thats used on the front wheel of an 85 SX KTM?

KTM Newcastle - 85 SX 17/14 2013 - FRONT WHEEL

Same part number and all: 0625 069050 BALL BEARING 6905 J1LLUC3
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April 14th, 2019, 12:39 AM   #8
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wrong.

the 6905 bearing is the one in the crankcase for the intermediate shaft to go through. the balancer bearing is NOT available.

does anyone know anyone at the top of KTM? because if KTM had that bearing made under licence they should have been prepred to sell the bearing to the public.

cheers

Taffy
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April 14th, 2019, 06:51 PM   #9
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Taffy, is that the same deal for rebuilding the bottom end of a 650? are parts still available for these?
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April 14th, 2019, 11:02 PM   #10
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John prior should have the balancer bearings at the right price

The bearings start as a standard c3 and cost about 10 dollars then it takes about 5 minutes of machining to make them narrower so they fit.

His contact details are in my signature I also believe he is on Facebook
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