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May 21st, 2019, 01:09 AM   #1
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Cracked cylinder sleeve on FS650e 2006

https://imgur.com/a/1nfo196 - picture of the sleeve.

So I was taking the cylinder head off to renew my valve springs when I noticed that there was small nodge on top of the cylinder. Further investigation revealed that the whole top of the cylinder sleeve had been cracked clean off. In the picture the ring on top of the sleeve and the sleeve it self should be one part.

I have never heard that anyone would have had this kind of crack on their cylinders on any vehicle. I know that really tuned engines can crack their cylinders on boost but usually the cracks are horizontal and not like this.

Only explanation to me would be some kind of extra stress to the sleeve but I don't really understand how. It's also weird how the engine was working perfectly fine before I opened it. Maybe when I removed the head it released the tension on the crack.

The bike is stock Husaberg FS650e 2006 with 230 hours on it and about 30 hours after rebuild (Crank, bearings, pistons and other normal stuff).
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May 21st, 2019, 01:37 AM   #2
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Wow! Weird.
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May 21st, 2019, 02:29 PM   #3
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any observant member here would know that this is NOT the rare occurence one would think. if you didn't have coolant in the oil before you stripped the engine then you have cracked it in the process of stripping the engine I'm afraid.

you'll have to take your chances with a new liner but they aren't at all well made I reckon.

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May 21st, 2019, 11:25 PM   #4
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I've been having 400 and 501 liners made. I have the drawings ready for the 650s when Husaberg stop making them.

you did something wrong though fella i suspect? sorry but.....

as you poured coolant in the radiator, it would have appeared in your oil. so if you were stripping a "normal" engine it means the broken liner wasn't like that when you started!

cheers

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May 23rd, 2019, 08:55 PM   #5
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I broke liner tighten head bolts too tight some expert give wrong advice tighten bolts 65nm when real advice is 45nm
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May 23rd, 2019, 11:14 PM   #6
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i use 46LB/foot which i think is about 62N/mm?
33LB/fot and 44 N/mm is recommended but Dale Lineweaver put us onto it and I have never had a head gasket leak in all these years. It came from the factory men themselves.

I've had 3 or 4x450 liners snap. all on 2004s.

the factory changed the manufacturer from Mahle years ago and I'm afraid the quality is poorer.

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May 24th, 2019, 09:46 AM   #7
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Originally Posted by Jussi View Post
I broke liner tighten head bolts too tight some expert give wrong advice tighten bolts 65nm when real advice is 45nm
Mine weeped coolant around the outer of the head at the correct (per manual) 44nm, so had no option but to go tighter. I'm running 65nm and it's perfectly fine. I'm amazed 44nm was ever recommended. Having worked on cars now for 15 years, with head torques commonly being the 40-60nm plus 180 degrees, I was shocked the manual only recommended 44nm. Seems far to little.

I also spent ages making sure my liner was centralised in the casings so it didn't go down wrong.

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May 25th, 2019, 01:45 AM   #8
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all the head gasket does is crush the aluminium collar at the top. the problem is the lower machine cut for the liner where it wears the three liner 'O' rings. the mouth at the top doesn't align with the mouth at the bottom. this puts pressure on the liner to move over.

to do this, it has to crack.

I had a special tool made to measure the 'run out' on the inside of the bottom mouth. it was like the 3.30 at chepstow!!!!! (a horse race over fences).

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May 31st, 2019, 09:54 AM   #9
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I have also leaking coolage little bit head gasget,but i ha re opened engine to get honed liner and install high comp piston after that if new gasget will leak i could re tighten head little bit or use radiator stop leak but absolutely not 65nm,when i was tighten first head bolt 65nm i tought thats too tight and it was:/
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