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April 9th, 2020, 11:28 AM   #1
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I Ride: 2006 Husaberg FE650, 2007 KTM 525EXC, 2005 KTM 200EXC
2006 FE 650 Top end rebuild

Hi all just wanted to verify that I need to split the cases to get to the cylinder and piston to do a top end rebuild? I lost compression and the bike died on me yesterday on a ride. Trying to do a run down on all the parts I'm going to need to order, so I can hopefully do it all in one go. Wondering if I should take care of the bottom end too while I'm at it?

Thanks and hope everyone is safe and well out there.
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April 10th, 2020, 12:54 AM   #2
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you ought to find what the problem is first and then make that decision.

only the head can be removed as you rightly surmised. engine out and tear down just to get at the piston and liner.

cheers

Taffy
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April 10th, 2020, 06:31 AM   #3
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May as well do it all (main bearings, timing chain, water pump bearings, etc) while you're there. Not sure I've ever done just a "top end" rebuild, except to replace valve springs to dvsk. I recommend reviewing Bushmechanic's main bearing thread for good measure.
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April 10th, 2020, 04:07 PM   #4
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I Ride: 2006 Husaberg FE650, 2007 KTM 525EXC, 2005 KTM 200EXC
Looks like a busted exhaust valve spring. I'm guessing the valve probably hit the piston a couple times if that happened right? This was fully rebuilt by the local KTM dealership about 150hrs ago for the old owner. You all still think I should do a full rebuild, or is it possible to just replace the valve spring?

Sorry for the stupid questions new to motorcycles but not totally inept. I find working on them relaxing and fun. Rebuilt a KTM 200 last year and did a top end on a KTM 525 the year before.
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2006 FE 650 Top end rebuild-img_1323.jpg  
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April 10th, 2020, 10:53 PM   #5
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so are you going to listen to those that know this time!

go to DVSK and replace both exhaust valves. due to the percussion, the heads fall off as soon as you rebuild the top end.....on the next ride sometimes.

while you're there fit an upgraded auto decomp spring i sell.

new headgasket and you should be good to go.

Taffy
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April 11th, 2020, 10:10 AM   #6
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WhiskeyRider775, a broken exhaust valve spring is a common occurrence especially on the 650. Nothing unusual here.
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April 11th, 2020, 11:20 AM   #7
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Thanks guys! Pulled the head and doesn't look like the exhaust valve smacked the piston at all. Cylinder looks pretty clean. Some marks in it but you can still see the crosshatching. Still debating if I should rebuild or not now that I have the engine out of the frame.
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2006 FE 650 Top end rebuild-img_1339.jpg   2006 FE 650 Top end rebuild-img_1337.jpg   2006 FE 650 Top end rebuild-img_1340.jpg  
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August 3rd, 2020, 08:25 PM   #8
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Wow did you get lucky!
I purchased a valve drop (07) 650 that took out the piston, rod , liner, and trashed on the head!
Ive purchased a good condition head w/dual springs so far.
Still looking for the other parts used in good condition!

Proflow
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August 3rd, 2020, 11:53 PM   #9
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dear oh dear oh dear. there's nowt as blind as those that will not see............

Taffy
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