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May 4th, 2020, 01:58 PM   #11
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I Ride: Husaberg fs 650 2007
I am very pleased that those shavings do not come from the crank case. If the shaft bearings are ok, why change them?
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May 4th, 2020, 07:07 PM   #12
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I Ride: Husaberg FS650 2004, KTM 400 EXC 2006, Honda Hornet CB600F 2000
I'm not sure actually, mostly for peace of mind I suppose. I've read so much about the mains going bad and eventually causing the case to crack so I guess that I felt like I might aswell "upgrade" the bearings while I've already torn the engine apart.

I'll look for some more input regarding changing the mains or not, might as engine hardware about it too.

I've tried shaking the flywheel as hard as I can but there was at most 0.01mm of play in a small part of the whole crank revolution.
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May 4th, 2020, 10:59 PM   #13
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I think the cam was too far to the left? that wear mark, if it was the chain should be just the width of the rivets. it might be that it was the auto decomp and that the ADC had floated out. on the old bikes there was nothing to stop it floating out.

regards

Taffy
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May 5th, 2020, 01:23 AM   #14
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I see, that very well could be the case, is there any way to stop it from happening? How has it been solved on the later models?

I will check the width and compare with the timing chain rivets
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May 5th, 2020, 01:44 AM   #15
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your decomp spring became unwound or it broke with wear (they can rub until they snap in half).

try and replace the fool that did it originally. shop HIM out for a newer MkII model!!!

Taffy
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May 7th, 2020, 09:32 AM   #16
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Hm, I couldn't find any indication that the decomp spring had become unwound but I will take a closer look tomorrow.

Update again:

Engine case is now split in half

Had some trouble at first as the case didn't really want so separate. But that might just have been because of the bolt next to the ignition sensor that I forgot to remove :P


Heated the case halves to 150 degrees C (158 actually) in an industrial oven at work, sadly only one bearing fell out without any persuasion. All other bearings had to be driven out


Began taking some measurements and inspecting the now completely disassembled engine.

The piston was sadly quite banged up. Several deep scratches, mostly on the forward skirt, that caught a nail so I'll have to order a new one.

As for the cylinder liner it had 3 scratches that caught a nail, not sure if I should let it slide or if the Nikasil will need to be replaced. Any suggestions?


I've attached some pictures of the different parts as well as 2 videos of the piston & cylinder liner scratches. Album here:



The main bearings actually looked pretty mint, might've been able to get a couple more hours out of them but oh well

The mains inner bearing races also looked very good, no obvious damaged.


Conrod "small end" bearing looked a bit banged up, some pitting in there- forgot to take a picture though. I saw that you've got replacement small end and big end bearings in stock Taffy so I'll place an order when I've made a list of everything I will need Was afraid that I might've had to replace the entire conrod but hopefully it's salvagable.

Also, the top of the conrod has been rubbing against the cylinder "roof", displacing some material. Forgot to take a picture of this also but I will take some more tomorrow.


The gearteeth on the waterpump shaft that meshes with the crankshaft balancer seem to have been rubbing up against something. Picture in the album.


Here's something I found strange! There was a seal ring beneath the waterpump bearing with the sealing side towards the engine case. I've not been able to locate this seal ring in the exploded views. Is this an original seal or something a previous owner might've mounted?

Third picture in the album shows the seal ring

Anyone ever seen it before?


That was all for now, hope someone all of this interesting or helpful

Cheers!
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May 7th, 2020, 10:19 AM   #17
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that rubber washer on the side of the outer water pump bearing is standard. but it is meant to stay INtact with the bearing.

not unususual to hear about a rod rubbing on the underside of the piston.

cheers

Taffy
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2004, 650, amount, excessive, flakes, fs650, magnet, metallic, oil



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