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August 17th, 2004, 07:23 AM   #1
BD
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Valve cover/ rocker ccover /head cover

The weld repair went well, but valve cover did not remain flat enough to seal against the top of the head. Still leaks. SO, I was wondering if any of you Berg mechanics have a good used valve cover available for sale to fit a 2002 400e. ? . All I need is the cover; my rocker shafts, arms, etc are still very usable. Dealers? Thanks, BD
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August 17th, 2004, 10:01 AM   #2
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try this thread. go to "here" in the opening post. i cured it, same year and same model. good luck!

regards

Taffy
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August 17th, 2004, 01:30 PM   #3
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BD - Is it possible to press (read bash with a hammer ) the repaired cover, on wooden blocks, as straight possible then lap it flat on a sheet of wet 'n dry laid over a piece of plate glass? If you can get it so that bugger all metal is lapped from around the cam bearing bosses it should work OK. This method certainly works well to flatten heads & barrel tops.
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August 17th, 2004, 11:32 PM   #4
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whoa! another 2002 fe in the NW!

im in seattle, howsabout you? i know of two other husabergs around, and one of them is another 02 fe400e!!
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August 18th, 2004, 09:40 AM   #5
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Hi Brad. I thought about "bashing" it a bit, but it is a rather thin wall, intricate casting, and not being "billet", (rolled alloy), it gets it's strength from it's cast shape. The welding warpage is significant enough that I am not sure I can correct with machining only, but at this point I have nothing to lose. I was just trying to save some money. I'll probably try some very light "cold working", followed by machining/grinding. The warpage affects the alignment of the intake rocker shaft bores as well.

Taffy, thanks for the link, but the only "here" I found in your maintenance journal did not open. The gallery links work but the "here" did not. I'm going to get a new cover, but will keep working on the old one to see if it can be salvaged as a back-up. My friends did a beautiful job of welding; it just warped too much. If there were one more bolt at the right rear of the cover, I think I could have made it work as-is. BTW, I replaced my rocker roller bearings since I had the cover off, and found the tell-tell signs of early bearing wear on the original axles from the roller contact. One of the rollers was definately ready to be replaced. The bike probably only has about 100 hours by my best estimations. I use DELO 400 and change it often. Scotts filter. Valves adjusted often, (10-15 hour intervals). I replaced with stock for that year due to availability. I may update with the newer design later, but it was very easy to do, so maybe not if the bearings remain available.

Thanks for the help guys. SURFERGUY80, doesn't LOGJUMP have an FE400e, or do I have that wrong? Ever try the GP's that the OVERTHEBARSGANG puts on near Goldendale? Lot of fun! BD
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August 18th, 2004, 10:08 AM   #6
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BD

a cure or two are at the bottom of page 3 under troubleshooting.

Taffy
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