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August 4th, 2007, 02:45 AM   #1
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Rebuild or not rebuild - that is the question!

Hi Boys
Recently the bike developed some engine noises.
Miles from nowhere in the middle of the bush of course and so decided to ride it out for a couple of hours.
Anyway the noise turned out to be rocker arm bearing colapse on the intake and the subsequent cam damage - it removed a fair bit off the top of the intake lobe.
Lot's of fine metal dust in the oil and filter and some larger bits on the screen and still up top.
I'm after some opinions whether I should tear it apart and clean it all out or if I should just fix the busted bits and hope the leftover metal gets caught by the filters.
Can the cam be re-ground or are they throw aways?

The internal faces of the rocker arm are damaged also - scored by the broken roller pins. So does this mean I'm up for a complete rocker arm or has anyone else out there got a fix for it?

Coops
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August 4th, 2007, 03:41 AM   #2
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Hey Coastie,

Replace the rocker arms - it's not worth the risk.

Personally I would also strip the engine down and clean up. If those roller pins have gone walkabout anywhere it could spell further disaster.

The camshaft is surface hardened only so if you do get it re-ground just get it treated appropriately afterwards. But given the situation, it might be worth considering something like the Lineaweaver LX1 or LX2 cams as they will prolong your valvetrain life and they work very well. Because Dale does a swap he might accept your damaged one (which he did with a scored one of mine) - always worth giving him a shout and asking.

Hope this helps,
Simon
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August 4th, 2007, 04:34 AM   #3
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I agree with Simon.

Strip it/ clean it out.

I saw a friends 501 eat up its piston/liner not long after a dealer had "repaired" his intake roller failure too- without stripping/inspecting and cleaning out the engine.

Little bits of ground up hardened steel doesnt do much for component life.

As for the rocker, its a throwaway( and I believe you will find Husaberg dont list the 03 roller tips seperate- but they are out there I believe )

Ive got one similar, and I wouldnt even consider fitting a new roller tip to it.
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August 4th, 2007, 10:19 AM   #4
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Ausberg: makes me think someone is selling USED rollers on eBay. "Only" 20 hours.
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August 4th, 2007, 01:45 PM   #5
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Thanks guys - thats what I thought you'd say.
Next question is how far of a strip down. Split the cases type stuff or just take off the sidecover and clean it all up.
You probably know how these things go - come this far I might as well do this and do that, then pretty soon you've totally pulled it apart and replaced everything.
This is my first berg and I'm learning that the parts are expensive with a capital "F".
I was told by a local berg dealer here that you can only buy the complete rocker assembly and not just the bearing tips but I see posts here about how to do them and they are in the parts manual so they must be out there.
The intake has the damage so I'll need the complete assembly but I can't see the point of replacing the whole exhaust rocker (except maybe to line the parts mans pocket) and it'd be stupid not to replace the exhaust bearing tip since it's partner just died.
Anyone know where to get them or some other manufacturers part N#s - KTM perhaps?
I'll probably check out 1 of Dale's cams and Dale if you're reading this what's the deal?

Coops
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August 4th, 2007, 02:18 PM   #6
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You usually go step by step, according to your confidence level.

I have worked on the top and will not work on the bottom for a while, maybe ever, unless dramatic engine explosion.

Taking the case out, splitting it open, working on it, putting it back together and in the bike can be quite a far step for the non-mechanically inclined.
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August 4th, 2007, 04:07 PM   #7
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Hey Coastie,

You are going to hate me!

but only because what I say might put doubts into your mind

Given what has gone on your motor it means you probably have small bits floating around somewhere. These bits are most likely to drop down into the casing to the left within your clutch area and maybe also to travel into your gearbox. If you drain the oil you might already find remnants in there on the magnetic plug.

In order to really make sure eveything is clean you will have to split the cases. You'll probably be lucky enough not to have any further damage and therefore the cost of parts for the clean up job is going to be negligable barring the seal kit. The cost then becomes only labour. You are unlikely to have to replace a lot of additional parts, if any, it's only about cleaning it all up. Considering what you already have to fix, it's not a huge amount on top, really.

Of course, you can simply replace what has broken, take the whole clutch side casing off and clean it out and then flush the engine a couple of times. I have used to very good effect an oil/petrol mixture as an engine flush which works really well - you just run the engine till hot, flush out, then take it for a ride with a new flush solution and then empty and put proper oil in afterwards.

The flushing will often get rid of bits but you will never know, because you can't get into each and every bearing to blow it out with a compressor or similar.

Either way could be fine but given the risk, it is entirely up to you. For the sake of an extra few hours of labour - on your part or someone elses, it might be worth the trouble.....

As for the rockers it always used to be the exhaust ones that went first. You'd be better off replacing them both and I'm surprised you can't get just the rollers, you always used to be able to.

Mail Dale directly about the cam as I don't think he makes it on here very often with his other commitments.

And by the way, these engines are fairly simple to work on. If you've not had a lot of experience, take your time, be really patient, double check all your work and use the workshop manuals available.

All the best,
Simon
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August 5th, 2007, 05:19 PM   #8
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Hi Froggy
It's not that I'm not mechanically inclined it's just coz I have a couple of problems.
1. A wife
2. Money - related to problem N#1
3. Never done a bottom end on a berg before.

Hi Simon
Don't worry I already had those doubts in my mind.
I've decided I'll take the challenge and pull it completely apart and clean it all out.
I got it 2nd hand so I'm not real sure of the history so with all the stories of mains failures and the like I figure it'll be a good chance to check out the condition of the rest of it and then at least I'll know that I shouldn't have any other problems in the near future.
Except of course if I manage to screw it up completely.

Anybody out there know where I can get my hands on some rocker bearings?

Coops
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August 5th, 2007, 07:03 PM   #9
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Having a wife is not an excuse but an extra motivation to go lock yourself in the garage to work on the engine.
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August 5th, 2007, 07:45 PM   #10
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Yeah good point
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