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May 21st, 2015, 01:50 AM   #41
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I Ride: 2008 700FK, 2002 628FST
Originally Posted by aaron View Post



In an earlier post Taffy mentioned there would be no oil feed in that head. At the time I thought that was a reference to the external oil feed I was intending to add. However, now I can see what you mean - there is no oil gallery in the corresponding location.

I assume there must be an oil gallery elsewhere perhaps running through a bolt hole? Will I be able to have this drilled for the 501 located oil feed or is this head swap just not possible? Going to need to address this before I go spending on parts. The 501 head has some minor damage so it will be a toss up between which is the more economical to repair or modify.
the newer cases still have the oil gallery drilled its just the heads that are different so as far as oil galleries are concerned you can out a new head on an old bike and its the same setup as a stock 04-08

on my 08 I run an external oil line from the oil filter cover to inside the exhaust rocker pin and have modified things there to direct the lube where i want it. as stock it was just splash lubed but i flog the piss out of my bikes on 40deg C + days so the extra oil up there helps

the 02 head has a complex oil feed system as stock and is required as the rocker arms run on bronze bushings
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May 26th, 2015, 07:33 PM   #42
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I Ride: 2002 Fe501
Got talking with another '02 fe501 owner on FaceBook last night who is looking for a head and crank. Sounds like his bike has suffered the same fate, so Garry if you're reading this..good luck mate, lots of help to be found here. Can't promise it's going to be easy or cheap!

Turns out the exhust rocker in the new head has a stripped thread for a tappet adjuster...grrr.

Picked up WP suspension owners manuals in my travels this week. I'm a big lad (>100kg) so I may need to consider upping the spring rates or losing more pork. Frankly, the latter is the better option. I've been gradually accumulating riding gear but I'm leaving the purchase of pants until later, like until I actually need them. At least my head and feet won't be changing size anytime soon.

Read through a bunch of threads on the Yamaha R6 starter modification this morning - so just leaving this here for my own reference so i can find it again. A used R6 starter seems to go for about $110 AUD and there is one listed NEW at $114 at the moment.

restarter upgrade '02 650

The saga continues...
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May 26th, 2015, 11:14 PM   #43
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may well have a crank, probably thinking about at least my 550 crank. I defo have several heads.

Taffy
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May 31st, 2015, 06:06 PM   #44
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I Ride: 2002 Fe501
Photo upload time!

Here is the FCR - no choke
Various shots of the chewed up original cam side by side with the replacement "08" cam.
Note the ADC stopper was dislodged, I pressed that back in but have yet to weld it (my father took his bottle of Migshield back home - how rude).

I pulled the ADC spring out and modified it. Unwound it to leave approx 12 turns on the spring. It doesn't feel remarkably stronger but I can notice a slight increase in tension.

Would I do better to get a KTM spring? Thankfully there is a KTM dealer a few blocks away from work in Melbourne's CBD. The dude on the parts counter is very helpful.

While I wait for parts to arrive I've been tinkering with a few other little bikes. This Suzuki JR80 came as a non-runner for $400. They tend to go for upwards of $1000. Only needed a carby clean and a few minor missing screws replaced, new levers, fix flat tire, straighten up the brake pedal etc. Let my 8 year old nephew have his first ride but I think the clutch/gears are a bit beyond him to master just yet. I got a Suzuki DS80 (pretty much the same bike) when I was 10 (in 1987) and I seem to remember figuring it out very quickly! I also picked up a 1999 Honda XR70 which is 3 speed semi auto for $150, but it needs rings. I've started cleaning that up and will let him buzz around on that until he can step up to the Suzuki. After that there is a 2000 RM80 to put back together - the engine was a mess but I've resurrected the crank. Some drongo stripped the left hand thread off the primary gear side and the barrel was shot, metal through the engine. Ready to go back together with new bits now.
Attached Thumbnails
Intro - Hoge's Husa (Australia)-photo-1-1-.jpg   Intro - Hoge's Husa (Australia)-photo-2-1-.jpg   Intro - Hoge's Husa (Australia)-photo-1-2-.jpg   Intro - Hoge's Husa (Australia)-photo-2-2-.jpg   Intro - Hoge's Husa (Australia)-photo-3-2-.jpg  

Intro - Hoge's Husa (Australia)-photo-3-1-.jpg   Intro - Hoge's Husa (Australia)-photo-4-1-.jpg  
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May 31st, 2015, 06:13 PM   #45
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I Ride: 2002 Fe501
ADC spring...
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June 10th, 2015, 05:28 PM   #46
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Well the hunk of junk valve spring tool arrived yesterday and I wasted no time in removing 1 inlet and 1 exhaust valve from the newer head before work today.

The tool itself bent very easily. I should have remembered to give the valve retainers a quick tap with a plastic hammer BEFORE using the tool, so as to loosen the colletts, but I still think its a piece of crap given how easy it bends. I'll actually chop it up and just use the useful parts in making a stronger spring compressor tool.
Attached Thumbnails
Intro - Hoge's Husa (Australia)-photo-4-3-.jpg   Intro - Hoge's Husa (Australia)-photo-2-3-.jpg   Intro - Hoge's Husa (Australia)-photo-1-3-.jpg  
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June 11th, 2015, 03:44 PM   #47
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I Ride: 2008 700FK, 2002 628FST
nice pics hoges

the valve spring compressor is a crackup .. i made one out of a G clamp

about the rod /crank, I ordered some bits of Orangeberg yestdy

he let me know hes got ex andy caldecotts old stock for the older bikes and quite a bit of rod and big end gear generally
Thanks from aaron
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June 11th, 2015, 09:40 PM   #48
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Good to know. I've been squirreling away cash for rod kit etc and as of next pay will be all systems go for an Orangeberg parts order.

Kibblewhite RFS valves and springs ordered and paid for too. Worked out $450 AUD with shipping.

Here is the bike trailer my father and I have been building. He's been making horse floats for years and I credit all welding to him. It started out as a 6x4 trailer he got at the local tip. The floor was totally eaten by rust, even so, I put a piece of ply in there and we just used it around the farm and I once did a road trip to Adelaide and came back loaded with Mazda rotary engines. Decided it was time to re-create it so out came the grinder and I was left with a useable axle/springs and hitch/A-frame. The rest of it is new steel (Duragal - galvanised).

I roughly copied the dimensions of the old 6x4 but added an extra foot into the front to make it 7x4 internal and an extra 6" either side for the perimeter tie rails. I left the axle set as per the 6x4 measurements to make it easier to reverse without jack-knifing. The bike channels are now retained by Riv-nuts so they bolt-on/bolt-off. Still need to get a ramp folded up. That will be held down by the two gold coloured wing nut thingymabobs (spare wheel retainers salvaged from a Mitsubishi Magna). Just kinda made this up as we went without a plan but I'm very happy with how it turned out. Aim has been to sell it when finished to fund the Berg!
Attached Thumbnails
Intro - Hoge's Husa (Australia)-photo-1-4-.jpg   Intro - Hoge's Husa (Australia)-photo-2-4-.jpg   Intro - Hoge's Husa (Australia)-photo-3-4-.jpg   Intro - Hoge's Husa (Australia)-photo-4-4-.jpg   Intro - Hoge's Husa (Australia)-photo-5-2-.jpg  

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June 12th, 2015, 12:19 AM   #49
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I Ride: Husaberg FE 450 Force Edition
Originally Posted by aaron View Post
Well the hunk of junk valve spring tool arrived yesterday and I wasted no time in removing 1 inlet and 1 exhaust valve from the newer head before work today.

The tool itself bent very easily. I should have remembered to give the valve retainers a quick tap with a plastic hammer BEFORE using the tool, so as to loosen the colletts, but I still think its a piece of crap given how easy it bends. I'll actually chop it up and just use the useful parts in making a stronger spring compressor tool.

The tool is fine. Put the closed side in a vice and let the lower side rest on the table. Use correct attachment to go around the spring retainer. Tighten slowly and when tight tap the top of the tool with a hammer.
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June 18th, 2015, 06:03 PM   #50
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I Ride: 2002 Fe501
Kibblewhite kit arrived from eBay seller "atv_zone". That was fast!
$269.95 USD plus $39.95 shipping = $309 USD ($450 Aussie)

96-96000 Kit includes:

1x Titanium Intake Retainer (2pcs) 96-96001
1x Intake Valve Spring set (2pcs) 96-96002
1x H.T. Steel Intake basewasher (2pcs) 96-96003
1x Intake spring shims (2pcs) 96-96035
1x Titanium Exhaust Retainer (2 pcs) 96-96036
1x Exhaust Valve Spring set (2pcs) 96-96037
1x H.T. exhaust basewasher (2 pcs) 96-96038
1x Exhaust spring shim (2 pcs) 96-96039

Separate packet
2x Intake Valve 96-96004
2x Exhaust Valve 96-96007
4x Valve stem seal 6mm 700-100029


Starting to feel real now! I also pressed the ADC stopper back into the timing gear and welded it on the back side.

Despite having my own Mig welder I don't have my own gas to run it. My dad left his bottle of Argon/Migshield at home and it would have been a 140km round trip to go get it so I had to hunt around for another bottle. Luckily Total Tools are now doing a bottle swap-and-go program. $330 later I had gas to do the job. $200 of that is a deposit on the bottle. Ah, the silver lining is at least I can practice my welding whenever I want now.
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