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December 22nd, 2014, 06:31 AM   #1
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I Ride: 2002 FS 650
Gavbey's 2002 fs 650 build thread

Hi Guys,

Im Gavin. Im relitivly new to the Husaberg breed. Infact the bike i have now is my first and ive fallen in love.

My story began when i bought a bike without hearing it run or even seeing it. yeahhh i might have payed a bit too much for it however i fell in love with it.

When i bought it i literaly rode it to the MOT station and back then bam! The F***R died.

It turned out to be Con rod bearing that had went. further investication into it found that the last owner had done 750 YES 750 miles WITHOUT an oil change!

the oil pilot on the 02's are microscopic and this had starved the con rod of oil and well you guessed the outcome.

this thread is mainly so i can keep track of bits and bobs ive done

anyway here is my spec now

Husaberg 650
2002
standard cases
650 wosner tall boy piston
upgraded 2004 rod (1mm longer)
new rod bearings
new upgrade roller bearings
all seals and bearings have been replaced
drilled my oil pilot to 3mm
1.5mm thick washer behind oil pump relief valve to up the oil pressure
stainless oil filter
fcr 41
fcr 41 tune up kit with taffys needle
ported cylinder head
double valve springs
kick-start sledge upgrade
upgraded cam chain tension-er
upgraded cam chain sliders
ISIW cam chain
53 cam
and upgraded unknown exhaust.




next post shall be full of pictures.

Thanks for looking all comments welcome

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December 22nd, 2014, 06:33 AM   #2
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From: Livingston

Posts: 80
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I Ride: 2002 FS 650
here is some pictures of my build



Is this cam chain guide bolt supposed to be this angle?





This cam chain guide looks a bit broken?




Engine cover off. No major looking problems here.





I found this bolt to be loose??





The bore doesn't look bad? There is some marks of detanation on the piston though?




I was turning the engine over with a 17mm socket and t bar. I could feel a reall stiff spot at really random times. I thought I had spun a shell until I found out I don't have shells. I then soaked the barrel and piston in oil and after a good few rotations it got easy until the stiffness has gone. I can't actualy make the engine get stiff when rotated anymore.

I think I've melted a ring or piston?

How hard is it to change a piston on these beasts?




n.[/QUOTE]
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December 22nd, 2014, 06:34 AM   #3
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I Ride: 2002 FS 650


Is this a standard piston? The numbers are hard to read. 212....





Is there an uprated version of these? Could this have been a problem?






Timing chain marks on the top cover?




The head with gasket on.





And my pile of bits some cleaned some not.
Like I say I still think a piston and rings wouldn't harm it however the cam chain is quite suspect now. Hmmm

Look forward to any rely
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December 22nd, 2014, 06:34 AM   #4
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I Ride: 2002 FS 650



is it too far gone?




the piston has some major scrapes on both sides of the piston.







small end bearing is a bush?


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December 22nd, 2014, 06:35 AM   #5
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I Ride: 2002 FS 650
Here is the main bearings I'm going to use.



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December 22nd, 2014, 06:35 AM   #6
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From: Livingston

Posts: 80
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I Ride: 2002 FS 650
Not much of an update. Been playing with the oil system and cleaning faces and parts up. Everything looks good.

I drilled my crank feed hole to 3mm instead of 0.75. When I looked through it the hole was actually blocked so the crank was starved of oil.

Here is a pic of it drilled to 3mm




I found a brass washer that would do the job of increasing the relief valve for oil pressure.






And here's it fitted.




Also fitted my modified decompression spring.



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December 22nd, 2014, 06:36 AM   #7
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I Ride: 2002 FS 650
Done some more bits and bobs.
Cleaned up my valves, ported the head, ground some material away for the double valve springs etc







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December 22nd, 2014, 06:36 AM   #8
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I Ride: 2002 FS 650


Thanks from bushmechanic and makazica
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December 22nd, 2014, 06:37 AM   #9
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I Ride: 2002 FS 650
So masive update.
Must say thankyou to taffy for all the parts and 24hr service haha.

so first things first then new parts..





double valve springs fitted and also modified my cam chain blade with a longer bolt wich touches the head to stop it bending





pistons



measuring axial play


new barrel and piston in


head on and all timed up


engine back in to the frame


time for a blast


changed the oil. there was aloto of old metal floaring about. changed oil twice after this and now there is none and she runs nice and smooothe





so finally its back on the road and running great.

Thanks from bushmechanic
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December 22nd, 2014, 06:38 AM   #10
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I Ride: 2002 FS 650
went out for a few runs in the ice and snow

Thanks from bushmechanic
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