Gavbey's 2002 fs 650 build thread

[GAVBEY]

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

 

[GAVBEY]

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]

 

[GAVBEY]

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

 

[GAVBEY]

is it too far gone?

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

small end bearing is a bush?

 

[GAVBEY]

Here is the main bearings I'm going to use.

 

[GAVBEY]

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.

 

[GAVBEY]

Done some more bits and bobs.
Cleaned up my valves, ported the head, ground some material away for the double valve springs etc

 

[GAVBEY]

 

[GAVBEY]

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.

 

[GAVBEY]

went out for a few runs in the ice and snow

 

[GAVBEY]

and this is my new exhaust. i have no idea what make it is

 

[Goose916]

She looks fantastic! Great job on the rebuild. I'm going to spend some serious time checking out all the mods various posters have done before my next rebuild. Thank for showing the drilled out oil feeder. I noted it for my next rebuild as something to address. Thanks for all the pix too. It really helps guys like me to understand what you're doing and why.

 

[johnyberg]

Nice job, the piston is the "tallboy" from taffy? If yes the compression ratio has change a little bit right?

 

[Taffy]

Hi Gav

years ago I had a tailpipe like that, I still do. I put up the name of it here years ago but the name plate fell off. it was like three letters long starting with M**.

sorry, can't recall. I know I checked at the time and there was nobody about of that name.

regards

Taffy

 

[GAVBEY]

She looks fantastic! Great job on the rebuild. I'm going to spend some serious time checking out all the mods various posters have done before my next rebuild. Thank for showing the drilled out oil feeder. I noted it for my next rebuild as something to address. Thanks for all the pix too. It really helps guys like me to understand what you're doing and why.

cheers buddy . I havnt yet measured the oil pressure now but i can imagine its a good bit more than standard. drilling the oil pilot should sort of flood the conrod with oil helping it stay lubed and cool

Ive built a few cars, my latest is my large single turbo Mazda RX7. Pics deffinatly do help.

Nice job, the piston is the "tallboy" from taffy? If yes the compression ratio has change a little bit right?

yes i did my friend.

my last setup the piston was about 3mm short, top of the barrel. this piston is flush! or 0.2mm from the top. MAJOR up in compression. the bike is a complete animal to drive and you really do have to watch when you open it up. its defiantly controllable at sliding. its scary fast and thats compared to my 185bhp R1

 

[GAVBEY]

Hi Gav

years ago I had a tailpipe like that, I still do. I put up the name of it here years ago but the name plate fell off. it was like three letters long starting with M**.

sorry, can't recall. I know I checked at the time and there was nobody about of that name.

regards

Taffy

i shall call it MAD

haha cheers taffy

 

[AwesomeFE550]

Holy... Nice pics and all man... Where did you source out the parts?

And by chance did you keep a record of all the parts and parts numbers?

 

[tourist]

yummy! how did i miss this thread ??

 

[GAVBEY]

Holy... Nice pics and all man... Where did you source out the parts?

And by chance did you keep a record of all the parts and parts numbers?

nope im sorry my friend. most of the info came from bushmechanic and taffy.

Ill help you where i can with part numbers

 

[GAVBEY]

yummy! how did i miss this thread ??

i just created it today gavbey melted piston?? was my last thread