Joined Jun 2007
4K Posts | 1K+
south east WA Australia
seems to be a common question particularly for older bikes.
for the old bikes you can check the parts listings in service manuals on the left of the main page and then search for them at the munn racing fiche.
I've found some "no longer available parts" for my 02 by checking individually with husaberg dealers and parts suppliers all over the world.
for example Rick bozarth at boss offroad and Dan at moto exotica are great people to ask for this kind of stuff.
if I can't get piston or a rod for an older bike, even kwakas and suzis need rods
I look first to the catalogs of prox and carillo for the rods and wossner for the piston specs.
http://www.pro-x.com/downloads/technical.pdf
http://wossneronline.com/2014_wossoner_motorcycle_pistons_catalog.pdf
carillo rods on page 64 Catalogs
what I do is measure the squish, piston to valve clearance and the Compression ratio, measure up the rod the big end pin and the piston including piston volume.
for a good example of checking the piston to valve clearance see Dr_Cs videos https://www.youtube.com/user/Massegossen I won't tell you which one its in you have to watch them all
example of rod dimensions required thanks Wardog
the pins obviously you need OD and length but also oil gallery placement and weight should also be considered.
for balancing and crank welding info check here http://husaberg.org/mechanical/17329-balancing-80mm-650-crank.html
with the right information I am able to choose rod/pistons that work even if they are not listed for that model.
when the gallery is back up there will be most berg rods in 3d models and ISO drawings. http://husaberg.org/mechanical/17362-conrod-drawings.html
the hardest bit is usually the pin, Trick titanium will make you anything you want in steel or Ti .. for a price. Alpha bearings in the UK is another contact, there are heaps of people with pin grinders but most are old school and don't do the inter web, ask around locally.
If you need to modify a pin to make it work eg a proX pin kawasaki honda suzi yam or a Jawa pin you can have the ends ground cylindrically to the correct Diameter and also if needed have this done on an offset to adjust the required rod length or machine out the crankpin bore in the crank to achieve the same thing.
http://husaberg.org/mechanical/16703-husaberg-ktm-hybrid-engine.html
this a good one, big end pin made from a rover piston pin http://husaberg.org/mechanical/7603-1994-501-conrod.html
if the big end oil holes do not align take a 3mm diamond coated spherical burr in a die grinder and grind a 1-2mm deep groove in the ID of the crank pin bore to connect the oil passages. if the oil passages require enlarging use diamond coated burrs, if the pin is too long grind it down, if the pin is too short split the difference either side and weld the pin ends.
its sometimes a little disheartening when parts are discontinued but Rods pins and Pistons are the bread and butter of single cylinder internal combustion engines and with the inter web resources we have, they are relatively easy to obtain.
.
for the old bikes you can check the parts listings in service manuals on the left of the main page and then search for them at the munn racing fiche.
I've found some "no longer available parts" for my 02 by checking individually with husaberg dealers and parts suppliers all over the world.
for example Rick bozarth at boss offroad and Dan at moto exotica are great people to ask for this kind of stuff.
if I can't get piston or a rod for an older bike, even kwakas and suzis need rods
I look first to the catalogs of prox and carillo for the rods and wossner for the piston specs. http://www.pro-x.com/downloads/technical.pdf
http://wossneronline.com/2014_wossoner_motorcycle_pistons_catalog.pdf
carillo rods on page 64 Catalogs
what I do is measure the squish, piston to valve clearance and the Compression ratio, measure up the rod the big end pin and the piston including piston volume.
for a good example of checking the piston to valve clearance see Dr_Cs videos https://www.youtube.com/user/Massegossen I won't tell you which one its in you have to watch them all
example of rod dimensions required thanks Wardog
the pins obviously you need OD and length but also oil gallery placement and weight should also be considered.
for balancing and crank welding info check here http://husaberg.org/mechanical/17329-balancing-80mm-650-crank.html
with the right information I am able to choose rod/pistons that work even if they are not listed for that model.
when the gallery is back up there will be most berg rods in 3d models and ISO drawings. http://husaberg.org/mechanical/17362-conrod-drawings.html
the hardest bit is usually the pin, Trick titanium will make you anything you want in steel or Ti .. for a price. Alpha bearings in the UK is another contact, there are heaps of people with pin grinders but most are old school and don't do the inter web, ask around locally.
If you need to modify a pin to make it work eg a proX pin kawasaki honda suzi yam or a Jawa pin you can have the ends ground cylindrically to the correct Diameter and also if needed have this done on an offset to adjust the required rod length or machine out the crankpin bore in the crank to achieve the same thing.
http://husaberg.org/mechanical/16703-husaberg-ktm-hybrid-engine.html
this a good one, big end pin made from a rover piston pin http://husaberg.org/mechanical/7603-1994-501-conrod.html
if the big end oil holes do not align take a 3mm diamond coated spherical burr in a die grinder and grind a 1-2mm deep groove in the ID of the crank pin bore to connect the oil passages. if the oil passages require enlarging use diamond coated burrs, if the pin is too long grind it down, if the pin is too short split the difference either side and weld the pin ends.
its sometimes a little disheartening when parts are discontinued but Rods pins and Pistons are the bread and butter of single cylinder internal combustion engines and with the inter web resources we have, they are relatively easy to obtain.
.
