Jammed piston

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grillbritt

Joined
Jul 21, 2008
Messages
52
Location
Sweden
Hello,

I went out riding Friday after work. After about 1 hour of hard dirt road riding, the bike made a dull ticking sound and died. I quickly pulled the clutch.

Now the piston is stuck.

I started to remove the engine from the frame today, and when I emptied the oil there was LOTS of water in it.

What can I expect when I open it up? Will it be completely trashed?

The bike has about 200 hrs. I don't think the bearings, piston etc has been changed.

Thanks!

Dennis
 
get it stripped fella, no point in asking us when you are so close to stripping it anyway?

sounds as though the liner is broken but that would be the worst result I can imagine.

regards

Taffy
 
Well... here are my recent discoveries:

One of the inlet valves had snapped off and crushed between the piston and head.
Some bits had followed the piston and cracked the liner, just as you said Taffy.

Do I need a new piston? Or is it enough to grind of the unregularity and install with new rings?
Why isn't the piston lining up with the cylinder top?

[attachment=2:tk7yvbv9]5.jpg[/attachment:tk7yvbv9]

[attachment=1:tk7yvbv9]2.jpg[/attachment:tk7yvbv9]


Do I need a new top, or is it enough with new valves and the seats taken care of?

[attachment=0:tk7yvbv9]1.jpg[/attachment:tk7yvbv9]
 

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[attachment=1:1vquocqe]3.jpg[/attachment:1vquocqe]

Is the liner fixable or do I need a new one?

[attachment=0:1vquocqe]4.jpg[/attachment:1vquocqe]

Please help me guys! Feeling a bit sad for my broken monster...
I don't want it to cost a fortune.
 

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Maaaate. Shes cactus. New piston. New liner, and it would be a brave man who took on that head machining job. The potential for cracks is huge. New mains while you are at it if it has 200 hours on it. I would be contacting my local berg 'Spurt to do a full rebuild.
 
I would have though Taffy'd answer this one by now

maybe someone can save the head but its not going to be cheap

liner is cracked so you need a new one don't risk using the piston again

cheapest fix Id guess is get a second hand head from ebay, and all the other bits off Taffy
 
Thanks for the answers,

Not the answers I wanted to hear, but anyway.

Not many used Husaberg heads out there... Does any KTM head fit? What about the other parts?

I'm not so thrilled paying $2000 for a couple of parts...
 
To be honest grillbro I have had heads that have had alot worse damage ( like an exhaust valve stem smashed up into the sparkplug and its mushroomed the end of the plug like serious and an inlet valve head that was turned 90 deg and smashed up into the exhaust valve seat and all the other associated damage whilst it ran down from 15000+ rpm(little 4 cylinder kawasaki) than that repaired before with good success. I sent it too a good kiwi engineer with a note asking him to change the plug and set the valve clearances for me (I was being an optimistic smart arse at the time). He welded the compustion chamber back together, remachined, installed 4 new valve seats and sent it back with a bill for $460. The real expensive bit was the small pile of kawasaki parts to put it back together.
From what I can see in the photo it doesn't look too bad at all, but a close inspection may uncover more. Not sure how heavy the Berg castings are.
If you do get it repaired then factor in a rod kit to go with the new mains and balancer bearings.
just my two cents worth.
 
Hi Bergbro
That's a nice story... it brings some hope back to me :)

If I look closer it does look like the steel valve seats hasn't got a scratch. It's the aluminum around it that got some scratches.

I think I will try to split it and see what else I can find.

No one got a nice liner to sell?
Is it smarter to buy all four valves new or just the two ugly ones?
 
been away all weekend having a good time.....

the head is VERY repairable. the piston may have twisted over the top if the rod. to check the rod you need to split the crank ideally. as has been said...new mains while you're there, I'd do a new pin and bearing and ask for the rod to be trued up while there. I'd also go for a new little end.

I think another head could come off a valve in days especially it's sister so defo one if not all 4. shock damage you see....

regards

Taffy
 
Hi Taffy, thanks for the answer. Hope your weekend been good with lots of riding?

I can't find the pin and bearing for the rod, do I have to buy the complete conrod repair kit?

Little end? What is that? Internal nickname?

I saw in your shop that you repair liners, but I guess it's like bushmechanic said that I need a new one?

Best regards
Dennis
 
your liner is toast as they say. completely 100% destroyed. little end is also known as the small end bush - the opposite end to the big end thus the name: little and big end!

I sell pins and bearings.

regards

Taffy
 
You need a tool to remove the flywheel, its the same as a ktm. you can do it without but you wont get it back together.
 
grillbritt said:
Do I really need the special tool to split the engine?
Click to expand...
Just make your own ten minutes work if you can weld, am on my phone can't post a link but if you do a search for 'special tool' on the forum you will find more info.
 
Hej.
Topplocksverkstan.se repaired my head when i had a broken valve in my 501 and it was not so expensive as i tought.
Change all valves, valveguides and sealings.

Regards
Jampe
 

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