1999 FE 400 Engine Issues

Hi Guys,

Just got a *cheap* 09/1999 FE400 with an alleged ignition fault. Found a broken wire on the coil pack and voila good spark restored A 12mm plug has been bodged into the head, so a heli-coil back to 10mm needed.

The real bad news is... still no starting or even a fire off ether and a bizarre compression "rock" when you kick the thing which is explained by...

Further teardown shows both intake adjusters have snapped at the rocker, one of which has gone under the cam and been punched through into the coolant passage underneath the camshaft bath leaving a 20mm hole. Crap. The intake rocker arm roller has collapsed as well.

One broken adjuster found in the hole with a chunk of head, the other I suspect has been removed by PO when he found it was an ignition fault. LOL.

So head off and into my machinist, his welder isn't good enough so off to local radiator guy - no problem. Quoted $60 to weld, no problem. The guy is good, has welded alloy swingarms and suspension linkages for me and others before.

Everything else up top looks OK, no damage to cam and timing chain is tight. So I pulled the barrel, the rod, piston and bore all visual OK, so I am thinking a light hone and a set of rings.

For the top end 2 x adjusters and the rocker roller, with a head service.

What I believe has happened is the rocker roller has seized then collapsed, causing the intake adjusters to get loaded so they snapped causing the other carnage. I suspect from lack of valve adjustments by PO.

The bike has been ridden hard but looks like it has been well maintained until this guy got it. I don't believe he was capable of maintaining it either.
I also pulled the clutch cover and no sign of the missing adjuster or any metal, munch marks etc. I do not believe it could have got into the gearbox area either.
Inside of engine is very clean indicating regular oil changes although some fresh water contamination (expected)..

My questions are

- Do you guys with your experience of Husabergs agree with my conclusions or am I missing something else?
- Should I replace both rollers and all valve adjusters and valves as a precaution?
- Anything else you can think of?

Rest of the bike is pretty solid, just a bit ratty from 15 years of use.

Thanks in advance.
Waldy

My questions are

- Do you guys with your experience of Husabergs agree with my conclusions or am I missing something else?
- Should I replace both rollers and all valve adjusters and valves as a precaution?
- Anything else you can think of?

if you are on the original cone shaped single valve springs I would do both CFBs while I was there. if you can make the good CFB clonk by about 0.1mm then it is on the verge anyyway.

the follower bearing hgas gone for sure first, what tends to happen is that the owner keeps ignoring the rattle, the 'wheel' or outer race of the CFB grinds down and then as a 'C' it comes off the pin and then bangs under the cam etc.

there are many owners here who will testify to it actually going the other way and coming through the top of the rocker cover. this is the first time I've ever heard of it going downwards and through the head: very unlucky.

can't answer yo on the top end. I can't do half a job so for me it would be guides, valves, seats cut, valve stems squared, valves faced. DVSK as a nice finish.

you should find your rocker shafts completely trashed but sometimes you can turn them over. always put the worst wear on the top as the engine would sit.

If the cam has gone I would buy a KTM cam complete with the later auto decomp, get a steel cam sprocket from a 2002-2008 Husaberg and fit that. you can get them as a complete cam really cheap. I would get my stronger auto decomp spring so thats
complete cam
mod decomp spring
steel cam sprocket

if the bottom end is good, why not treat the top end?

regards

Taffy

Also timing chain (taffmeisters) and the plastic water pump impeller can be replaced w/a KTM unit (which may be the same as a 04-08 Hberg) as it will become embrittled, as all plastic will, from going through many heat cycles.You will need to sand a few mm's off of it as it is slightly larger in diameter.

Thanks for the replies, looks like I've got a parts list in motion to get this thing back together. Both intake valves were razor sharp and needed replacing as well.

Before and after photos of the head damage and repair, welder said the alloy was really good to weld.

Cheers
Waldy

Gday Waldy,

nice to know roughly how thick the head is at that point, thanks for the pics

yes the head and cases are easy to weld, the alloy is also prone to a reasonable amount of creep over time compared to other bike castings.

canberra... do you know a bloke called Ben ? rides a new 450berg "spiderpig" on here "bluerider" on DBW

G'day bushmechanic,

Yep interesting place to find a water leak, bit unexpected. lol

Turns out even though it is complianced as 09/1999 its a 2000 model with hydraulic clutch and later style frame and suspension from the earlier models. Good bikes from what I hear so maybe I'll luck out when its all together.
Just waiting parts to fix the old girl up..

Nah don't know him, Canberra is a small place but I do keep to myself and my old crap!

Cheers
Waldy