2001 FE650E basket case - rebuild

Hello all! I haven't posted anything since my little new user intro and I thought it was about time to jump in here and share my Husaberg tale.

Last year I acquired a basket case 2001 Husaberg FE650E from a friend. I have no prior affinity for Husabergs and no experience with them. I just can't sit by knowing that a dirt bike lies in ruins with little to no chance of ever being repaired. Thus, against my better judgment, I decided to step in and try to save this beast. Anyway, I'll try to document the work I'm doing in this thread. Hopefully you guys enjoy it (more importantly, hopefully I succeed at getting this thing back on the trail).

Here are a couple of pics showing the bike the day after I brought it home...

The first thing I did was to clean the frame. I wanted to get a rolling chassis built first. It's just easier to go park the thing someplace than manage a whole bunch of parts boxes. I figured I'd tackle the motor once I had the chassis done.

So I cleaned the frame, as well as the triple clamps. The bearings actually looked OK so I cleaned and greased them and mounted the clamps.

After that I tackled the forks. Lots of work here. One of the forks was smashed at the seal. I managed to get the fork disassembled but it took some massaging to get the "dent" out of that one outer fork tube. I used some round steel stock and got it close to round (not quite). I was aftaid I would permanently damage the thing if I kept going.

Internally, the forks had a few problems. I was able to get the parts I needed and got them re-assembled.

I also ordered up a new rear fender and mud flap. The bike didn't come with that stuff. I started installing stuff onto the frame as I went. I cleaned the shock and got it mounted. The seat, tank and shrouds are the only things I mounted that haven't yet been cleaned/prepped. The frame is a good place to store them in the meantime.

While cleaning the swingarm, I found a [non-oem] shock bolt. The shock bolt situation is not fully resolved. I can't source the OEM ones and it's tough to find one with the correct grade and the correct shoulder length. For now, I'm utilizing a lot of washers. Not ideal, I know.
If the thing ends up running, it will receive further shock bolt attention.

I got three wheels with this thing. A pretty beat up front (with buchanon spokes), a really nice 19" rear with (with buchanon spoked), and a thoroughly thrashed 18" rear (with buchanon spokes).

The 18" wheel's hub had cracked at some point and had to be welded!!! The friend from whom I got the bike is pretty gnarly (has raced King of the Motos) and he'd been riding with that hub for some time so I'm going to run it too.

I did pull the 21" and 18"" wheels apart to clean and more thoroughly inspect them. I have a trueing stand and a wee bit of experience with it so I was comfortable doing that.

I dug up some old crappy tires and finally had a rolling chassis.

The front brakes were in several pieces. I cleaned everything, installed a master cylinder rebuild kit, and got them mounted up and bled.

The engine saga is next and that is ongoing. I'm definitely going to need some help.

Keep up the great work, I'm going to be follow this for sure.
Good luck with the build.


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Good on you. I would do this to a 2000 FE600e if i could find one.

44014 said:

Good on you. I would do this to a 2000 FE600e if i could find one.

Click to expand...

Have a look at this one then mate and it's in Brissy too.....


MOTORCYCLE OFF ROAD on Gumtree MOTORCYCLE OFF ROAD | Motorcycles | Gumtree Australia Brisbane North West - Brisbane City | 1137548729

Damo

Oh, and keep up the good work mx563! :thumbup:

I'm very happy to see a true gem being restored instead of parted out!

Damo

FE600 renewal

Hi MX. Looks like you are doing well. That swing arm is off a later model. Should be same key points tho. Your FE had a massive blocky looking arm as OE. It was to fat for the chain run so the factory finally put it on a slimming program. The OE one worked fine, if one kept an eye on the guides. It is hard not to work on a Husaberg. Must be the spirit of that Swedish cromo frame. I have the same frame here. There was a Swiss engineer named Egli who designed about the most beautiful bikes anywhere. Our Husaberg frames look suspiciously like his work. Those diagonal rods and huge back bone are things he always did. Hope so anyway. Good luck, L

It is hard not to work on a Husaberg

There's some truth to this. I'm a long way from being done with this 650 and I'm already starting to think about a 93' Smets replica. These things were definitely ahead of their time. I keep watching the Husaberg factory videos over and over again on youtube. The lady dropping bearings into the cases and assembling the head is motivational.

Just a preview of the engine work...my buddy complained about the shift mechanism slide piece always getting stuck. He parked the bike after nursing it home stuck in 3rd gear. What I'm seeing is that one of the bearing cages (the one behind the clutch basket) came apart. Instead of being evenly spaced, all the balls are resting together. I split the cases over the weekend and found some metal inside. :-/

PS big fun

Hi MX. Almost forgot. Starting around year 2000, ex US open class motocross champion Chuck Sun got ahold of loads of Husaberg FE models. His plan was to do guided desert rides and training. Husaberg even GAVE him his first eight 400s to get things going, if my info was right. Story was, a lot of the hot MX riders of the day went on these rides, saying they learned so much. I can just picture those peaceful group rides, with the whole pack charging for the holeshot. Doing 100 mph all over the place, getting huge air off every bump, etc. Love it!
Anyway, I bet you got one of Sun`s old bikes. Sure glad you are checking the whole works carefully. If it survived that use, should be fine for our trail cruises.
Oh, when you get sick of those rock hard tires, try Dunlop MX52. Can not believe the grip those things have. Full speed ahead! L

Damo W said:

Have a look at this one then mate and it's in Brissy too.....


MOTORCYCLE OFF ROAD on Gumtree MOTORCYCLE OFF ROAD | Motorcycles | Gumtree Australia Brisbane North West - Brisbane City | 1137548729

Damo

Click to expand...

Already looked at it
Its a FE600 Not a FE600E.
There is no way I'm riding one of these things with out a e start.
My old 600 was impossible to start hot on the side of a hill by kicking it.

44014 said:

Good on you. I would do this to a 2000 FE600e if i could find one.

Click to expand...

That is not easy I heard. Reason I heard it is that I got one -00 FE600E engine in mint condition in my garage waiting for the frame. No it's not mine, it belongs to a friend. And no it's not for sale...

All it needs is a working ignition system and a new starter (we have located both). He who renovated it told me it was pure luck that he found the parts he needed, and a few of them brand new.

This is not to "rub it in", but to prove with a bit of luck it can happen! Don't give up!

the frame will have to be an electric start specific frame then won't it.

taffy

Yep, the frame is in my friends garage But sorry for the topic derail... This is about a 650!

Like I mentioned before one of the bearings in this motor was destroyed. I've split the cases. Here's a shot of the bearing and some of the bits of metal I found inside.

So now it's time to order bearings and seals. Taffy seems like a good one-stop-shop for all of this but with shipping from England to California, it might end up being an expensive proposition. I'll have to dig around on this website to see what alternatives I can find. Please don't hesitate to chime in with suggestions. It seems there is some debate as to whether or not some of these bearings are "bespoke" Husaberg or if they're generic.
I'm thinking the safe thing to do is replace everything.

Oh and by the way, I haven't yet figured out how to get that crankshaft gear and nut off. Might have to partially re-assemble the motor, maybe use the clutch basket to have something I can grab hold of when I take the impact gun to that nut. My mistake for not thinking of this before.
Any ideas?

mx563 said:

Like I mentioned before one of the bearings in this motor was destroyed. I've split the cases. Here's a shot of the bearing and some of the bits of metal I found inside.

So now it's time to order bearings and seals. Taffy seems like a good one-stop-shop for all of this but with shipping from England to California, it might end up being an expensive proposition. I'll have to dig around on this website to see what alternatives I can find. Please don't hesitate to chime in with suggestions. It seems there is some debate as to whether or not some of these bearings are "bespoke" Husaberg or if they're generic.
I'm thinking the safe thing to do is replace everything.

Oh and by the way, I haven't yet figured out how to get that crankshaft gear and nut off. Might have to partially re-assemble the motor, maybe use the clutch basket to have something I can grab hold of when I take the impact gun to that nut. My mistake for not thinking of this before.
Any ideas?

Click to expand...

My friend, let me tell you a small anecdote and let's see if you get the underlying message. BTW, we spell things out to our cousins....

If the American postal system was competitive, "we" would be in a lot of trouble, I mean serious phuqin trouble. your 'used' parts are cheaper than ours but luckily your postage is a shameful mess, it costs double the item to get the posted!

luckily in Europe and especially the UK, the postage is very, very competitive and cheap. We are also quick (they go hand-in-hand). so everyday, I thank the American postal system for making my business competitive.

as for the gear, just airgun it, you know, b-r-u-m, b-r-u-m....done.

as for what to put in a 2002 650? concentrate all your money on the front of the engine, scrimp not on the bottom end. if it's in the cases = do it right.

new balance bearings
new roller mains (0.6mm float)
new big end bearing if not rod
new little end bush
new intermediate inner beating
re-nikasil usually
new piston always

upgraded CCTB (rip the blob of alloy off the tensioner)

the cylinder head will cost you a fortune
new 37mm inlets
cut all 4 seats
face the exhausts
kiss the stems of the exhausts
DVSK
new cam bearings
later ADC and modified spring
go to the 08 cam

look for wear as follows
tappet pads cupped
rocker bushes
rocker shafts
cam follower bearings
seal off the L bar hole as the ADC will work

down the bottom left
clutch steels
grind the spalling off the gear selector
sledge mod
blank off the kickstart decomp hole
cam chain

you should be about Ok with this, the rest is detail like flat covers, clean metal, washing shyte away,

if you go to Facebook/Taffmeisters/Video I have a video lf a 2002 NTB 650 with a 3mm taller piston fitted and it starts first time......

yup -3mm taller! no ****.

if you're doing the engine, you must conmsider your carb part of this otherwise the bike won't run properly.

regards

Taffy

Doing well

Hi. You are doing a lot better than myself with your rebuild. I currently have my 2002 Fe501e at a machine shop in an attempt to have the swing arm bolt removed. Tried heating and rapidly cooling it. Even tried pressing it out with my 20 ton wood splitter. No luck here.

Alby said:

Hi. You are doing a lot better than myself with your rebuild. I currently have my 2002 Fe501e at a machine shop in an attempt to have the swing arm bolt removed. Tried heating and rapidly cooling it. Even tried pressing it out with my 20 ton wood splitter. No luck here.

Click to expand...

I've had success removing stuck swing arm bolts using a pneumatic impact hammer. Sometimes the shock generated by each of the successive impacts beats a steady application of force. I also like to use a penetrant called Kroil (made by Kano Labs).
Sounds like your swing arm bolt might be too stubborn even for that.
Best of luck!

I think I'm due for an update.

I ended up using Taffmeisters for the majority of parts that were needed to get the motor back together. I also utilized Taffy’s advice and youtube videos. I don’t think I’d be where I am with this build without Taffy (credit must also be given to Julie who was very helpful with all my orders).

I’ve overhauled dirt bike engines before but the Husaberg is different than anything I’d ever worked on. I think it took three tries to get the cases and cylinder sleeve back together correctly (at least I *think* I got them assembled correctly).

So last night, the motor finally went back into the frame and the attached images show what that looks like (as if you guys have never seen such a sight…ha ha!)

Next, I’ll be going through the wiring rats nest. At one time, the previous owner was running a capacitor in place of a battery, and he had some generic toggle switches wired in as well. I’m not very good with the electrical side of things so I expect this to be a relatively challenging phase of the rebuild.

Cheers

Looking Gooooood hope the rest works out well. Great Job